PD 11MAY2023.pdf

VIBB 23-40-1000

11 May 2023

PURCHASE DESCRIPTION FOR THE ACQUISITION OF HEAT

TREAT FURNACE

SCOPE.

Scope. The content of this specification describes the minimum requirements for the design, operation, construction, installation to building 3001, Tinker AFB, Oklahoma, and acceptance procedures for a Horizonal loading Air Furnace and water quench tank and accessories described herein. The furnace will be used to perform various heat treating processes including solution heat treating of aluminum parts.

APPLICABLE DOCUMENTS. The documents listed in this section are cited in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed in section 2. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

Government Documents.

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

STANDARDS – FEDERAL

FED-STD-H28B: Screw Thread Standards for Federal Service

FED-STD-313F: Material Safety Data, Transportation Data, and Disposal Data for Hazardous Materials Furnished to Government Activities

U.S Department of Labor, Occupational Safety and Health Administration

(OSHA)

29 CFR 1910: General Industry, OSHA Safety and Health Standards

(Application for copies should be addressed to the OSHA Publications Superintendent of Documents P.O. Box 37535 Washington, D.C. 20013-7535)

MILITARY STANDARDS

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property Item Unique Identification Marking (IUID)

(Application for copies should be addressed to Air Force Product Data Systems Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg. 262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257- 0870 or 0853 or https://quicksearch.dla.mil/qsSearch.aspx)

Other Government Documents, Drawings, and Publications. The following other

Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

LOCAL FACILITY DOCUMENTS

ATTACHMENT A: Replacement Furnace Location

(Applications for these documents should be addressed to the contracting officer)

Non-Government Publications, Specifications, Standards, and Handbooks. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

American National Standards Institute, Inc. (ANSI)

ANSI/NEMA-FB 1 Fittings, Cast Metal Boxes, and Conduit Bodies for Conduit and Cable Assemblies, (2007 edition)

ANSI/NEMA ICS-1 Industrial Control and Systems General requirements (R2008)

ANSI/NEMA MG1 Motors and Generators, (2010 edition)

ANSI/NEMA Publication 250 Enclosures for Electrical Equipment (2008 edition)

Applications for copies should be directed to the American National Standards Institute, 1300 North 17th Street: Suite 1752 Rosslyn, VA, 22209 Phone: (703)841-3200/3258)

National Electrical Manufacturers Association (NEMA)

NEMA 250: Enclosures for Electrical Equipment (1000 V Maximum)

NEMA MG 1: Motors and Generators

(Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Rosslyn, VA 22209)

National Fire Protection Association (NFPA) https://quicksearch.dla.mil/qsSearch.aspx

NFPA 70: National Electrical Code

NFPA 86: Standard for Ovens and Furnaces

(Applications for copies should be addressed to the National Fire Protection Association, ATTN: Support Services, 11 Tracy Drive, Avon, MA 02322)

Society of Automotive Engineers (SAE)

SAE AEROSPACE MATERIAL SPECIFICATION (AMS) 2750: (R) Pyrometry

(Application for copies should be addressed to: Society of Automotive Engineers 400 Commonwealth Drive, Warrendale PA 15096)

American Society For Testing and Materials (ASTM)

ASTM SI 10: American National Standard for use of the International System of International System of Units (SI) The modern Metric System, (2010 edition)

ASTM D3951: Standard Practice for Commercial Packaging

Applications for copies should be directed to the American Society for Testing and Materials 1916 Race St., Philadelphia, PA 19103.

MILITARY STANDARDS

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property Item Unique Identification Marking (IUID)

(Application for copies should be addressed to Air Force Product Data Systems Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg. 262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257- 0870 or 0853 or https://quicksearch.dla.mil/qsSearch.aspx)

Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulation unless a specific exemption has been obtained.

2.4 Acronym Definitions Not Explicitly Listed in Text. The following acronyms not explicitly listed in each section text are defined as follows:

a. JIS- Japanese Industrial Standards

b. DIN- German Institute for Standardization https://quicksearch.dla.mil/qsSearch.aspx

c. EN- European Standard

REQUIREMENTS.

Design. The items offered shall be new and a current, commercially-available model.

Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The system design and construction shall include all parts, components, and features necessary to provide high temperature, required air capability, and be as energy efficient as modern construction methods allow.

