TECHNICAL ORDERING DATA.pdf

Pit Furnace with Retort 24x36 work zone

1. SCOPE

1.1. Scope. The purchase description set forth below describes the minimum requirements of the Government for a Pit Furnace. It is the Government’s intent that a single primary contractor be awarded this turn-key contract and be responsible for the provision of equipment, and the accomplishment of all work detailed by this specification. This turn-key contract will include: removal and disposal of an existing pit furnace, furnace controller, and main electrical disconnect; installation of new main electrical disconnect, furnace controller, and pit furnace;

NRTL certification and training.

1.1.1. The existing pit furnace #9 and associated equipment is located in PSNS B452 Heat Treat Room.

2. APPLICABLE DOCUMENTS

2.1. General. 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 specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

2.2. Government Documents.

2.2.1. Specifications, Standards, and Handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

FEDERAL STANDARDS

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

(Copies available online at http://quicksearch.dla.mil/)

MILITARY STANDARDS

MIL-STD-130N w/ Change 1 ------------ Identification Marking of U.S. Military Property

(Copies available online at http://quicksearch.dla.mil/)

NAVSEA

OSHECM Chapter 250 Rev 1 ------------ NAVSEA Occupational Safety, Health and Environment Control Manual for Naval Shipyards Chapter 250

(Copies available online at http://www.navsea.navy.mil/Home/Shipyards/Norfolk.aspx)

2.2.2. Other Government Publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein.

Unless otherwise specified, the issues of these documents shall be the current edition at time of solicitation.

COMBINED FEDERAL REGULATIONS

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

29 CFR 1915 -------------------------------- Occupational Safety and Health Standards for Shipyard Employment

40 CFR 82 ----------------------------------- Protection of Stratospheric Ozone

(Copies available online at http://www.gpo.gov/fdsys)

LOCAL ATTACHMENTS

Attachment A ------------------------------- Site Specific Regulations

(Copies attached to the solicitation)

2.3. Non-Government Publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents shall be the current edition at time of solicitation.

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION

ISO 4414 ------------------------------------- Pneumatic Fluid Power - General Rules and Safety Requirements for Systems and Their Components

(Copies available at http://webstore.ansi.org/ or American National Standards Institute, Dept. 969, 1430 Broadway, New York, NY 10018)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION

NEMA MG 1 ------------------------------- Motors and Generators

NEMA Z535.4 ------------------------------ Product Safety Signs and Labels

NEMA 250 ---------------------------------- Enclosures for Electrical Equipment (1000 Volts Maximum)

(Copies available at http://www.nema.org or National Electrical Manufacturers Association, 1300 North 17th Street, Suite 1752, Rosslyn, VA 22209)

NATIONAL FIRE PROTECTION ASSOCIATION

NFPA 70 ------------------------------------- National Electrical Code

NFPA 79 ------------------------------------- Electrical Standard for Industrial Machinery

NFPA 86 ------------------------------------ Standard for Ovens and Furnaces

(Copies available at http://www.nfpa.org or NFPA, 1 Batterymarch Park, Quincy, MA 02169)

2.4. Order of Precedence. Unless otherwise noted herein or in the contract, 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 regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1. Design. The item offered shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. 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.

3.1.1. New Developments. The contractor shall identify any new developments that would improve the efficiency, accuracy or productivity of the equipment or would decrease its operating costs. The contractor shall notify the Contracting Officer and technical POC in order that the new developments may, at the Government's option, be included in the equipment. Reports of such developments shall be addressed to the Contracting Officer.

3.1.2. Measuring and Indicating Device Graduations. All measuring and indicating devices on the Pit Furnace shall be graduated in the inch/pound or both inch/pound and metric.

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

3.1.4. OSHA Compliance. The equipment installation and its component parts shall be in compliance with 29 CFR 1910, NFPA 70, NFPA 79 and NFPA 86. 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.

3.1.5. 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.

3.1.6. Safety Guarding. Covers, guards, or other safety devices shall be provided per NFPA

86. The safety devices shall not interfere with the operation of the Pit Furnace. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

3.1.7. Audible Noise Level. Audible noise emitted by the equipment shall not exceed 85 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 85 dB requirements.

