2-19-5220 - SOW.docx

Attachment C – Environmental Protection Requirements

Specification for a New Ultrasonic Test Immersion Inspection System

Spec. # 2-19-5220 Rev. A

Manufacturing Engineering Work Group Watervliet Arsenal Watervliet, New York 12189 2/25/2019

Department of the Army

TACOM

Scope:

The contractor shall be required to provide the turn-key installation of a new Ultrasonic Test Immersion Inspection System (UTIIS). The contractor shall furnish all labor, material, equipment, and services to fabricate, deliver, install, and test the system. The UTIIS (also referred to herein as “machine” or “system”) shall be used to conduct precision measurements on steel or Inconel alloy mortar tubes; to include the tube for the 120mm and 81mm mortars. The control system shall be a Windows based computer with the ability to position the tube/part under test to acquire and store the data. At a minimum, this data shall include but not be limited to analyzing the material soundness of the complete part, store the collected inspection data, and generate the required output.

Applicable Standards and Publications:

All work performed and procedures followed in association with this project shall meet or exceed all applicable and current Watervliet Arsenal, OSHA, local, state, and federal government codes and laws relative to fire, safety, environmental, and electrical issues. The quality of all work performed and material provided shall meet or exceed the latest applicable industry standards and engineering practices for this type of equipment and its intended function. In all instances material, quality, and workmanship shall meet or exceed OEM specifications.

Applicable Documents:

The following list of documents form a part of this specification.

· 13042934 - Envelope Drawing, Ultrasonic Inspection Equipment and Procedures for Cannon Tube, 120mm

· 12577299 – Cannon Tube

· 13042932 - Ultrasonic Inspection Standard, Longitudinal Defects, Cannon Tube, 120mm

· 13042933 - Ultrasonic Inspection Standard, Circumferential Defects, Cannon Tube, 120mm

· TBD - Ultrasonic Inspection Standard, Longitudinal Defects, Cannon Tube, 81mm

· TBD - Ultrasonic Inspection Standard, Circumferential Defects, Cannon Tube, 81mm

· ASTM E-213-14

· AMS-STD-2154

Requirements:

All requirements are mandatory from the standpoint of intended function. Wherever a specific requirement would force an offeror to depart from his standard practice or configuration, the Arsenal will accept, for evaluation, alternative offers for achieving the intended function. Any such alternative offers must be accompanied by sufficient technical information to allow the evaluator to reach a definite conclusion that the alternative is equal to or better than that specified.

General Requirements

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3.1

3.1.1 Design and Engineering. The machine shall be designed and engineered in accordance with the latest standards recognized or adopted by the Association for Manufacturing Technology (formerly the National Machine Tool Builders Association). The design and engineering shall incorporate only concepts, systems, materials and new components which have been proven in prior use. Modifications to manufacturers’ standard designs to achieve requirements specified herein are not permissible if they result in deviations from good design practice.

3.1.2 Materials. Materials incorporated in the construction of the machine shall be of sound and uniform quality, free from defects and shall conform in specification, heat treatment and suitability to the standards recognized or adopted by the Association for Manufacturing Technology for this type and class of equipment.

3.1.3 Construction. All parts of the machine shall be new and unused and shall be constructed so as to be capable of withstanding all forces encountered during operation to its maximum rated capacity. The structure and assembly of the machine and its components shall be sufficiently rigid that workpiece finish and accuracy are not impaired by machine vibrations.

3.1.4 Workmanship. Workmanship throughout the machine and its equipment shall be of good quality and in conformance to the manufacturer's engineering drawings and to standards recognized or adopted by the Association for Manufacturing Technology. Shims that do not appear on the engineering drawings shall not be incorporated in the machine. Spacers that do appear on the engineering drawings are permissible.

3.1.5 Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. Weldments, if used, shall be braced, ribbed and gusseted to obtain strength equal to or better than the strength of castings, and shall be properly stressed relieved.

3.1.6 Maintainability. All parts subject to wear, distortion or failure and all parts which require periodic adjustment shall be readily and safely accessible for repair, replacement or adjustment as applicable. Instructions for maintenance and adjustments shall be clear, concise and definite in application.

3.1.7 Interchangeability. All parts bearing the same part number shall be functionally interchangeable.

3.1.8 Applicable Power Source. The power source to which the machine will be connected furnishes a nominal 115 volts, single phase, 60 Hz AC. However, the machine shall be tolerant enough of line fluctuations to operate normally at source voltages ranging from 103 to 127 volts.

3.1.8.1 Conversion Equipment. If DC or reduced voltage AC is required to meet any specified requirement, the necessary conversion or transformation equipment shall be furnished with the machine by the contractor. All transformers must meet NEMA TP 1-2002 energy efficiency requirements.