The furnaces systems shall be complete so that when installed and connected to the specified utility sources it can be used for all operations for which it was designed as designated in this specification. Materials exposed to the internal environment of the furnace chambers shall be compatible with the type of atmosphere and temperature conditions specified for the furnace. The furnaces shall be designed to load parts into the heat treating chamber horizontally. Construction shall be free from any characteristic or defect that will prevent the furnaces from passing any of the examinations and tests specified herein.

Measuring and Indicating Device Graduations. All process parameters shall be displayed in the English system or units (degrees Fahrenheit, etc.), in accordance with ASTM E 380-91. Non process specific parameters, such as cooling water temperature gages and pressure gages, may be displayed in standard units of psig or degrees Fahrenheit.

Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's work station(s).

Safety and Health Requirements. All machine parts, components, mechanisms, and assemblies furnished on the machine, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910 or equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11 equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded part, and shall be easily removed to facilitate inspection, maintenance, and repair of the parts.

3.1.3.2 Safety Devices. The system shall be equipped with all safety devices required by 29 CFR 1910 and NFPA-86 AMD 1. These shall include but are not limited to:

1.Limit switches on automatic movements 2.Breaker-equipped electrical cabinets 3.Red emergency stop button

a. The emergency stop button shall immediately shut down all electrical current to furnace heating elements. All other systems shall remain in operation. The emergency stop button shall require an active reset on the part of the operator to resume operation. No automatic resets are permitted.

b. The system shall be set up that in the event of a water failure of any kind the diffusion pump and heat contractor are automatically shut off and a manual restart is required. The machine shall notify the operator of a water failure, should it occur.

c. The system shall be equipped with a main breaker which shall disconnect all electrical flow to the system. Additional breakers shall be provided to disconnect electrical flow to individual heating zone elements.

3.1.3.3 Equipment Protection. Short circuit protection shall be provided for auxiliary controls, instruments, relays, and sensing devices, etc. All electric motors of ¼ horsepower and larger shall be provided with short circuit and thermal trip overload protection. Motor sizes shall be such that driven load will not exceed the continuous duty rating of the motor with a maximum load in the chamber. Solid state reduced voltage (soft start) motor starters shall be provided for polyphase motors 25 horsepower or larger.

Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

Hazardous Material Exclusions. Supplies or materials being provided as part of the equipment shall be free of known hazardous materials. These materials shall not be brought on site without prior approval of the Government. Radioactive materials or instruments capable of producing ionizing radiation as well as materials which contain asbestos, mercury, lithium, methylene chloride, lead (= or >0.06%), or polychlorinated biphenyls (PCB’s) are prohibited. Definitions of hazardous materials are specified in the latest version, including revisions adopted during the term of the contract, of FED-STD-313F.

Nickel Metal Hydride and lithium batteries are permissible for memory backup. Class I Ozone Depleting Substances as defined in 40 CFR 82 shall not be used in the performance of this contract, or be provided as part of the equipment. Exceptions to the prohibition of these materials must be referred to the Contracting Officer in writing, for consideration, not later than 60 calendar days after effective date of contract and prior to any work being performed.

Environmental Protection. Under the operating, service, transportation, and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prohibited by federal, stale, or local statutes in effect at the point of installation.

Lubrication. Means shall be provided to ensure adequate lubrication for all moving parts. Recirculating systems shall include filters, which are cleanable and/or replaceable. Each lubricant reservoir shall have visible or mechanical means for determining fluid level. All oil holes, grease fittings, and filler caps shall be accessible.

Parts consuming fluids shall be clearly identified as such, along with the recommended periods of additions and the specific fluids required for functional system operation over the life of the machine.

Replacement Parts. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts.

Foreign-sourced replacement parts shall either be interchangeable with domestically supplied components or be readily available from a domestic source.

Construction. The machine shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the machine to its maximum rating and capacity without distortion.

Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, filling with solder or paste shall be used for reclaiming any defective part.

Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed. All such parts that are subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently deformed.

Threads. All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28B and the applicable “Detailed Standard” section referenced therein or equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

Gears. All gears shall be of proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine. Gears in drive trains shall be hardened and ground steel.

Surfaces. All surfaces shall be clean and free of harmful or extraneous materials.

External surface edges shall be rounded or beveled unless sharpness is required to perform a necessary function. Except as otherwise specified herein, the condition and finish of all surfaces shall be commensurate with the manufacturer’s standard commercial practice.

Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

Painting. The machine shall be painted in accordance with the manufacturer’s commercial practice. All paint shall be of the lead free type.

Workmanship. Workmanship of the machine shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

Components. The machine shall consist of not less than the following components:

Base. The base shall be a stress relieved, heavy duty, ribbed casting or steel weldment having characteristics that minimize both thermal and vibration effects, while providing the strength and size to assure maximum rigidity and support for any load within the rated capacity of the machine. Means shall be provided for accurate, ease of leveling.

Heating Elements. The insulation and heating element(s) shall be designed and arranged to minimize heat loss and assure temperature uniformity and heating requirements specified herein.

Thermocouple Extension Wire and Connectors. All thermocouple extension wire shall comply with AMS 2750.

Furnace Control Thermocouples. One control thermocouple is required per furnace control zone, and one additional thermocouple is required for over temperature protection. All control thermocouples and over-temperature thermocouples shall be type “K” and shall meet accuracy and calibration requirements as detailed in AMS 2750. The control and over -temperature thermocouples shall be of non-expendable configuration.

Each thermocouple shall have a corresponding temperature controller defined in Section

3.3.18 and 3.3.19.

Pneumatic System. Under the condition that a machine has a pneumatic system, the system shall conform to ISO 4414. The system shall be complete, including all valves, piping, cylinders, and pressure controls. A machine that does not require a pneumatic system to operate properly shall be considered acceptable.

Electrical System. The machine shall conform to NFPA 79 or current equivalent ISO/EN/DIN/JIS/IEC standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements. The existing source power available at the facility is 480 Volt, 3- phase. The machine’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete, including any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated, and fused, single disconnect device shall be utilized on the machine with means of lockout in the off position only.

Electrical Enclosures. Construction of the electrical enclosures shall be in accordance with NEMA 250 type 12 or current equivalent ISO/EN/DIN/JIS/IEC standards and shall provide for ventilation of components and shall be designed for an indoor non-hazardous location. All electrical components shall conform to NFPA 79 or equivalent ISO/EN/DIN/JIS standards. The machine shall be provided with interlocks on its electronic cabinet that shall instantly remove power from the equipment when the door is opened in accordance with NFPA 79 or current equivalent ISO/EN/DIN/JIS/IEC standards. Exposed wiring shall be housed in conduit conforming to NEMA FB 1. All electrical housings and cabinets shall meet the requirements of NEMA Publication 250, Type 12. All electrical wiring shall be visually tagged identifying its function and a L.E.D. to identify positive signal transmission. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

3.3.8.1.1 Cabinet Specification. A free standing or integrated NEMA 12 control cabinet provided to house all instrumentation, power meters, motor controls, relays, alarms, control power transformer, and any other accessories required, along with ventilation and cooling for the system.

3.3.8.1.2 Interconnecting Furnace Requirements. Complete conduit and interconnecting wiring for the furnace components shall be provided in accordance with the ANSI/NEMA ICS 1, NEMA FB 1 and ANSI/NFPA

86 AMD 1.

3.3.8.1.3 Ammeters and voltmeters. Ammeters and voltmeters shall be provided for each heating element bank(s). An ammeter shall be included to monitor the gas blower and motor current. Each instrument shall be identified with a nameplate for the item they represent and shall be mounted on the control panel.

3.3.8.1.4 Circuit Breakers. Circuit breakers shall be provided in ANSI/NEMA ICS 1 enclosures. The main power supply circuit breaker shall allow the power to the entire furnace system to be independently shut-off.

3.3.8.1.5 Grounding. The equipment shall have a single point grounding stud 5/8” diameter or larger. The resistance between the grounding stud and all other exposed metallic parts shall not exceed 2.0 OHMS.

3.3.8.1.6 Power Supply Requirements. The furnace power supply shall have 3 phase, 480 volt, water cooled, including an SCR type linear power controller. Controllers and instruments shall be operated using 115 volt nominal, 60 Hz input. The 115 volt input line shall be equipped with a filter to protect the system from line spikes and variations.