3.1.8. Hazardous Material Exclusions. Supplies or materials being provided as part of the equipment shall be free of known hazardous materials. Hazardous materials shall not be brought on site without prior approval of the Government Point of Contract and cognizant shipyard personnel. Hazardous materials not needed for this project are prohibited.

Definitions of hazardous materials are specified in the latest version, including revisions adopted during the term of the contract, of FED-STD-313. Notwithstanding any other hazardous material usage permitted in this contract, 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. 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.

3.1.9. Environmental protection. Under the operating, service, transportation, and storage conditions described herein, the Pit Furnace shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

3.1.10. Lubrication. Means shall be provided to ensure adequate lubrication for all moving parts. Recirculating lubrication systems shall include a filter that is cleanable or replaceable.

Each lubricant reservoir shall have at least a 24-hour capacity. When a low lubricant level condition occurs, the machine shall complete the current operation and come to a complete stop. When a low oil pressure condition occurs in a continuously pressurized system, the machine shall enter an emergency stop condition. The machine shall indicate that oil or lubrication is required. All oil holes, grease fittings, and filler caps shall be accessible. A lubrication plate shall be securely attached to the equipment, see 3.6.1.

3.1.11. 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.

3.2. Construction. The Pit Furnace 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 Pit Furnace to its maximum rating and capacity without distortion.

3.2.1. 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.

3.2.2. 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.

3.2.3. Threads. All threaded parts, either US or SI, used on the Pit Furnace and its related attachments and accessories shall conform to FED-STD-H28B and the applicable "Detailed Standard" section referenced therein.

3.2.4. 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.

3.2.5. 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.

3.2.6. 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 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.

3.2.7. Workmanship. Workmanship of the Pit Furnace 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. Components. The Pit Furnace shall consist of not less than

3.3.1. Furnace Control Enclosure. The furnace control enclosure shall have a hinged front door and interior sub panel. The panel shall contain a programmable temperature controller, a high temperature limit controller with manual reset, a silicon-controlled rectifier “SCR”, a control circuit rectifier, an over temperature disconnect contactor, an over temperature alarm and silencing relay and all sub-components necessary to control the furnace.

3.3.1.1. The programmable temperature controller.

3.3.1.1.1. Shall be capable of storing 20 recipes (minimum).

3.3.1.2. The high temperature limit controller shall shut off the heat to protect the furnace from an over-temperature condition. The controller shall have a digital set point and display.

3.3.1.3. The SCR shall control the power to the heating elements.

3.3.2. Furnace Body. The furnace body consists of the outer shell, bottom, top plate, refractory lining, heating elements, and lid.

3.3.2.1. The outer shell sidewall shall be constructed from 3/16 inch thick steel plate. The shell shall be reinforced with structural steel members.

3.3.2.2. The bottom shall be constructed from 3/8 inch steel plate.

3.3.2.3. The top plate shall be constructed from steel and shall be bolted to the shell.

3.3.2.4. The heating elements shall be the rod overbend style.

3.3.2.5. The lid shall be steel. The lid seals to the retort. The lid suspends the circulating fan inside the retort.

3.3.2.5.1. The lid shall be pneumatically operated. The pneumatic system shall conform to ISO 4414. The lid opening device shall lift the lid assembly clear of the retort and rotate the lid assembly away, to provide clear unobstructed crane access to the inside of the retort.

3.3.3. Retort. The retort shall be fabricated from Inconel and shall be plumbed for single pass freshwater cooling and shall include nitrogen gas connection.

3.3.3.1. The retort shall be outfitted with lifting lugs to facilitate removal.

3.3.3.2. The work zone shall accept work baskets 24 inch diameter x 36 inch height.

3.3.3.3. The retort shall seal to the furnace lid.

3.3.4. Circulating Fan. The atmosphere circulating fan shall be water cooled.

3.3.5. Electrical Disconnect. The main electrical disconnect shall be provided as part of this is an energy isolating device which shall be rated for 240 VAC, 3 phase, 400 Amps. The enclosure shall be NEMA rated.