3.1.8.2 Motors. All motors provided shall be of the optimum type and horsepower rating to meet intended application and usage based on accepted engineering practice. All motors shall be equipped with thermal overload protection. All motors shall be housed in enclosures of the appropriate NEMA type for the class and severity of service. Each motor shall bear an identification plate containing, as a minimum, the identity of the manufacturer, the model, serial number, input voltage, amperage, horsepower, phase, frequency and frame or mounting. All AC unidirectional motor housings shall bear a directional arrow to indicate proper rotation direction when correctly wired. All AC motors rated at 25 hp or greater shall be equipped with a "soft start" mechanism which provides for reduced voltage starting. All polyphase AC motors rated at 1 Hp or greater shall be tested per IEEE Standard 112-Method B and must meet Premium Efficiency requirements per NEMA MG 1-2006 Table 12-12 or IE3 (IEC 60034-30:2008). All motors are to be permanently lubricated and sealed unless the contractor can substantiate that this feature cannot be offered by two (2) or more major motor manufacturers.

3.1.8.3 Protective Devices For Electronic Equipment: Shall have sufficient shielding against RFI and EMI, normally present in an industrial environment. A filter system shall eliminate electromagnetic and radio frequency line noise which is capable of generating false data in the computer. The machine and its equipment shall be protected with circuit breakers which comply with NEMA standards for thermal magnetic types.

3.1.8.4 Cabinet Enclosure for Electronic Equipment. All separate electrical hardware / circuitry are to be housed in a NEMA rated enclosure/cabinet. Should forced ventilation be necessary to maintain the interior of the enclosure at a temperature to ensure good product reliability, filtered air shall be forced into the cabinet to maintain an over pressure condition in the cabinet. Cabinet shall not inhibit operator access to the controls and/or adjustments.

3.1.8.5 Interconnecting Wiring. All wiring shall comply with accepted National Fire Protection Association (NFPA) Standards.

3.1.8.6 Operator Control Voltage. All electrical controls meant for use by the operator of the machine shall carry a maximum of 120 volts AC @ 60 Hz.

3.1.9 Safety and Environmental Features. The contractor shall review the environmental requirements documented in Attachment C and comply as applicable.

3.1.9.1 Protection of Machine Operator. Protection of the machine operator and other personnel shall be accomplished in accordance with all pertinent state, federal, local laws and regulations.

3.1.9.2 Protection of the Machine. The machine shall be fully equipped with the devices necessary to prevent selfdamage in the event of malfunction and/or ordinary operator negligence insofar as practical. The system shall be equipped with the necessary protective devices required to prevent electrical/electronic damage to the system because of over-travel, power failure, and the resultant start and stop due to power failure. A surge protector (power conditioner) must be supplied for the computer system and its peripherals.

3.1.9.3 Equipment Safety: The equipment supplied shall meet the safety regulations for general industry standards per OSHA requirements. The locations which have hazardous equipment or require operator caution shall have permanent decals specifying the hazards. Electrical connections and installed equipment shall have decals to identify operating voltage and electrical safety hazards. A protective cover or guard shall be provided for all rotating and moving equipment and extreme temperature surfaces to prevent accidental operator or maintenance personnel injury. All switches shall have permanent plastic or metal tags with non-fading lettering.

3.1.9.4 Noise Levels. The government's preference is to achieve noise levels not in excess of 80 dba and shall be accomplished at no additional expense to the Government.

3.1.9.5 Ozone Depleting Substances. Section 326 of Public Law 102484 precludes the Dept. of Defense from awarding any contract that directly or indirectly requires the use of a class I ozonedepleting substance within the Government specification or standards set forth in the contract. Attachment B is a list of the restricted Class I CFC's and Halons. All shall be replaced by new functionally equivalent substances or systems that are approved for use by the Environmental Protection Agency (EPA) and have an "OzoneDepletionPotential" (ODP) rating of zero. Material Safety Data sheets (MSDS) shall be submitted for approval to Watervliet Arsenal at the time of the submission of proposal.

Definition: OzoneDepletionPotential (ODP). The relative capacity of a substance, per unit weight, for destroying the earth's stratospheric ozone layer, in comparison with CFC11, CFC12 and CFC 114, each having been assigned an ODP of 1.00.

Note: Offerors are responsible to obtain and adhere to the most current list of prohibited substances as of the date of the submission of bids or proposals.

3.1.9.6 Asbestos and Mercury Free Certification. All materials utilized in the system shall be certified as asbestos and mercury free unless substitute materials do not exist. This certification shall be provided prior to machine delivery.

3.1.9.7 Safety Data Sheets: The offeror shall provide Watervliet Arsenal with all safety data sheets (SDS) at the time of the submission of their proposal.

3.1.9.8 LeadFree and ChromiumFree Paint Certification. All paints and primers applied to the system shall be certified as lead free and chromiumfree. Lead based paint is paint that contains more than nine thousandths of one percent (0.009%) lead by weight. This certification shall be provided prior to machine delivery.

3.1.9.9 PCBFree Certification. To the extent that the machine may have been charged with lubrication and/or hydraulic fluids at the contractor's plant for preliminary acceptance inspection, these fluids shall not contain Polychlorinated Biphenyl’s (PCB’s). The machine and their equipment shall be certified as PCBfree prior to being shipped.

