01573805-00229-SOW VTL Rebuild.pdf

Statement of Work (SOW)

42” Bullard Cutmaster Vertical Lathe Refurbishment Repairs Puget Sound Naval Shipyard, Bremerton, WA

Part 1

General Information

1. GENERAL: This SOW provides removal, rebuild and installation of a 42” Bullard Cutmaster Vertical Lathe machine for PSNS & IMF Bremerton in Building 431. The contractor shall provide all personnel, equipment, supplies, facilities, transportation, tools, materials, supervision, and other items and non-personal services necessary to perform removal, rebuild and installation as defined in this SOW except for those items specified as government furnished property and services.

1.1 Background: PSNS&IMF Shop 31’s 42” Bullard Cutmaster vertical lathe SN 27938 is not functional.

Because the production output of vertical turning is critical to the shop meeting its mission it requires a vertical turning lathe that is fully functional, this is in accordance with the Shop 31 equipment recapitalization plan and Shipyard 2030 plan. The Vertical Lathe SN 27938 has been in use at Puget Sound Naval Shipyard and Intermediate Maintenance Facility (PSNS & IMF) since 1953. The work in this SOW is needed to bring in a vertical lathe that can meet the shop’s needs as soon as possible.

1.2 In-stock trade benefits: In order to expedite returning critical vertical turning capability back to the shop it is in the government’s best interest to have the contractor rebuild a 42” Bullard Cutmaster vertical lathe that the contractor has in stock in their facility. The contractor would take the 42” Bullard Cutmaster Vertical Lathe SN 27983 as trade stock, removing it when they deliver the rebuilt lathe. This is beneficial to the government because it; a. reduces the time to delivery of the fully functional lathe by months,

b. reduces the cost of shipping required vs. having to send the government owned lathe to the vendor and shipping it back,

c. and avoids the cost of disposal for the lathe and instead provides a discount for the rebuild of the in-stock lathe.

1.3 Period of Performance: The period of performance shall be for Six (6) months from time of award.

1.4 Place of Performance: The work to be performed under this contract will be performed at the contractor facility and Puget Sound Naval Shipyard, Bremerton WA in B.431.

2. APPLICABLE PUBLICATIONS (CURRENT EDITIONS)

2.1. The Contractor must abide by all applicable regulations, publications, manuals, and local policies and procedures. OSHA 1910, 29 CFR 1910, NFPA 70 and NFPA 79, NEMA Z535.4.

PSNS&IMF:

P5100 (14) Visitor and Contractor Handbook P5090 (4) Contractor’s Guide to Environmental Compliance P5090 (5) Contractor’s Guide to Hazardous Waste Compliance

3. REQUIREMENTS:

3.1. Rebuilt 42” Bullard Cutmaster Vertical Lathe. Rebuild a 42" Bullard Cutmaster Vertical Lathe configured with a Cylindrical Ram Head on the Cross Rail and a Sidehead with a Trabon Automatic Lubrication System on both the Ram Head and Sidehead, Independent Outside Motor Driven Rapid Traverse System and Newall Digital Readout System four axis system installed. The lathe shall have a built in 4-jaw chuck, pendant control and use 220 volt, 3 phase, 60-hertz power.

3.1.1. Size and Capacity. The size and capacity of the Bullard Cutmaster Vertical Lathe shall be not less than specified in Table 1.

Table 1 Size and Capacity

Max swing with side head above table top 42 inches Max swing with side head below table top 50 inches Max height table to rail 36 inches Cross rail vertical travel 24 inches Cylindrical Ram Head travel 40 inches Max distance table to underside of side head slide 27.5 inches Side head vertical travel 36 inches Side head horizontal travel 20 inches Table spindle speed 5 to 145 rpm Feed speed .0026 to .500 ipr Spindle motor HP 30HP

3.1.2. Alignment and Accuracy. The alignment and accuracy of the Bullard Cutmaster Vertical lathe shall not be greater than specified in Table 2.

Table 2 Alignment and Accuracy

Flatness of work table surface (concave only) 0.0005/12-inches Rotary table trueness of axis rotation (table periphery) 0.0015 inches Side head vertical travel to table .0005 inches Parallelism of top surface of work table to head travers travel 0.001 inch/12-inches Cross rail travel square with table 0.0005 inch/12-inches Ram travel square with table 0.0005 inch/12-inches Side head horizontal travel parallel with table 0.001 inch/12-inches Turret indexing accuracy for each turret ±0.001 inch Turret hole to hole accuracy ±0.001 inch

3.1.3. Perform Tolerance and Mechanical Rebuild. The rebuild of 42" Bullard Cutmaster Vertical Lathe shall consist of not less than the following actions.

