23-20-1101 PD 10DEC24.pdf

23-20-1101 10 December 2024

PURCHASE DESCRIPTION FOR THE ACQUISITION OF (2)

TWO AUTOMATED SHOT PEEN BOOTHS

1.0 SCOPE.

1.1 Scope. The content of this specification describes the minimum requirements for two

(2) shot peen booths in building 794 NAS Jacksonville, Florida.

2.0 APPLICABLE DOCUMENTS. The documents listed in this section are cited in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed in section 2.

Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

2.1 Government Documents.

2.1.1 Specifications, Standards, and Handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein.

STANDARDS – FEDERAL

FED-STD-H28B: Screw Thread Standards for Federal Service

FED-STD-313F: Material Safety Data, Transportation Data, and Disposal Data for Hazardous Materials Furnished to Government Activities

U.S Department of Labor, Occupational Safety and Health Administration

(OSHA)

29 CFR 1910: General Industry, OSHA Safety and Health Standards

(Application for copies should be addressed to the OSHA Publications Superintendent of Documents P.O. Box 37535 Washington, D.C. 20013-7535)

Environmental Protection Agency (EPA)

40 CFR 82: Protection of Stratospheric Ozone

(Application for copies should be addressed to the EPA Ariel Rios Building 1200 Pennsylvania Avenue, N.W. Washington, DC 20460)

DEPARTMENT OF DEFENSE

MILITARY STANDARDS

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property Item Unique Identification Marking (IUID)

(Application for copies should be addressed to Air Force Product Data Systems Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg. 262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257- 0870 or 0853 or https://quicksearch.dla.mil/qsSearch.aspx)

2.1.2 Other Government Documents, Drawings, and Publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

LOCAL FACILITY DOCUMENTS

GOVERNMENT DRAWING

Attachment A: B794 Overview (Distro D)

Attachment B: Fixture Base Plate (Distro D)

Attachment C: Aisleway Travel (Distro D)

Attachment D: Compressor Distance Overview (Distro D)

Attachment E: Current Shop Layout (Distro D)

Attachment F: Proposed New Locations (Distro D)

2.2 Non-Government Publications, Specifications, Standards, and Handbooks. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

American Gear Manufacturers Association (AGMA)

AGMA ISO 1328-1-B14: Cylindrical Gears - ISO System of Flank Tolerance Classification - Part 1: Definitions and Allowable Values of Deviations Relevant to Flanks of Gear Teeth

(Address application for copies to: 500 Montgomery Street, Suite 350, Alexandria, VA 22314-1581 USA)

American National Standards Institute, Inc. (ANSI)

B11/STD B11: General Safety Requirements Common to ANSI B11 Machines https://quicksearch.dla.mil/qsSearch.aspx

ANSI B11.25-2015 Safety Requirements for Large Machines

(Address application for copies to the American National Standards Institute, 11 West 42nd Street, New York, NY 10036)

American Society of Mechanical Engineers (ASME)

ASME Y14.5: Dimensioning and Tolerancing

(Applications for copies should be addressed to ASME International Three Park Avenue New York, NY 10016-5990 or www.asme.org)

International Organization for Standardization (ISO)

ISO 4413: Hydraulic fluid power-General rules and safety requirements for systems and their components

ISO 4414: Pneumatic Power-General rules and safety requirements for systems and their components

(Application for copies should be addressed to the International Organization for Standardization (ISO) 1 rue de Varembé, Casepostale56, CH211Geneva 20, Switzerland)

National Electrical Manufacturers Association (NEMA)

NEMA 250: Enclosures for Electrical Equipment (1000 V Maximum)

NEMA MG 1: Motors and Generators

(Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Rosslyn, VA 22209)

National Fire Protection Association (NFPA)

NFPA 70: National Electrical Code

NFPA 79: Electrical Standard for Industrial Machinery

(Applications for copies should be addressed to the National Fire Protection Association, ATTN: Support Services, 11 Tracy Drive, Avon, MA 02322)

Society of Automotive Engineers (SAE)

SAE AEROSPACE MATERIAL SPECIFICATION (AMS)

2430 Automatic Shot Peening (SAE, https://www.sae.org/standards/content/ams2430 http://www.asme.org/ https://www.sae.org/standards/content/ams2430

AMS 2432 Computer Monitored Shot Peening (SAE, https://www.sae.org/standards/content/ams2432d/)

AMS 2431/4 Peening Media (AWS) Conditioned Stainless Steel Cut Wire Shot https://www.sae.org/standards/content/ams2431/4

(Application for copies should be addressed to: Society of Automotive Engineers 400 Commonwealth Drive, Warrendale PA 15096)

2.3 Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulation unless a specific exemption has been obtained.