Arc Flash Protection. The machine enclosures shall be marked for arc flash in accordance with NFPA 79 Paragraph 16.2.3 “Safety Signs for Electrical Enclosures” or current equivalent ISO/EN/DIN/JIS/IEC standards for arc flash safety. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

Solid-State Components. Electrical devices used to power electrical servo and spindle motors of control voltage delivered to solid-state electrical components shall be solid-state devices. Such devices shall be equipped to handle the electrical load imposed by operation of the machine to its maximum potential. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

Motors. All motors shall be ball or roller bearing type and rated for continuous duty. Each AC motor used in the machines system shall be dual voltage and suitable for its application and shall meet the requirements for either drip-proof or totally enclosed fan cooled enclosure. All motors shall meet the requirements of NEMA MG-1 or current equivalent ISO/EN/DIN/JIS/IEC standards. Power factor correction capacitors will be installed for AC motors rated at 25 HP or greater. Electric motors 75 Hp and larger shall consist of three phase construction. Where standard “V” belt drives are used, they shall be sized to transmit 150 percent of developed horsepower.

Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

Hour Meter. The machine shall be equipped with a non-resetting type, hour meter to display accumulated operating time of the drive motor(s), mounted on the main electrical panel visible from the outside, sealed to prevent the entrance of dust and moisture, and shall be mounted to withstand shock and vibration generated by the machine.

The meter shall have a range of 0 to 99,999.9 hours in increments of one (1) tenth of one

(1) hour. A CNC control that tracks and displays total machine on time (a non-resetting type), controller on, program runtime, and run time of the servo motor(s) shall be considered to meet this requirement. The meter shall be sealed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by the machine.

3.3.12 Control Cabinets. All instrumentation and controls shall be functionally grouped, permanently identified, and conveniently located for single operator control. The panel shall provide for either semi-flush mounts or flush mounts for all instruments.

3.3.13 Interlock and Limit Switches. All necessary controls shall be interlocked to provide maximum safety for personnel and equipment.

3.3.14 Instrumentation. All instrumentation and controls shall be front panel mounted in a single console. The enclosure shall be a NEMA ICS 1 Type 12 enclosure with panel doors.

3.3.15 Furnace Controls. Contractor shall provide data/literature of the set point programmer and programmable logic controller design; customer references shall be provided with the proposal. The furnace set point programmer and programmable logic controller shall be configured with sufficient In/Out and logic memory capacity to ensure complete control of all furnace programs, routines, and events; and shall provide the following integrated functions:

a. Loop, logic, and sequence control

b. Data acquisition

c. Set point programming

d. Recipe storage for 60 recipes

3.3.16 Temperature Uniform Survey. TUS thermocouple ports shall support enough thermocouples to comply with the number of TUS sensors required by AMS 2750 (Latest revision) according to the minimum work space. Survey thermocouples and their ports shall be type “K” compliant.

3.3.17 Resident SAT Thermocouple Port. A type “N” resident SAT thermocouple shall be mounted in the furnace for each control zone(s). The resident SAT thermocouple shall be installed and positioned IAW AMS 2750 (Latest revision). A labeled thermocouple jack panel shall be present on the front face (standard 2 pin connectors) of the control cabinet for each SAT thermocouple. All thermocouples, extension wire, and thermocouple connector plugs shall be type “N”.

3.3.18 Temperature Controller. The temperature controller shall be compliant and meet all the requirements for Temperature Controllers listed in AMS 2750 (Latest Revision).

This instrument shall be a separate instrument from the furnace controls. A type “K” thermocouple shall be provided for the exclusive use of this instrument. The temperature controller shall be mounted on the control cabinet.

3.3.19 Over Temperature Controller. The over-temperature controller shall be compliant and meet all the requirements for Over-Temperature Controllers listed in AMS 2750 (Latest Revision). The controller shall function to shut off electricity to the heating elements of the furnace in the event the over-temperature control point is reached. This instrument must be manually set before each furnace run. This shall be a separate instrument with control circuitry physically separate from the main controller. A type "K" thermocouple will be provided for the exclusive use of this instrument. Should the over-temperature control point be exceeded an audible alarm shall sound.

3.3.20 Chart Recorder. A new multi-channel chart recorder that is compliant with AMS 2750 with AH (Aerospace Heat Treatment) option shall be installed. Standard channels shall come preprogrammed or shall be programmable onsite with the addition of a channel displaying the control thermocouple per zone(s), over-temperature thermocouple(s), and one spare. The chart recorder shall have a minimum accuracy equivalent to a digital instrument noted in AMS 2750.