3.1.3.1. Disassemble machine to component parts. Clean all component parts.

3.1.3.2. Remachine all bearing surfaces of the Cross Rail to remove localized wear & scoring.

3.1.3.3. Remachine all bearing surfaces of the saddle to accept Turcite way material to compensate for material removal and to assure correct alignment of the downfeed shaft.

3.1.3.4. Install Turcite to all bearing surfaces of the saddle.

3.1.3.5. Remachine bearing surface to correct height to assure proper alignment of downfeed shaft and feed box.

3.1.3.6. Precision scrape, block and hook frost the Cross Rail for appearance and retention of lubrication oil.

3.1.3.7. Precision hand scrape and fit the saddle to the Cross Rail assuring proper bearing contact.

The saddle will be fitted to the cross rail with a .001" preload for alignment purposes.

3.1.3.8. Manufacture three new meehanite cast iron gibs for the saddle. Precision scrape and fit allowing for full adjustment to compensate for any future wear.

3.1.3.9. Oil groove saddle gibs for proper delivery of lubricating oil. Clean all lubrication fittings.

3.1.3.10. Manufacture and install new double lead crossfeed screw and nut. Align nut body to assure proper alignment.

3.1.3.11. Replace all lubrication fittings to the saddle.

3.1.3.12. Disassemble the Cylindrical Ram Head completely.

3.1.3.13. Precision grind the Ram to a standard size for a commercially available oil seal, 6.875" diameter.

3.1.3.14. Setup the Ram Carrier with a standard removable shim pack between top and bottom halves. The Carriers will be bored to accept Belzona way material.

3.1.3.15. Re-line the Ram Carrier with Belzona, a low friction wayliner, to reestablish bearing fit between Ram and Carrier.

3.1.3.16. Fit the Rams’ carrier halves to the reground Ram. A new micarta or phenolic keyway will be manufactured and installed.

3.1.3.17. Assemble the Ram and the top carrier cap and re-pin.

3.1.3.18. Install a new triple lead acme leadscrew and split nut sets into the Ram.

3.1.3.19. Replace all lubrication fittings on the Ram and check for proper operation. Two additional Zerk fittings will be added for improved lubrication.

3.1.3.20. Rebuild the electro-hydraulic shifter solenoid box. The following work will be performed.

3.1.3.20.1. Disassemble and clean all component parts.

3.1.3.20.2. Examine condition of upper block valve seats. Replace the Clutch/Brake and Unloading Valve seats.

3.1.3.20.3. Precision grind block to assure all new seats are flush. Reseat upper ball seats using OEM seating tool.

3.1.3.20.4. Regrind all speed shifter pins to the correct size. The clutch/brake and unloading valve pins will be hand lapped to their respective upper seats to assure no leakage. Block and pin measurements will be taken and the clutch/brake and unloading valve pins will be ground to correct overall length.

3.1.3.20.5. Remove all pistons from the lower block and checked for scoring and wear.

3.1.3.20.6. Check the condition of the shifter interlock units and replace components as needed.

3.1.3.20.7 Check the quick exhaust bypass for brake operation and replace ball and spring.

3.1.3.20.8. Check the metering valve for clutch speed operation and set for proper operation.

3.1.3.21. Replace all bearings in the clutch case unit and install new oil seal on pulley. The parts replaced will be as follows:

Qty Part # Key# Description 1 Comm. 842 National Seal - #416888 1 Comm. 839 MRC Bearing - 209M 4 Comm. 831 BCA (Cone) - 12175 4 Comm. 831 BCA (Cup) - 12303 4 Comm. 841 BCA (Cone) - 34306

4 Comm. 841 BCA (Cup) – 34478

3.1.3.22. Recondition the center miter distribution box.

3.1.3.23. Reset the clutches for rail operation centering for proper rail elevation. Mechanical safety stops will be adjusted and checked for proper operation.

