Attachment 0001 - SOW.docx

Forward Repair System Air Compressor Overhaul Scope of Work (SOW) Revision 1 (dated 21 Nov 2019) Attachment 001

1. INTENT

The intent of this action is to establish a Three year IDIQ.

2. Background:

The Forward Repair System (FRS) is a mobile/deployable maintenance and repair shop used by the U.S. Army. The FRS contains an 80 gallon/50cfm air compressor used to supply air for on-board pneumatic tools, inflation of tires, and compressed air cleaning. The air compressor assembly is shown on drawing RIA149321, sheets 1-9. The air compressor base unit is an Ingersoll Rand model 7100. Drawing RIA149321 is provided for reference only. The air compressors have been in service in the field and are required to be overhauled.

3. Overhaul Requirements:

The contractor shall overhaul the FRS air compressor IAW the parameters outlined in this SOW. The contractor shall provide all tools, equipment, and supplies required to perform the overhaul. The air compressor assembly only will be supplied to the contractor for overhaul. The contractor is required to have an 80 gallon tank and the required electrical controls to Equipment Manufacturer (OEM) parts may be used for the overhaul process. The following four documents are included by attachment for overhaul reference:

a) Parts List T30 Model 7100 Two Stage Industrial Air Compressor (attachment A).

b) TM 9-4940-568-24P Field and Sustainment Maintenance Air Compressor Assembly parts list (Attachment B).

c) Ingersoll Rand 7100 Owner’s Manual, Ingersoll Rand Maintenance Pak Instructions (Attachment C).

d) TM 9-4940-568-23-2 Field Maintenance instructions (Attachment D).

A test report is to be prepared as the overhaul work is performed. A blank copy of the test report “A” and “B” are included. Mandatory initial evaluation/service and any additional repairs are also to be recorded. The reports are to be submitted when the overhaul is complete.

4. Mandatory Initial Evaluation/Service Process (CLIN 0001):

a. Cleaning- The air compressor shall be cleaned and degreased.

b. Overall condition inspection- Prior to performing any work, the air compressor overall condition shall be evaluated through a visual inspection. Items including, but not limited to the following are to be inspected and noted- broken/dented housings, cracked gauges, damaged electrical connections, obvious major damage to the compressor, etc. Approval to repair/replace components that are not listed as mandatory replacement parts must be obtained before proceeding with any further work, including mandatory initial evaluation/service.

c. The heater and thermostat are to be checked for proper operation. Appropriate power is to be applied to the thermostat. A temperature probe is to be used to ensure that the oil temperature reaches approximately 180 deg. F.

d. Oil change- The air compressor oil is to be drained and changed IAW Ingersoll Rand 7100 Owner’s Manual instructions.

e. Low oil switch - The low oil switch is to be checked for operation. A continuity check is to be performed on the switch prior to either draining or filling the unit with oil. A second continuity check is to be performed on the switch as the unit is either draining or filling with oil to ensure that the switch triggers properly.

f. Air filter change- The air filter is to be changed IAW Ingersoll Rand 7100 Owner’s Manual instructions.

g. V-belt change - The V-belts are to be changed IAW Ingersoll Rand Owner’s Manual instructions.

h. Replace after cooler and inner cooler safety/relief valves.

i. Pressure Switch Inspection- The pressure switch contacts are to be inspected for arcing/discoloration. The pressure switch is to be replaced IAW TM 9-4940-568-23-2 Air Compressor Pressure Switch Replacement if there is arcing/discoloration.

j. Valve inspection - The inlet and discharge valves are to be inspected. Valves are to be inspected for broken/cracked parts. Valves are to be cleaned, as required. Valves are to be maintained IAW Ingersoll Rand Maintenance Pak Instructions. Approval to repair/replace components that are not listed as mandatory replacement parts must be obtained before proceeding with any further work, including mandatory initial repair.

k. Fastener Torque - All fasteners shall be checked and tightened as required. The following fasteners are considered to be critical and must be tightened to specific torque values: high pressure head bolts, low pressure head bolts, high pressure inlet valve screws, low pressure inlet valve screws, high pressure outlet valve screws, low pressure outlet valve screws, and unloader cover fasteners. Fasteners are to be torqued IAW with the fastening sequences and values outlined in the Ingersoll Rand Maintenance Pak Instructions.

