Attachment_1_Statement_of_Work_v1.pdf

DESCRIPTION/WORK STATEMENT/SPECIFICATION

FOR

Universal Hydraulic Pump and Motor Test System

1.0 Scope. This specification establishes the requirements for a Universal Hydraulic Pump and Motor Test System to be located in building 117 at Anniston Army Depot, Anniston Alabama designed, fabricated, and installed by the contractor with all functions and capabilities as delineated herein. The contractor shall provide the resources necessary to design, manufacture, transport, install, site cleanup, calibrate, demonstrate the functional operation, provide training of Anniston Army Depot (ANAD) operator, Calibration, and Maintenance personnel, and documentation of a Hydraulic Pump and Motor Test System (from hereon referred to as the test system). Upon installation at ANAD, the test system shall be fully capable of meeting all requirements of this specification. The test system will be used to performance test hydraulic pumps and motors utilizing fire resistant hydraulic oil per MIL-PRF-46170. The test system fabrication, installation, acceptance, and training of Government personnel must be complete within 365 calendar days of award of contract. This specification describes the minimum anticipated operational and performance requirements.

1.1 Order of Precedence. In the event of a conflict between the text of this specification and the references cited herein, the text of this specification shall take precedence.

2.0 Applicable Documents. The following documents of the issue in effect on date of invitation for bids or request for proposals form a part of this specification to the extent specified herein:

American National Standards Institute (ANSI)

ANSI AS35411 Fittings and Lubrication

ANSI B93.114M Pneumatic Fluid Power Systems - Standard for Industrial Equipment and Machine Tool Applications

ANSI 14.2-2000 Ladders, Fixed - Safety Requirements

Institute of Electrical and Electronics Engineers (IEEE)

IEEE C2 (2007; Errata 2007; INT 2008) National Electrical Safety Code

IEEE STD 142 (1992) Recommended Practice for Grounding of Industrial and Commercial Power Systems - Green Book

International Organization for Standardization (ISO)

ISO 4414:1998 Pneumatic Fluid Power - General Rules Relating to Systems

National Fluid Power Association (NFLPA)

NFPA T2.25.1R2 200X Pneumatic Fluid Power - Systems Standards for Industrial Machinery - Supplement to ISO 4414:1998

NAFPA / JIC T2.24.1R1 Hydraulic Fluid Power - Systems Standard for Stationary Industrial Machinery

National Electrical Manufacturers Association (NEMA)

NEMA 12 Enclosures for Electrical Equipment (1000 Volts Maximum)

NEMA MG 1 (2007) Standard for Motors and Generators

NEMA ICS 1 (2000; R 2005) Standard for Industrial Control and Systems General Requirements

National Fire Protection Association (NFPA)

NFPA 70 (2007; AMD 1 2008) National Electrical Code - 2008 Edition

NFPA 79 (2007) Electrical Standard for Industrial Machinery (DOD adopted)

U.S. National Archives and Records Administration (NARA)

29CFR 1910 General Industry, OSHA Safety and Health Standards

3.0 Description. The test system shall be composed of two completely independent stands with each test stand being capable of testing pumps and motors either automatically, semi-automatically, or manually to determine if the unit under test meets specifications. It shall be possible to install and operate the test stands at separate locations without any alterations to the test stands. The test stands should conserve space to the maximum extent possible while being safety, ergonomic, operation and maintenance friendly. The test stands shall be capable of operating 24 hours a day, 7 days a week for extended periods. To help accommodate future and unforeseen changes, critical components (pumps, motors, gauges etc.) of the test stands shall at a minimum be 120% of the actual size required by the test procedures in appendixes 1 & 2.

3.1 Test Stands. Each test stand will consist of an operator’s console, test chamber, and power pack. The test stands may be of the exact same design, but they shall not share any parts or utilities. The operator’s consoles and the test chambers shall be located in an existing room which has HVAC while the power pack shall be located in an existing enclosed shed to the rear of the operator’s consoles/test chambers. To the maximum extent possible, electrical controls/drives shall be separated from the hydraulic items with the electrical controls/drives located in an HVAC controlled environment. Each test stand will have its own separate “lock out – tag out” system per Occupational Safety and Health Administration (OSHA) 29 CFR 1910.147 so that it shall be possible to have one test stand “locked and tagged out” for maintenance purposes while the other test stand is still in full operation. The test stands shall be computer controlled, however, it must also be possible to manually operate the test stands, even if the computer is down or removed. Each test stand shall be capable of testing hydraulic pumps and motors to the requirements of section 13.

3.1.1 Operator’s Console. The operator’s console is a centralized station from which the operator can observe and control test stand operations. At a minimum the operator’s console shall contain the computer system, gauges, warning lights/indicators, and controls (valves, switches etc.) required to verify that the test stand is ready for operation, and to operate the test stand. The equipment shall display all units of measure in the U.S. Customary System of Units. All controls, gauges, and indicators shall be marked with identification plates.

3.1.1.1 Computer System. The computer system shall be protected from and withstand any hydraulic oil on the hands of the test stand operator. It must also be protected from hydraulic oil sprayed/dripped or otherwise discharged from a failed hydraulic component.