3.1.9.10 Lockout/Tagout Procedures:

The manufacturer is required to provide the proper control of hazardous energy (lockout/tagout) per OSHA 29 CFR 1910.147. This information shall be incorporated into the maintenance manual. The control of hazardous energy sources includes electrical, pneumatic, hydraulic, chemical, mechanical, UV, electromagnetic and thermal.

3.1.10 Identification Plate. A corrosionresistant metal plate shall be securely attached to the machine in a visible location in the vicinity of the operator's workstation. This plate shall bear, as a minimum, the information called for as follows, with space at the bottom for one additional line of information to be applied by the government.

Nomenclature Manufacturer's name Model Manufacturer's Serial Number Power Input (voltage, phase, frequency, and total amps) Government Contract Number Date of Manufacture

3.1.11 Lubrication. The machine shall be equipped to provide sufficient lubrication to every moving part where lubrication is essential to prevent damage. If the machine requires periodic, additional lubrication over the life of the machine, a lubrication plate (or plates) shall be permanently fastened to the machine and shall clearly indicate the type and viscosity of lubricant and the service interval for all automatic and manual lubrication reservoirs and fittings. The plate shall include a simple diagram which depicts the physical location of all lubrication points on the machine structure. The contractor is requested to choose required lubricants, fluids, and oils from Attachment A.

3.1.12 Painting. All exterior machine surfaces shall be painted except where bright metal, aluminum, granite, or other critical surfaces are required for machine function or to otherwise adhere to the requirements of this specification. Paint shall be chromiumfree and leadfree. Quality and manner of application shall be such as to afford protection throughout the normal life of the machine. Danger areas shall be painted red and caution areas shall be painted yellow in accordance with OSHA Standard 1910.144. Appropriate warning signs, tags or emblems will be affixed to respective areas of the machine in accordance with OSHA Standard 1910.145.

3.1.13 Machine Hold Down and Leveling: The contractor shall be responsible for providing and installing all hold-down and leveling hardware if required.

3.1.14 Technical Data. All data shall be in the English language and shall be furnished in accordance with the quantities, formats and delivery dates below. All data shall be packaged and delivered separately from the machine itself marked to the attention of the Technical POC. Please note any AutoCAD drawings provided shall be saved as AutoCAD 2017 files.

a. Foundation Drawings, Standard or Special (see note): Shall be complete in all construction detail to permit pricing and construction by a general contractor and shall be furnished as soon as possible after contract award, prior to scheduled delivery of the machine. All drawings shall be dimensioned in English units. One electronic copy on CD in AutoCAD .dwg or .dxf format shall be provided within 30 days after contract award. When drawings are finalized the contractor shall certify the accuracy of the drawings by providing a stamped and signed hard copy of the drawings to the Watervliet Contracting Officer.

NOTE: Typical floor thickness at Watervliet is 8”-10”. A special foundation is one which exceeds thickness, load bearing capability and vibration insulation of Watervliet Arsenal's standard monolithic concrete flooring of 1,000 pounds per square foot load rating and/or one which requires a specific thickness, specificallyshaped excavations for coolant housings, chip conveyors, electrical circuits and conductors, etc.

b. Machine and Equipment Floor Plan: One digitized machine and equipment floor plan in AutoCAD .dwg or .dxf format shall be provided on a CD. This plan shall depict the complete machine space envelope including all ancillary equipment and the dimensioned bolt-hole pattern of the hold-down bolts for the machine. This AutoCAD drawing(s) shall also contain information that indicates the type, magnitude, and connection points of all plant utilities (electrical power including the full load amperage requirements, air, water, etc.) required to operate the machine. This data shall be furnished as soon as possible after contract award, prior to scheduled delivery of the machine. Also, if a foundation is required for the offered machine then this drawing shall also clearly depict the outline of the foundation and provide locating dimensions from a fixed point on the machine to at least one corner of the foundation. When drawings are finalized the contractor shall certify the accuracy of the drawings by providing a stamped and signed hard copy of the drawings to the Watervliet Contracting Officer.

c. Catalog of Standard Tooling and Accessories shall be furnished 30 days after award of contract. For offers of foreign built machine tools (i.e., machines built outside the United States, its possessions or Canada), the catalog shall set forth U.S. domestic sources of supply. (one electronic copy on CD)

d. NonStandard (special) Tooling and Accessories. To the extent that this specification requires the development of unique tooling and/or accessories not generally available commercially, a set of drawings and specifications sufficiently complete to permit manufacture of such tooling and accessories shall be furnished at the time of machine delivery. Dimensional information shall be in English units. One electronic copy on CD in AutoCAD .dwg or .dxf format shall be provided prior to machine delivery.

e. Installation Instructions and Drawings containing all necessary information to install the equipment. This shall include a drawing containing the certified dimensioned locations of all equipment mounting/holddown holes. To be furnished as soon as possible after contract award, prior to scheduled delivery of the machine. One electronic copy on CD in AutoCAD .dwg or .dxf format shall be provided prior to machine delivery.