3.3.21 Uninterruptible Power Supply (UPS). A UPS shall be provided to supply 30 minutes of emergency power to the controllers and MMI for proper furnace system shutdown in the event of a commercial power failure. The UPS shall provide voltage regulation in order to automatically correct both high and low voltages so that the controllers and MMI receives voltages within the normal range. The UPS shall also provide surge protection to all connected 115V equipment.

3.3.22 Man Machine Interface (MMI). The contractor shall provide a furnace control system that utilizes Allen Bradley furnace controllers; or equivalent to Allen Bradley SLC 505 series, to perform all furnace sequencing and alarm functions. Specifications for the given brand name are the minimum requirement. This non- pc based interface shall provide:

a. All the control and interface features as specified in section 3.3.12,3.3.13 and 3.3.14.

b. Any program features or tools that are required for operation.

c. Sufficient description, illustrations, and customer references of this option shall be provided at time of proposal for evaluation purposes.

d. Color touch screen.

3.3.23 Controller Programming. The controller shall be programmed/configured to provide all logic control necessary for automatic furnace operation, sequencing, and safety interlocks.

3.3.24 Set-Point Programming. Recipe programming shall be configured such that the following parameters can be specified:

a. Ramp rates (rate of temperature rise or fall, in °F/min, for any given temperature interval).

b. Soak temperature (provides a programmed temperature hold at a specified temperature).

c. Soak duration.

d. Events (Based on or initiated by parameters such as: time, process variable, or deviation).

e. Event Parameters (operator specified parameters/values that control events)

3.3.25 Furnace Routines. The following program routines shall be configured in the furnace control system:

3.3.25.1 Over Temperature. This routine shall turn off hot zone power if the furnace or workload temperature exceeds an operator specified over-temperature level. This routine is to protect workload parts, and is not the same as the Over-temperature Control.

3.3.25.2 Alarms. In addition to alarms initiated by the above referenced routines, the following alarms (and any additional alarms that the Contractor routinely provides or believes are necessary) shall be displayed/sounded to notify furnace operators of the following events:

a. Furnace over temperature.

3.3.26 Safety Interlocks. The furnace system shall have all of the necessary safety interlocks to ensure failsafe operation and protection to the equipment, operator, and workload parts.

3.3.27 Feed- through Guards. The power feed-through located on the chamber body shall be safety protected by guards.

Size and Capacity. The size and capacity of the machine shall be not less than specified in Table I.

Table I: Size and Capacity Maximum installation space (L,W,H)

35 Feet x 16 Feet x 18 Feet

Heat chamber working space (L,W,H)

13 Feet x 3 Feet 9 Inches x 2 Feet

Hot Zone (L,W,H) (minimum) 13 Feet x 3 Feet 9 Inches x 2 Feet Furnace operating temperature range 250 Deg Fahrenheit. to 1,000 Deg Fahrenheit

Alignment and Accuracy Tolerances. The alignment and accuracy tolerances of the machine shall be as specified in Table II.

Table II: Accuracy Furnace temperature uniformity including the range of 250 Deg Fahrenheit to 1,000 Deg Fahrenheit)

± 10°F

Standard Tooling and Equipment. All standard tooling and equipment required for proper operation and maintenance of the machine shall be provided. A list of these items shall be furnished at time of proposal.

3.6.1 Consumable Parts. The contractor shall provide one spare Type “K” control thermocouple and one spare Type “K” over-temperature thermocouple. All recommended start-up and consumable items needed for installation, start-up, acceptance testing and initial production (3 months) shall be provided by the contractor. Contractor must provide a detailed list of the kit and line item costs as part of the proposal. Safety Data Sheets (SDS) for any paint, oil, grease, or other hazardous materials must be provided to the contracting officer and engineering point of contact 60 calendar days prior to shipment.

3.6.2 Spares Kit. The contractor shall supply a spares kit consisting of components that are subject to failure or require replacement. This kit shall consist of, as a minimum, spare elements or element sections, element stand-offs, hangers, or fasteners, etc. The Contractor must provide a detailed list of the kit and line item costs of each as part of the proposal.

Marking on Instruments, Control Panels, and Plates. All words on plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

Lubrication Plate. A lubrication plate shall be permanently and securely attached to each machine. The plate shall contain the following information.