3.1.1.1.1 Hardware. The computer hardware shall be open architecture, consisting of standard computer hardware that can be replaced by commercially available parts. The video display shall be a 21-inch (minimum) TFT active matrix LDC color monitor. The monitor shall be capable of a maximum resolution of 1600 X 1200 pixels and able to display at least 16.7 million colors (24 bit). The monitor shall be installed in a convenient location to allow the operator to view the monitor, operate the console control, and view the unit under test (UUT). The printer shall be capable of printing a minimum of 30 pages per minute (ppm) at 1200 X 1200 dots per inch maximum resolution. The printer shall have a minimum of 24 megabyte(MB) installed RAM memory. The printer shall be easily accessible by the operator. The contractor shall supply two (2) sets of printer replacement cartridges.

3.1.1.1.2 Software. The contractor shall develop a series of test sequences that meet all test requirements as defined in section 13. All component test program software shall be open source, meaning the Government shall have the capability and right to make future changes to the component test software as needed. The software shall be the latest released (stable) version of a commercial application package commonly used for data acquisition, instrument control and industrial automation. The software shall contain all utilities, instrument drivers and libraries required to maintain, or modify the contractor developed test sequences supplied with the system. A copy of any compilers, assemblers, linkers, program editors, or other software tools used to create the contractor-developed test sequences shall be delivered on CD with the test stand.

The contractor shall deliver the original install CD (or CDs) containing the executable machine code and/or runtime engine for the application package with the test stand.

This will permit re-installation of the software in the event of hard disk failure.

3.1.1.1.2.1 Semi-Automatic Operation. In the semi-automatic mode, the software shall perform test stand startup sequencing, emergency shutdowns, monitoring of limits, receiving operator input and translating them into control actions. The software shall require operator interaction to select the appropriate individual test to be executed from a menu. The software shall also allow the operator to stop and then restart a test step without having to restart the entire test sequence. Data acquisition determined by the selected test shall be performed automatically by the software. After execution of the selected individual test has been completed, semi-automatic test sequencing shall be halted awaiting further action by the operator. The software shall generate a report of the test results at the completion of the test or when requested by the operator via the operator's console. Upon completion of any test, the software shall save the automatically generated report to memory (archived) for future retrieval. If a UUT fails a particular test, the test sequence shall indicate to the operator the failed test results.

3.1.1.1.2.2 Manual Operation. Discrete digital meters and gauges shall be provided on the operator’s console to allow manual operation in the event that the data acquisition system and/or computer becomes dysfunctional. The test stand shall normally be computer controlled in the automatic or semi-automatic mode. The manual mode of operation shall provide all control functions to allow the operator to completely control all aspects of the testing operations without the use of the data acquisition system and the computer. In manual mode the operator shall be responsible for all startup sequencing, emergency shutdowns, test sequence operations, and data collection.

3.1.1.2 Gauges. If a gauge is composed of a remote sensor and a display (or other/addition components) the total error of the gauge components must meet the requirements of this section (paragraphs 3.1.1.2 thru 3.1.1.2.7). To the maximum extent possible, it must be possible to calibrate gauges from the operator’s console. All gauges use to display/measure a test requirement or result must be calibrated. The physical reconfiguration required to calibrate the gauges of a test stand must be minimized to the maximum extent possible. Gages subject to continuous surges or extreme pressure fluctuations shall be protected by snubbers or dampeners.

3.1.1.2.1 Pressure. All pressure gauges used to display test settings/results shall be accurate within +/- 0.5% of reading and must be on the operator’s console. Pressure gauges requiring calibration must include isolation valves and test ports. All other pressure gauges shall be within +/- 2%.

3.1.1.2.2 Temperature. All gauges used to display test temperature measurements shall be accurate within +/- 2%.

3.1.1.2.3 Flow. All gauges used to display test flow settings/results shall be accurate within +/- 0.5%.

3.1.1.2.4 Torque. All gauges used to display test torque settings/results shall be accurate within +/- 0.5%.

3.1.1.2.5 Speed. All gauges used to display test revolutions per minute (RPM) settings/results shall be accurate within +/- 5 RPM.

3.1.1.2.6 Current. Any ammeters used to measure current will be accurate within +/- 1%.

3.1.1.2.7 Voltage. Any voltmeters used to measure AC or DC voltage will be accurate within +/- 1%.

3.1.1.3 Indicators. An indicator (warning lights etc.) of the status of each critical test stand function shall be readily visible on the operator’s console. The intent is protect both the test stand and the test stand operator. For example, indicators which would help protect the test stand could include but not be limited to a light which indicates if the filters need replacing, or a light that indicates the hydraulic fluid level in the reservoir is low.

3.1.1.4 Controls. All valves, switches, etc. needed to operate the test stand shall be on the operator’s console. Switches will be of a type that will clearly indicate the position/status of the switch. Valves will be of a type that are easily turned even when under pressure.

3.1.1.5 Identification Plates. All identification plates will be of a material which is resistance to near constant exposure to MIL-PRF-46170 hydraulic oil and solvents used to clean the operator’s console (primarily alcohol). The identification plates will be permanently attached via screws, bolts, rivets etc. The use of adhesives to mount the identification plates is not permitted.

