SOW.pdf

McAlester Army Ammunition Plant Quality Assurance Test Division

JMMC-QAT

1 C Tree Road McAlester, OK 74501-9002

STATEMENT OF WORK (SOW)

FOR

Conveyance and Ball Bearing Tables for a 450kv X-ray System

MCAAP JO/PCN:

09 December 2015

1. SCOPE

This statement of work outlines the requirements for the purchase and successful integration of an electrically powered conveyor system for an existing 450kV x-ray vault with x-ray source and digital imaging panel detector at McAlester Army Ammunition Plant (MCAAP). The conveyor and ball bearing tables will enable the x-ray system in digital format, to radiographically inspect (DRI) munitions such as 120 mm mortars.

Contractor work activities described in this SOW shall be co-supervised by a Contracting Officer’s Technical Representative (COTR) and MCAAP’s Administrating Contracting Officer.

The equipment furnished under this Statement of Work (SOW) shall be fabricated and constructed by a manufacturer regularly engaged in the production of this type of equipment and it shall be of the manufacturer’s design and carried in stock, or producible within a 180 day period of time. The supplier shall previously have made and supplied this type of equipment to industry, other than for his own use.

2. SYSTEM REQUIREMENTS

2.1 Conveyor System. The electrically powered conveyor system shall move the 120mm mortars in the vertical/upright position loaded in provided conveyor racks from a conveyor loading station to the x-ray vault, through the x-ray inspection operation, and moving the x-rayed projectiles to a conveyor offloading station and to a rack return conveyor/ball bearing table. Reference MCAAP DEE drawing number SK1433.

Conveyor belts, if used, shall be conductive.

2.1.1 The conveyor shall be comprised of separate sections, which may be controlled either independently or together. At a minimum it shall have one section from the projectile loading station to the x-ray vault, one section inside the x-ray vault, and one section from the x-ray vault to the unloading station. A fixture rack return ball-bearing top table and a conveyor shall be provided that will return the unloaded fixture racks to the loading station to repeat the process. It shall be equipped with sensors that allow bridging of sections automatically as product transfers.

The conveyor operation shall be integrated for continuous, safe, and successful operation with the existing x-ray inspection system. The conveyor operation shall be electrically-powered and have a stand-alone or remote control console, which will independently function manually with the operating tools to provide full conveyor control. The conveyor will be capable of coming to a full stop, reversing its motion, and re-starting motion depending on the discretion of the inspector/operator.

Safety features must be provided at the projectile loading and unloading stations that provide a visible warning that the conveyor is ready to move and prevent advancement until both the load and unload operators press and release a control. Emergency stops are to be provided at all locations deemed necessary for safe operation; at a minimum include the control room, the conveyance area inside the annex, and at the primary building where conveyance adjoins.

A minimum of two (2) ball-bearing tables will be provided with dimensions of 4 foot x 15 foot and 4 foot x 18 foot (minimum). The conveyor and ball bearing table system shall be of sufficient construction strength, design, and durability to be rated two (2) times as strong as the minimum weight, gage, or load rate required to ensure total system reliability and reduce premature deterioration from wear and fatigue.

In order to allow access to the flat panel detector, the conveyor shall be hinged or otherwise modified to allow a section to be moved in order to allow access to the imaging panel and panel manipulator inside the x-ray vault. The conveyance system shall be designed for maximum throughput, durability, and stability. It shall be designed to not allow munitions that are to be radiographically inspected to tip, fall, or otherwise drop from the respective surfaces to the floor.

2.1.2 The conveyor system shall have color cameras to cover the full length of the conveyor and inspection operation (a minimum of six (6) color digital cameras) and provide a minimum of six (6) color monitors (10 inch screen minimum) in the x-ray control room for continuous monitoring. Cameras inside the x-ray building shall be commercially available cameras.

2.1.3 The existing Government provided vault has two (2) openings for conveyor access that measure approximately 50 inches tall and 33 inches wide, aligned with one another and on opposing walls. The distance from the centerline of the conveyor openings and the primary or x-ray target wall is approximately 50 inches. The digital flat panel detector and its shielded holding fixture/manipulator will be located in this area of the vault, between the conveyor and the primary or target wall. The base of the conveyor openings is approximately 31 inches from the floor.

2.1.4 The contractor will provide a control console that will provide the x-ray inspection personnel a manual means of opening and closing the conveyor doors to provide access to the vault during the radiographic exposure, and work in conjunction with the vault radiation safety interlocks. The console must have a light to visually indicate and verify the conveyor doors in the completely open and completely closed position from the remote x-ray control room.

2.2 Cable Lengths. Cable lengths for all applicable equipment are to be determined by the contractor via review of MCAAP DEE drawing SK1433. All applicable and connecting service and operational cables from the inspection viewing/control room to the 450kV vault/enclosure and the equipment therein shall be mounted or laid in an adjoining contractor provided and installed overhead cable tray. Contractor is to ensure all required cables are of adequate continuous length with no splices or breaks allowed with the correct cable end terminations provided.