Points of Lubricant Application Servicing Interval Type of Lubricant Viscosity Military or Federal Specification for Each Lubricant (If available) Size and Type of Each Lubricant Filter

Nameplate. A nameplate shall be permanently and securely attached to each machine. The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

Nomenclature Manufacturer’s Name Manufacturer’s Model Designation Manufacturer’s Serial Number Power Input (Volts, Total Amps, Phase, Frequency) Contract Number Date of Manufacture

Note: The serial number of the furnace shall also be imprinted on a main chamber member in a prominent location.

Identification Marking of Military Property. An Item Unique Identification Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text. At a minimum this tag shall contain the information listed in paragraph 3.7.2 Nameplate.

Technical Data. Three (3) hard copies and one (1) electronic copy(s) of technical data shall be provided with the machine. Technical data shall contain specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language.

Operation Manuals. Operation manuals shall include a general overview section containing a description of the furnace system including labeled diagrams and pictorials of the furnace with all subsystems and their functions. Operating Instructions to include:

a) Daily routine checks and start up procedures.

b) Programming instructions necessary for full operation of the furnace, such as entering values and parameters, and selecting routines. The contractor shall also furnish a printout of the ladder logic programming to assist personnel in understanding furnace operation for maintenance and troubleshooting.

c) Safety precautions.

d) Process and system alarm description and operator response and recovery actions.

e) Step by step descriptive narrative of furnace process sequences.

f) Operator inspection and maintenance procedures.

3.8.2 Maintenance Manuals. Maintenance manuals shall include:

a. Descriptive literature and brochures for all components, subsystems, and assemblies.

b. Component manuals, authorized service center information, and other material received by the contractor with the components and sub-assemblies of the furnaces.

c. Maintenance, troubleshooting, and repair instructions for the furnaces, furnace subsystems, components, and controls.

d. Preventative Maintenance Plan. The preventative maintenance plan will be used by maintenance personnel to perform all maintenance actions not performed by equipment operators. The plans shall be sectioned by daily, weekly, biweekly, monthly, quarterly, biannual and annual actions as applicable to the specific furnace and furnace subsystems.

e. Recommended Spare Parts. The spare parts and consumables list shall identify the part name, the contractor’s part number, the manufacturer's name and address, the manufacturer's part number if different from the contractor's part number, the part cost, and the number required per system or quantity recommended for spare parts inventory.

f. Calibration Summary. The calibration summary shall identify all equipment and components that require periodic calibration. This summary shall provide detailed instructions for performing calibration of the identified equipment on a step by step basis and include calibration values. The calibration summary shall be provided in an indexed and sectioned format with major and minor divisions clearly identified for rapid access.

3.8.3 Plan of Action and Milestones (POA&M). The contractor shall provide a POA&M to identify contractor performance dates of all major events from contract award to completion of all contract requirements. The initial POA&M shall be delivered thirty (30) calendar days After Contract Award (ACA). The milestones shall be prepared using a recognized project management technique (preferably Microsoft Project). The Government and the contractor shall review the report on a monthly basis. The contractor shall notify the Government prior to making any changes to the POA&M. All changes to the POA&M shall be approved in advance by the Government. The POA&M shall detail such items as engineering, procurement of major hardware, assembly, operational debug, factory acceptance, shipment, installation, training, and final acceptance test.

3.8.4 Acceptance Test Plan (ATP). The Contractor shall prepare an Acceptance Test Plan (ATP). The ATP shall be a step-by-step written instruction on how to verify compliance during Contract Quality Assurance Inspection and the Final Inspection/Acceptance Test specified in Sections 4.4 and 4.5. The Contractor shall develop and provide dimensioned drawings of the proposed test part specified in Paragraph 4.7.3. The Manufacture’s standard testing procedures shall be included in the ATP. Any procedures necessary for compliance with Section 4, which are not covered by the Manufacturer’s standard testing procedures, shall be identified and included in the ATP. The initial ATP shall be submitted thirty (30) calendar days ACA for Government review and approval. The accepted test procedures shall become part of this contract.

3.8.5 Engineering Reports. The contractor shall provide the following reports and documents:

3.8.5.1 Design Review Report. The design review report shall provide the following data and documents within 60 days of contract award for review and approval:

a) Preliminary Installation Drawings: These drawings shall provide preliminary information on proposed furnace placement and specify all required single point service connections, to include water, gas, and electric. The contractor shall provide drawings in electronic PDF and AutoCAD drawing file format.

b) Installation Plan: The installation plan shall describe in detail the logistics of furnace installation beginning with shipment of the furnaces from the contractor’s facility and ending with the furnace installation, testing, and training at Tinker AFB. This plan shall identify the responsible parties for each segment of the installation plan to ensure efficient project completion and provide a schedule of events.

c) Training Plan: The training plan shall address all training requirements specified in paragraph 3.10. The contractor shall clearly identify content and scheduling of the training in such a manner as to assure complete compliance.