3.3.6. Energy Isolating Devices. The equipment shall be provided with energy isolation devices (e.g. power switches, safety devices, circuit breakers, valves) that protect personnel from the release of hazardous energy and are integral to the component being isolated and locked out. The devices shall be designed and manufactured such that they can be padlocked in the OFF position. This includes both mechanical and electrical devices. An energy isolation device shall be installed as the first energy control device on all major components of the system such that the component can be isolated at the component level.

3.3.7. Electrical System. The machine shall conform to NFPA 70 and NFPA 79. The existing electrical power source available at the installation site is 230 Volts, 3 phase, 400 Amps. The machine’s electrical system shall be tolerant of voltage fluctuation of ± 10 percent. The electrical system shall be complete, including transformers required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device, controlling all electrical power to the equipment, shall be utilized on the machine with means of lockout in the off position only. A surge protection device “SPD” shall be installed in the furnace controller or the machine disconnect. The SPD shall be capable of interrupting maximum available fault current.

3.3.7.1. Motors. Motors shall be rated for continuous duty and shall have ball or roller bearings of the sealed and permanently lubricated type. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors 1 HP and above shall meet the requirements of NEMA MG 1. Each motor shall have an identification plate to identify manufacturer, model identification, serial number, voltage, amperage, horsepower, phase, frequency and frame number written in the English language. Servo motors are exempt from these requirements. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s), unless otherwise specified herein.

3.3.7.2. Solid-State Components. Solid-state design shall be employed throughout for electronic components. Use of selenium and other similar aging devices shall be permitted only in the application of voltage surge protection to other solid-state components. Solid-state components shall not be adversely affected when subjected to power line transients and surges typically experienced in industrial environments. Series and parallel connections of solid-state devices without forced sharing circuitry for voltage and current, respectively, is not permitted. Solid-state devices shall be capable of handling the electrical load imposed by operation of the machine to its maximum capability.

3.3.7.3. Electrical Enclosures. Electrical components of the equipment shall be contained in enclosures of drip-proof construction and of minimum size consistent with good design practices and ventilation of components, and shall be NEMA rated.

3.3.7.4. Cable and Hose Carriers. All flexible power lines, cables, conduits, and hoses necessary to connect the linear sliding, powered, assemblies to stationary utilities and controls shall be contained within a flexible cable and hose carrier arrangement.

Conductors located on the cable and hose carrier shall be adequately cradled or secured at regular intervals and in an orderly manner. Cable and hose carrier design shall ensure that flexible conductors are not stretched, crimped, pinched, or scraped over the full travel of the track. A guide arrangement shall be provided to insure straight motion of the track, parallel to slide motion, without twist or binding. Each cable and hose carrier shall be located in a position that will allow access and egress to the operator and control panel without interference as well as afford the best possible protection of the conductors. All conductors shall be of sufficient length to allow full travel of connected components and shall be connected at both ends to junction boxes and manifolds in proximity to the track ends to facilitate replacement of conductors. All conductors shall be labeled at both ends.

Installation of the cable and hose carrier s in the overhead position is not allowed.

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

3.3.7.6. Hour Meter. The Pit Furnace shall be equipped with an analog hour meter mounted on the furnace control enclosure panel visible from the outside. A digital hour meter embedded in the controller shall be acceptable. The hour meter shall be installed to display accumulated operating time of the furnace heating elements. The meter shall be of the non-resetting type and shall have a range of 0 to 99,999.9 hours in increments of 0.1 hours, and shall revert to zero (0) upon reaching the maximum count. All analog hour meter shall have a NEMA enclosure rating, and shall be mounted to withstand shock and vibration generated by the equipment in an accessible location.

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

Table I Size and Capacity Maximum Installation Space for Furnace (W, L,Pit Depth) W=78 inches L=88 inches Pit

Depth = 90 inches Maximum Installation Space for Control Enclosure (W,D,H)

60 inches, 20 inches, 72 inches

Minimum Work Zone (Diameter, H) 24 inch dia, 36 inch H Gross Work Load 1650 lbs (minimum) Operating Temperature 850°F – 2000°F

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

Table II Alignment and Accuracy 850F – 1950F +/- 25F (Class 5 furnace)

3.6. 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.

