11123052-SOW.pdf

Scope of Work for Betts-Bridgeford Tailstock Upgrade

1. SCOPE

1.1. Scope. The purchase description set forth below describes the minimum requirements of the Government for a new 50-ton work piece capacity, 12-inch diameter quill with 12-inches of stroke, Betts-Bridgeford tailstock top. This procurement shall include manufacturing, shipping, installation, training and technical data. It is the Government’s intent that a single primary contractor be awarded this contract and be responsible for the provision of equipment, and the accomplishment of all work detailed by this specification.

2. REQUIREMENTS

2.1. Design. The item offered shall be new and a currently available model. The tailstock shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

2.2. Construction. The tailstock shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the tailstock to its maximum rating and capacity without distortion.

2.2.1. Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

2.2.2. Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

2.2.3. Corrosion Control. All system components shall be protected against corrosion and deterioration by appropriate material selection, application of coatings and sealants. Painting shall result in a highly wear-resistant finish, which guarantees continued protection to the surfaces covered against the specified environment under all service conditions. Exposed ferrous parts such as screws, bolts, nuts, washers shall be treated to resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as cadmium or chrome plating, galvanizing or other electrical/chemical process, or stainless steel is acceptable. All paint shall be lead and chromate free.

2.2.4. OSHA Compliance. 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.

2.2.5. Safety Signs and Labels. 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.

2.2.6. Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11. The safety devices shall not interfere with the operation of the tailstock. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

2.2.7. Measuring and Indicating Device Graduations. All measuring and indicating devices on the shall be graduated in the inch/pound or both inch/pound and metric.

2.3. Components. The tailstock shall consist of not less than the following components.

2.3.1. Quill Housing. The contractor shall provide a one piece, steel welded, tailstock quill housing. The quill housing will house the quill, quill spindle, spindle bearings, and the quill drive system. The base of the quill housing shall be precision machined to mate with top surface of existing tailstock base. Quill housing to base alignment shall use the existing tapered keyway and slideway. Provisions for adjustment in the x-axis shall be provided.

2.3.2. Quill Assembly. The quill assembly shall be a 12 inch diameter forged quill with 12 inches of travel. The quill shall house a forged spindle rotating on precision spindle bearings. The spindle nose shall be capable of accepting a 60 degree bolt-on flanged center with a tapered pilot. Quill clamping shall be manual with clamping mechanisms located on the operator side of the machine.

2.3.3. Bolt-On Flanged Center. Two (2) bolt on flanged centers, MTR P/N 61B3288, shall be supplied. One bolt-on flanged center shall come installed on the quill assembly. The bolt-on flanged center shall be capable of handling a part weight of 50-tons between centers and have a TIR of 0.0005 inches or less.

2.3.4. Quill Drive System. The quill shall be equipped with a power drive system. The power drive system shall traverse and thrust the quill into the work piece. The quill drive system shall be operated by using electrical push buttons mounted conveniently for the machine operator. The quill drive system shall include provisions for thrust and compensation for thrust for any changes in shaft length. The quill drive system shall provide feedback to a thrust indicator display that indicates the thrust of the tailstock on the workpiece. The quill drive system be capable of producing enough thrust to support a 50-ton work piece.

2.3.5. Power Cable Reel. A power cable reel for supplying power to the tailstock electrical components shall be provided. Installation and electrical hook up of the cable reel will be the responsibility of the Government. The power cable reel shall provide enough cable to allow the tailstock to traverse the entire length of the bed.

2.3.6. Heavy Duty Plug Electrical Connection. A male and female plug to disconnect the tailstock from line power shall be provided. This shall occur at the junction of the power reel and the control cabinet mounted to the tailstock and include the ability to manually release the strain relief that holds and pulls the cable on the reel. Safety tags shall be installed. One tag shall warn of the danger of uncoupling the plugs with the tailstock in use. The other shall warn of the danger associated with releasing the strain relief from the tailstock.

2.3.6.1. Safety Tags. Safety tags shall be installed. One tag shall warn of the danger of uncoupling the plugs when the tailstock is energized. The other shall warn of the danger associated with releasing the strain relief from the tailstock.

2.3.7. Hardware. Any additional hardware that is required for clamping the tailstock to the bed of the lathe or mating the tailstock to the base shall be supplied by the contractor.

