12003240-SOW.pdf

Scope of Work for Radio Frequency (RF) Press

Document #: 1200-3240

1. SCOPE

1.1. Scope. The purchase description set forth below describes the minimum requirements of the Government for a TURN-KEY Radio Frequency (RF) Press. 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 current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine 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 Radio Frequency (RF) Press 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 Radio Frequency (RF) Press 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. Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

2.2.4. Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's work station(s).

2.2.5. 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.

2.2.6. 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.

2.2.7. 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 Radio Frequency (RF) Press. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts. All exposed chains and pulleys shall be guarded and shielded such that operators and personnel cannot make contact.

2.2.7.1. Two Hand Operation. Two hands shall be required to engage the press when operating directly adjacent to the machine to prevent operator hands from getting caught.

2.2.7.2. Radio Frequency Shielding. The RF Press shall provide shielding from radio frequency such that less than one (1) milliwatts per square centimeter of electromagnetic field shall be at the operators’ position.

2.2.7.3. Arc Suppressor. In the event of arc flash the machine shall immediately shut down and utilize arc suppression to reduce the amount of radio frequency encountered by the operator.

2.2.8. Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 dB(A) as measured on the "A" scale and 92 dB(C) as measured on the "C" scale, at any point three feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment.

2.2.9. Lubrication. Means shall be provided to ensure adequate lubrication for all moving parts. Recirculating lubrication systems shall include a filter that is cleanable or replaceable.

Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low oil condition. When a low oil pressure condition occurs, the machine shall enter an emergency stop condition. All oil holes, grease fittings, and filler caps shall be accessible. A lubrication plate shall be securely attached to the equipment, see 2.9.2.

2.2.10. Interchangeability. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts. Foreign-sourced replacement parts shall be interchangeable with domestically supplied components or be readily available from a domestic source.

2.2.11. Measuring and Indicating Device Graduations. All measuring and indicating devices on the Radio Frequency (RF) Press shall be graduated in the inch/pound or both inch/pound and metric.

2.3. Components. The Radio Frequency (RF) Press shall consist of not less than the following components.

2.3.1. Radio Frequency Platen. The RF Press Platen shall utilize an air operated C Press with a twin rod assembly for guided die positioning. No less than a six (6) inch diameter cylinder shall provide force per Table I. An air silencer shall be equipment for reduced exhaust noise. Dimensions and performance of the platen shall comply with Table I.

2.3.1.1. Radio Frequency. The Press shall provide no less than 15 kilowatts of power at the frequency specified per Table I.

2.3.2. Table. The machine shall have a work height no less than 32 inches and no greater than 38 inches. The table shall have the workable dimensions specified in Table I.

2.3.3. Operating Controls. The machine shall have a pedestal mounted controller with no less than a ten (10) foot cable. There shall be an adjustable press down switch, allowing the platen to be lowered to preset heights. Repeatability of the platen shall be per Table II. A dial shall be used for power control. There shall be meters designating both the grid and plate current. Indicators shall be used for showing the status of the blower, safety circuits, RF heat, and plate overload.

2.3.4. Coolant System. A flood type coolant system shall be provided. The coolant system shall include a sump or reservoir, a power driven pump, and all necessary piping. The system shall have means for draining and cleaning. Means shall be provided to permit the operator to direct and control the amount of coolant over the entire work area.

2.3.5. Pneumatic System. The pneumatic system shall conform to ISO 4414, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls including protection from over-pressurization.

2.3.6. Electrical System. The machine shall conform to NFPA 79. The existing electrical power source available at the installation site is 240 Volts, 3 Phase, 60 Hertz, 100 Amps.

The machine’s electrical system shall be tolerant of voltage fluctuation of ± 10 percent. The electrical system shall be complete, including transformers required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device, controlling all electrical power to the equipment, shall be utilized on the machine with means of lockout in the off position only.

2.3.6.1. 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.

2.3.6.2. Solid-State Components. Solid-state design shall be employed throughout for electronic components. Use of selenium and other similar aging devices shall be permitted only in the application of voltage surge protection to other solid-state components. Solid-state components shall not be adversely affected when subjected to power line transients and surges typically experienced in industrial environments. Series and parallel connections of solid-state devices without forced sharing circuitry for voltage and current, respectively, is not permitted. Solid-state devices shall be capable of handling the electrical load imposed by operation of the machine to its maximum capability.

2.3.6.3. 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.

2.3.7. 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.

