Attachment 1-Statement of Work (downloadable).pdf

10 December 2024

DESCRIPTION/WORK STATEMENT/SPECIFICATION

10 Dec 2024

1. Scope. This specification establishes the requirement for one (1) X1100 Oil Pump Test Stand hereafter referred to as the Equipment, Test Stand , to be provided to Anniston Army Depot (ANAD), Anniston, Alabama. The intended application is for the final acceptance testing of X1100 Oil Pumps per the applicable National Maintenance Work Requirements (NMWR), NMWR 9-2520-276. The test stand sought will be replacing an existing test stand at Anniston Army Depot, and the new stand to mimic the user functionality of the current stand (loading/unloading of unit under test, method of submerging the unit under test, and driving of unit under test). The current stand allows the pump(s) to be mounted above the tank with fluid and mechanical drive connects made at that time, and then the pump(s) are fully submerged into the oil tank for testing. See appendix A for description of specific test requirements. The Equipment shall be designed and fabricated by the contractor with all functionalities, capabilities and features as described herein. The contractor shall provide all resources necessary to design, manufacture, deliver, transport, install, demonstrate the functional operation of and provide operator and maintenance training for the equipment.

1.1 Scope Change Statement: The contractor shall not proceed with any verbal or written change(s) to the scope of work from sources other than the Contracting Officer, who will provide changes in writing.

2. Applicable Documents.

2.1 References. The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

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 14.2-2017 Ladders, Fixed Safety Requirements

Institute of Electrical and Electronics Engineers (IEEE)

IEEE C2-2017 2017 National Electrical Safety Code

IEEE STD 142-2007 Recommended Practice for Grounding of Industrial and Commercial Power Systems

International Organization for Standardization (ISO)

ISO 4413:2010 Hydraulic Fluid Power General Rules and Safety

Requirements for Systems and Their Components

ISO 4414:2010 Pneumatic Fluid Power - General Rules and Safety

Requirements for Systems and Their Components

National Electrical Manufacturers Association (NEMA)

NEMA 250-2014 Enclosures for Electrical Equipment (1,000 V Maximum)

NEMA MG 1-2016 Motors and Generators

NEMA ICS 1-2000 Industrial Control Systems: General Requirements

National Fire Protection Association (NFPA)

NFPA 70 National Electrical Code - 2017 Edition

NFPA 79 Electrical Standard for Industrial Machinery - 2018

Edition

Occupational Safety and Health Administration

29 CFR 1910 Occupational Safety and Health Standards

2.2 Order of Precedence. In the event of a conflict between the text of this Equipment specification and the references cited herein, this specification shall take precedence. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained by the Government.

3.0 Responsibilities.

3.1 Contractor. In addition to the requirements described herein, the contractor shall be responsible for the following items.

3.1.1 The contractor shall provide all resources to deliver and install the Test Stand in building 475 at ANAD.

3.1.2 The contractor shall provide all interconnect cables, hoses, manifolds, and regulators and any supporting structure required to connect the Test Stand to the ANAD provided utilities.

The contractor shall make all connections to ANAD supplied utilities.

3.1.3 The contractor shall meet with the Contract Officer Representative (COR) and other ANAD personnel onsite at ANAD within 14 business days after contract award. The purpose of the visit will be to demonstrate the existing test stand and testing process used by ANAD.

3.1.4 The contractor shall provide to the COR a Gantt type project plan including milestones for the deliverables herein within 28 business days after contract award.

3.1.5 The contractor shall present a preliminary concept design to the Government within 60 business days after contract award. The design will be reviewed and approved by the Government within 30 business days after receipt of preliminary design before proceeding with a detailed design. The specification MIL-A-70625 shall be used to guide the design evaluation requirements.

3.1.6 The contractor shall present a detailed design to the Government within 60 business days after preliminary concept design is approved. The design will be reviewed and approved within 30 business days after receipt by the Government before proceeding with implementation into fabrication.

3.1.7 The contractor shall present the final design in the form of computer solid models, drawings, specifications, and schematics. The final design shall contain the final as-built configuration of the test stand and the results of all passing evaluation tests. All files submitted shall be compatible with Dassault Systems SolidWorks 2022 or Adobe Acrobat. These files shall be provided to the government upon completion of all passing evaluation tests. As follows in section 7 of this SOW.

3.1.8 The contractor shall be responsible for the off-loading of the Test Stand from the shipping transport vehicle upon its arrival at ANAD.

3.2 Government. The Government will be responsible for the following items:

3.2.1 ANAD will provide access to the installation site during normal operating hours. A request may be made to the ANAD Contracting Officer in writing to allow work outside of normal operating hours. The ANAD Contracting Officer may deny any such request.

3.2.2 ANAD will provide any Oil pump(s) required for the tests stated in paragraph 5.3.

3.2.3 ANAD will provide all equipment and labor required for the loading and unloading of oil pumps as required for the tests stated in paragraph 5.3.