f. Lubrication Diagram or Instruction. To be delivered at time of machine delivery (if required). One electronic copy on CD in AutoCAD .dwg or .dxf format shall be provided.

g. Operating Instructions. These instructions shall be in the English language and be provided in separate manuals from other technical data provided. Instructions must include all updates for hardware and software. To be delivered upon machine delivery. Three hardcopies and one electronic copy on CD shall be provided.

h. Maintenance and Troubleshooting Instructions for all machine systems. This material shall also include the machine’s mechanical assembly drawings. To be delivered at time of machine delivery. Three hardcopies and one electronic copy on CD in AutoCAD .dwg or .dxf format of the machine’s mechanical assembly drawings.

i. Electrical and hydraulic schematics To be considered acceptable, these schematics must clearly portray all as-built electrical and hydraulic ties to their respective main systems. Two hardcopies and One electronic copy on CD in AutoCAD .dwg or .dxf format. Final as-built drawings to be furnished not later than 30 days after final acceptance of the machine.

NOTE : If, during installation and testing, the actual electrical and/or hydraulic systems are configured differently than depicted on the schematics, receipt of the revised "AsBuilt" schematics shall be a condition of final acceptance.

j. Repair Parts Catalog. This catalog shall encompass every replaceable part in the machine and shall include appropriate identification and ordering data. Items which can normally be purchased locally may be so indicated provided they are sufficiently described. The repair parts catalog shall include illustrations which clearly locate parts within larger subassemblies. To be furnished not later than 30 days prior to delivery of the machine. (one electronic copy on CD)

k. Programming Manuals. Programming manuals for all DCC languages and functionality shall be supplied and be of the latest revision. These manuals shall include, or be supplemented by, a clear summary of the control functions actually implemented. These manuals shall be delivered at machine delivery and include two hardcopies and one electronic copy on CD.

l. Software Documentation. The offeror shall provide copies of all system software and/or ladder logic developed to control and interface with machine, controller, and computer hardware and include one electronic copy on CD. To be delivered to the technical POC 30 days after final acceptance of the machine.

m. Calibration Documentation. Calibration manual and certified results from the factory runoff shall be supplied prior to machine delivery. (one electronic copy)

3.1.15 Training Required. The contractor shall be responsible for providing acceptable training of Arsenal personnel. The type and extent of training shall depend upon whether the machine specified or offered is equipped with numerical control. All instructions and materials, oral or written, shall be in English. "On-Site" means "At Watervliet Arsenal", and "Off-Site" means "a location within the U.S. away from Watervliet Arsenal as determined and arranged for by the contractor". The quality of the training shall be such that at the conclusion of the specified training time, each individual within their assigned category shall be capable of repairing or operating the machine to its productive capacity. The contractor shall provide at least 5 days of on-site assistance for system set up, functional testing, and training. Training shall be in accordance with the applicable areas of the following schedule:

on site

Note: For all training, the associated technical data (see 3.1.14) shall be on hand at the time of instruction and its use and interpretation shall be covered during the training. A training schedule showing the hours of training for each person under their assigned category, shall be sent in with proposals for review.

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3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 3.1.9 3.1.10 3.1.11 3.1.12 3.1.13 3.1.14 3.1.15

3.1.16 Pneumatic Requirements. If air is needed for any machine operation or function, the machine shall be fully equipped with all necessary piping, valving, etc., fully installed to the point of connection to which the Arsenal will connect shop air. Available shop air at the Arsenal is 85 psi and if higher or lower pressure is needed at the machine, the machine shall be fully equipped with the devices needed to modify the 85 psi supply pressure. The machine shall also be equipped with devices to remove the normal moisture and other contaminants usually present in shop air supplies. Normal moisture is defined as that moisture produced when air at a relative humidity of 75% has been compressed to 85 psig.

3.1.17 Special Tools. If any element of machine operation or maintenance requires the use of specially designed tools, these tools shall be provided with the machine and shall become the property of the Government.

3.1.18 Site Conditions. This machine will be installed in a machine shop area, within an air conditioned enclosure with a temperature range of 60 °F to 80 0F. The temperature outside the enclosure will range from 60 °F to 99 °F and relative humidity will range from 20% or less to 95% on any given day. The proposal shall include all environmental information as to what will be required to meet the specified performance of the equipment.

3.1.19 Machine Installation, Startup and Testing.

3.1.19.1 Work to be Performed by the Arsenal. Upon receipt of the required installation and foundation drawings (see 3.1.14), Watervliet Arsenal will prepare the intended installation site prior to delivery of the machine. After placement of the machine by the contractor/riggers, Watervliet Arsenal will run utilities to first points of connection. However, if the installation instructions supplied by the contractor are incomplete or insufficiently detailed, installation work will stop and the contractor will be required to dispatch a service engineer. Installation will resume upon his arrival and continue under his guidance.

