SOW- REV 1.pdf

JML ___________

STATEMENT OF WORK

For Three (3) Electroplating Rectrifiers at

PUGET SOUND NAVAL SHIPYARD & INTERMEDIATE MAINTENANCE FACILITY (PSNS&IMF), Naval Base Kitsap, Bremerton, WA

Bldg. 893

1. SCOPE - This statement of work summarizes those characteristics that are essential to the minimum needs of the Government for three (3) electroplating rectifiers at Puget Sound Naval Shipyard & Intermediate Maintenance Facility (PSNS & IMF) Bremerton, WA.

1.1. Each rectifier shall be solid state reversing with thyristor technology, 5% ripple filter, remote operating counsel and lifting skid. The vendor must provide the Bill of Materials (BOM) included within the Standard Operation and Maintenance manuals & Electrical diagram. The manuals should be provided in three (3) hard copies and one (1) electronic format. Each rectifier shall third party certification label. The vendor shall supply each testing report in electronic format as a pdf file.

1.2. One (1) each of the following rectifiers shall be provided:

1.2.1. Serial number 518820-002-001, AC Input 480 V, 90 A, 3 Ph, 60 Hz., DC Output 0 to +/-9 V, 0 to 6,000 A, Duty CONT with internal 5% ripple filter previous serial number 785394 with 5% Ripple filter.

1.2.2. Serial number 518820-001-001, AC input 480 V, 250 A, 3 Ph, 60 Hz., DC output 0 to +/-12 V, 0 to 10,000 A, KW 72, Duty CONT with internal 5% Ripple filter.

1.2.3. Serial number 518820-003-001, AC input 480 V, 60 A, 3 Ph, 60 Hz., DC output of 0 to +/- 9V, 0 to 4,000 A, Duty CONT with Internal 5% ripple filter previous serial number C-18586.

2. PROJECT REQUIREMENTS & SPECIFICATIONS

2.1. Design. The item offered shall be of new construction. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, and sold.

Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

2.2. Construction. Each rectifier 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.

2.2.1. Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

2.2.2. 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.

2.2.3. Corrosion Control. All system components shall be protected against corrosion and deterioration by appropriate material selection, application of coatings and sealants. The system and its parts shall be painted on all sides, prior to assembly, except mating surfaces such as mounting flanges and motor shafts. Painting shall result in a highly wear-resistant finish, which guarantees continued protection to the surfaces covered against the specified environment under all service conditions. Exposed ferrous parts such as screws, bolts, nuts, washers shall be treated to resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as cadmium or chrome plating, galvanizing or other electrical/chemical process, or stainless steel is acceptable. Stainless steel parts shall be passivated. Aluminum parts shall be anodized or chemically treated followed by two coats of weather-resistant exterior paint. Dissimilar metals shall not be used in direct contact with each other without suitable means for preventing electrolytic corrosion. All paint shall be lead and chromate free.

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

2.2.5. 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.

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

2.2.7. OSHA Compliance. The equipment installation and its component parts shall be in compliance with 29 CFR 1910, NFPA 70 and NFPA 79. Approval shall be as specified under the “Approval” and “Acceptance” criteria in the OSHA regulations Subpart “O”, Machinery and Machine Guarding paragraph 1910.212 and Subpart “S” Electrical, paragraph 1910.303 and paragraph 1910.399.

2.2.8. Safety Signs and Labels. Safety signs and labels in accordance with NEMA Z535.4 shall be securely attached to the equipment in visible locations, at the point of hazard(s), with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the signs.

2.2.9. Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

2.2.10. Interchangeability. 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 be interchangeable with domestically supplied components or be readily available from a domestic source.

2.2.11. Measuring and Indicating Device Graduations. All measuring and indicating devices on the controllers and rectifiers shall be graduated in the inch/pound or both inch/pound and metric.

2.3. Each rectifiers shall meet the following specifications:

2.3.1. Type: 6 Pulse Thyristor regulated to =/- 1% voltage or current with solid state reversing.

2.3.2. Cooling: Forced Air

2.3.3. Controls: Single Unit Rectifier HMI rRemote console with touch pad controller including digital meters, push button controls and functions for local and automated control. Each remote console is located within 60 feet of the rectifiers and will be one building level below the rectifiers. Connect by CAT5e cable and interconnecting wiring.

2.3.4. Communication Connections: Reference and feedback of voltage and current via analog signals or with digital signals over Ethernet.

2.3.5. Filter: A single polarity ripple filter shall be provided. The AC RMS ripple content in the DC output voltage shall be filtered via an LC filter to maintain less than 5% of the full scale over the full range of output (10-100%).

The filter shall consist of an iron core inductor and a capacitor bank as well as a contactor interlocked with the control electronics to disconnect the polarity sensitive capacitors from across the DC terminals when the equipment is operated in reverse polarity.

2.3.6. Lifting Points: Each rectifier shall be on a welded structural steel base frame assembly which will be fitted with fork tubes and lifting points which will be suitable for lifting with a forklift or from above with a spreader bar and other appropriate rigging equipment.