3.8.5.2 Monthly Reports. Monthly reports shall specify progress to date, any changes to estimated completion date, and status of all major milestones. These reports shall be in a standard, commercial format and be sent by the 5th calendar day of each month.

3.8.5.3 Preliminary Installation Drawings. These drawings shall provide preliminary information on proposed furnace placement and specify all required single point service connections, to include water, gas, and electric. The drawings shall be a paper copy or an AutoCAD drawing file.

3.8.5.4 Engineering Drawings. These drawings shall consist of general layout, electrical, mechanical, piping, hot zone and element drawings, and any other drawings that the contractor provides as their standard practice. The drawings shall be provided in AutoCAD drawing file format and on paper. The contractor shall provide three complete electronic sets and a total of three paper copies of the new furnace drawings.

3.8.5.5 Installation Drawings. These drawings shall detail the as installed furnace siting and service connection locations. The drawings shall be provided in AutoCAD drawing file format and on paper.

Installation. A complete turnkey installation shall be provided by the contractor. The furnace shall be installed in the heat treat facility, building 3001, Tinker AFB, Oklahoma.

Final layout is dependent on the contractor's verified measurements of the existing site after award and must be approved by the government that it fits in the designated location.

Contractor shall be responsible for ingress and egress of the furnace. The contractor shall provide all labor, equipment, and materials necessary for installation of the Furnace at Tinker AFB. The contractor shall be responsible for receipt and acceptance of all furnace shipments to Tinker AFB, both prior to and during installation. The contractor shall direct the unloading, staging, and site location of all furnace shipments. The contractor will provide all forklifts, cranes, equipment operators, and rigging service necessary for furnace unloading and site location.

Installation Site Access. All work performed at Tinker AFB shall be done between the hours of 0700 to 1600 Monday through Friday excluding government holidays and furlough days. Authorization to work outside these hours may be granted by the designated government point of contact, but no additional funding will be provided. The contractor shall be responsible for general housekeeping of the work area. Before departing each day, the contractor shall pick up and dispose of all packing material, material remnants, and debris from the area.

3.9.1.1 Field Service Engineer. The contractor shall provide a field service engineer to provide technical direction during furnace receipt, installation, and testing at Tinker AFB.

3.9.1.2 Installation Site Services. All utility, roof penetration, and exhaust requirements shall be coordinated and confirmed prior to furnace installation. All single-point services such as electrical, gas, and water, will be provided by the Government to within 25 ft. of the designated installation sites. The contractor shall be responsible for connecting to these utilities.

3.9.1.3 Disassembly. The contractor shall be responsible for the disassembly of the existing air furnace and associated accessory equipment. The furnace shall be disassembled and moved to a government defined staging area in or near building 3001. The Contractor shall skid, band, and cover the equipment with heavy duty plastic wrap or tarps and straps to protect the equipment from wind and rain. At the completion of the contract, all protective coverings will be property of the government. All oils will be drained from the furnaces prior to the contractor arriving on site to perform the disassembly. The contractor shall be responsible for palletizing the furnace that is to be removed. The palletizing shall be IAW ASTM D3951.

Training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is proficient in the English language, shall be provided for specialized training to familiarize Government personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage.

The training shall be separated into two (2) separate consecutive week blocks. Each block of training shall be for eight (8) operators. Training shall be performed at the Government facility and shall not be less than three (3) consecutive eight (8) hour workdays, between 7:00 am and 3:30 pm excluding weekends and federal holidays. The course shall utilize as-built drawings and manuals provided under this contract, and shall include both classroom and hands on portions. All printed training aids shall be supplied for the course, be in the English language, and become the property of the Government. Training at a minimum shall contain following:

a. General description of furnace and furnace subsystems and components including illustrations and functions.

b. Start-up, operating, and shut down procedures for furnace operators including recipe and parameter programming.

c. Operator safety, warnings and cautions.

d. System fault diagnostics, alarm indications, and troubleshooting guidance.

e. Emergency procedures and operator response to alarms.

f. Preventative maintenance procedures.

g. Any other training the contractor deems necessary for the successful operation and maintenance of the new furnace system.