4. Test Stand Requirements. The contractor shall design, manufacture, deliver, install, demonstrate functional operation, and provide operator and maintenance training for one (1) Test Stand with all functions, capabilities and equipment as described herein.

4.1 Installation Location. The Test Stand shall be installed at Anniston Army Depot, Anniston, AL in Building 475, Transmission Shop.

4.2 Test Stand Utility and Dimensional Requirements. The Test Stand dimensions shall be no greater than 115 inches in width x 108 inches in depth. So that clearance is sufficient for an existing overhead crane system, the test stand height shall not exceed 132 inches. The following utilities are located within the test cell.

a. Voltage: 480 V 3 phase 60 Hz

b. Electrical Full Load Amperage (FLA): TBD

c. Electrical KVA: TBD

d. Compressed Air Pressure Required: Not-to-Exceed 80 psi

e. Compressed Air Consumption: Not-to-Exceed 25 cfm

4.3 Test stand construction. The Test Stand shall be designed for durability and constructed from materials which will support production testing at a level where the minimum time between tests is based on the amount of time required for the operator to remove the current unit being tested and place the next unit to be tested on the test stand. This will depend on the design of the test stand and the accessibility of the unit on the test stand by the operator. Due to the unpredictability of the production schedule this requirement is based on time between tests instead of number of units per day.

4.4 Test Stand Material. The Test Stand shall be constructed of corrosion resistant material or material that is treated or coated to be corrosion resistant.

4.5 Test Stand Components and Subsystems. Equipment to be provided under this contract includes the items listed below for one (1) complete and operable Test Stand. Other equipment may be required although not specifically mentioned in these specifications. The following items are listed for the convenience of the contractor in understanding the scope of supply.

4.5.1 Input Drive Unit Assembly. The input drive shall consist of an AC motor and variable frequency drive (VFD) and the required components to interface with the oil pump(s).

The interface shall use the minimum number of components practical.

4.5.1.1 The motor shall have sufficient power to conduct the test plus an additional 20%. For reference, Pump NSN 4320-01-077-7857 requires 49 HP minimum, and Pump NSN 4320-01- 075-4981 requires 6.3 HP minimum.

4.5.2.2 Speed shall be infinitely variable from 0 to greater than 2000 RPM.

4.5.2.3 The VFD shall be the most recent ABB model with the following salient features:

compatibility with ABB Drive Composer programming and maintenance software.

4.5.2 Test Stand Enclosure. All test stand components shall be integrated into a single enclosure.

4.5.2.1 The enclosure shall be constructed of a welded steel frame and panels. All frames and panels shall be of 12 gauge minimum and stiffened as to not flex during handling. Vertically hinged panels shall be used where components will require regular maintenance. These panels shall include tool-less latching systems. All other panels shall either be vertically hinged with tool-less latching systems or Panels shall fit well and shall not contribute to the noise generated during test stand operation.

4.5.2.2 The Test Stand Enclosure shall incorporate secondary oil containment, such that oil leaks or spills are contained within the enclosure.

4.5.2.3 The surface adjacent to the test chamber sink must have a designated area to put the tested unit to allow oil to drain from the oil pumps when test is completed.

4.5.3 Oil System. The Test Stand shall have a system to supply oil to the unit under test.

4.5.3.1 The system shall have capability of to operate continuously.

4.5.3.2 The system shall maintain oil temperature automatically at 100°F ± 5°F.

4.5.3.3 100°F from room temperature in less than 20 minutes.

4.5.3.4 The system shall include devices to measure oil flow(s), oil temperature(s) and oil pressure(s).

4.5.3.5 The system oil filters shall be located near an enclosure panel and placed with clearance below so that a standard five-gallon bucket can be placed beneath when filters are being changed.

4.5.4 Test Chamber. Test Stand shall include a chamber where oil pumps are tested.

4.5.4.1 The test chamber shall consist of a tank and a transparent containment lid.

4.5.4.1.1 The tank shall serve as an oil bath. Oil pumps shall be submerged into the tank for testing.

4.5.4.1.2 The transparent containment lid shall guard the operator and surrounding area from oil splash, oil mist and any other debris generated during the test. The lid shall have a transparent opening so that the operator can see inside of the test chamber. The lid shall open so that the oil pump can be lifted directly overhead by crane without any interference. The lid shall open, such that any oil that is splashed on it shall run back into oil bath so that no oil drips or spills on floor, operator, or any area external to the test chamber. The lid shall be constructed to contain any mechanical failure that occurs within the test chamber. The lid shall have means for manual opening in the event of loss of machine power. When in the open position, the lid shall positively latch open to prevent accidental closing.

4.5.4.1.3 The test chamber shall be fitted with a proximity type safety switch. The switch shall be used to check whether the test chamber lid is open or closed. If the cover is open, the test shall not start and shall indicate the problem to the operator through way of a light, screen, or other indication method as accepted by the government. If the oil pump is being rotated by the input motor or oil pressure is being generated by the oil pump these conditions should cease when the lid is opened.