NOTE: If installation instructions, foundation drawings and electrical and hydraulic schematics are not delivered at or before the times specified (see 3.1.14), the Government reserves the right to forestall delivery and/or final acceptance testing of the machine by an amount of time equal to the delay in receipt of instructions, drawings or schematics.

3.1.19.2 Work to be Performed by the Contractor. This project is classified as a turn-key with the contractor being responsible for all costs and work associated with the installation unless otherwise stated. The Contractor shall be solely responsible for all costs associated with skidding and shipment, rigging, and installation at WVA. Once an installation site is identified by Watervliet personnel and if required, a foundation is constructed, the contractor or their designated third party shall install the machine. Contractor personnel shall arrange for rigging services to off load the machine and contractor personnel shall be on-site at Watervliet when the machine arrives and is off loaded to supervise the placement of the machine on the installation site by the rigging service. Outside rigging services should be advised that only certified grade 8 chains are permitted to be used at the Arsenal and that all rigging slings must be tagged and certified for the weights being lifted. In most cases no Arsenal forklift services and/or Arsenal personnel will be available for the installation. Only propane powered forklifts are permitted and must also be equipped with a roll cage. Operators of forklifts shall have and be able to produce valid forklift licenses. Arsenal overhead pendant cranes (within load capacities) can be used by the contractor/rigging service for the installation. The contractor shall provide written certification to the WVA representative that all contractor/rigger personnel are qualified, through either formal training or experience per OSHA, to operate pendant controlled overhead cranes. Contractor personnel shall also adhere to the WVA requirements to wear OSHA approved non-tinted safety glasses with side shields and safety shoes while in the manufacturing shop areas. The contractor shall ensure they bring all equipment/material necessary for the installation of the machine(s). Watervliet does not have the resources to provide such material. Crane capacity within each building is limited (2, 5, 10 or 15 tons) and therefore if not adequate then the contractor will need to provide alternate means necessary for the installation. Specific building crane capacities where the equipment is to be installed should be verified with the WVA technical POC.

Once the machine is positioned and rough leveled by the contractor, WVA personnel will run utilities to the machine. Watervliet must be provided with sufficient time to accomplish these connections. The contractor, through his own service personnel shall be fully responsible for the startup and testing of the machine, conduct any acceptance tests specified in sections 3 & 4 and perform the required on-site training. The contractor and the service personnel shall remain until the machine activation and testing have been successfully completed. Under no circumstances should the contractor plan on gratuitous Arsenal assistance for diagnosis, troubleshooting or repair of the equipment during activation and testing. Should such activity prove necessary, it shall be the contractor's responsibility to provide the appropriate labor and materials. If the contractor chooses to request Arsenal assistance in lieu of providing his own resources, the request will be reviewed by the Technical POC who shall reserve the right to impose a charge for the assistance. Approvals, even on a charge basis, should not be taken for granted since there is no guarantee that appropriate Arsenal personnel will be readily available. In such cases, the Arsenal will not be held responsible for delays in acceptance of the equipment resulting from nonavailability of Arsenal personnel or Arsenalfurnished equipment.

IMPORTANT: Under normal circumstances the contractor will be allowed to work as long as is desired during normal work days. Contractor work outside Watervliet’s normal work days cannot be guaranteed. Watervliet is on a condensed work schedule. Normal work hours/days for this schedule are four 9-hour workdays (Friday off) one week and four 9-hour days, one 8-hour day (Friday) the following week. Contractor work on the Friday off and weekends cannot be guaranteed. Contractor’s classified as foreign nationals may further restrict work hours and days available.

If the contractor requests Watervliet Arsenal to ship misc. material via UPS, FedEx or by other similar carrier then the contractor shall provide their carrier account number for this purpose.

Machine Specific Requirements:

A complete automated C-SCAN UTIIS shall meet or exceed the measurement requirements. The UTIIS is a complete automated six axis (X,Y,Z,R,A,B), five channel Ultrasonic system used for inspecting 120mm diameter, 8’ length steel mortar tubes. In addition to the required hardware and software, comprehensive systems training and service options shall be included to ensure a fast user startup and minimize any possible production down time. The machine shall be designed to inspect 120mm and 81 mm mortar forgings and finished tube configurations for surface breaking and subsurface discontinuities (flaws) such as cracks, fissures, and inclusions. It shall also be able to inspect tube wall thickness to within 0.001”. The machine shall be able to measure and detect flaws in steel and Inconel alloy mortar tubes. The machine will be used for various sizes of tubes to include tubes shorter in length and smaller in diameter than the 120mm diameter tube. Rollers, scanners, and software shall be easily adjustable to accommodate all tube sizes. The system shall be designed such that any changes required to measure the different flaw lengths and flaw depths, such as changes to the software and transducers, shall be easily accomplished. The machine shall detect the following flaws:

· Steel gun tube minimum detectable linear flaw level of 0.015” Depth X 0.030” long for 120mm

· Steel gun tube minimum detectable linear flaw level of 0.006” Depth X 0.012” long for 81mm Basic System:

The basic system shall possess (but is not limited to) the following items and features, shown in table below:

Scan Envelope: 8 feet length x 2 feet width x 2 feet depth X,Y,Z axis Frame Assembly Stepper Motor Controller Six (6) automated motion axis (X,Y,Z,R, A Gimbal, B Gimbal) Stainless Steel Tank Assembly Resolution 0.001 inch Maximum X velocity 20 inches per second Motorized Z with manipulator Water Filter System Dust Cover panel for inspection tank

1000 pound max load Adjustable idlers Fully encoded. Scan or index

19 inch LCD Wide Monitor, 3.2 GHz CPU

(2) each USB 130 GB Hard drive Latest Windows OS compatible with contractor’s Ultrasonic software Heavy duty power supply High output fan with filter

Targets:

Targets (notches and flat bottomed holes) in the standards represent discontinuities in each inspection area. The notches provide a signal of consistent amplitude which is used to set the system's sensitivity. A reject level will be established at a point below the amplitude of a standard notch (initially 6db down). Any discontinuity that produces a signal larger than the reject level will be considered a rejectable defect. Reject criteria associated with flat bottom holes shall be set in accordance with AMS-STD-2154, Class AA.

Gates:

The machine shall provide for multiple gates and shall be able to verify the rejection levels over the length of the tube.

Default to Reject:

It is a design requirement that the system be fail-safe: that is, failure of any electrical, mechanical, hydraulic, or pneumatic system shall result in rejection of the item being inspected. The accept/reject mechanism in the Automated System shall normally be in the "reject" position and require a definite "accept" signal to accept the part.

System Configuration:

The system shall be configured for manual part loading, unloading, and marking.

Operational Modes:

Part Inspection:

The machine shall have an operator place a part in the inspection fixture. The equipment will then scan the item for discontinuities. At the end of the scan the transducers will return to the home position. A green light will indicate an acceptable part. The operator will remove the part and manually mark it in accordance with the marking procedure. A red light will indicate a rejectable part. The operator will remove the part and place it in a secure reject area.

System Stop:

When in the inspection mode, the capability to stop the system anywhere in the inspection cycle shall be provided.

Calibration Mode:

The system shall also have a calibrate mode to accommodate a single but complete or partial inspection cycle of a calibration standard or single part. With variable longitudinal motion index (Axis of Part).

Alarms:

The system shall be furnished with audible and visual alarms. A common audible alarm may be used for all channels, however, two separate visual alarms will be required for each channel. One shall provide a reject indicator which will be latched on during the inspection cycle when the intermittent alarm indicates a defect.

Data Acquisition:

The system must be capable of recording and printing the following data:

1. Project/item number

2. Date and time

3. The position along the scan path during which the rejectable flaw signal were detected, with a minimum resolution of 0.020".

4. The highest amplitude of rejectable flaw signal detected between scan position increments, recorded in percent (%) of screen height.

5. The number of the monitoring gate(s) that detected rejectable flaw signals.

6. Party responsible for evaluation

7. Time of Flight range for the indication

8. Estimated distance from part centerline

Production Inspection Mode:

In the production inspection mode. This mode shall be automatic when flaws are detected during production inspection. This mode shall also be used when details are required to monitor the actual status of the calibration of the system.

Flaw Display:

The system shall be capable of displaying all targets and/or flaws in a "C scan" presentation. This will be the display used during production inspection.

Full Wave A-scan:

The system shall be capable of capturing full wave for from A-scan.

Indication Evaluation:

Indications may be either manually evaluated or automatically identified to be in the regions deemed acceptable for all indications per Note 10 on standard drawing 13075798. These evaluations have additional data requirements.

Scanning Speed / Rotation Speed:

The inspection system shall have the capability to vary the transducer scanning speed and test item rotational speed. In establishing the limits for these two variables the standard target design must be taken into consideration. The transducer scanning and test item rotational speeds established for the inspection shall, as a minimum, provide for at least two full engagements of the sound beam with each target during the inspection cycle. Also in the establishment of the test item rotational speed, the pulse repetition rate (PRR) must be considered. The PRR selected must have a rate to detect at least 2 full engagements of the notches at the scanning speed. After establishment of the scanning speed, & rotational speed the PRR and scan index shall not be changed during the inspection cycle.

Automatic Verification:

The system shall incorporate automatic verification:

Automatic Verification System:

The automatic verification system shall monitor the flaw detection loop which includes the transducer positioning and the pulser/receiver functioning. This system shall assure proper system calibration for each inspection cycle.

Monitored Characteristics:

The following system characteristics shall be monitored and verified for each inspection cycle:

1. Operation and position of the transducers

2. Operation of the pulsers (amplitude)

3. Operation of the receiver amplifiers (gain/attenuation)

4. Operation of the gates (position, width, and threshold level) Fault Indication:

If for any reason, after initial calibration, the auto verification detects deterioration of inspection sensitivity that results in a loss of 3 dB or more, the system shall inhibit and indicate a fault. If for any reason, after initial calibration, the auto verification detects that the monitoring gates are out of position or width by more than 500 nanoseconds, the system shall inhibit and indicate a fault. If for any reason, after initial calibration, the auto verification detects that the threshold level of any monitoring gate has increased by more than five percent (5%) of screen height, the system shall inhibit and indicate a fault.