2.3.8. Work Envelope Lighting. The equipment shall include LED lighting to illuminate the work envelope. The lighting shall comply with NFPA 79 requirements, and have a protective shield.

2.4. Facility Electrical Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

2.5. Hour Meter. The Radio Frequency (RF) Press shall be equipped with an analog hour meter mounted 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.

2.6. Size and Capacity. The size and capacity of the Radio Frequency (RF) Press shall be not less than specified in Table I.

Table I Size and Capacity Max Allowable Installation Space (W,D,H) 50 in x 75 in x 95 in Max Allowable Weight 3200 lbs Radio Frequency 27.12 MHz Radio Frequency Power 15 kW Platen Force 2800 lbs @ 100 PSI Maximum Throat Depth 16 in Maximum Daylight 11 in Maximum Radio Frequency Leakage 1 mW per cm2 at operators position Upper Platen Dimensions (L x D) 20 in x 18 in Work Height 32-38 in Working/Table Dimensions (L x D) 36 in x 25 in Power Requirements 240V 3 Ph 60 Hz 78 FLA (100A Protection)

2.7. Alignment and Accuracy Tolerances. The alignment and accuracy tolerances of the Radio Frequency (RF) Press shall be as specified in Table II.

Table II Alignment and Accuracy Adjustable Platen Height +/- 1/8 in

2.8. Standard Equipment. All standard equipment required for proper operation of the Radio Frequency (RF) Press (such as special tools) shall be furnished.

2.9. Marking on Instruments, Control Panels, and Plates. 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.

2.9.1. PCB Label Plate. A label plate containing the Polychlorinated Biphenyls (PCB) Certification information shall be permanently and securely attached in the vicinity of the manufacturer’s identification plate. The plate shall recite the contract number and state that there are no detectable amounts of PCB’s.

2.9.2. Lubrication Plate. A lubrication plate shall be permanently and securely attached to each 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

2.9.3. 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

2.10. Operating and Maintenance (O&M) Manuals. Three (3) hard copies and one (1) electronic copy(s) of O&M Manuals shall be provided with the machine. O&M Manuals shall contain technical information, specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language. Technical Data shall contain at a minimum:

a. Data shall enable an average journeyman mechanic to operate, program, maintain, and repair the equipment.

b. Complete instructions and information for all equipment, components, assemblies, subassemblies, attachments, and accessories.

c. Operating instructions including programming requirements, pre-operational checks, start up, shut down and emergency shutdown procedures.

d. Maintenance and service instructions, including all preventive maintenance schedules, and lubrication charts.

e. Trouble-shooting guides.

f. Parts list containing: illustrations, part numbers, part nomenclature, original manufacturer, cross reference numbers, and recommended spare parts, including quantities.

g. Energy control procedure, in accordance with 29 CFR 1910.147, to bring equipment to a zero energy state for maintenance.

h. All mechanical and electrical schematics with a table of contents showing discrete components, block diagrams, wiring diagrams with inputs and outputs identified, system electrical interface documents, and drawings for the specific model of all machine equipment/drives/controls supplied.

2.11. OSHA Approved Certification. The equipment and its installation specified herein shall be inspected and labeled by a Nationally Recognized Testing Laboratory (NRTL) as defined in 29 CFR 1910.7 and approved as defined in section 2.2.7 of this statement of work, OSHA Compliance. A satisfactory NRTL Field Evaluation Report shall be provided to the receiving activity after equipment delivery and installation, and prior to destination testing.

See https://www.osha.gov/dts/otpca/nrtl/nrtlmrk.html for a list of OSHA recognized NRTL’s.

2.12. PCB Certification. Written certification from the manufacturer that the equipment contains no detectable Polychlorinated Biphenyls (less than two (2) parts-per-million) shall be provided. The certification shall be on manufacturer’s letterhead, and signed by a company official who is empowered to provide same. A PCB label plate stating the PCB compliance certification shall be supplied and attached to the equipment.

2.13. Workmanship. Workmanship of the Radio Frequency (RF) Press shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

2.14. Shipping and Delivery. All materials, components, and equipment shall be packaged and shipped in weatherproof packing that is easily handled by forklift. The weatherproof packaging shall prevent water intrusion and rusting. All packages shall be prominently marked with “NOT FOR OUTSIDE STORAGE”. Delivery shall be to Building 460 and transported to the third floor “Sail Loft”.

2.15. Floor Load Limit. During delivery, removal, and installation of the Traversing RF Press the Contractor shall not exceed the floor load limits of the installation site. The floor load limit at the installation site is 75 pounds per square foot.