2.4 Acronym Definitions Not Explicitly Listed in Text. The following acronyms not explicitly listed in each section text are defined as follows:

a. JIS- Japanese Industrial Standards

b. DIN- German Institute for Standardization

c. EN- European Standard

2.5 Proposal Format. Proposal shall be submitted using the following mathematical conventions:

a. Whole numbers will be expressed where one thousand is written as 1,000.

b. Decimals will be expressed where one-tenth is written as 0.1.

c. Submission of compliance statement and descriptive literature shall be in the same units as the units listed in this document.

d. In accordance with ASME Y14.5, all values listed in parenthesis will be treated as reference units and not the official proposed value in determining acceptability. For example, 300mm (11.8 inches), the 300mm will be used in determination of acceptability, and the measurement in parenthesis will not be considered in determining acceptability.

3.0 REQUIREMENTS.

3.1 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.

3.1.1 Measuring and Indicating Device Graduations. All measuring and indicating devices on the machine shall be graduated in the United States customary units. An https://www.sae.org/standards/content/ams2432d/ https://www.sae.org/standards/content/ams2431/4 electronic control system that demonstrates switching between manufacturer standard units to United States customary units will be found acceptable. The machine shall demonstrate all applicable standards using media in accordance with AMS 2431/4 sizes AWS 14 through 28.

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

3.1.3 Safety and Health Requirements. All machine parts, components, mechanisms, and assemblies furnished on the machine, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910 or equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

3.1.3.1 Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11.25-2015 Safety Requirements for Large Machines or equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded part, and shall be easily removed to facilitate inspection, maintenance, and repair of the parts.

3.1.4 Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

3.1.5 Hazardous Material Exclusions. Supplies or materials being provided as part of the equipment shall be free of known hazardous materials. These materials shall not be brought on site without prior approval of the Government. Radioactive materials or instruments capable of producing ionizing radiation as well as materials which contain asbestos, mercury, lithium, methylene chloride, lead (= or >0.06%), or polychlorinated biphenyls (PCB’s) are prohibited. Definitions of hazardous materials are specified in the latest version, including revisions adopted during the term of the contract, of FED-STD-313F.

Nickel Metal Hydride and lithium batteries are permissible for memory backup. Class I Ozone Depleting Substances as defined in 40 CFR 82 shall not be used in the performance of this contract or be provided as part of the equipment. Exceptions to the prohibition of these materials must be referred to the Contracting Officer in writing, for consideration, not later than 60 calendar days after effective date of contract and prior to any work being performed.

3.1.6 Environmental Protection. Under the operating, service, transportation, and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

3.1.7 Lubrication. Means shall be provided to ensure proper lubrication for all moving parts in accordance with manufacturer requirements. All oil holes, grease fittings, and filler caps shall be easily accessible.

3.1.7.1 Lubrication Data. The Contractor shall provide the following information on all liquid or grease lubricants contained within equipment/system or in bulk (5 gallons or more) supplied under this procurement.

a. Liquid Lubricants

i. Viscosity grade in ISO units

ii. Viscosity Index

iii. AGMA and/or SAE classification as applicable

iv. Mil Spec and/or NATO Code as applicable

v. Okuma Specification Number as applicable

vi. Viscosity in Centistokes (cst) @ 40° C and 100° C

vii. Type Additive package. Example: ZDDP, Rust inhibitors, Foam inhibitors.

viii. Neutralization, the TBN (alkalinity) and/or TAN (acidity).

ix. Flash point

x. Pour point

b. Grease Lubricants

i. National Lubrication and Grease Institute (NLGI) Number

ii. Type and percent of thickener

iii. Dropping point

iv. Maximum Service Temperature

v. Base oil viscosity range in SUS or centipoise

3.1.7.2 Recirculating Lubrication. When the machine is equipped with a recirculating lubrication system, it 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 lubrication condition. When a low lubrication condition occurs, the machine shall complete the current operation and come to a complete stop. The machine shall indicate that lubrication is required.