2.4. Spares. All standard spares required for proper operation of each rectifier including any special tools shall be furnished.

2.5 Marking on Instruments, Control Panels, and Plates. All words on instruments, control panels, and 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.

2.5.1 Certification Label. Each rectifier shall be labeled with a UL or other Nationally Recognized Testing Laboratory certification label. See section 3.1.2 of this SOW.

2.5.2. Lubrication Plate. A lubrication plate shall be permanently and securely attached to each rectifier. 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 applicable) Size and type of each lubricant filter

2.5.3. Nameplate. A nameplate shall be permanently and securely attached to each rectifier. 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 or Order Number Date of manufacture

3. CONTRACTOR RESPONSIBILITIES

3.1 Deliverables

3.1.1 Pre-Inspection of 480 3ØAC Supply. Within two (2) week of award of contract, awardee will complete an onsite inspection of the existing AC supply system for three (3) rectifier(s) and provide a detailed report on findings and recommendations with in five (5) day(s).

3.1.2 Removal / Disconnection. Provide removal and disposal of existing interconnecting buss bar from three power-supplies to reversing module. Disconnecting of the output bussing for threes reversing modules, in preparation for removal of equipment by others. Disposal of three electroplating rectifiers removed by others, Removal and disposal of existing remotes, Removal and disposal of interconnecting control wiring for three obsolete reversing unit, Removal and isolation of power wiring for three obsolete reversing unit. Removed by others defined as rigging provided by PSNS & IMF.

3.1.31 Operating and Maintenance (O&M) Manuals. Three (3) hard copies and one (1) electronic copy(s) of O&M Manuals shall be provided with each rectifier. O&M Manuals shall contain technical information, specifications, instructions for the operation, maintenance of the rectifier and controller and recommended spare parts list. All copies of technical data shall be legible and written in the English language. Technical Data shall contain at a minimum:

a. Data shall enable an average journeyman mechanic to operate, program, maintain, and repair the equipment.

b. Complete instructions and information for all equipment, components, assemblies, subassemblies, attachments, and accessories.

c. Operating instructions including programming requirements, pre-operational checks, start up, shut down and emergency shutdown procedures.

d. Maintenance and service instructions, including all preventive maintenance schedules, and lubrication charts.

e. Trouble-shooting guides.

f. Parts list containing: illustrations, part numbers, part nomenclature, original manufacturer, cross reference numbers, and recommended spare parts, including quantities.

g. Energy control procedure, in accordance with 29 CFR 1910.147, to bring equipment to a zero energy state for maintenance.

h. All mechanical and electrical schematics with a table of contents showing discrete components, block diagrams, wiring diagrams with inputs and outputs identified, system electrical interface documents, and drawings for the specific model of all machine equipment/drives/controls supplied.

3.1.42. OSHA Approved Certification. The equipment specified herein shall be inspected and labeled by a Nationally Recognized Testing Laboratory (NRTL) as defined in 29 CFR 1910.7 and approved as defined in section

2.2.7 of this statement of work, OSHA Compliance.

3.1.53 One Year Warranty on Parts and Labor with Installation by Contractor. Twelve (12) months from signature of Acceptance Handover Protocol.

3.2. Workmanship. Workmanship of the rectifiers 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.

3.3. Examination. The rectifiers shall be examined to determine compliance with all requirements of this specification.

3.4 Contractor shall provide shipping, installation, commissioning and training of each rectifier at PSNS&IMF Bremerton.

3.4.1 Installation. For each rectifier installation includes leveling and fastening of rectifier, connecting all utilities and installation of controller and supply, install and connect all CAT5e cable and interconnecting wiring required to connect remote to corresponding rectifier. Install interconnecting buss-bar to connect the low voltage high current output of the rectifier to the original connection points of the reversing unit for three rectifiers. Rigging/placement of new rectifiers provided by PSNS & IMF. Awardee will confirm proper AC phase rotation after conduit and wring have be installed by others.communication wiring between rectifier and controller.

3.4.2 Site Commissioning. For each rectifier shall include operating rectifier over full range of operating range.

Shall provide one (1) factory representative or Dynapower approved representative for five days per unit for commissioning and calibration of the quoted power-supply. Calibration of rectifier displays and controls to NIST standards and per MIL-STD-45662A | ANSI/NCSL Z540-1 | AMS2750-F. Ripple report will include a graph of the output waveform with both True RMS AC ripple and Peak to Peak calculations for both voltage and current. Report will be provided for both forward and reverse mode. Certification of buss-bar voltage loss at 80% of full load amperage. Certification of amp-hour totalizer.

3.4.3 Training. Includes showing operating and maintenance personnel how to operate and maintain the rectifiers and controllers.

4. Delivery address:

The "Ship/Deliver to" address on the Bill of Lading (B/L) should include the JML number as shown below.

Puget Sound Naval Shipyard & IMF Receiving Officer PSNS, N4523A Bldg. 514, JML- 1400 Farragut Ave.

Bremerton, WA 98314-5001