3.6.1. 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 applicable) Size and type of each lubricant filter

3.6.2. 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, full load amps “FLA”, phase, frequency) Short Circuit Current Rating “SCCR” Contract Number or Order Number Date of manufacture

3.6.3. 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.

3.7. Technical Data. Three (3) hard copies and one (1) searchable electronic copy of the following technical data shall be provided with the machine.

3.7.1. Operating and Maintenance (O&M) Manuals. O&M Manuals shall contain technical information, 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. 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.

i. All final “as-built” contract drawings shall be provided on CD or DVD disc(s). The format of the drawing files shall be in AutoCAD version 2010 or older. Files shall have DWG or DXF extensions.

3.7.2. OSHA Approved Certification. The equipment and its installation specified herein shall be inspected, approved as defined in 29 CFR 1910.399, and labeled by a Nationally Recognized Testing Laboratory (NRTL) as defined in 29 CFR 1910.7. The NRTL inspection shall include validation of the OSHA compliance requirements in paragraph 3.1.4. A satisfactory NRTL Field Evaluation Report shall be provided to the receiving activity after equipment delivery and installation, and prior to destination testing.

3.7.3. Test Data Results Used for Evaluation of Equipment to Meet Specification Requirements. The Contractor shall submit a written test report of all tests and results conducted at origin and destination. The test report shall be submitted within 10 working days after the tests are performed.

3.8. Installation. Contractor shall be responsible for attached Installation Responsibilities chart and Local Documents Attachment A for site specific facility requirements.

3.8.1. Structural Installation. The Contractor shall accurately set, align, plumb, field connect with sufficient bolts, or weld all structural steel required to make installed equipment permanent. Temporary bracing shall be provided, and subsequently removed, as necessary.

3.8.2. Mechanical Installation. The Contractor shall provide all labor, fluids, piping, interconnecting hoses, and any other materials to move, locate, set level, align, lubricate, and make ready to operate all equipment required by this contract. All machinery shall be installed to original manufacturer's tolerances.

3.8.3. Electrical Installation. The Contractor shall provide all labor, wiring, cables, disconnects, connectors, and any other materials for complete installation of any requisite electrical equipment from the government point of delivery. Installation shall include necessary power, control, and interconnecting wiring installed in conduit.

3.8.4. Installation/Foundation Drawings. The drawings shall contain at least, but shall not be limited to, the following information and requirements of Attachment A:

a. Overall and principal dimensions in sufficient detail to establish limits of space in all directions required for installation, operation and servicing. See Table 1 for maximum allowable footprint.

b. Amount of clearance required to permit opening of doors and removal of plug-in units

c. Clearance for travel or rotation of any moving parts

d. Interface mounting and mating information, such as dimensions of location for attaching hardware, and meet the manufacturer vibration design requirement

e. Interface pipe and cable attachments required for installation and co-functioning of the item to be installed with related items

f. Mounting place details, hardware requirement lists, drilling plans and shock mounting buffers

g. Weight of each component and total unit

h. Location, type and dimensions of cable entrances, terminal boards, electrical connectors, and ducts

i. Interconnecting and cable detail

j. Peak electrical load (Amps) requirement to support all proposed equipment in its fully configured and operational state, including all accessories

3.8.4.1. Installation/Foundation Drawings (Preliminary Submission). Not later than sixty (60) calendar days after effective date of contract, installation drawings shall be provided with soft metric measurements using the manufacturer’s standard format. An electronic copy shall also be provided in DWG or DXF format and download to AutoCAD 2010 version or older. The Government shall notify the contractor in writing within ten

(10) working days of receipt of drawing if they comply with this specification. If revisions are required, the contractor has ten (10) working days to make revisions and resubmit for a new review. Rejection of drawings does not relieve the contractor from final delivery date of contract performance period.