4.6 Test Stand Instrumentation.

4.6.1 The Test Stand Instrumentation shall incorporate the necessary transducers, signal conditioning, and data acquisition required to measure, display and record all parameters simultaneously required by the NMWR with maximum total error of 1% of reading.

4.6.2 Pressure transducer circuits shall incorporate snubbers, ball valves and fittings to facilitate calibration of the transducers with a hydraulic hand pump. Calibration valves and fittings shall be panel mounted or located immediately behind an enclosure panel with sufficient clearance to connect Government reference standards. Fitting type shall be specified by the Government.

4.6.3 Flow circuits shall include a full flow ball valve and fittings to facility calibration using a Government reference flow meter placed in-line with the test stand flow meter. Valves and fittings shall be panel mounted or located immediately behind an enclosure panel with sufficient clearance to connect Government reference standards. Fitting type shall be specified by the Government.

4.6.4 Temperature circuits shall include a male to female to facilitate calibration using a Government reference source connected to the male connector located on the measurement device.

4.6.5 When a programmable logic controller (PLC) is used as part of the test stand, that PLC shall have the following salient features: compatibility with Allen Bradley RS Logix programming and maintenance software and compatibility with Allen Bradley communication cables. If PLC does not have compatibility with Allen Bradley RS Logix programming and maintenance software or utilize the connectivity of Allen Bradley communication providers, a major commercial PLC manufacturers programming software, connection cables, and training of how to use and communicate with the PLC must be provided.

4.7 Operator's Controls.

4.7.1 The Operator Controls shall include all controls, instrumentation, and indicators required to test the oil pump(s) in accordance with the NMWR test requirements and specified herein.

4.7.2 The Operator Controls shall include a computer, keyboard, monitor(s), printer, emergency stop control, and all controls required to operate the Test Stand.

4.7.3 All Test Stand Instrumentation shall be monitored by the control system and displayed on a computer monitor as virtual instruments (gages, sliders, meters, lights, etc.). All measurements shall include a digital readout.

4.7.4 The Test Stand shall normally operate in automatic mode. In automatic mode, the test stand shall perform all test functions automatically from start to finish with minimum operator input. The test stand shall also have a manual mode of operation. The manual mode of operation shall provide all control functions to allow the operator to completely control all aspects of the Test Stand required to configure test conditions using physical buttons, switches, and knobs. In manual mode the operator shall be responsible for configuring test conditions and collecting data. When in manual mode, the test stand shall be responsible for closed loop control and interlocks.

4.7.5 Communication between components if required shall be an open industry standard, including, but not limited to IEEE 1394, RS-232, RS-485, Ethernet, Universal Serial Bus (USB), or equivalent.

4.7.6 All computer hardware shall be open architecture, consisting of standard hardware that can be replaced by commercially available parts. The computer shall meet the following minimum requirements:

a. A workstation class computer operating on Windows 10 Professional 64-bit built by a major computer OEM such as Hewlett Packard or Dell.

b. Intel Xeon microprocessor operating at a minimum of 3.6 GHz base frequency

c. Minimum of 16 GB (gigabytes) of Random Access Memory (RAM)

d. Two (2) identical SSD enterprise grade SATA internal HDD with a minimum capacity of 1 TB each installed in a RAID 1 mirrored array configuration for real-time backup

e. Internal DVD writer optical disc drive

f. Ergonomic English Language QWERTY type USB wired extended keyboard, with a minimum of ten (10) function keys, cursor keys, and numeric keypad keyboard design shall be IP68 compliant and compatible with the environmental conditions surrounding the operator's console.

g. One (1) wired USB optical wheel mouse. A touch pad or joystick type pointer may also be used and shall be IP68 compliant and compatible with the environmental conditions surrounding the operator's console.

h. One (1) laser printer capable of printing a minimum of 30 pages per minute

i. One (1) monitor monitor shall be installed in a convenient location to allow the operator to view the monitor, operate the Operator Controls, and calibrate the test stand.

4.7.7 Software shall be provided to perform the following functions:

a. Operating System - The data acquisition and control software shall be the latest released (stable) version of a commercial application package commonly used for real-time control and data acquisition, instrument control, and industrial automation.

The applications 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/DVD with the Test Stand. The contractor shall deliver the original install CD/DVD (or CD/DVDs) containing the executable machine code and/or runtime engine for the application package with the Test Stand. This will permit automatic single-installer installation, uninstallation or repair of the application software in the event of hard disk failure.

b. Test Sequence Software - The contractor shall develop a series of pre-programmed test sequences that meet all test requirements for the Oil Pumps in accordance with the NMWR specified above. In 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. The software shall automatically perform data acquisition required by the selected test. After execution of the selected individual test has been completed, automatic test sequencing shall be halted awaiting further action by the operator. The software shall generate a report of the test results including pass/fail limits and pass/fail status for each measurement at the completion of the test when requested by the operator. If a unit under test fails a particular test, the test sequence shall indicate to the operator the failed test results.