QUALITY ASSURANCE.

Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein and in accordance with the attached Quality Assurance Provision (QAP). Except as otherwise specified in the contract or purchase order, the contractor may use his own facility for the performance of the inspection requirements specified herein, unless disapproved by the Government. The Government reserves the right to witness any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

Responsibility for Compliance. All items must meet all requirements of sections 3 and 4.

Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. Contract quality assurance inspection (Origin) (see 4.4).

b. Final Inspection/Acceptance test (Destination) (see 4.5).

Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient temperature conditions in the range of 55° F to 100° F and 10% to 95% relative humidity.

Contract Quality Assurance Inspection (Origin). Contract quality assurance inspection shall be applied at the contractor’s facility prior to being offered for acceptance under the contract. The machine and all peripheral equipment added to the machine shall be fully assembled and perform all functions in accordance with this specification. Quality conformance inspection shall consist of the examination in 4.6 and the tests in 4.7. The machine shall pass the examination, all tests, and contract quality assurance inspection to be acceptable for shipment.

Final Inspection/Acceptance Test (Destination). Final Inspection and acceptance test shall be performed on the machine to ensure conformance with this purchase description.

The acceptance test shall be performed only after the machine is installed at its final location. The acceptance test shall consist of the examination in 4.6 and all tests in 4.7. The machine shall pass the examination and all tests to be accepted.

Examination. The equipment shall be examined for design, dimensions, construction, materials, components, electrical equipment and workmanship to determine compliance with the requirements of this specification.

Tests. Unless otherwise specified within this document, all programs, instruments, materials, material handling equipment, qualified personnel, and tools required to perform and evaluate the tests shall be furnished by the contractor. All measurement tools and indicating devices shall be calibrated in accordance with the attached QAP. If a malfunction occurs during the test, the test shall be restarted each time until all tests in 4.7 are completed without a malfunction. Three (3) consecutive failures without completion of the test may be considered cause for rejection of the system. For the purpose of this test, a “failure” is defined as any equipment malfunction which requires remedial action to restore the system to full operation in accordance with this specification.

Operational Test. The furnace shall be operated to test the control functions and furnace response to various control parameters. Three (3) failures in a row to complete the operational test may be cause for rejection of the entire system. After successful completion of the operational test; proper operation of all controls, motors, adjusting mechanisms, emergency stop devices, and accessories shall be verified.

Uniformity Test. An initial temperature uniformity survey shall be performed and tested in full accordance with AMS 2750 (Latest revision). The furnace workload temperature shall not exceed +/- 10 F deviation from any controlled set-point within the range of 250 degrees Fahrenheit to 1000 degrees Fahrenheit. A survey heating test cycle shall be performed during temperature equilibrium established at 250 F, 850 F, and 1000 F temperatures. The data collection shall conform to the requirements listed in AMS 2750.

This test shall be conducted three separate times.

Heating Test. The furnace heating rate shall meet or exceed the industry standard throughout the operating range of 250 F to 1000 F. This test will be conducted three separate times to verify consistency.

4.7.2.2 Software/Programming Test. Acceptance of the software/programming shall be accomplished by running various furnace cycles. If programming “bugs” are found, corrections shall be made and re-tested to ensure compliance.

Audible Noise Level Test. The equipment shall be tested for compliance with paragraph 3.1.4. “Audible Noise Level”.

INSTALLATION RESPONSIBILITIES

Government Contractor ☒ ☐ a. Provide machine foundation in accordance with the

Manufacturer’s design requirements ☐ ☒ b. Furnish labor and material handling equipment for off-loading and placing item on foundation ☐ ☒ c. Provide and install anchor bolts and nuts ☐ ☒ d. Set and rough level the machine on its foundation ☐ ☒ e. Level and align machine ☐ ☒ f. Connect machine to the provided utilities hook-up ☐ ☒ g. Provide all necessary tools, gages, and instrumentation necessary to perform the required tests ☐ ☒ h. Provide and charge all systems with fluids in accordance with manufacturer's instructions ☒ ☐ i. Material for performance testing at Government facility ☐ ☒ j. Material for performance testing at Contractor's facility ☐ ☒ k. Material handling, Rigging equipment and Qualified

Personnel for performance testing

GOVERNMENT RESPONSIBILITIES

☒ Provide utilities hook-up within 25 feet of the machine