3.1.8 Replacement Parts. 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 either be interchangeable with domestically supplied components or be readily available from a domestic source.

3.2 Construction. The machine 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 machine to its maximum rating and capacity without distortion.

3.2.1 Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, filling with solder or paste shall be used for reclaiming any defective part.

3.2.2 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.

3.2.3 Threads. All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28B and the applicable “Detailed Standard” section referenced therein or equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

3.2.4 Hydraulic System. Under the condition that a machine has a hydraulic system, the system shall conform to ISO 4413. The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls. A machine that does not require a hydraulic system to operate properly shall be considered acceptable.

3.2.5 Pneumatic System. Under the condition that a machine has a pneumatic system, the system shall conform to ISO 4414. The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls. A machine that does not require a pneumatic system to operate properly shall be considered acceptable.

3.2.6 Gears. All gears shall be of proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine. Gears in drive trains shall be hardened and ground steel in accordance with

AGMA ISO 1328-1-B14.

3.2.7 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.

3.2.8 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.

3.2.9 Painting. The machine shall be painted in accordance with the manufacturer’s commercial practice. All paint shall be of the lead-free type.

3.2.10 Workmanship. Workmanship of the machine 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.

3.3 Components of Machine One. This machine shall consist of not less than the following components:

3.3.1 Location. Proposed New location can be found in Attachment A. The Access door to room is 10 feet tall by 12 feet wide. Booth may be brought in pieces and assembled in room. Ceiling in room is 30 feet tall. Access of top of the booth is required.

3.3.2 Base. The base shall be a stress relieved, heavy duty, ribbed casting or steel weldment having characteristics that minimize both thermal and vibration effects, while providing the strength and size to assure maximum rigidity and support for any load within the rated capacity of the machine. Means shall be provided for accurate, ease of leveling.

3.3.3 Turntable and Work Surface.

3.3.3.1 Turntable. The turntable shall be proportioned to support and withstand the maximum capacity work-piece weights and fixtures for the peening process. The turntable shall be precision fitted to operate with the booth’s robot. The top of the turntable shall be machine finished for a work mounting surface, and demonstrate a mount existing fixture provided in Attachment 2. The turntable shall demonstrate ergonomic loading of parts that ensures artisans are able to load our parts between 50- 200 pounds with appropriate lift equipment. The turntable will meet the following minimum specifications:

a. 0.3-30 RPM range

b. 600 pound capacity

3.3.3.2 Work Surface. The work surface shall conform and match the Government drawing of the Fixture Base Plate. Where thru holes are designated on the Fixture Base Plate Drawing, there shall be sufficient clearance underneath the work surface to place a bolt through and nut attached. The work surface shall be a minimum of one inch but no greater than three inches thick. Stanchions may be used on top of the turntable to provide any necessary clearance underneath the work surface to achieve correct angles and standoff distances for the robot.

3.3.3.3 Material Handling. Material handling equipment shall be provided that handles the minimum of at least 600 pounds and allow for ergonomic loading and unloading of parts directly onto the work surface by the artisan.

3.3.4 Robot. The robot shall be a 5-axis gantry robot to make maximum use of the workspace. The robot shall be programmable from the booth’s (HMI). The robot shall be accessible for maintenance. The robot shall meet the following minimum requirement specifications:

a. Stroke Lengths (Linear axes): X-axis – 48 inches

i. Y-axis – 60 inches

ii. W-axis – 60 inches

b. Positioning Speeds: 400 inches/minute

c. Positioning Repeatability and Accuracy: 0.02” for all linear axes

3.3.5 Hose Support. The machines shall include a hose support to keep the blast hoses from interfering with the peening process. The support will allow for free movement of the robot and be resistant to reflected peening media..

3.3.6 Doors and Grating.

3.3.6.1 Work Door. The booths must have a front access door in order to accommodate part loading. The door shall demonstrate loading the maximum size part.

The door must be electrically interlocked to the safety system of the booth. The door must be able to function with the part loading system and provide sufficient sealing to prevent escape of peening media during normal operation.