The software shall also include the capability for user defined and savable test sequences.

c. Display Software - The software shall display messages describing adjustments or other actions to be taken by the operator during testing. All designated safety alarm conditions shall be displayed in red, and all test limit alarms shall be displayed in yellow.

d. Data Management and Report Generation Software - The contractor shall provide data management utilities with the following minimum capabilities:

1. Accepts operator input for the new oil pumps or recall data from previously tested oil pumps to allow certain tests to be rerun.

2. Stores data after each test step is completed.

3. Prints a test report showing test data, highlighting failed data by showing pass/fail limits and pass/fail status if applicable.

4. Allow on-screen viewing/editing of final test data before printing.

5. Search history files by serial numbers, display reports, and print on demand.

4.7.8 The Test Stand data acquisition and control software shall also be capable of the following:

a. Report generation shall be in accordance with NMWR.

b. Calibration: The calibration routine shall include a wizard driven menu to assist in the calibration process. Calibration records shall be kept in a file on the system and shall be accessible for review.

4.7.9 Source Code. The contractor shall provide to the Government all source code for any application developed by The contractor that is executed on the test stand PLC or PC. Source code shall be fully documented using programming best practices. The Government shall have the right to modify code as desired.

4.7.10 The Test Stand shall be fitted with a physical hour meter to measure operating time.

The time totaling meter shall be the non-resetting type and shall have a range of 0 to 100,000 hours in increments of 1 hour and 99999 shall be the maximum readout. The least significant digit on the meter readout shall be 1 hour. Upon reaching the maximum accumulative hours, the meter readout shall automatically revert to zero and continue to total time. The meter shall be designed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by the Test Stand. The meter shall be located as to be readily visible, but not subject to abuse relative to the operating environment of the Test Stand. The hour meter shall be connected such that it measures the time that the field of the motor in the Input Drive Unit Assembly is energized.

4.8 Spare Parts Kit.

A spare parts kit shall be included with delivery of the Test Stand. The kit shall include one (1) set of Contractor recommended spare parts.

4.9 Hardware and Special Tools.

All hardware and special tools required for the complete and proper installation, operation, and maintenance of the Test Stand shall be furnished.

4.10 Performance Requirements. The test stand described in this specification shall be used in the performance of the tests specified in the applicable NMWR. The test stand shall be designed for durability and constructed from materials which will support production testing at a level where the minimum time between tests is based on the amount of time required for the operator to remove the current unit being tested and place the next unit to be tested on the test stand. This will depend on the design of the test stand and the accessibility of the unit on the test stand by the operator. Test stand shall be designed so part dismount, part mount, to test start change time is 15 minutes or less and test stand can changeover ability to test between pump types in 45 minutes or less.

4.10.1 The test stand shall retain the same method of user functionality as the current oil pump test stand. The current stand allows the pump (UUT) to be mounted above the tank with fluid and mechanical drive connections made at that time, and then the UUT is fully submerged into the oil tank for testing. The mechanical drive components follow the UUT down into the oil bath as it is submerged. The current stand also has a dedicated holding fixture for each style of pump that is mounted to the test stand, the UUT is then mounted to that fixture. Approval must be explicitly granted to the contractor by ANAD to deviate from these primary design elements exhibited in the current test stand in the design and construction of the new test stand.

4.11 Additional Requirements.

4.11.1 Original Equipment Manufacturer shall have a minimum of 15 years of experience successfully designing, manufacturing, and installing mechanical/hydraulic component test stands.

4.11.2 The contractor shall have experience successfully designing, manufacturing and installing test stands.

4.12 General Requirements.

4.12.1 General.

4.12.1.1 Original Equipment Manufacturer's part numbers referenced herein are intended to be descriptive and not restrictive; and are not intended to preclude the use of any item otherwise conforming to this specification.

4.12.1.2 The Test Stand and its components shall be standard unmodified products of an Original Equipment Manufacturer regularly engaged in the manufacturing of such products.

Components of the same type and purpose shall be identical and supplied by the same manufacturer.

4.12.1.3 The Test Stand (as defined in this specification) includes the engineering, selection, procurement, design, manufacture, assembly, testing, delivery, installation, training, and commission, and includes all related equipment, spare parts, materials, supplies, components, documentation, and all other items required to make a production ready system.

4.12.2 Electrical Requirements.

4.12.2.1 All electrical work shall comply with IEEE C2, NFPA 70, and, unless outdoors or in an electrically hazardous classified area, shall be installed to meet NEMA 13 rating. 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. All wire shall be copper; no aluminum wire shall be used. Conduit feeds to the T shall be IMC or rigid conduit. Conduit runs shall be installed perpendicular and parallel to facilities and the Test Stand to be installed. When the Test Stand is installed near existing power lines, the Test Stand shall be located for proper clearances in accordance with IEEE C2. Oil-resistant, liquid-tight, flexible metal conduit may be used to connect to Test Stand components (valves, motors, switches, sensors) but the length shall not exceed six (6) feet.