3.1.1.6 Name Plate. A nameplate shall be attached to the test stand and shall contain, as a minimum, the following information:

a. Nomenclature.

b. Manufacturer’s name.

c. Serial number.

d. Test stand model designation.

e. Power input (volts, total amperes, phase, and frequency).

f. Short-circuit/over current rating.

g. Contract number or purchase order number.

h. National stock number (if applicable).

i. Date of manufacture.

3.1.1.7 Timer. A digital timer shall be provided on the front panel with good visibility to the operator. The timer shall have a range of at least 60 minutes with 1 second increments. The timer shall feature a single start/stop button and a reset button.

3.1.1.8 Storage Space. A suitable storage area or space shall be provided for the operating manual and other documentation for the test stand. This area or space shall be permanently attached to the operator’s console, and shall be readily accessible.

3.1.2 Test Chamber. The test chamber is a test stand enclosure in which the UUT is mounted and connected during UUT operation/testing. The design, layout, and assembly of the cabinet and its component parts shall be such as to facilitate high volume production of units under test and ease of maintenance. At a minimum the test chamber shall include a UUT mounting plate, work bench, UUT and hose enclosure, and shaft adapters, hoses, and hardware necessary to connect/test the pumps and motors. The test chamber shall include a vacuum gage with a minimum range of 0 to 30 inches of mercury (Hg). The vacuum gage shall be located on the supply line of the pump under test as close as possible to the pump inlet port. The pressure/vacuum measurement shall be displayed on the operator’s console.

3.1.2.1 UUT Mounting Plate. The UUT mounting plate shall allow for the quick installation and removal of pumps and motors. If adapters are needed to mount pumps verses motors, time to change from testing a motor to a pump or from a pump to a motor shall take less than 10 minutes. The default mounting configuration shall be for a pump.

3.1.2.2 Work Bench. The work bench shall provide the mechanic with an area on which to install or remove test fittings, and to allow fluid to drain from pumps or motors after testing. The work bench/drip pan shall consist of a perforated metal work bench supported above a drip pan. All hydraulic fluid escaping from a UUT, hoses, fitting, or from a draining pump or motor shall be captured by the drip pan and automatically returned to the test stand reservoir. The work tray shall allow for easy recovery of any small parts, tools, or hardware which is dropped into/onto the work tray. Any drains connected to the work tray shall be covered by a screen to prevent any lint or debris from entering the drain. This screen shall be reusable and shall be easily accessed, removed, cleaned and replaced.

3.1.2.3 UUT and Hose Enclosure. The UUT and Hose enclosure shall protect the operator and the surrounding from flailing hoses, flying UUT fragments, any fluid spraying or otherwise released during testing. Any fluid released by the UUT, hoses, fitting etc. shall be captured and returned to the test stand reservoir. It shall also be possible to observe, and if necessary, to adjust the UUT with the enclosure in place.

3.1.2.4 Shaft Adapters, Hoses and Hardware. Each test stand shall include all adapters, hoses and hardware necessary to mount and test the pumps and motors.

3.1.2.4.1 Hose Identification. All hose assemblies shall have corrosion resistant steel identification bands or tags attached which clearly state the hose assembly part number and drawing number.

3.1.3 Power Pack. Due to space, heat and noise considerations, the hydraulic power pack and the electric motors for each test shall be located in an existing shed located behind the test consoles.

3.1.3.1 Hydraulic Power Pack. At a minimum the hydraulic power packs shall consist of the hydraulic pumps, reservoirs, spill containment, filtration systems, and temperature control systems needed to provide hydraulic flow/power to the UUT.

3.1.3.1.1 Hydraulic Pumps. Pumps providing flow to the UUT must be variable displacement piston type.

3.1.3.1.2 Reservoirs. Each test stand shall have a hydraulic reservoir with a 100 gallon capacity. At a minimum the reservoirs will include a manway/inspection hatch, fluid level indicator, fluid temperature indicator, data plate, filtration unit, an intake screen and a low fluid level auto shutoff.

3.1.3.1.2.1 Manway/Inspection Plates. The manway for the reservoir will be a minimum of 18” in diameter or 18” on a side if square. The manway shall be located on an unobstructed end or side of the reservoir.

3.1.3.1.2.2 Fluid Level Indicator. The fluid level indication will give a clear indication of when hydraulic fluid should be added and the amount of fluid needed to return the reservoir to “full”.

3.1.3.1.2.3 Fluid Temperature Indicator. The reservoir fluid temperature measurement shall be visible at the reservoir and at the operator’s console.

3.1.3.1.2.4 Data Plate. The data plate shall be permanently mounted adjacent to the reservoir fill cap/neck. The data plate shall display the total capacity of the reservoir and the type of hydraulic fluid contained “MIL-H-46170”.

3.1.3.1.2.5 Filtration Unit. The reservoir filtration system shall be designed to circulate and clean the hydraulic oil in the hydraulic reservoir even when the rest of the test is not in operation. It shall include a dirty filter indicator(s) at the filter, an on/off control(s) and status indicators on the operator’s console, and remove particles and water so that the hydraulic fluid meets the cleanliness requirements of the test specifications. The particulate filter shall be a 3 micron filter.