3.8.4.2. Installation/Foundation Drawings (Final submission). Submission of final installation/foundation design drawings shall be not later than sixty (60) calendar days of Government acceptance of preliminary drawing. These final drawings shall bear a complete title block with a permanent drawing number, signature, date, and an original stamp or seal of a Professional Engineer (PE) licensed in the state of the receiving activity where the equipment will be installed. The final drawing submission shall include an engineering report with structural calculations used in the design. The engineering report shall also be stamped by a PE. The Government shall notify the contractor in writing within ten (10) working days of receipt of drawing if they comply with this specification. If revisions are required, the contractor has ten (10) working days to make revisions and resubmit for a new review. Rejection of drawings does not relieve the contractor from final delivery date of contract performance period.

3.9. Hazardous Energy Control (HEC) Program, Lockout/Tags-Plus (LOTP). HEC/LOTP shall be accomplished in accordance with OSHECM Chapter 250 and 29 CFR 1915.89.

3.10. Training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is a United States citizen proficient in the English language, shall be provided for specialized training to familiarize receiving activity personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage. The training shall be for number of operators and be performed at customer facility and shall not be less than one 8-hour workday, between 7:00 am and 3:30 pm excluding any 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 at no additional cost to the government, and be in the English language.

4. QUALITY ASSURANCE

4.1. Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein. Except as otherwise specified in the contract or purchase order, the contractor may use his own facility or any other facility suitable for the performance of the inspection requirements specified herein, unless disapproved by the Government. Only supplies that totally conform to the specifications shall be offered for inspection and test. The contractor's test schedule shall allow consecutive inspection and test of the supplies offered. The Government reserves the right to charge the contractor for any Government re-inspection cost when supplies are not ready at the time requested by the contractor or when necessitated by prior rejection. The Government reserves the right to perform any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

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

4.2. 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).

4.3. Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient conditions of 55 degrees F to 100 degrees F and 10 percent to 95 percent relative humidity.

4.4. 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 shall be fully assembled and perform all functions in accordance with this specification. Quality assurance inspection shall consist of the examination in 4.6 and the tests in 4.7. The machine shall pass the examination, all tests, and the contract quality assurance inspection to be acceptable for shipment. At the option of the Government, tests may be witnessed by technical representatives of the receiving activity.

The Contractor shall notify the Government Point of Contact of the scheduled date, time, and location of the tests.

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

The acceptance test shall be performed only after the Pit Furnace 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, all tests, and the final inspection to be accepted.

4.6. Examination. The Pit Furnace shall be examined to determine compliance with all requirements of this purchase description.

4.7. Operational Test. The Pit Furnace shall be operated at no load for not less than four hours. Proper operation of all controls, motors, adjusting mechanisms, and accessories shall be verified during the trial period.

INSTALLATION RESPONSIBILITIES

Government Contractor

(XX) ( ) a. Provide machine foundation in accordance with the manufacturer's design requirements.

(XX) ( ) b. Disconnect all electrical, gas, air, and water connections to Furnace #9 and Furnace #9 electrical disconnect.

( ) (XX) c. Remove Furnace #9 electrical disconnect, Furnace #9 controller, and Furnace #9.

( ) (XX) d. Dispose Furnace #9 electrical disconnect, Furnace #9 controller, and Furnace #9.

( ) (XX) e. Furnish labor and material handling equipment for off-loading and placing item on foundation.

( ) (XX) f. Provide and install anchor bolts and nuts.

( ) (XX) g. Set and rough level the machine on its foundation.

( ) (XX) h. Level and align machine.

( ) (XX) i. Connect machine to the provided utilities hook-up.

( ) (XX) j. Provide all necessary tools, gages, and instrumentation necessary to perform the required tests.

( ) (XX) k. Provide and charge all systems with fluids in accordance with manufacturer's instructions.

(XX) ( ) l. Material for performance testing at Government facility.

( ) (XX) m. Material for performance testing at Contractor's facility.

Attachment A, Site Specific Requirements for

Puget Sound Naval Shipyard & IMF, Bremerton Site and Naval Base Kitsap

A-1

SCOPE

1.1. Scope. This attachment covers the site specific requirements of Naval Base Kitsap (NBK) and Puget Sound Naval Shipyard & Intermediate Maintenance Facility (PSNS & IMF) for contract work.