l. Set pressure switch. The pressure switch shall be set IAW TM9-4940-568-2 Air Compressor Pressure switch adjustment.

m. Pump-up Test- A pump-up test shall be performed on the air compressor to verify that unit is operating properly. The pump up test procedure is as follows:

1. Run unit for at least (45) minutes to bring up to operational temperature.

2. Drain receiver tank of all air pressure and water.

3. Start air compressor and monitor the time it takes the unit to come up to pressure.

4. Repeat this process a total of three times. Determine the average pump up time. The average pump up time must be between 2.55 and 3.20 minutes.

5. If pump up time is not between 2.55 and 3.20 diagnose the deficiency. Approval to repair/replace components that are not listed as mandatory replacement parts must be obtained before proceeding with any further work, including mandatory initial repair.

6. Re-torque all head bolts IAW with the fastening sequences and values outlined in the Ingersoll Rand Maintenance Pak.

7. Run Test- A (1) hour run test shall be performed on the compressor. Check for oil and air leaks at 0 minutes, 15 minutes, 30 minutes, 45 minutes, and 60 minutes. Note any irregular vibration, sounds, or other irregularities. If the unit does not pass the run test, diagnose the deficiency. Approval to repair/replace components that are not listed as mandatory replacement parts must be obtained before proceeding with any further work, including mandatory initial repair.

5. Mandatory Replacement Parts (CLIN 0002):

The following parts are mandatory replacement parts. They are to be replaced on all units, regardless of condition.

a. Approximately (3-4) quarts of oil, L245X Anderson Oil

b. (1) filter element, 84081N

c. (1) second stage head gasket, 32252801

d. (2) second stage spacer plate gaskets, 32252819

e. (1) second stage valve plate gasket, 32252827

f. (1) first stage head gasket, 32172926

g. (1) first stage valve plate gasket, 32172942

h. (1) low pressure manifold gasket, 32153801

i. (1) high pressure manifold gasket, 32153827

j. (1) inner cooler safety/relief valve, 72062185

k. (1) after cooler safety/relief valve, 32174286

l. (2) belts, 95369351

6. Unidentified Repairs (CLIN 0003):

If there are repairs that are needed, but were not identified in the scope, then the contractor is required to notify the Contracting Officer Representative (COR) and the Contract Specialist. The contractor shall provide an itemized report identifying the additional repairs. The COR and Contracting Officer shall review and if the repairs are approved a contract modification shall be issued prior to the contractor proceeding.

7. Warranty:

Contractor to provide a 12 month warranty from the date the overhauled air compressor is accepted by RIA-JMTC. The warranty shall cover all work performed and parts replaced per the approved work on test reports A and B performed by the contractor.

8. Lead Time:

After an air compressor is received by the contractor. The contractor has 15 days to complete repairs and return the completed unit to Rock Island Arsenal.