3.1.3.1.2.6 Intake Screen. A suitable strainer, which shall be easily accessible for removal and cleaning, shall be provided between the reservoir and inlet to the pumps.

3.1.3.1.2.7 Auto Shutoff. The reservoir shall be provided with a low fluid level switch that will shut down the test stand to prevent damage to test stand or UUT in the event the reservoir fluid level is low.

3.1.3.1.3 Spill Containment. The hydraulic power pack shall include a fluid containment system or pan capable of containing the maximum volume of hydraulic oil the test stand can hold (including oil in hoses and components under test) in case of a major fluid spill. In accordance with 40 CFR § 112, the containment system shall be constructed so that any discharge from a primary containment system, such as a reservoir or pipe, will not escape the containment system before cleanup occurs. The fluid containment system shall be easily accessible so that it may be emptied. Fluid containment system shall be covered in such a way as to prevent a tool from being dropped into or a person from stepping into the oil containment area.

3.1.3.1.4 Filtration Systems. The filtration system shall include all particle and water filters/removal units needed to clean the hydraulic fluid to UUT test instruction requirements. At a minimum, the hydraulic power pack shall include 3 micron filters in the pressure lines leading to the UUT. The filters shall be easily and ergonomically accessible for maintenance. The filters shall include a dirty filter indicator at the filter and on the operator’s console. The filters shall include an automatic shutoff valve which stops flow when the filter element/canister is removed. Fluid leaving the work tray shall be filtered prior to entering the reservoir.

3.1.3.1.4 Temperature Control System. The test stand shall be capable of regulating the temperature of the test fluid within ± 5° Fahrenheit of the fluid temperature set point. It shall be possible to set the test fluid temperature set point at any temperature between 125 °F and 170 °F. A digital readout indicating the test fluid operating temperature shall be provided on the operator’s console. The test stand shall be capable of displaying the test fluid temperature with an accuracy of ± 2%. The heating/cooling system shall be protected from adverse temperature conditions (overheating & freezing).

3.1.3.1.5 Cooling. The cooling systems using flow through cooling water, or chillers are not permitted.

3.1.3.1.6 Heating. These heat system shall maintain the temperature of the fluid within +/- 5° F when the control is set in the range of 125 °F to 170 °F. The warm-up time of the test stand oil to the set point temperature shall not require more than 5 minutes per 10 °F increase.

3.1.3.2 Electric Motors. Electric motors shall be alternating current (AC) type.

3.1.4 Electrical Controls/Drives. The electric motor drives and PLCs shall be located in an HVAC controlled environment and protected from foreseeable hazards.

3.1.4.1 Electric Motor Drives. Any electric motor drives shall be Allen Bradley brand product PowerFlex 700 or equal with the following salient characteristics: compatibility with Allen Bradley programming interface cables, compatibility with Allen Bradley programming software, and compatibility with Allen Bradley executables.

3.1.4.2 Programmable Logic Controllers. Any PLC shall be Allen Bradley brand name or equal with the following salient characteristics: compatibility with Allen Bradley programming interface cables, compatibility with Rockwell Logix R/S 500 or 5000 programming software, and compatibility with Allen Bradley executables.

3.2 Design and Construction. The design, layout, and assembly of the cabinet and its component parts shall be such as to facilitate high volume production of units under test (UUT) and ease of maintenance.

3.2.1 Material. All material used shall be as specified herein. Material not specified shall be of the best quality used for the purpose in good commercial practice. The material shall be free from all defects and imperfections that might affect the serviceability of the finished product. The offerer/contractor is also encouraged to use recovered materials to the maximum extent possible in accordance with paragraph

23.403 of the Federal Acquisition Regulation (FAR).

3.2.1.1 Protective treatment. Materials used in the construction of the equipment that are subject to deterioration when exposed to climatic and environmental conditions likely to occur during service usage shall be protected against such deterioration in a manner that will in no way prevent compliance with the performance requirements of this specification. As applicable, the protective treatment shall be a color commonly used by the contract on test stands, preferably gray, white, or tan.

3.2.2 Metals. Metals shall be of corrosion resistant type to the maximum extent possible.

3.2.2.1 Dissimilar Metals. Unless suitably protected against electrolytic corrosion, dissimilar metals shall not be used in intimate contact with each other.

3.2.3 Structure. All components shall be located within an all-metal, fully enclosed cabinet suitably braced to carry the load imposed. The cabinet shall be fully guarded to shield fan blades, heating coils, electrical connections, and any other component parts that may present a safety hazard to the operator. The cabinet shall be so constructed that it will withstand transportation by common carrier without damage. Instrument panels shall be constructed of 11 gage or heavier metal suitable for the purpose. Doors and cabinet panels other than instrument panels shall be a minimum of 14 gage metal.

The cabinet or enclosure shall be rated for indoor use and shall provide a degree of protection against dust, falling dirt and dripping non-corrosive liquids.

3.2.4 Base design. All cabinets and sections of the test stands shall include longitudinal channels or other approved base design to permit the use of a standard fork lift truck for positioning or moving purposes. These provisions shall be a permanent part of the test stand, of sufficient strength and rigidity to support the load without undue stress or strain on the test stand itself, and shall be so arranged as to distribute the floor load evenly over the floor space occupied by the test stand.