3.1.3.24. Install a rebuilt heavy-duty three plate clutch and rebuilt brake. Replace the following parts.

Key # Detail # Description Qty 322 47740 Drive Friction Plate 1 256 48902-1 Toggle Roll 3 982 91766 Driver Friction Plate 2 981 U-18902-2 Friction Plate Unit 2 983 91766 Clutch Gear Plate 2 311 U-18902-1 Friction Plate Unit 1 254 47449-1 Clutch Fork Shoe 2

3.1.3.25. Rebuild the primary section of the transmission replacing all bearings.

3.1.3.26. Remove the secondary of the machine and check for proper operation. Install a new "E" clutch for correct high-speed operation. Replace all bearings.

3.1.3.27. Replace the unloading valve, high pressure safety valve and check valve assemblies with new Vickers or equivalent components.

3.1.3.28. The column ways will be hand scraped, block and hook frosted for appearance and oil retention.

3.1.3.29. The side head carrier will be precision scraped and fitted to the column assuring proper bearing fit and correct relationship to spindle centerline.

3.1.3.30. Regrind all bearing surfaces of the side head ram to remove localized wear and scoring.

3.1.3.31. The side head ram carrier surfaces will be broken up, blocked and stoned for refitting of the ram.

The ram will be refitted to the carrier assuring full bearing contact and perpendicular alignment to the spindle centerline.

3.1.3.32. Completely clean all interior cast areas of the main transmission and clutch case. The exterior of the machine will be primed and painted machine tool gray.

3.2.3.33. Replace all way wipers on the machine with new to protect machined surfaces.

3.1.3.34. Rewire the machine. A standard Bullard operators two-station system will be installed. Provide a current wiring diagram with the machine.

3.1.3.35. The main drive motor will receive new bearings.

3.1.3.36. The Cross Rail will be re-leveled and the top of the table will be recut to assure parallelism with Cross Rail. The sliding jaws from the four jaw chuck will be removed and reground for operation below table top.

3.1.3.37. Install a Trabon Lubrication System covering the conversion of all hand oil points to pressurized lubrication. The system will be composed of a self-contained oil reservoir, four block feeder assembly, master distribution block, air pump with high pressure blowout assembly, solid state controller and remote audio alarm. The system will account for surface areas for each point of lubrication and size individual block units to deliver the proper amount of lubricant. Provide a systematic diagram of the system with the machine.

3.1.3.38. Install a motor driven rapid traverse system providing rapid traverse operation running off a separate 5 HP motor coupled on top of the RH miter bracket. The rapid traverse system will include the following.

3.1.3.38.1. Install a 5 HP AC motor to drive the rapid traverse system.

3.1.3.38.2. Be mounted to top of Right Hand miter bracket assembly. Including drive gearing, couplings, belts and belt guard.

3.1.3.38.3. Use existing coolant starter and electrical wiring. Remark for rapid traverse operation.

3.1.3.38.4. Hard wire motor to starter and modify electrical print as required.

3.1.3.38.5. Install a set of four Allen Bradley or equal heavy duty limit switches with mounting brackets to install on rear of both feed boxes.

3.1.3.38.6. Modify soft plugs in rear of feed boxes to accept approx. 4" length extensions. Manufacture extensions with ramped incline to trip limit switches when extensions are moved to operating position.

Install into operating shafts.

3.1.3.38.7. Install new oil seals as required sized to extension diameter.

3.1.3.38.8. Wire to existing starter and modify electrical print for changes.

3.1.3.39. Install a direct motor driven hydraulic pump allowing servicing of the hydraulic pump without removal from the machine. The system will use bulkhead fittings through the rear of the clutch case to connect to the existing lines of the machine. Including installation of two E-Stop Pushbutton stations that will provide an E-Stop capability that maintains hydraulic pressure by using an outside motor driven pump system and run it on a time delay. That will allow the shut down of the main motor immediately, stop the table using full braking power, stop rotation of the Vertical Spline shafts and ultimately time out the Hydraulic Motor. The following will be added to the machine.

3.1.3.39.1. Install a three pushbutton station for mounting on the face of the Cross Rail Feed box to control the following:

3.1.3.39.1.1. Run / Jog Selector Pushbutton (Table Start)

3.1.3.39.1.2. Spindle Stop Pushbutton (Normal Table Stop)

3.1.3.39.1.3. E-Stop Pushbutton

3.1.3.39.2. Modify the 6 Pushbutton Station on the front of the control station to include an E-Stop Pushbutton.

3.1.3.39.3. Install new wiring to the main electrical cabinet as needed. Included in wiring diagram.

3.1.3.39.4. Install a time delay relay to provide adjustable time delay for running Hydraulic Pump during an E-Stop actuation.