False Signals:

Precaution shall be taken to eliminate conditions that may contribute to the generation of false signals. This would include such features as electrical filtering to suppress spurious electrical signals, shielding to eliminate picking up radio frequency signals and design features that would minimize the adverse effects of the introduction of air into the water during the inspection of the test item.

Electrical Panel Temperature:

All electrical panels used in the system shall be provided with a means to control the temperature so that the maximum rated temperature of the equipment is never exceeded. The air circulation system used to provide this control shall be equipped with a filter to remove any contaminates which may have an adverse effect on system reliability.

Ultrasonic Flaw Detection Instrumentation:

A locked cover which will allow visibility of the ultrasonic flaw detector controls, will be provided to prevent access by unauthorized personnel. The ultrasonic inspection instrument, conventionally consisting of a multi-channel pulser, receiver amplifier, timer, monitoring gates, signal display, and associated controls, shall be designed to allow digital and programmable control of most functions including gain & Dac The following are required, as a minimum:

Programmable Receiver/Amplifier:

The receiver/amplifier shall be programmable and digitally controllable over a range of 80db with a resolution of 1db.

Multiple Gates for Scanning Transducers:

To comply with the inspection characteristics verification and the requirement for inspection sensitivity compensation per it is required that multiple gates be used for each scanning transducer. Each gate shall be individually controllable and programmable for:

1. "Start" with a resolution of 250 nanoseconds.

2. "Width" with a resolution of 250 nanoseconds.

3. "Gain" (for the duration of the gate) with a resolution of 1 dB and a range of 80 dB.

4. "Threshold" (reject level within the gate) with a resolution of five percent (5%) of a one hundred percent (100%) screen height.

All of the above parameters shall be instantly changeable via program at any time during the scan of any transducer. The instant parameter changes shall take place within 0.005" scan length of their programmed actuation point.

Each monitoring gate shall be identified by a number to accommodate the data acquisition requirements and to identify the channel/transducer that may have failed in case of a fault condition.

Immersion Tank:

A method shall be provided to couple the ultrasonic energy to the item under test using a liquid. Should a stream or thin film of liquid be used to couple this energy, controls shall be used to monitor the coupling and assure its effectiveness. Should an immersion method be used, a tank shall be provided with the following:

a. Be fabricated of corrosive resistant materials. Dissimilar metals shall not be used due to possible electrochemical reactions.

b. Be large enough to allow easy insertion and removal of the part, contain the support fixture, the transducers with their manipulators and leave sufficient room for convenient adjustment of the transducers.

c. Have water supply and drainage connections. Rigidly plumbed.

d. Have a filtration system of sufficient capacity to remove particles larger than 15 microns without aerating or inducing vapor into the water.

e. Provide a temperature control to maintain the water temperature at least 3 degrees Celsius within the temperature of the test item.

f. Contain water to which a suitable rust inhibitor, wetting agent and fungicide shall have been added.

g. A means shall be provided to prevent or remove air bubbles from the face of the transducers and the surface of the test item.

Transducer Fixtures:

The transducer shall be held in fixtures furnished with the following:

a. Corrosion resistance materials shall be used throughout.

b. Adjustments that will allow for all required transducer movements needed to position the transducers into the proper settings. Mechanisms shall be incorporated to facilitate precision adjustment.

c. A means of securing the transducer at the desired setting which will not impart any transducer movement during locking or allow for any unwanted movement during the inspection cycle.

d. To facilitate adjustment, it shall be required to use graduations that will allow for visual indication of all fixture settings.

e. A design that will minimize transducer vibrations throughout the range of operating speed.

f. To facilitate adjustment, it would be desirable to use a fixture that is easily accessible when the part is under test.

g. Transducers will be pulsed in a manner that will not allow cross talk.

Transducers:

It is required that a minimum of 5 transducers be utilized, two to produce shear waves in the longitudinal direction, two to produce shear waves in the circumferential direction, and one normal to the surface. They shall scan the entire length of the forging. This does not preclude the incorporation of additional transducers that travel, or are fixed in position, in order to provide maximum inspection coverage. The following are requirements for all transducers:

a. For each transducer used in the inspection system at least one spare transducer shall be provided.

b. Transducers, fixed and scanning as required shall be chosen to optimize detection of natural discontinuities as represented by targets contained in the standard(s) referenced in paragraph 2.0.

c. For each transducer the following data shall be provided:

1. Beam profile

2. Real time wave form

3. Frequency spectrum

4. Beam focus information Signal Amplitude Disparity:

For each scanning transducer covering an area that includes two (2) or more calibration notches, the disparity of the optimum signal amplitudes of those notches shall not exceed 2 dB.