3.2.5 Toe Clearance. Toe clearance shall be provided at the areas frequently accessed by the operator. The toe clearance shall be minimum of 6 inches high and 4 inches deep.

3.2.6 Leveling. Provisions for leveling the test stand shall be provided.

3.2.7 Vibration. The cabinet shall be constructed so that vibration from components such as pumps and motors shall not be transmitted through the structural members to any instrumentation, thus impairing readability and accuracy.

3.2.8 Lights. If required for maintenance purposes, any lighting required shall be vapor proof, of ample wattage, and be powered by nominal 120 volt, single phase, 60 Hertz current. Guards shall be provided around incandescent light bulbs to prevent personnel contact and inadvertent bulb breakage.

3.2.9 Ventilation. Louver type air vents shall be provided in the cabinet to promote air circulation, or the cabinet shall be provided with forced ventilation to prevent overheating of instruments and any electrical/electronic components.

3.2.10 Panel holes. All holes through test stand panels which may be required for installation of valves and fittings shall be of a standard size and type to permit replacement without rework of the panels.

3.2.11 Leaks. The stand components/connections (lines, fittings etc.) shall not leak.

All hydraulic connections will be of a type designed not to loosen (leak) due to pressure pulses and temperature variations.

3.2.12 Maintainability. The test stand shall be constructed using commercial off-the-shelf components to the maximum extent possible to ensure the prompt availability of repair parts. The contractor shall provide evidence that repair parts and service for the test stand are readily available. The contractor shall also provide information on the normal maintenance actions required for the test stand including type of maintenance, required interval, and mean time to perform maintenance and number and skill of people required to perform the maintenance actions.

3.2.12.1 Spare Parts Kit. A spare parts kit shall be included with delivery of the test stand. The kit shall include all contractor recommended spare parts for the test stand.

3.2.12.2 Lubrication Plate or Chart. A lubrication plate or chart shall be attached to the test stand. The information provided on the plate or chart shall include:

a. Points of lubricant application.

b. Servicing interval.

c. Type of lubricant(s) with SAE number or lubricant identifier.

3.2.13 Electrical. The test stand shall be designed to operate on 460 volt, three phase, 60 hertz electrical power. All wiring methods and practices shall conform to National Fire Protection Association (NFPA) 79-02 and NFPA 70. Industrial control devices for starting, stopping, regulating, controlling, or protecting electric motors shall conform to the requirements of Underwriters Laboratories UL 508. Adjustable-speed drives and accessories for use with adjustable-speed drives are covered by the Standard for Power Conversion Equipment, UL 508C. Devices that regulate temperature and/or control refrigeration equipment are covered by the Standard for Temperature-Indicating and –Regulating Equipment, UL 873, and other applicable standards. All electrical wiring and components shall be sized for 460 VAC operation.

3.2.13.1 Electrical noise. The electrical power at Anniston Army Depot is subject to noise. If the test stand requires clean electrical power for proper operation, the contractor shall supply a properly sized power conditioning unit with the test stand. If the test stand is susceptible to interference from adjacent industrial machinery, the contractor shall provide proper shielding with the test stand to minimize test stand malfunctions.

3.2.13.2 Electrical Enclosures. To the maximum extent possible, electrical components shall be in National Electrical Manufacturers Association (NEMA) type 4X enclosures.

3.2.14 Safety and Health Requirements. The test stand shall be in compliance with Occupational Safety and Health Administration (OSHA) 29 CFR 1910.212. The test stand shall include warning lights/indicators to alert the test stand operator to unsafe operating conditions. The test stand shall include at least one category 0 (uncontrolled) emergency stop switch as defined by NFPA 79-02 which shall immediately remove power to the machine actuators. Hinged or sliding doors containing ready access to moving parts that may pose a hazard shall be interlocked. Rotating or otherwise hazardous equipment components shall be guarded.

3.2.16 Noise Level. Noise emitted by the test stand and the UUT test chamber during UUT testing shall be no greater than 80 decibels as measured per ANSI S12.23-1989.

The 80-decibel limit is absolute. Techniques such as sound level averaging or exposure time weighing shall not be used in meeting this requirement. Any shields, baffles, enclosures or other devices required to bring the equipment into conformance with this requirement shall not interfere with safe operation of the test stand.

3.2.17 Ergonomics. The test stand shall be ergonomically designed to prevent the occurrence of repetitive stress injuries.

3.2.18 Environmental Compliance. The test stand provided under this contract shall meet all applicable Environmental Protection Agency (EPA) restrictions in effect on the date of the contract. These regulations apply to the emission of materials hazardous to the environment or the user’s health and shall be adhered to during the manufacture, service, transportation, storage and operation of the test stand.

4.0 Preliminary Acceptance. The test stand shall be ready for the preliminary acceptance inspection/testing no later than 300 calendar days after contract award.