4.12.2.2 The contractor shall not install conduit in a manner or location that interferes with equipment or interferes with personnel access to the Test Stand or existing equipment for operation or maintenance. The contractor shall not install conduit in a manner or location that interferes with the direct access to work-in-process (WIP), component containers and racking.

The contractor shall not install conduit in a manner or location that interferes or in any way limits the full design motion of any crane.

4.12.2.3 Test Stand Service Voltage - The Test Stand shall be wired to draw all of its electrical power from a single circuit. If the Test single circuit amperage does not exceed the requirement of a 20-amp circuit, the Test Stand may be designed to operate on 120-volt, 1-phase, 60-of a 20-amp circuit, the Test Stand shall be designed to operate on 480-volt, 60-Hertz (Hz) input power. The Test Stand shall be equipped with a manual, fused, or breaker type disconnect switch, readily accessible to the operator, that will deactivate the entire Test Stand.

4.12.2.4 Electrical Noise - The electrical power at ANAD may be subject to electrical noise.

If the Test Stand requires clean electrical power for proper operation, a properly sized power-conditioning unit shall be included with the Test Stand. If the Test Stand is subject to interference from adjacent machinery, the Test Stand shall include the proper shielding to prevent malfunctions.

4.12.2.5 Electrical Connections - Connections to screw-type terminals shall be mechanically secured with means to prevent loss of tightness. All other electrical connections shall be mechanically secured and soldered or brazed. Rosin base fluxes shall be used in all soldering operations. Wiring splices including soldering, crimp splices are not acceptable connections.

All connections must take place within a suitable electrical enclosure.

4.12.2.6 The Test Stand process parameters and machine functions shall be automatically, continuously monitored and maintenance warnings automatically issued before any parameter reaches unacceptable levels.

4.12.2.7 The Test Stand shall be equipped with suitable grounding devices for static discharge.

4.12.3 Motors.

4.12.3.1 Motors shall be rated for continuous duty and shall have ball or roller bearings of the sealed and permanently lubricated type. All motors, unless otherwise specified, shall conform to the requirements of NEMA MG 1. Motors shall be AC, 60-Hz, or DC industrial-type motors with drip proof enclosures. All motors 10 HP or greater shall have a soft start controller. Each motor control shall conform to the requirements of NEMA ICS 1.

4.12.4 Pneumatic Systems.

4.12.4.1 If the Test Stand requires a pneumatic system, the pneumatic system shall conform to the requirements of ANSI B93.114M and Section 43 15 00.00 20 E, LOW PRESSURE COMPRESSED AIR PIPING (NON-BREATHING AIR TYPE) applies to this section. The pneumatic system shall comply with ISO 4414:1998 and NFPA T2.25.1R2 200x.

4.12.4.2 The contractor shall not install pneumatic systems in a manner or location that interferes with the Test Stand or existing equipment or interferes with personnel access to equipment for operation or maintenance. The contractor shall not install pneumatic systems in a manner or location that interferes with the direct access to work-in-process (WIP), component containers and racking. The contractor shall not install pneumatic systems in a manner or location that interferes or in any way limits the full design motion of any crane.

4.12.5 Hydraulic Systems.

4.12.5.1 If the Test Stand requires a hydraulic system, the hydraulic system shall conform to the requirements of NFPA / JIC T2.24.1R1. The hydraulic system shall be complete including all pumps, valves, piping, cylinders, and pressure controls. Overpressure protection shall be provided in the high-pressure line to prevent damage to components. A filter system shall be provided to ensure delivery of clean fluid. The hydraulic reservoir shall have means for determining fluid level, a provision for draining, and a cleanout access plate if the reservoir is not removable.

4.12.5.2 The system shall be equipped with a hydraulic fluid requirements plate mechanically attached to the Test Stand at the hydraulic reservoir fill point. The plate shall contain the Type of fluid (SAE or Military or Federal specification number) and Type of filter.

4.12.5.3 The contractor shall not install hydraulic systems in a manner or location that interferes with the Test Stand or existing equipment or interferes with personnel access to equipment for operation or maintenance. The contractor shall not install hydraulic systems in a manner or location that interferes with the direct access to work-in-process (WIP), component containers and racking. The contractor shall not install hydraulic systems in a manner or location that interferes or in any way limits the full design motion of any crane.

4.12.6 Plumbing, Drainage and Waste.

4.12.6.1 If the Test Stand requires chilled water, incoming water lines shall have adequate anti-siphon provisions to prevent water supply contamination.

4.12.6.2 If the Test Stand requires water, the contractor shall install a Fresh Water Back Flow Check Valve.

4.12.6.3 The contractor shall not install plumbing, drainage or waste systems in a manner or location that interferes with the Test Stand or existing equipment or interferes with personnel access to equipment for operation or maintenance. The contractor shall not install plumbing, drainage or waste systems in a manner or location that interferes with the direct access to work-in-process (WIP), component containers and racking. The contractor shall not install plumbing, drainage or waste systems in a manner or location that interferes or in any way limits the full design motion of any crane.