9. Paint The Government (JMTC) shall CARC paint. Contractor shall remove rust and cover bare areas with primer.

Test Report A

Test Report B image1.emf

Microsoft_Excel_Worksheet1.xlsx Sheet1

Air Compressor serial number

ITEM MANDATORY OVERHAUL CHECKLIST INITIALS DATE

1 AIR COMPRESSOR CLEANED & DEGREASED YES/NO

2 OVERALL CONDITION ACCEPTABLE- VISUAL INSPECTION YES/NO

3 HEATER AND THERMOSTAT TEMPERATURE ACCEPTABLE YES/NO

4 OIL CHANGED YES/NO

5 LOW OIL SWITCH CONTINUITY TEST PASS YES/NO

6 AIR FILTER CHANGED YES/NO

7 V-BELT CHANGED AND TENSIONED YES/NO

8 V-BELT TENSION VALUE LBS

9 REPLACE AFTER COOLER & INNER COOLER RELIEF VALVES YES/NO

10 PRESSURE SWITCH CONTACTS OK VISUAL INSPECTION YES/NO

11 VALVES INSPECTED & CLEANED (IF REQUIRED) YES/NO

12 ALL FASTENERS CHECKED FOR TIGHTNESS YES/NO

13 HIGH PRESSURE HEAD BOLT TORQUE FT-LBS

14 LOW PRESSURE HEAD BOLT TORQUE FT-LBS

15 HIGH PRESSURE INLET VALVE SCREW TORQUE FT-LBS

16 LOW PRESSURE INLET VALVE SCREW TORQUE FT-LBS

17 HIGH PRESSURE OUTLET VALVE SCREW TORQUE FT-LBS

18 LOW PRESSURE OUTLET VALVE SCREW TORQUE FT-LBS

19 UNLOADER COVER TORQUE FT-LBS

20 PRESURE SWITCH CUT-IN PRESSURE PSI

21 PRESSURE SWITCH CUT-OUT PRESSURE PSI

22 AVERAGE PUMP-UP TIME MIN

23 HIGH PRESSURE HEAD BOLT RE-TORQUE FT-LBS

24 LOW PRESSURE HEAD BOLT RE-TORQUE FT-LBS

25 OIL/AIR LEAKS- 0 MIN YES/NO

26 OIL/AIR LEAKS- 15 MIN YES/NO

27 OIL/AIR LEAKS- 30 MIN YES/NO

28 OIL/AIR LEAKS- 45 MIN YES/NO

29 OIL/AIR LEAKS- 60 MIN YES/NO

30 PAINT REPAIR COMPLETE YES/NO

ADDITIONAL OVERHAUL WORK DESCRIPTION INITIALS DATE

Sheet2

Sheet3 image2.emf

Microsoft_Excel_Worksheet2.xlsx Sheet1

ITEM MANDATORY OVERHAUL CHECKLIST INITIALS DATE

1 AIR COMPRESSOR CLEANED & DEGREASED YES/NO

2 OVERALL CONDITION ACCEPTABLE- VISUAL INSPECTION YES/NO

3 HEATER AND THERMOSTAT TEMPERATURE ACCEPTABLE YES/NO

4 OIL CHANGED YES/NO

5 LOW OIL SWITCH CONTINUITY TEST PASS YES/NO

6 AIR FILTER CHANGED YES/NO

7 V-BELT CHANGED AND TENSIONED YES/NO

8 V-BELT TENSION VALUE LBS

9 REPLACE AFTER COOLER & INNER COOLER RELIEF VALVES YES/NO

10 PRESSURE SWITCH CONTACTS OK VISUAL INSPECTION YES/NO

11 VALVES INSPECTED & CLEANED (IF REQUIRED) YES/NO

12 ALL FASTENERS CHECKED FOR TIGHTNESS YES/NO

13 HIGH PRESSURE HEAD BOLT TORQUE FT-LBS

14 LOW PRESSURE HEAD BOLT TORQUE FT-LBS

15 HIGH PRESSURE INLET VALVE SCREW TORQUE FT-LBS

16 LOW PRESSURE INLET VALVE SCREW TORQUE FT-LBS

17 HIGH PRESSURE OUTLET VALVE SCREW TORQUE FT-LBS

18 LOW PRESSURE OUTLET VALVE SCREW TORQUE FT-LBS

19 UNLOADER COVER TORQUE FT-LBS

20 PRESURE SWITCH CUT-IN PRESSURE PSI

21 PRESSURE SWITCH CUT-OUT PRESSURE PSI

22 AVERAGE PUMP-UP TIME MIN

23 HIGH PRESSURE HEAD BOLT RE-TORQUE FT-LBS

24 LOW PRESSURE HEAD BOLT RE-TORQUE FT-LBS

25 OIL/AIR LEAKS- 0 MIN YES/NO

26 OIL/AIR LEAKS- 15 MIN YES/NO

27 OIL/AIR LEAKS- 30 MIN YES/NO

28 OIL/AIR LEAKS- 45 MIN YES/NO

29 OIL/AIR LEAKS- 60 MIN YES/NO

30 PAINT REPAIR COMPLETE YES/NO

Air Compressor Serial No. Date

ADDITIONAL OVERHAUL WORK DESCRIPTION INITIALS DATE

Sheet2

Sheet3