This inspection/testing shall be conducted at the contractor’s facility and is to verify that the test stand meets the requirements of this document. The contractor shall notify the Government, in writing, of any deficiencies discovered. The Government reserves the right to be present at the contractor’s facility during the inspection/testing. The Contracting Officer’s Representative (COR) may give consideration to failures deemed unrelated to the test stand (i.e. acts of God, failure of the unit under test, etc.) or otherwise insignificant. However, the Contracting Officer or his/her designated representative shall have sole authority in resolving disputes that may arise from failures during the final acceptance test. The test stand shall not be shipped to Anniston Army Depot until successful completion of the inspection.

5.0 SHIPPING, HANDLING, AND STORAGE. The contractor shall be responsible for delivering the test stand to building 117 at Anniston Army Depot. Once the test stand is delivered to ANAD, the contractor shall have 30 calendar days to install the test stand and complete all test stand acceptance requirements. The contractor shall be responsible for all shipping, storage, and handling of the test stand and all materials.

The Government shall not be responsible for furnishing any labor, equipment, or warehouse space for the moving or storing of any materials. There are no docks at building 117 for unloading the test stand from a trailer. If a dock is required for unloading the test stand, the test stand will have to be unloaded at building 513 at Anniston Army Depot and then transported to building 117 (a distance of approximately 1/2 mile). If the test stand is unloaded at building 513, the contractor will be responsible for all labor and equipment required to move the test stand to building 117. The Government will make available if possible, space for a contractor furnished trailer or van for the storage of the materials. Trailer space will be made available as close to the job site as possible, depending on the parts stored in that area.

6.0 Installation. The test stand shall be installed by the contractor. The contractor shall be responsible for all plant, labor, and materials required for a complete installation. The contractor shall be responsible for insuring that the installation is compatible with existing facilities. Unless otherwise approved by the Contracting Officer, installation shall be done during normal depot working hours. The area where the equipment is to be installed is in operation. The contractor shall not interfere with ongoing Government operations and production unless authorized by the Contracting Officer. The contractor shall protect the surrounding shop area and equipment near the installation site from damage due to dust, debris, etc., during the installation. SAFETY NOTE: Floor surfaces inside and outside the building near the installation site may be slippery due to leakage of hydraulic fluid from components being repaired in the shop.

All contractor employees working in this area must use extreme caution. The contractor will be responsible for ensuring that all of its employees, as well as any subcontractors, are aware of this condition and take the necessary precautions to ensure employee safety. Installation is to be complete and equipment operational within 14 calendar days after work begins.

6.1 INSTRUCTIONS FOR INSTALLATION. Within 60 days after award of contract, the contractor shall provide ANAD four (4) copies of all documentation and instructions necessary for installation of the test stand. ANAD will use the documentation to review utility and space requirements of the test stand. This documentation is to include, as a minimum, the following:

a. Floor plan drawing of the test stand showing floor space requirements.

b. Space required around the test stand after installation for maintenance purposes.

c. Foundation requirements, if any.

d. Maximum overall length, width, and height dimensions.

e. Approximate weight of the test stand.

f. All utility requirements, including capacities of required utilities and approximate location of utility connections on the test stand.

g. Minimum doorway opening required to bring the test stand into the building where it is to be installed.

h. Industrial waste disposal requirements, if any.

i. Ventilation requirements, if any.

6.1.1 Location. The test system shall be installed at Anniston Army Depot in building

117. The building is comprised of a conditioned space where equipment operators and units under test are located and an unconditioned space where hydraulic power packs are located. A partition separates the two spaces.

6.1.2 Wall Penetrations. The wall thickness between the shop interior and the shed is expected to be 12” to 24”. Determining the wall thickness is the responsibility of the contractor. All wall penetrations created by the contractor at a minimum shall:

a. Protect the hose, wiring, etc. extending through the wall from any sharp edges or rough surfaces that are part of the wall.

b. Shall be sealed to prevent the ingress of outside air into the environmentally controlled section of the building.

c. Shall have a professional appearance.

6.1.3 Equipment Allowable Footprint. The test stand or portion thereof that is to be installed in the conditioned area of the building shall have a footprint no greater than 8- 1/2 feet wide by 8 feet deep. The portion of the test stand (i.e. hydraulic power pack) that is installed in the unconditioned area of the building shall have a foot print no greater than 8 feet wide by 7 feet deep.

6.2 Utilities. The Government will provide utilities within 20 feet of each test stand installation site. The capacities of the utilities (wire sizes, pipe sizes, etc.) will be based on information supplied by the contractor. The contractor will be responsible for making all test stand utilities connections. The following utilities can be made available at the installation site:

Electrical: 3 Phase, 60 Hertz, 460 Volts Shop Air: 90 PSI Water 75 PSI

6.3 Electrical. All electrical work shall comply with American National Standards Institute (ANSI) Publication C2 – National Electric Safety Code, with National Fire Prevention Association (NFPA) Publication No. 70 – National Electric Code and with NFPA 70E: Standard for Electrical Safety in the Workplace. All materials used in the installation shall conform to applicable National Electrical Manufacturers Association (NEMA) and Underwriters Laboratory (UL) listings. Workmanship shall be in accordance with standard commercial practices. Runs shall be installed perpendicular and parallel to existing facilities and the equipment to be installed. When equipment is installed near existing power lines, equipment shall be located for proper clearances in accordance with ANSI C2. New equipment shall not be connected to Government power without prior approval of the Contracting Officer. No high voltage work will be accomplished without prior approval of the Contracting Officer. All connections to Government power and all high voltage work shall be performed in the presence of a qualified Government electrician.