3.1.3.39.5. Install the following components for the Outside Motor Driven Hydraulic System.

3.1.3.39.5.1. Baldor 5HP High Efficiency 1200 RPM Motor for operation on 230/460 VAC

3.1.3.39.5.2. Magnaloy Aluminum Pump/Motor mounting kit

3.1.3.39.5.3. Coupling with neoprene insert

3.1.3.39.5.4. Vickers V-20 Pump setup for LH rotation with SAE 2 bolt mount

3.1.3.39.5.5. Steel Mounting Plate

3.1.3.39.5.6. Assemble setup for operation running from the left rear of the machine.

3.1.3.39.6.6. Install a modified Clutch Case Cover (Key #327, p. 49) with two bulkhead fittings.

3.1.3.39.6.7. Install four new hoses to connect existing system with external system.

3.1.3.40. 2. Install an analog hour meter. Mount the analog hour meter on the main electrical panel visible from the outside. The hour meter shall be installed to display accumulated operating time of the main drive motor. The meter shall be of the non-resetting type and shall have a range of 0 to 99,999.9 hours in increments of 0.1 hours, and shall revert to zero (0) upon reaching the maximum count. The meter shall have a NEMA enclosure rating of 4X, and shall be mounted to withstand shock and vibration generated by the equipment in an accessible location.

3.1.3.41. Install a four (4) axis Digital Readout System. System to include the following.

3.1.3.41.1. Newall DP1200 - 4 axis display or equivalent with Switchable Resolution, Absolute / Incremental Mode, Zero Reset, Home Reference, Preset Features, Inch / Metric switchable, Arc Contouring, Downloadable Software Upgrades, Feed Rate Display, Programmable Memory, Taper Calculations, Centerline and Linear Error Compensation, 5 Year Warranty and Spherosyn Scales with .0005"/.0002" Resolution.

3.1.3.41.2. Manufacture all necessary brackets for installation. Machine slides for installation of brackets to facilitate ease of tramming the machine.

3.1.3.41.3. Supply all necessary electrical wiring, connectors and manuals.

3.1.3.41.4. Size scales to include full range of travel plus safety dimension.

3.2 Markings: The following signs, labels, placards and certifications will be placed on the machine in an accessible and readable location. All words on instruments, control panels, and plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

3.2.1. OSHA Compliance certfication by National Recognized Testing Laboratory (NRTL). The equipment installation and its component parts shall be in compliance with 29 CFR 1910, NFPA 70 and NFPA 79. Approval shall be as specified under the “Approval” and “Acceptance” criteria in the OSHA regulations Subpart “O”, Machinery and Machine Guarding paragraph 1910.212 and Subpart “S” Electrical, paragraph 1910.303 and paragraph 1910.399.

3.2.2. Safety signs and labels in accordance with NEMA Z535.4 shall be securely attached to the equipment in visible locations, at the point of hazard(s), with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the signs.

3.2.3. A PCB Certification information shall be permanently and securely attached in the vicinity of the manufacturer’s identification plate. The machine will contain no PCBs.

3.2.4. A lubrication plate shall be permanently and securely attached to the machine. The plate shall contain the following information:

Points of lubricant application Servicing interval Type of lubricant

Viscosity Military or Federal Specification for each lubricant (If applicable) Size and type of each lubricant filter

3.2.5. A nameplate shall be permanently and securely attached to the machine. The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

Nomenclature Manufacturer's name Manufacturer's model designation Manufacturer's serial number Power input (volts, total amps, phase, frequency) Contract Number or Order Number Date of manufacture

3.3. Acceptance Testing: The machine will be setup for acceptance testing at the contractor facility. The following tests will be performed and the resulting tolerances will be charted. The government reserves the right to be present at the time of testing.

Check #1 - Column square to centerline of table Front to back:

Cross rail positioned 14" above table Rail moved upward 28" Start position .0000" Finish position +/-.00075" Right to left:

Rail moved downward Start position .0000" Finish position +/-.00075""

Check # 2 - Ram alignment Left to right reading:

Start position - cross rail at 14" from top of table.

Ram head travel - 30" Start reading .0000" Finish position +/-.00075" Front to back readings:

Start position .0000" top Finish position +/-.0015"

Check #3 - Side head alignment Left to right reading:

Start position - side head at 6" from top of table.