2.16. Removal of Existing Equipment. Prior to offloading and placing the RF Press onto the final installation site, the contractor shall coordinate with the Government for the removal of the existing piece of equipment. The existing piece of equipment is an older RF Press. The contractor shall be responsible for disconnecting all utilities and removing any anchors. Upon completing the full un-installation of the existing equipment, the contractor shall transport the equipment onto a Government conveyance.

2.17. Installation. Contractor shall be responsible for attached Installation Responsibilities chart and Local Documents Attachment A for site specific facility requirements. Installation shall comply with EM 385-1-1 and UFC 3-301-01.

2.17.1. Contractor Installation and Set-Up. The equipment shall be assembled, installed, set-up and tested by the contractor in the area(s) designated as its functional work area by the receiving activity.

2.17.2. Plan of Actions with Milestones (POAM). The contractor shall provide a Plan of Actions with Milestones (POAM) detailing key events with dates of the following:

https://www.osha.gov/dts/otpca/nrtl/nrtlmrk.html

a. Utility modifications

b. Manufacturing

c. Equipment delivery

d. Equipment set-up/installation

e. Training

f. Final completion date

2.17.3. Structural Installation. The Contractor shall accurately set, align, plumb, field connect with sufficient bolts, or weld all structural steel required to make installed equipment permanent. Temporary bracing shall be provided, and subsequently removed, as necessary.

Steel weight dispersion plates, also known as foot pads, shall be used as necessary for compliance to 2.15.

2.17.4. 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. New air pipe fittings, locking valves, and flexible air connections shall be provided.

2.17.5. Electrical Installation. The Contractor shall provide all labor, wiring, cables, disconnects, connectors, and any other materials for complete installation of any requisite electrical equipment from the government point of delivery. Installation shall include necessary power, control, and interconnecting wiring installed in conduit. The 100 amp disconnect from the existing RF Press shall be retained for reuse for the new RF Press.

Circuit breaker fuses and conductors shall be replaced to upgrade the existing 70 amp circuits to 80 amps.

2.17.6. Utility Connection. The contractor shall install and connect utilities (electrical power, fire suppression, and/or air) to the RF Press from the circuit breaker locations that are within 50-feet of the work site.

2.17.6.1. Service Utilities. Reasonable amounts of water, shop air (80-90 psi) and electricity shall be made available adjacent to the assembly site at no cost to the contractor. The Contractor shall be responsible for any costs incurred in connecting, converting and transferring the utilities to the work.

2.17.7. Work Site Visit. Upon award, it is required for the contractor to visit the Government designated installation site for discussions and planning of utility hook ups and installation.

2.18. 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.

2.19. On-Site Operator Training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is a United States citizen proficient in the English language, shall be provided for specialized training to familiarize receiving activity personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage. Training shall include preparation of part programs and preparation of equipment for safe operation of the equipment. The training shall be for number of operators and be performed at customer facility and shall not be less than one (1) workday between 7:00 am and 3:30 pm excluding any federal holidays. All printed training aids shall be supplied at no additional cost to the government, and be in the English language.

3. QUALITY ASSURANCE

3.1. Examination. The Radio Frequency (RF) Press shall be examined to determine compliance with all requirements of this purchase description.

3.2. Warranty. Supplies and services furnished shall be covered by warranty from defects in design, materials and workmanship. The warranty shall be the manufacturer’s standard commercial warranty which shall conform to all the requirements of the contract. Acceptance of the manufacturer’s standard commercial warranty shall not minimize the rights of the Government under clauses in the contract, and in any conflict that arises between the terms and conditions of the contract and manufacturer’s warranty, the terms and conditions of the contract shall take precedence. The warranty period shall commence when final acceptance has been achieved as determined when all contract line item numbers have been processed.

INSTALLATION RESPONSIBILITIES

Government Contractor

( ) (X) a. Furnish labor and material handling equipment for off-loading and placing item on foundation.

( ) (X) b. Provide and install anchor bolts and nuts.

( ) (X) c. Level and align machine.

( ) (X) d. Provide facility electrical utility modifications for the machine.

(X) ( ) e. Provide air utilities within 10 feet for hook-up to the machine.

( ) (X) f. Connect machine to the utilities / hook-up.

( ) (X) g. Perform installation of the item.

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

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

2.17.7. Work Site Visit. Upon award, it is required for the contractor to visit the Government designated installation site for discussions and planning of utility hook ups and installation.