6.3.1 Main Disconnect. The Government shall furnish and install a main disconnect furnished with 460 volt, three phase power for each test stand.

6.4 Plumbing. All plumbing work shall comply with National Association of Plumbing- Heating-Cooling Contractors/American Society of Plumbing Engineers (NAPHCC/ASPE) Publication - National Standard Plumbing Code. All materials used in the installation of the equipment shall conform to industry standards and shall be compatible with and shall meet the performance requirements of the equipment being installed. Workmanship shall be in accordance with standard commercial practice.

Runs shall be installed perpendicular and parallel with existing facilities and the equipment being installed. Bypasses shall not be installed at steam reducing stations.

All heating coils shall be trapped independently. Unless otherwise specified, steam and condensate piping shall be insulated with 1-1/2 inch thick calcium silicate with aluminum cover for outside lines and 1-1/2 inch thick fiberglass with all service jacket for interior lines unless subjected to water or vapor.

6.5 Concrete. Concrete used in the installation of the equipment shall be Class A and shall have a minimum allowable compressive strength at 28 days of 3,000 PSI unless otherwise specified. Samples for concrete strength tests shall be provided, stored, and tested as directed. Unless otherwise specified, the contractor shall be responsible for the design of all concrete work, including formwork and reinforcing.

Ready-mixed concrete shall be used and shall be delivered and discharged within 45 minutes after the introduction of water to the cement and aggregate. Placing of concrete shall conform to Chapter 4 of the American Concrete Institute Standard ACI

318. Workmanship shall be in accordance with standard commercial practice.

6.5.1 Foundation Hardware. All foundation hardware required for installation of the test stand shall be furnished by the contractor and included in the bid price.

6.6 Drainage. The test stand shall not require drainage.

6.7 Trades. Coordination of trades (Electricians, Plumbers, etc) installing the equipment shall be the responsibility of the contractor.

6.8 Site Visit. A site visit is recommended to ensure that the proposed test stand will be compatible with existing facilities. The contractor is responsible for verifying all dimensions and locations of utilities at the installation site and reporting any discrepancies to the Contracting Officer or the Contracting Officer’s Representative (COR) before installation has begun. Any discrepancies not reported prior to beginning of installation shall become the responsibility of the contractor and will not be an acceptable reason for work delay.

7.0 Calibration. Upon completion of test stand installation at ANAD, the contractor shall verify test stand calibration using the calibration procedure and test equipment provided with the test stand per paragraph 10.2 herein. Test stand calibration shall be performed by ANAD calibration personnel and verified by the contractor. Training for ANAD calibration personnel shall be provided (see requirements of paragraph 8.0 herein). Any special adapters, fixtures, tooling, etc. required to perform calibration shall be provided with the test stand.

7.1 Performance Test. Upon completion of test stand calibration, the contractor shall demonstrate the test stand's ability to successfully test one each of pumps 12285278 and 12287040 and one each motor 12283111 in automatic, semi-automatic and manual modes. During these tests, the contractor shall demonstrate proper operation of all test stand controls, functions and features. All tests shall be witnessed by the ANAD Contracting Officer or Contracting Officer's Representative. Should a test stand malfunction or failure occur during any test, the contractor shall correct the problem and repeat the complete test on that component.

7.2 Acceptance. Final acceptance testing shall be conducted at Anniston Army Depot in accordance with paragraph 7.1. The final acceptance test will be considered successful when the assemblies of paragraph 7.1 are tested with no failures, as evidenced by data recorded from the test stand gages and/or instrumentation. The Contracting Officer’s Representative (COR) may give consideration to failures deemed unrelated to the test stand (i.e. acts of God, failure of the unit under test, etc.) or otherwise insignificant. However, the Contracting Officer or his/her designated representative shall have sole authority in resolving disputes that may arise from failures during the final acceptance test. The Government will accept the test stand only after the contractor successfully completes the requirements of paragraphs 7.0, 7.1, and

7.2 herein, provides all training and documentation required herein and removal of shipping/installation debris has been verified by the Contracting Officer or his/her designated representative.

8.0 Training. The contractor shall provide 5 days total of training for the operation, maintenance, and calibration of any equipment provided by the contractor, and shall be conducted immediately upon successful completion of performance test in paragraph

7.1. Training shall be conducted at Anniston Army Depot, Anniston, Alabama during normal depot working hours and on consecutive days, if possible, for a maximum of 10 Government personnel. All training shall be provided in the English language.

9.0 Site Cleanup. The contractor shall remove all debris, scrap material, trash, etc.

from the job site daily. All trash shall be placed in Government provided roll-off boxes or drums. Anniston Army Depot will be responsible for disposal. ANAD will provide an outdoor location for the cleanup of contaminated material if requested by the contractor.

No equipment will be provided by the Government to perform any of the cleanup performed by the contractor.