2.3 Performance Requirements. The conveyor system shall provide for x-ray of the mortars in the vertical/upright orientation.

The conveyor system shall be built for mass production and high speed volumes with a minimum throughput rate of one (1) projectile per 90 seconds for 120MM mortar inspection. Production rate is 340 rounds per 10 hour shift for 120MM mortar rounds.

Intended use of the system is 15 years. Provide in quotes a spare parts list for high wear, low life expectancy items.

3.0 GOVERNMENT SUPPLIED MATERIAL

MCAAP will provide the control room which will house the x-ray inspector’s workstations and system controllers in addition to the x-ray imaging panel (Perkin Elmer XRD 1620 AN15 CS or equivalent), 450 kV shielded vault, and 450kV (Varian HPX- 450-11) x-ray tube. See MCAAP DEE drawing number SK1433 for building layout and electrical plan. Electrical service will be provided to the building bay by MCAAP.

Contractor is responsible to provide all other electrical materials, conduit, and service to install x-ray components and conveyor purchased under this statement of work. The government will also provide test projectiles required for the acceptance testing of the conveyor system. Contractor is responsible to provide all lifting, handling and rigging equipment, tools, etc., needed for the installation. MCAAP will provide no other materials or equipment.

4.0 SITE VISIT

Site visit shall be required by all prospective offerors. Contractors will be shown the building bay where the 450kV x-ray vault and control room are installed. The site visit date and time will be included in the solicitation.

5.0 PACKAGING AND DELIVERY

Equipment is to be delivered FOB Destination to McAlester Army Ammunition Plant, 1 C Tree Rd, Warehouse 8, Attn: Brad Black, McAlester, OK 74501-9002. Packaging and marking will be in accordance with ASTM-D3951.

6.0 INSTALLATION AND TRAINING

6.1 The contractor will install and integrate the complete conveyance and ball bearing table system at the McAlester Army Ammunition Plant. Tests will be witnessed by the

COTR.

6.2 The contractor will provide training to x-ray personnel, 8 persons, in operation of the conveyance system. Contractor will provide conveyor and repair training to two (2) MCAAP line mechanics. Training will be on site, McAlester, Oklahoma, and will be of sufficient depth and duration that MCAAP personnel can operate all components of the conveyor system without assistance from the contractor.

7.0 CONTRACT PERFORMANCE

7.1 Contractual Direction. Contractor performance to the requirements of this SOW shall be under the administrative direction of MCAAP’s Administrating Contracting Officer or their authorized representative. This direction includes all administrative direction, guidance, and approvals which establish all understandings and agreements between the contractor and MCAAP. Sole authority to make changes, revisions, or amendments on behalf of MCAAP and to effect deviations (by way of additions or deletions) from the work described herein rests with MCAAP’s Administrating Contracting Officer or their authorized representative. Any changes impacting scope or costs must be approved by MCAAP’s Administrating Contracting Officer or their authorized representative. Direction, guidance, and clarifications from such representative are valid only when confirmed in writing or electronic transmission when verified verbally. Acceptance of unauthorized direction may result in disallowance of cost.

7.2 Technical Direction. Contractor performance to the technical requirements of this SOW shall be under the technical direction of the COTR. Technical direction shall consist of guiding the contractor within the written parameters, and schedules of this SOW, as required to achieve the program objectives. Any deletions, additions, changes, or amendments to this SOW and any exhibits or documents referenced herein are not considered technical direction and shall not be implemented by the contractor unless confirmed in writing by MCAAP’s Administrating Contracting Officer.

8.0 DESIGN REVIEW

The government will hold a post award conference under direction of MCAAP’s Administrating Contracting Officer with the contractor, via teleconference, approximately 2 weeks after contract award to review the contract objectives and project schedule (paragraph 10.1). The government will perform design reviews via teleconference 90 days after contract award. Contractor is to provide an overview of progress against the schedule, presentation of completed and in-progress parts and drawings for designed items (conveyor system).

9.0 TEST AND ACCEPTANCE

9.1 Conveyor System. Initial product testing will be performed by the manufacturer at the manufacturing plant. The COTR may witness performance of factory tests and may review and obtain copies of the inspection procedures and records upon request.

Following installation at MCAAP, McAlester, Oklahoma, the COTR will perform on-site acceptance. The conveyor system will be tested in a manner of continuous operation at full rated production output for three hours. Less than 5-minute interruptions that can be reset by the control console operator shall not be considered equipment failure. The number of failures per test event allowed shall not exceed four per hour. If, in any period, this number is exceeded, the test is nullified and repeated. A sample lot of 120mm mortars will be inspected for a total of 340 inspections.

9.1.2 Durability: The system must demonstrate that it is functionally rigid and not shake, lean, leak, sway, bow, vibrate or bounce. Fasteners shall not work loose during operation and all items that will require maintenance must be easily accessible.