Calibration of Inspection System:

As a minimum, the standards will be inspected at the beginning and end of each shift to assure proper system function. If all targets in the standards are not detected twice and rejected, then the system must be adjusted to the proper levels before testing may continue. In the event of a calibration verification failure, all tube forgings inspected since the last successful calibration check shall be retested.

Government Approval:

Government approval is required prior to fabrication or publication of the following:

1. Inspection system design

2. The Dynamic Acceptance Test plan

3. Specifications for commercial items

4. Set up procedures

5. Calibration procedures

6. Operating instructions

7. Marking Procedures

8. Maintenance and troubleshooting procedures

9. Verification procedures

10. Inspection map

Preliminary Design Review:

The contractor shall provide to the Watervliet Arsenal, a preliminary set of equipment design, configuration, and proposed hardware for approval prior to the start of fabrication. Alternatively, the contractor can schedule a post award preliminary design review meeting to answer contractor questions and clarify equipment design requirements.

Machine Delivery:

The contractor shall deliver an acceptable machine within 180 days after receiving order.

Spare Parts:

The contractor shall submit a list of recommended spare parts along with pricing. The Watervliet Arsenal shall have the option to include add any combination of spare parts to this contract.

Requirements for Demonstration of Conformance:

Certification of Completeness:

Prior to machine shipment, the contractor shall provide written certification that the machine is complete and has been visually examined for appearance, workmanship, maintainability and completeness, including all specified systems, accessories, markings, safety devices, geometric and accuracy requirements.

Ultrasonic Test Standards:

The contractor shall develop an inspection map that identifies where each transducer channel and each wave mode begins and ends inspecting a part under test based on set-up work with the ultrasonic standard(s). Any edges, portion of a feature, areas, and/or distance to an edge that are not inspected on a specific transducer or by a specific wave mode, shall be identified in inches or millimeters and submitted to the government for review and approval.

Dynamic Acceptance Test:

A dynamic acceptance test will be conducted at the system vendor's site after the system has been set up in accordance with the operating instructions, a second test will be conducted at the contractor's site to demonstrate the capabilities of the installed inspection system. A plan defining details of these tests will be prepared by the contractor and submitted to the government for approval.

Additional Testing:

During machine installations, Watervliet Arsenal personnel may elect to have the contractor demonstrate or verify the machine’s compliance with any requirement in this specification.

Testing Provisions:

All equipment, tooling, and materials required during machine testing and installation shall be supplied by the contractor.

Quality Assurance Provisions:

Responsibility for Inspection:

The contractor shall be responsible for performing all certifications and tests required in paragraph 3.4 and shall provide such materials, supplies and equipment as specified.

Preliminary Acceptance Inspection:

Preliminary acceptance inspection shall occur at the contractor's facility prior to machine shipment to WVA and shall consist of the certifications and tests specified in paragraph 3.4. When the certification of conformance is completed, the contractor shall provide no less than 14 calendar days notice to the Arsenal Contracting Officer that the machine is ready for the preliminary acceptance inspection.

Re-inspection Provisions:

If, during the course of preliminary acceptance inspection, deficiencies are disclosed which cannot be satisfactorily corrected during this visit, preliminary acceptance will be withheld and the contractor will be required to take corrective actions. In such cases, the Arsenal's Technical POC reserves the right to dispatch Arsenal representatives to observe a re-inspection and to charge the contractor's account for the travel and per diem costs of such re-inspections.

Post Preliminary Inspection Procedures:

The Arsenal's representatives will not grant authority to ship the machine following preliminary acceptance inspection, even in cases where there have been no apparent instances of nonconformance. Authority to ship will be granted only by the Arsenal's Contracting Officer. In cases where it is determined that the machine and its equipment conform to specification, the Arsenal's Contracting Officer will grant shipping authority within (10) working days of completion of the preliminary acceptance inspection. In cases where deficiencies requiring correction are disclosed, the Arsenal's Contracting Officer will furnish a formal listing of required corrective actions within 15 working days of completion of the preliminary acceptance inspection. Also, in such cases, the provisions of paragraph 4.2.1 shall apply.

Final Acceptance Inspection:

Final inspection and acceptance of the machine shall be after installation at the Arsenal. At this time the machine shall again be subjected to, and required to pass, the test procedures specified in paragraph 3.4.

Warranty:

Upon final acceptance of the machine a Standard Commercial Warranty shall commence for duration of Three Years, to include as a minimum, parts and labor for the duration of the warranty, at no cost to the Government. The one year period shall commence from the date of notification by the Contracting Officer of the final acceptance. Final acceptance is defined as the act of an authorized representative of the Government, by which the Government assumes ownership of existing supplies/equipment and/or approves specific services rendered, as partial or complete performance of the contract (i.e. testing, training, and delivery of all required technical documentation). This requirement does not waive any warranty requirement of FAR 52.212-4.

Preservation, Packaging and Delivery Instructions:

3 The contractor shall utilize…