4.12.7 Foundation.

4.12.7.1 The Test Stand shall utilize the existing foundation located in Building 475. The foundation is a 9-inch concrete slab on 8-inch compacted crusher run subbase material on stego wrap 10-mil vapor retarder, reinforced with 6x6-W2.9xW2.9 welded wire fabric, 3 inch below surface. The contractor shall perform any required modifications to the existing foundation. The Test Stand shall have tie-down anchoring bolts and leveling bolts on the base to facilitate leveling and shall meet all manufacture's requirements.

4.12.8 Safety and Health Requirements.

4.12.8.1 The Test Stand shall comply with OSHA limitations and control of noise levels, radiation, electromagnetic emission, noxious vapors, heats etc., as applicable.

4.12.8.2 The Test Stand shall be equipped with safety devices to adequately protect the operator from all hazards incident to its operation.

4.12.8.3 The Test Stand shall be in compliance with Occupational Safety and Health Administration (OSHA) 29 CFR 1910. The Test Stand shall include warning lights/indicators to alert the Test Stand operator to unsafe operating conditions. The Test Stand shall include a manual emergency shutdown switch and shall have the ability to automatically shut down when under automatic control. All parts, components, mechanisms, and assemblies furnished on the Test Stand, whether or not specifically required herein, shall conform to all requirements of OSHA 29 CFR 1910. Covers, guards, or other safety devices normally furnished as standard on the manufacturer's commercial Test Stands supplied to the commercial market shall be provided for the point of operation and all other parts of the Test Stand that present safety hazards. All special guarding shall meet OSHA 29 CFR 1910. The safety devices shall not interfere with the operation of the Test Stand. All guards shall allow access to the guarded part(s).

4.12.8.4 Safety devices shall be provided for all parts of the Test Stand presenting safety hazards. Guards shall be removable to provide easy access to the guarded parts. The Test Stand shall comply with the standards promulgated under OSHA 29 CFR 1910 that are applicable to the Test Stand itself.

4.12.8.5 Protection against electric shock shall be incorporated. All front access panels and doors shall be furnished with electrical interlocks to remove power from the cabinets while panels or doors are open.

4.12.8.6 Corrosion resistant "Caution" or "Warning" plates shall be securely attached to the equipment, visible to maintenance personnel and permanently marked.

4.12.8.7 Noise Level. Noise emitted by the Test Stand shall be no greater than 80 decibels measured at the location or three (3) feet from any point on the test stand whichever is closer. The 80-decibel limit is absolute. Techniques such as sound level averaging or exposure time weighting shall not be used in meeting this requirement. Any shields, baffles, enclosures or other devices required to bring the Test Stand into conformance with this requirement shall not interfere with visibility needed for safe operation of the Test Stand. Operators shall be able to use this Test Stand without the need for hearing protection.

4.12.8.8 Ergonomics. The Test Stand shall be ergonomically designed to prevent the occurrence of repetitive stress injuries.

4.12.9 Environmental Compliance. The Test Stand provided under this contract shall meet all applicable Environmental Protection Agency (EPA) and Alabama Department of Environmental Management (ADEM) regulations and restrictions in effect on the date of the contract.

4.12.10 Energy Efficiency. The Test Stand and its components that directly consume energy in normal operation shall be designed and constructed for energy efficiency in accordance with the developments available within the industry. Pneumatic circuits shall be designed for minimum air consumption.

4.12.11 Documentation. The contractor shall provide all documentation with the Test Stand as specified herein.

4.12.12 System of Units. The Test Stand shall display all units of measure in the U.S.

Customary System of Units "English", not Metric.

4.12.13 Nameplates.

4.12.13.1 The Equipment shall have the manufacturer's name and address, and the model and serial number in a visible place.

4.12.13.2 A nameplate shall be mechanically attached to the Test Stand adhesive alone will not be considered sufficient to meet this requirement, and shall contain, at a minimum, the following information:

a. Nomenclature.

b. Manufacturer's name, Address and Phone Number.

c. Serial number.

d. Model designation.

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

f. Facility Circuit Breaker or Buss Duct Switch Location Reference Number

g. Short-circuit/over current rating.

h. Contract number.

i. National stock number (if applicable).

j. Date of manufacture.

4.12.13.3 Laminated plastic nameplates shall be provided for equipment devices and panels furnished. Each nameplate shall identify the device; such as pump "P-1" or valve "VLV-402". Laminated plastic shall be 1/8-inch-thick, white with black center core.