9.1.3 Ergonomics: The system must demonstrate that it ergonomically fits the 95th percentile of the work force, taking into consideration the elimination of bending, reaching, leaning, repetition, walking, lifting, or adjusting.

9.1.4 Inspection Rate: The system must demonstrate achievement of the inspection rate required in 2.3.

9.1.5 Critical issues that CAN NOT occur:

a. Part dropping or falling from conveyor or tables.

b. Electrostatic discharge.

9.2 Final Acceptance. Final acceptance of the complete system is determined by the

COTR.

10.0 DATA AND MANUALS.

10.1 Project schedule. Provide initial schedule, delineating project milestones and deliveries; to be provided within 30 days of contract award to MCAAP’s Administrating Contracting Officer.

10.2 Monthly Report. Provide a monthly contractor summary report to MCAAP’s Administrating Contracting Officer in the format agreed upon by the Government and the Contractor’s Integrated Product Team (IPT), with report due no later than the 15th of each month immediately following the reporting period. Include:

- Description of progress made against milestones during the reporting period.

- Results, positive or negative, obtained related to any previously identified problem areas with conclusions and recommendations.

- Problem areas affecting technical, schedule, or other elements, with background and any recommendations for solutions within and/or beyond the scope of the contract.

- Contract schedule status.

- Plans for activities during subsequent reporting period.

10.3 Final Project Report. Provide a final report at project completion, summarizing the project, accomplishment against SOW objectives and schedule.

10.4 Manuals. Provide 2 copies of operating and maintenance manuals for all conveyance system components, hard copy. Include in the documentation a listing of all parts, their respective identification number and/or manufacturer’s identification number and model number. Detailed drawings/schematics of full assemblies, sub-assemblies, system installation, and overall system operations will be provided. The drawings will be of a quality, completeness, and reference that provides MCAAP maintenance/repair personnel full understanding of the overall mechanical requirements for successful and maintained system operation.

10.5 Provide preventative maintenance lists and instructions for conveyor.

10.6 Provide 3 copies of electrical drawings for added electrical service from the breaker panels, 2 hard copies and one electronic DVD.

11.0 WARRANTIES AND UPGRADES

All equipment and software will be warranted free from defects in material and workmanship and shall perform in accordance with the product specifications for a minimum of twelve months from the date of product acceptance by the COTR. Warranty shal l include parts and labor.

During the warranty period the contractor is responsible for time and material (on-call) to conduct system repairs. The contractor shall respond to service calls with a service technician on-site within 48 hours.

12.0 CONTRACTOR REQUIRED TRAINING

12.1 All contractor employees to be on site, to include subcontractor employees, shall complete AT Level 1 awareness training within 30 calendar days after contract start date.

The contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee, to the MCAAP Contract Administrator within 5 days after completion of training by all employees and subcontractor personnel. AT Level 1 awareness training is available at the following website:

https://atlevel1.dtic.mil/at. All on-site contractor employees will also be required to complete Operational Security training at the direction of the MCAAP Security team.

12.2 Contractor and all associated sub-contractors employees shall comply with applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative). The contractor shall also provide all information required for background checks to meet installation access requirements to be accomplished by installation Security Office.

Contractor workforce must comply with all personal identity verification requirements as directed by DOD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any individual facility or installation change, the Government may require changes in contractor security matters or processes.

12.3 Per AR 530-1, Operations Security, new contractor employees must complete Level I OPSEC training within 30 calendar days of their reporting for duty. All Contractor employees must complete annual OPSEC awareness training.

12.4 The contractor and all associated sub‐contractors shall brief all employees on the local iWATCH, Corps Watch, or See Something, Say Something program (training standards provided by the requiring activity ATO). This local developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the COR. This training shall be completed within 30 calendar days of contract award and within 30 calendar days of new employees commencing performance with the results reported to the COR NLT 5 calendar days after contract award.

12.5 The Contractor shall develop an OPSEC SOP/Plan within 90 days of contract award.

The OPSEC SOP/Plan must be reviewed and approved by the RA OPSEC Officer. The SOP/Plan will include the government's critical information, why it needs to be protected, where it is located, who is responsible for it, and how to protect it. In addition, the contractor shall identify an individual who will be an OPSEC Coordinator.

12.6 The Prime Contractor Company must have (or will have) a Facility Clearance (FCL) at the appropriate level (IAW the NISPOM DOD 5220.22‐M and AR 380‐49) prior to the start of the contract awarded period of performance. Contractor personnel performing work under this contract must have the required security clearance, per AR 380‐67, at the appropriate level at the start of the period of performance. Security Clearances and FCL requirements are required to be maintained for the life of the contract IAW the DD254 attached to the contract. If no FCL, the supporting Government Contracting Activity will sponsor the prime contract company in obtaining the FCL.