2.3.8. Electrical System. The tailstock shall conform to NFPA 79. The tailstock’s electrical system shall be tolerant of voltage fluctuation of ± 10 percent. The electrical system shall be complete.

2.3.8.1. Motors. Motors shall be rated for continuous duty and shall have ball or roller bearings of the sealed and permanently lubricated type. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors 1 HP and above shall meet the requirements of NEMA MG 1. Each motor shall have an identification plate to identify manufacturer, model identification, serial number, voltage, amperage, horsepower, phase, frequency and frame number written in the English language. Servo motors are exempt from these requirements. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s), unless otherwise specified herein.

2.3.8.2. Electrical Enclosures. Electrical components of the equipment shall be contained in enclosures of drip-proof construction and of minimum size consistent with good design practices and ventilation of components, meeting the requirements of NEMA Type 12.

2.3.9. Energy Isolating Devices. The equipment shall be provided with energy isolation devices (e.g. power switches, safety devices, circuit breakers, valves) that protect personnel from the release of hazardous energy and are integral to the component being isolated and locked out. The devices shall be designed and manufactured such that they can be padlocked in the OFF position. This includes both mechanical and electrical devices. An energy isolation device shall be installed as the first energy control device on all major components of the system such that the component can be isolated at the component level.

2.4. Size and Capacity. The size and capacity of the Click here to enter Main Item Name shall be not less than specified in Table I.

Table I Size and Capacity Quill diameter 12-inch Quill stroke 12-inch Quill clamp Manual Center point 60-degrees Center type Bolt on with taper flange, MTR P/N 61B3288 Center load capacity 25-tons, 50-ton workpiece

2.5. Alignment and Accuracy Tolerances. The alignment and accuracy tolerances of the tailstock upgrade shall be as specified in Table II.

Table II Alignment and Accuracy Center runout 0.0005-inches Quill Alignment, X-Axis Plane, Operator Side

+0.001-inches, from quill housing to end of quill with quill extended or as reasonably achievable with the condition of the machines slide ways and bed.

Quill Alignment, Y-Axis Plane, Top of Quill +0.001-inches, from quill housing to end of quill with quill extended or as reasonably achievable with the condition of the machines slide ways and bed.

2.6. Tailstock Base Machining and Realignment. The existing tailstock base on the machine is not geometrically sound and needs to be machined back to factory specifications to accept the new tailstock that mounts on top of the base.

2.6.1. Government Tailstock Base Responsibilies. The Government will be responsible for the following:

a. Removal of the existing tailstock top from the base and removal of the base from the machine.

b. Crating the tailstock base and taper shoes.

c. Finish machine the taper shoes and slide plates at MTR’s direction.

2.6.2. Contractor Responsibilities. The Contractor shall be responsible for the following:

a. Shipment of the crated tailstock base and taper shoes to MTR’s facility by common carrier.

b. Machining of the base to restore proper geometry to the horizontal base ways, vertical base way, top and quill housing mounting surface, trapezoidal keys, building up the taper shoes as needed, provide bronze liners, and install way wipers..

c. Supply a before and after test report for all base modifications (CDRL 0001).

d. Painting of the tailstock base to match the new tailstock.

e. Shipment of the completed tailstock base with the tailstock back to Puget.

f. Fitting the modified base and taper shoes to the machine bed, within the allowance of the wear on the bed.

2.7. Swivel hoist rings. The total weight of the equipment for determining lift point capacity shall be the estimated weight of the item plus 10% for unexpected growth in the weight of the item.

2.7.1. Sling load. The sling load at a given lift point shall be the vertical load at that point increased by the resultant sling angle.

2.7.2. Use of three or more swivel hoist rings. When installing three or four swivel hoist rings, only two shall be assumed to carry the load, unless a spreader or strongback is used.

2.7.3. Spreader or strongback use. The use of spreaders or strongbacks shall be kept to a minimum, but if they are deemed necessary, a lift sketch detailing the required spread, capacity and orientation of that gear shall be submitted. In addition, the individual loads for each point shall be calculated based on the rigged configuration of the equipment and its center of gravity.

2.7.4. Swivel hoist ring interface. The swivel hoist ring interface (i.e., threaded fitting, etc.)

shall be designed for the resultant sling load and be able to withstand the manufacturer’s required bolting torque, but it will not require proof testing. For steel, the minimum thread engagement shall be 1-1/2 times the diameter of the hoist ring fastener. An alternate method is to bolt through the structure using a washer and a SAE Grade 8 nut with full thread engagement (minimum two threads protruding). The hoist ring manufacturer may be consulted about the adequacy of the hoist ring/structure interface.