2. APPLICABLE DOCUMENTS

2.1. General. The following documents form a part of the site specific requirements to the extent specified herein.

2.2. Washington Administrative Code (WAC)

WAC-173-303 Washington Dangerous Waste Regulations

WAC-173-60 Maximum Environmental Noise Levels

WAC-173-304 Minimum Functional Standards for Solid Waste Handling

(Copies are available online at: http://apps.leg.wa.gov/wac/)

2.3. Code Of Federal Regulations (CFR)

29 CFR 1910.141 Sanitation

29 CFR 1910.146 Permit-Required Confined Spaces

29 CFR 1910.1200 Hazard Communication

29 CFR 1926.1153 Respirable Crystalline Silica

40 CFR Part 82 Protection of Stratospheric Ozone

40 CFR Part 89 Control of Emissions from New and In-Use Non-Road Compression- Ignition Engines

(Information is available at: http://www.ecfr.gov/cgi-bin/ECFR?page=browse)

2.4. American Society of Mechanical Engineers (ASME)

ASME B30.26 - 2015 Rigging Hardware

ASME BTH-1 - 2017 Design of Below-the-Hook Lifting Devices(Information is available at: https://www.asme.org/)

2.5. American Society for Testing and Materials (ASTM)

ASTM E709 – 17 Standard Specification for Structural Steel

(Information is available at: https://www.astm.org/)

2.6. American Welding Society (AWS)

Puget Sound Naval Shipyard & IMF, Bremerton Site and Naval Base Kitsap

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D1.1/D1.1M:2006 Structural Welding Code – Steel

(Information is available at: http://www.aws.org/technical/d1/D1scope.pdf)

2.7. Military Standards

MIL-STD-2035 Nondestructive Testing Acceptance Criteria

(Information is available at: https://assist.dla.mil/online/start/)

2.8. Unified Facilities Criteria (UFC)

UFC 3-430-07 Operations and Maintenance: Inspection and Certification of Boilers and Unfired Pressure Vessels

2.9. PSNS & IMF

Contractor Guide to Environmental and Safety Compliance

(Contact the Receiving Activity’s Point of Contact to obtain a copy of the guide)

2.10. NAVAL FACILITIES ENGINEERING COMMAND (NAVFAC)

NAVFAC P-307 Management of Weight Handling Equipment (June 2016)

(Copies available online at http://www.navfac.navy.mil/navfac_worldwide/specialty_centers/ncc/about_us/resources/ p307.html)

3. REQUIREMENTS

3.1. Prior to commencing work. The Contractor representative(s) shall meet in conference with the Receiving Activity’s Point of Contact, shop supervision, and other necessary Shipyard personnel to discuss and develop mutual understandings relative to environmental, safety, methods and schedules, security, waste management, and any other subject necessary for a smooth and successful execution of this contract. This meeting shall be held at the Receiving Activity within 30 business days of contract award.

3.2. Methods and schedules. The work shall be executed in a manner and at such times as to cause the least practicable disturbance to the occupants of the buildings and normal activities of the Shipyard.

3.3. Plan of Action and Milestones. Within 30 business days of contract award the Contractor shall provide a Plan of Action and Milestones (POAM) detailing key events with dates of the following:

a. Design

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b. Manufacturing

c. Equipment Delivery

d. Equipment Set-up/Installation

e. Equipment Testing

f. Training

g. Final Completion Date

3.4. Field Supervisor. The Contractor shall provide a full-time (start of installation to final acceptance) Field Supervisor to direct installation and testing of the equipment. The Field Supervisor shall be capable of reading, writing, and conversing fluently in the English language and have full authority to implement field decisions expeditiously. No work shall be accomplished when the Field Supervisor is not in the immediate work area. The Field Supervisor shall be identified to the Receiving Activity’s Point of Contact prior to the start of the installation and be responsible for coordinating security clearances of all Contractor personnel expected to perform on-site work. The Receiving Activity’s Point of Contact shall be notified of any change in personnel performing this duty.

3.5. Calibration. The Contractor shall provide calibration control instructions for each calibrated item.

3.6. Outages and permits. The Government’s process of review/approval for Utility, Area, and Track Outages may take up to 20 business days from the date the Contractor provides acceptable drawings, forms, and any other required information to the Receiving Activity’s Point of Contact.