Nameplates shall be a minimum of 1 by 3 inches with minimum 1/4-inch-high-engraved block lettering. Nameplates for devices smaller than 1 by 3 inches shall be attached by a stainless-steel chain or cable. All other nameplates shall be mechanically attached to the Test Stand or panel surface next to the device adhesive alone will not be considered sufficient to meet this requirement. The nameplate shall remain in place, undisturbed, when a component is replaced.

4.12.13.4 All words on instruments, control panels, charts, and plates shall be in the English language. Characters shall be permanently marked in boldface on a contrasting background. All plates shall be corrosion resistant. All plates shall be mechanically attached to the Test Stand adhesive alone will not be considered sufficient to meet this requirement.

4.12.14 Maintainability and Interchangeability. 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. When non-commercial off-the-shelf components are used The contractor shall provide all documentation including any electronic files and a manufacturing source required for production of those components. All replaceable parts shall be designed and manufactured to such standards as shall permit replacement and adjustment without the need for modification of the parts or the Equipment. All replacement parts shall be available domestically.

4.12.15 Workmanship. Standards of workmanship shall assure that the test stand shall have the stability, strength, safety, and efficient operating characteristics found in state of the market commercial units.

4.12.16 Tools. All tools, other than common hand tools, required for normal operation and maintenance of the Test Stand shall be provided.

4.12.17 Construction.

4.12.17.1 The Test Stand shall be so constructed as to be capable of performing the operations specified herein. All surfaces shall be clean and free of extraneous materials. External surfaces shall be smooth and free from sharp edges, rounded or beveled, unless sharpness is required for performance. All screws, pins, and similar parts shall be installed to prevent loss of tightness.

Parts subject to adjustment or removal shall not be permanently installed or deformed. The Test Stand shall be constructed of parts, which are new, without defects, and free of repairs. The structures shall withstand all forces encountered during operation of the Test Stand to its maximum rating and capacity without permanent distortion or failure.

4.12.17.2 Materials shall conform to the applicable specifications and shall be as specified herein and on the applicable drawings. Materials which are not covered by applicable specifications or standards shall be of the best quality, and entirely suitable for the purpose intended.

4.12.17.3 The Test Stand shall be constructed of corrosion resistant material or material that is treated or coated to be corrosion resistant. Test Stand materials not specifically designated herein or in the contract shall be of a quality commensurate with commercial practice within the applicable machine industry. When dissimilar metals are used in contact with each other, suitable protection against galvanic corrosion shall be applied.

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

4.12.17.5 Materials that are nutrients for fungi shall not be used.

4.12.17.6 Any nonmetallic material that is adversely affected by contact with Test Stand compounds shall not be used.

4.12.18 Lubrication.

4.12.18.1 A lubrication plate shall be attached to the Test Stand. The information provided on the plate shall include:

a. Points of lubricant application.

b. Servicing interval.

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

d. Viscosity

e. Federal or Military Specification Number (if applicable)

4.12.18.2 All bearings (except sealed-for-life type), mating gears, and sliding parts shall be provided with standard means for lubrication. Oil holes, grease fittings, and filler caps shall be accessible. Lubrication reservoirs, if applicable, shall have means for checking levels. Means shall be provided to ensure lubrication for all moving parts. Re-circulating lubrication systems shall include a cleanable or replaceable filter. Means for determining oil level in each reservoir shall be by an oil level sight gauge, a low oil level warning light or similar device and shall be in clear view of the operator's normal workstation. An automatic lubrication system shall be provided for all ways and axis screws. Each lubricant reservoir shall have at least a 24-hour capacity and means for determining fluid level. Any greases, oils, or fluids used to initially charge the lubricant system shall be free of contaminants known to be hazardous to human health.

4.12.18.3 Grease fittings conforming to ANSI AS35411 Fittings & Lubrication shall be provided in accessible positions not requiring removal of threaded fasteners at all necessary lubrication points. Pressure relief fittings shall be provided where use of high-pressure lubrication equipment could cause damage.

4.12.19 Drive Train Gears. The gears shall be of proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the Test Stand. Gears in the drive train shall be hardened and ground steel. Working surface hardness shall be not less than Rockwell C-48.

4.12.20 Castings and Forgings. Castings shall be free of visible blowholes, porosity, hard spots, shrinkage, defects, cracks, scale, mismatching or other defects. Forgings shall be free of visible scale, inclusions, cold shuts, mismatching, or other defects. Mechanical and chemical properties of the castings and forgings shall be adequate to meet the performance requirements of this specification. No processes such as welding, peen, plugging, or filling with solder or paste shall be used for reclaiming any defective part. Such processes may be used only for enhancing surface finish and appearance.

4.12.21 Welding, Brazing, and Soldering. Welding, brazing, and soldering shall be of a quality, which shall sustain the performance requirements of the welded, brazed, or soldered part. These operations, however, shall not be employed as repair measures for defective parts.

Welding, brazing, or soldering shall be employed only where specified in the original design.

Any material used for such operations shall be thoroughly removed from the part(s) upon completion of the operations.