2.7.5. Supporting structure. The structure supporting the swivel hoist ring attachments shall be designed to sustain the various lateral loads imparted by the arrangement of the swivel hoist rings and their induced sling angle loads.

2.7.6. Nameplate. A nameplate shall be permanently and securely attached to each 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

2.8. Technical Data. Three (3) hard copies and one (1) electronic copy(s) of technical data shall be provided with the machine. The technical data shall include but not be limited to the following (CDRL 0002):

a. Safety

b. Operating manuals.

c. Electrical including schematics, bill of material and spare parts list.

d. Mechanical including assembly drawing, lubrication, bill of material and spare parts list, lift plan.

e. Commercial bulletins

f. Inspection report.

2.9. OSHA Approved Certification. The Government will hire an OSHA certified Nationally Recognized Testing Laboratory (NRTL) to inspect the tailstock for compliance to all requirements in paragraph 2.2.4. It will be the contractors responsibility to make the tailstock compliant per the field evaluation report supplied by the NRTL.

2.10. Installation. Contractor shall be responsible for the Installation Responsibilities chart on page 6 and shall comply with EM 385-1-1 and UFC 3-301-01.

2.10.1. Mechanical Installation. The Contractor shall provide all labor, fluids, piping, interconnecting hoses, and any other materials to move, locate, set level, align, lubricate, and make ready to operate all equipment required by this contract. All machinery shall be installed to original manufacturer's tolerances.

2.10.2. Finish Machining of Taper Shoes and Bronze Slide Plates. The Government will finish machine the taper shoes and brass slide plates as directed by the contractor to achieve final alignment specifications. The Government will not be liable for misalignment of the tailstock after machining has been performed.

2.10.3. Electrical Installation. The contractor shall be responsible for making power connections from the power cable reel to the tailstock. The Government will be responsible for connecting power to the power cable reel.

2.11. Hazardous Energy Control (HEC) Program, Lockout/Tags-Plus (LOTP). The contractor shall accomplish HEC/LOTP in accordance with OSHECM Chapter 250 and 29

CFR 1915.89.

2.12. Training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative shall be provided for specialized training to familiarize receiving activity personnel with the tailstock operation.

3. QUALITY ASSURANCE

3.1. Final Inspection/Acceptance Test (Destination). Final inspection and acceptance test shall be performed on the tailstock to ensure conformance with this purchase description. The acceptance test shall be performed only after the tailstock is installed at its final location.

3.2. Tests. Upon completion of installation, the new tailstock top will be powered up and fully tested for functionality and accuracy. The following tests shall be performed using the contractor standard test methods.

3.2.1. Tailstock Center Runout Accuracy Test.

3.2.2. Headstock to Tailstock Center Height Test.

3.2.3. Quill Travel Parallel to Bed Way Test.

3.2.4. Quill Travel Test.

3.2.5. Quill Travel Limit Test.

3.2.6. Load Cell Test.

INSTALLATION RESPONSIBILITIES

Government Contractor

(XX) ( ) a. Furnish labor and material handling equipment for off-loading and placing item on the lathe.

( ) (XX) b. Connect tailstock to the power cable reel.

( ) (XX) c. Provide all necessary tools, gages, and instrumentation necessary to perform the required tests.

( ) (XX) d. Provide and charge all systems with fluids in accordance with manufacturer's instructions.

(XX) ( ) e. Material for performance testing at Government facility.

( ) (XX) f. Shipping all components to and from PSNS, Building 431.

GOVERNMENT RESPONSIBILITIES

(XX) PSNS will be required to provide from existing main panel 230 volts power at the tailstock end of the lathe bed. MTR will provide a power reel and cable from the PSNS supplied power source out to the tailstock control panel box.

(XX) PSNS to provide all rigging and crane lifts required for removal of the old tailstock top and installation of the new the new tailstock tops.

(XX) PSNS to connect power source to MTR provided power reel.

(XX) PSNS will provide finish machining of the taper shoes and bronze slide plates as directed by MTR.

2.3.9. Energy Isolating Devices. The equipment shall be provided with energy isolation devices (e.g. power switches, safety devices, circuit breakers, valves) that protect personnel from the release of hazardous energy and are integral to the compone...