10.0 Documentation. The contractor shall provide four electronic copies of all documentation, and four paper copies in binders of the operator’s manual, the maintenance manual, and the calibration specifications/procedures. The electronic documentation shall be provided on compact discs (CD-ROMs). Electronic copies of the documentation shall be in Microsoft Office format (Word, Excel) or Adobe Portable Document Format (PDF). Drawings and schematics shall be provided in PDF format and in Solid Edge (.dft), AutoCAD (.dwg) or Microstation (.dgn) format.

10.1 Content. The documentation shall include the following: material safety data sheets, operator’s manuals, maintenance manuals, calibration specifications/procedures, catalogs, fabrication drawings for all parts/fixtures/tooling not commercially available, spare parts lists and solid models of the test stands and the components of the test stands. Maintenance manuals shall include electrical, hydraulic, and pneumatic schematics, as applicable, detailed lockout/tag out procedures, parts lists, troubleshooting procedures, preventive maintenance requirements, lubrication schedule and any other maintenance procedures normally provided by the manufacturer. Schematics shall show and identify all parts down to and including components on printed circuit boards. Catalogs shall fully describe all special tooling, fixtures and attachments available for the equipment being furnished. The recommended spare parts lists shall be complete with part numbers and descriptions, required quantities, prices, recommended supply source, and estimated delivery time for the items. In addition, any other commercial vendor literature normally furnished with the test stand shall be provided. All documentation shall be furnished in the English language.

10.1.1 Solid Models. The solid models shall be complete, accurate, fully defined representations of the item and contain every feature the item being represented is intended to contain. All information necessary to adequately define the item shall be contained in the 3D solid model to include but not limited to materials, tolerances, geometric tolerances, drawing notes, revision data, etc. Solid models will preferably be submitted in Solid Edge format, else in accordance with (ISO) 10303 STandard for the Exchange of Product model data (STEP) format.

10.1.2 2D data based on 3D model. Data on 2D drawings based on the 3D solid models shall be sourced to the maximum extent possible from the 3D solid model.

There shall be no conflict in data between the 3D solid model and its associated 2D drawing.

10.2 Calibration Procedure. The calibration procedure/manual shall be arranged as follows:

a. Section I: Identification and Description. This section shall identify the test stand to be calibrated by nomenclature, manufacturer, and model number. It shall also include a table listing the test stand characteristics to be verified, performance specifications, and test method for verifying each performance specification.

b. Section II: Equipment Requirements. This section shall include a list of the calibration equipment and accessories required in the calibration process in tabular format. The list shall include the generic name, minimum use specifications (required range and accuracy), and one or more recommended equipment items that meet the minimum use specifications.

c. Section III: Preliminary Operations. This section shall include the test stand, accessory, and calibration equipment connections, warm-up instructions, setup instructions, and/or other operations that are preliminary to the complete calibration process.

d. Section IV: Calibration Process. This section shall describe the details (text, fixtures, illustrations, and tables) essential to the calibration of the test stand.

These details shall include step-by-step procedures for the entire calibration process.

e. Calibration Checklist/Performance Table. This table shall list all test stand characteristics to be verified, a place to record measured values, and the upper and lower tolerance limits. Each characteristic shall be verified at enough points over the range of use to verify required accuracy over the entire range of use.

10.3 Project Milestone Plan. The contractor shall provide a project milestone plan and timeline for the test stand project. The project milestone plan shall be a detailed Gantt chart format and list all major tasks and subtasks required for successful completion of the project. The project milestone plan shall be in Microsoft Project format. The contractor may propose an alternate format for consideration by ANAD. If an alternate format is offered, ANAD will review and accept or reject the proposed alternate format. If the alternate format is rejected, the contractor must provide the plan in Microsoft Project format. The contractor shall submit the project milestone plan to the ANAD Contracting Officer no later than 21 calendar days after date of contract award.

ANAD will review the project milestone plan and either approve or reply with questions/comments to the contractor. The project milestone plan must be approved by

ANAD before the contractor begins work. The project milestone plan will include a start of work meeting at ANAD and at least one project design review.

a. The project design shall be received by the ANAD Contracting Officer a minimum of 14 calendar days prior to the purchase of any materials.

b. The project design submittal at a minimum shall include electrical and hydraulic schematics, a bill of materials showing commercially available parts separately from contractor designed/fabricated parts, and a solid model of the test stand in Solid Edge (.par and .asm) format.

10.4 Material Safety Data Sheets (MSDS) and/or Safety Data Sheets (SDS). A copy of all applicable MSDS/SDS shall be provided to the Contracting Officer or the Contracting Officer’s Representative as early as reasonably possible, but no later than 240 calendar days after contract award.

11.0 Warranty. The test stand shall be covered by a warranty. The warranty period shall begin the day following Government acceptance of the test stand. During the warranty period, the contractor shall be responsible for all costs, including parts, labor, travel and lodging, required to complete repairs of any defects in test stand parts or workmanship. The contractor shall respond to requests for warranty service within 48 hours after requests.

11.1 Warranty Period. As a minimum, the test stand shall be covered by a 1-year warranty as specified in paragraph 11.0 above.

12.0 Responsibilities. The major responsibilities of the contractor and Government for the project are defined in the paragraphs below.

12.1 Contractor.

a. The contractor shall provide all parts, labor, tools and materials necessary for…