Sidehead moved up 18" Start reading .0000" Finish position +/-.00075" Front to back readings:

Start position .0000" top Finish position +/-.00075"

Check #4 - Side head alignment Start position - side head at 6" from top of table.

Sidehead moved horizontally - 18" Start reading .0000" Finish position +/-.00075"

3.4. Warranty: The rebuilt machine will have a full one-year warranty on all parts and labor which have failed and have not been the result of operator mistake of misjudgment nor neglect of recommended maintenance as identified in the Manual.

3.5. Removal: Remove 42” Bullard Cutmaster Vertical Turret Lathe SN 27983 from PSNS&IMF Bremerton Building 431.

3.5.1 Provide for the removal and shipping of the lathe.

3.5.1.1 Government will provide disconnect from power and remove all liquids.

3.5.1.2 Remove, load, package and transport the lathe to contractor facility.

3.6. Installation: Install Rebuilt 42” Bullard Cutmaster Vertical Lathe at PSNS&IMF Bremerton Building 431.

3.6.1. After the rebuild work and testing is complete at contractor facility, the contractor will transport the lathe to PSNS&IMF and fully install, and perform a full operational and functional testing.

3.6.1.1 Package to protect lathe during shipment and ship to PNS&IMF Bremerton WA for direct delivery to Building 431.

3.6.1.2. Installation includes blocking, anchoring, leveling and alignment of machine. Connecting of electrical system to disconnect within 20 feet of machine location. Contractor is responsible for all conduit, stands, etc. needed for electrical connection in accordance with NFPA 70 and NFPA 79.

3.6.1.3. Operational testing includes a full 8 hours of operation without failure.

3.6.1.4. Functional testing includes at least 3 hours of continuous use of all lathe functions without failure.

4. GOVERNMENT FURNISHED ITEMS:

4.1 Equipment: The Government will provide 42” Bullard Cutmaster vertical lathe SN 27983 as trade stock. It will be drained of all oil and coolant.

4.2 Materials: The Government will provide oil and coolant to fill installed rebuilt vertical lathe for testing and use.

5. CONTRACTOR FURNISHED ITEMS AND RESPONSIBILITIES:

5.1. General: The Contractor shall furnish all supplies, equipment, facilities and services required to perform work under this contract that are not listed under Section 3 of this SOW.

5.2. Materials. The Contractor shall furnish all new parts, motors, gaskets, screws, way covers, RDOs, spindles, rams, wipers, pumps, guards, wiring, conduit, switches, piping, etc. not listed under Section 3 of this SOW.

5.3. Equipment. The Contractor shall furnish a 42” Bullard Cutmaster vertical lathe for rebuild out of stock on-hand.

6. SECURITY

6.1. To obtain access to Naval Base Kitsap – Bremerton, refer to the security section of the issued contract.

6.2. Ten (10) business days prior to an on-site visit, the Contractor shall complete the visitor information portion of the PSNS&IMF “Visitor Badge Request”, PSNS form 5512/127, a “Vehicle Pass Request for Access to the Controlled Industrial Area (CIA)”, PSNS&IMF Form 5530/25

6.3. Upon receipt of the Visitor Badge and/or Vehicle Pass requests, and at least five (5) business days before the NAVSEA CIA badges are needed, the sponsor will submit the request(s) to the Naval Base Kitsap – Bremerton Pass and I.D. Office.

6.4. Proof of Citizenship: Contractors working within the CIA are required to be United States citizens and must show proof of citizenship (see Navy Commercial Access Control System (NCACS) or solicitation/award documentation) prior to receiving a NAVSEA CIA badge.

6.5. Working hours: All work is to be performed during PSNS&IMF’s regular work hours from 7:30 a.m.

to 4:00 p.m., Monday through Friday except for Federal Holidays.

6.6. Restrictions.

6.6.1. Restricted colors: PSNS&IMF uses the colors magenta, yellow, red and blue to identify specially controlled materials. The Contractor is specifically prohibited from using magenta, yellow, red or blue colored plastic wrapping materials or bags, tape, or other covering materials.

6.6.2. Radio restrictions: Operation of privately owned citizens band or amateur radio equipment (receive and transmit) within the geographic limits of PSNS&IMF is prohibited.

6.6.3. Computers and Cellular phones: The use of company or privately owned personal computers and cellular telephones without photographic capability by contractor personnel at PSNS&IMF is restricted but not prohibited as outlined below.