3.7. Excavation or drilling. An Excavation Permit request form will be provided to the contractor by the Receiving Activity’s Point of Contact. Prior to any excavation or drilling, the contractor shall:

3.7.1. Perform a Locate Service Survey of the installation site to locate and identify any subsurface interference(s). A copy of the Subsurface Interference Survey Report and a completed Excavation Permit form shall be provided, in electronic format, to the Receiving Activity’s Point of Contact for review, and approval by NAVFAC, no later than 20 business days prior to the start of excavation or drilling.

3.7.2. Post the approved Excavation Permit onsite from the beginning of excavation or drilling through completion.

3.7.3. Concrete excavation and drilling shall be accomplished in accordance with the process applicable section of 29 CFR 1926 Respirable Crystalline Silica.

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3.7.4. Construct adequate containments around the excavation or drilling site to minimize dust, and to prevent foreign material from becoming airborne, and intrusion on or into existing equipment in the vicinity.

3.7.5. Two Waste Information Sheets (WIS, Section 8.2) shall be submitted for concrete cut water. One for pH less than 11, and one for pH 11 or greater. The Environmental Safety and Health Office (Code 106.33) will classify each type of concrete cut water. The Contractor shall supply the pH test strips for determining pH level of concrete cut water

3.7.6. Upon completion of excavation or drilling, the Contractor shall provide the information on the Excavation Permit indicating completion and submit the permit to the Receiving Activity’s Point of Contact for closing.

3.8. Building columns. Welding, drilling, cutting, or clamping to original building columns and column bracing is restricted. Prior to performing any of these evolutions, the Contractor shall submit a request to the Receiving Activity’s Point of Contact for approval. The request shall include locations, components, materials, static loads, dynamic loads, moment forces, and structural calculations demonstrating that the load will not adversely affect the structural integrity of the column or its bracing.

3.9. Internal combustion engine operation inside buildings. The Contractor shall utilize the following ventilation controls when operating internal combustion engines inside buildings:

a. Open doors, windows, roof vents, and/or use blowers or other mechanical systems to move fresh air through work areas. In the event internal combustion engines will be operated for more than 30 continuous minutes, the receiving activity’s Environmental, Safety, and Health Department shall be notified in advance to survey the area to ensure there is adequate ventilation.

b. When operating internal combustion engines longer than 30 continuous minutes with less than 3 minutes between operations, attach an approved ventilation exhaust hose and exhaust the fumes to the exterior of the building where they cannot re-enter the workplace.

Regularly inspect the hose for defects and damage, and repair or replace as required. The Contractor shall provide an engineering solution for the use of long exhaust hoses to prevent engine back pressures.

c. Ensure internal combustion equipment is properly maintained and routinely inspected to minimize exhaust emissions.

d. Use of internal combustion equipment shall be coordinated with the Building Manager. This pre-planning will help ensure that indoor air quality issues are minimized.

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3.10. Non-Road Engines. All non-road engines rated 50 horsepower and above shall be identified to the Receiving Activity’s Point of Contact prior to being brought on to PSNS & IMF or NBK to prevent violation of Title V, Air Operating Permit. C/106.31 will determine the need for additional air pollution controls when using non-road engines (i.e.

skid or trailer mounted generators and pumps).

3.11. Boilers and Unfired Pressure Vessels. Boilers and unfired pressure vessels which meet the below criteria shall be identified to the Receiving Activity’s Point of Contact prior to being brought onto PSNS & IMF or NBK. The boilers and unfired pressure vessels that meet the below criteria shall be certified in accordance with UFC 3-430-07 Inspection and Certification of Boilers and Unfired Pressure Vessels.

a. Greater than 5 cu ft in volume and 250 psi design pressure

b. Greater than 3 cu ft in volume and 350 psi design pressure

c. Greater than 1-1/2 cu ft in volume and 600 psi design pressure

3.12. Utilities. Reasonable amounts of shop air (80-90 psi) and electricity (120 Volt) will be made available adjacent to the installation site at no cost to the Contractor. The Contractor shall be responsible for any costs incurred in connecting, converting and transferring the utilities to the work.