4.12.22 Painting. Unless otherwise specified painting and finishing of the Test Stand when allowed shall be in accordance with standard commercial practice provided the following minimum criteria are met or exceeded: all surfaces to be painted shall have been cleaned to be free of all foreign matter detrimental to painting, and at least one coat of industrial primer and one coat of industrial enamel, or equivalent, applied.

4.12.23 Environmental Compliance. The test stands 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 ll be adhered to during the manufacture, service, transportation, storage and operation of the test stand.

4.12.23.1 Recovered Materials. The contractor is encouraged to use recovered materials to the maximum extent possible in accordance with paragraph 23.403 of the Federal Acquisition Regulation (FAR).

5.0 Acceptance.

5.1 Preliminary Performance Test. Preliminary acceptance of the test stand shall take place at the contractor Government. The contractor shall notify the COR 30 days in advance of the date the testing will take place. During testing the c requirements of paragraph's 4.1 through 4.12 here in by testing a minimum of one (1) of each type of oil pump per the applicable National Maintenance Work Requirements (NMWRs). Each type of oil pump shall be successfully tested a minimum of three (3) times consecutively.

During these tests, the contractor shall demonstrate proper operation of all Test Stand controls, functions and features.

5.2 Conformance. The Test Stand shall meet the requirements of this specification and assurance practices. The Government reserves the right to, at any time during the contract period, require proof of such conformance or to inspect the Test Stand to determine compliance with the requirements of this specification.

5.3 Calibration. The contractor shall verify Test Stand calibration using the calibration procedure and test equipment provided with the Test Stand per paragraph 7.0 herein. The contractor shall not proceed with calibration until the ANAD Contracting Officer or Contracting Officer's Representative confirms that installation is complete and meets all related requirements herein. The contractor shall provide all resources, equipment, and instruments required to perform Test Stand calibration. All equipment and instrumentation used to calibrate the Test Stand shall be traceable to the National Institute of Standards Technology (NIST). Test Stand calibration shall be witnessed and verified by ANAD calibration and engineering personnel.

Training for ANAD calibration personnel shall be provided during calibration (see requirements of 7.0).

5.3.1 Certificate of Calibration. Upon completion of Test Stand calibration, the contractor shall provide a certificate of calibration stating the date of calibration, recommended date for next scheduled calibration, and NIST traceability information for the calibration equipment/instruments used. The certification shall also include the nomenclature, part/model number, and serial number of the Test Stand and shall be signed by the contractor.

5.4 Final Performance Test. Final performance testing will take place at Anniston Army Depot upon completion of Test Stand installation and calibration, the contractor shall

4.1 through 4.12 here in by testing up to five (5) of each type of oil pump per the applicable National Maintenance Work Requirements (NMWRs). During these tests, the contractor shall demonstrate proper operation of all Test Stand controls, functions and features. The Government will provide the components to be tested. The Government will provide all oil required for performance testing.

The Government will provide for the disposal of any oil used for the performance testing. All tests must be witnessed by the ANAD Contracting Officer or Contracting Officer's Representative. Should a malfunction or test stand failure occur during any test, the contractor shall correct the problem and repeat the entire test from the beginning.

5.5 Final Acceptance. Final acceptance of the test stand will take place at Anniston Army Depot. The Government will accept the Test Stand only after the contractor successfully completes the requirements of paragraphs 5.2, 5.3, and 5.4 including subparagraphs and provides all training and documentation required herein. Final acceptance will be at Anniston Army Depot. Upon acceptance of all items described above, the contractor shall submit a completed DD Form 250 for signature by the government representative, as final acceptance of the equipment required by this specification (see solicitation for form & instructions).

6.0 Installation and Delivery.

6.1 Delivery. The contractor shall be responsible for delivering the Test Stand to building 130 at Anniston Army Depot. Delivery and installation shall be completed and the Test Stand operational and accepted within 360 calendar days after award of contract.

6.1.1 Shipping, Handling, and Storage. Unless otherwise specified herein, 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 loading, unloading, transport, or storing of any materials. 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. Should the contractor not wish to furnish a trailer for equipment storage, then the contractor shall coordinate with the Contracting Officer, a date at which time the contractor may deliver this equipment to the building.

6.2 Installation. The contractor shall be responsible for installing the Test Stand to include all labor, materials, tools, and equipment required. The contractor shall be responsible for ensuring the Test Stand installation requirements are compatible with existing facilities. The contractor shall field verify all dimensions and locations of utilities at the installation site and report any discrepancies to the Contracting Officer before proceeding with installation. Any discrepancies not reported prior to beginning of installation shall become the responsibility of the contractor. Unless otherwise approved by the Contracting Officer, installation shall be completed during normal depot working hours. The contractor shall ensure that the installation of the Test Stand occurs in an operational environment without obstructing or disrupting ongoing activities in the area. The contractor shall not interfere with ongoing Government operations and production unless authorized by the Contracting Officer.

6.2.1 Instructions for Installation. No less than 60 calendar days prior to shipment of the…