3.13. Storage. Lay-down area(s) will be provided within the vicinity of the installation site for storage of Contractor’s materials and tools. The Contractor shall submit an Area Outage Request to the Receiving Activity’s Point of Contact no later than 20 business days prior to the outage date. The Government does not accept responsibility for security of Contractor’s materials or tools. The area must be kept clean and orderly, free of rags, paper, and other debris. Failure to maintain the area in a clean condition may result in the loss of the area. The Contractor shall be responsible to restore the storage area to original condition after use.

3.14. Contractor Training. The following training is available for Contractors whose work requires it. The training classes are held on Naval Base Kitsap (NBK) and are provided at no cost to the Contractors. For access to NBK see section “Access to NBK”.

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3.14.1. Contractors that anticipate generating or encountering hazardous waste during the performance of this contract shall attend Site Specific Hazardous Waste Accumulation Area Operator Training for Contractors, Course HW49 prior to generation of waste. This training is typically held on the third Thursday of each month and is approximately three

(3) hours in length. 5-business days prior to training the Contractor shall provide a list of names to the Receiving Activity’s Point of Contact of those who will be attending the training. The Receiving Activity’s Point of Contact will coordinate this training with the Shipyard Environmental, Safety, and Health Office (Code 106.33).

3.14.2. Any welding, burning, flame cutting or grinding occurring at PSNS & IMF or NBK requires a Hot Work Permit and Fire Watch Training. This training is typically held on the third Thursday of each month, is approximately one (1) hour in length, and is provided without charge. 5-business days prior to training the Contractor shall provide a list of names to the Receiving Activity’s Point of Contact of those who will be attending the training. The Receiving Activity’s Point of Contact will coordinate this training with the Shipyard Fire Inspector.

3.15. Lifting and rigger services. The use of privately owned cranes, multi-purpose machines, material handling equipment, or other construction equipment that may be used in a crane-like application to lift suspended loads on NBK and PSNS & IMF property by Contractor personnel is restricted (see NAVFAC P-307 Management of Weight Handling Equipment for information and forms). Contractors requiring this type of equipment in the performance of this contract shall provide the Receiving Activity’s Point of Contact with sufficient information (crane manufacturer documentation of maximum axle loads in a traveling configuration, crane manufacturer documentation of maximum outrigger loads (loaded and unloaded), compliance certification, crane certification, operator qualifications, crane wire certification, lifting sketches and designs, loads, locations, time, etc.) at least five (5) business days prior to equipment arrival for arranging Government inspection services and approvals. The Contractor shall furnish labor and provide all material handling and lifting equipment, rigging support services, and other support equipment (such as cranes, forklifts, Bobcats, man-lifts, etc.) necessary for continuous support of the installation and shall provide qualified personnel to operate it.

3.16. Crane clearance envelope. To allow for the safe travel of overhead traveling cranes, jib cranes, and hoists the Contractor shall not modify existing buildings or place equipment or temporary structures in any way, which would affect the working envelope of overhead traveling cranes, jib cranes, and hoists. Minimum clearances for working envelopes are:

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3.16.1. Top clearance. A minimum of three (3) inches between the highest point of the crane and the lowest overhead obstruction must be maintained. In areas where truss sag may become a significant factor, the Government will evaluate the need to increase the minimum clearance.

3.16.2. Side clearance. A minimum of two (2) inches between the end of the crane and side obstructions (building columns, knee braces, walls, etc.), assuming the crane is skewed in the worst case situation on the runway rails or when jib cranes are rotated, shall be maintained. Piping, electrical conduits, etc. must not reduce this clearance.

3.17. Lift points. The equipment shall be readily liftable via lift points meeting the requirements of this section to allow lifting by crane during equipment off-loading, installation, operation, and removal. Lift points shall be located, designed, and marked per the following to ensure the equipment is readily liftable when it arrives.

3.17.1. Integral (i.e., not bolt-on), lifting point items such as lugs, thru-holes, pad-eyes, trunnions, and ISO…