3.3.6.2 Access Door. The booths must have an operator door for access to the shop artisan. The purpose is to allow the artisan to closer inspect standoff distances, part placement, and easier programming process when using the teach pendant to program workload. The door must be electrically interlocked to the safety system of the booth and provide sufficient sealing to prevent escape of peening media during normal operation.

3.3.7 Grating. The booths shall have suitable grating on the floor of the interior of the booth so as to allow media to fall through into the reclamation system, as well as to allow an operator to freely walk about the interior of the booth. Must be load rated for an operator to walk on, with a minimum load rating of at least 350 lbs

3.3.8 Reclaim System. The machines shall have a media reclamation system. The reclamation system shall separate bad media from reusable media. Reusable media shall demonstrate the ability of recirculating and be reused in the peening process. The goal is a closed-loop media system. The reclaim system will have the following minimum components:

a. Dust Collector w/0.5 micron filters

b. Cyclone (for media separation)

c. Ductwork

d. Rejected Media Barrel

e. Mechanical Screening System

f. Media type: AMS 2431/4, Sizes AWS 14 and 28.

3.3.9 Pressure Pot System. The machines must be equipped with a pressure pot system to deliver media at specified pressures and flow rates. The minimum allowable range is from 3-30 lbs/min. The system must be equipped with both high and low alarms for notification the system is operating outside of desired ranges. The following flow rate accuracies are required minimums:

a. +/- 5% for flow ranges less than 8 lbs/min

b. +/- 3% for flow ranges between 8 and 15 lbs/min

c. +/- 2% for flow ranges greater than 15 lbs/min

3.3.9.1 Manual Blow-off. The booths must have a manual air blow-off nozzle inside the booth for the artisan to easily blow-off excess shot from the process part. The blow-off nozzle must be safety rated to prevent excess of 30 psi air from being used.

3.3.10 Compressor. The booths shall have a compressor suitable to meet the air pressure demands of both booths under continuous operation for one hour. The compressor shall be equipped with an air dryer and oil-separating system to ensure dry and oil-free air is used with the shot.

3.3.11 Electrical System. Machine one (1) and (2) shall conform to NFPA 79 or current equivalent ISO/EN/DIN/JIS/IEC standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements. The existing source power available at the facility is 460 volt, 3-phase, 60 Hertz (Hz). The machine’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete, including any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated, and fused, single disconnect device shall be utilized on the machine with means of lockout in the off position only.

3.3.11.1 Electrical Enclosures. Construction of the electrical enclosures shall be in accordance with NEMA 250 type 12 or current equivalent ISO/EN/DIN/JIS/IEC standards and shall provide for ventilation of components and shall be designed for an indoor non-hazardous location. All electrical components shall conform to NFPA 79 or equivalent ISO/EN/DIN/JIS standards. The machine shall be provided with interlocks on its electronic cabinet that shall instantly remove power from the equipment when the door is opened in accordance with NFPA 79 or current equivalent ISO/EN/DIN/JIS/IEC standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

3.3.11.2 Arc Flash Protection. The machines enclosures shall be marked for arc flash in accordance with NFPA 79 Paragraph 16.2.3 “Safety Signs for Electrical Enclosures” or current equivalent ISO/EN/DIN/JIS/IEC standards for arc flash safety. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

3.3.11.3 Solid-State Components. Electrical devices used to power electrical servo and spindle motors of control voltage delivered to solid-state electrical components shall be solid-state devices. Such devices shall be equipped to handle the electrical load imposed by operation of the machine to its maximum potential. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

3.3.12 Controller Features and Software.

3.3.12.1 Controller Features. The machines controllers shall consist of a computer numerical control (CNC) incorporating all standard features. The CNC unit shall provide programmable automatic control of machine functions, operating modes, axis movement and other part program directed functions for the machine. Movement in all axes shall be both synchronous and independent positioning. Control features shall include Manual Data Input (MDI), simultaneous control of all axes, programmable interface, part program edit, buffer edit capability, part program storage, fixed cycles, and control diagnostics. The CNC shall direct machine functions from command data stored in memory. The data stored in memory shall be input by the media specified herein. The control shall initiate a halt and error signal should a fault condition occur in the control. The control shall automatically shut down when internal operating temperatures exceed safe operating limits. The controller shall demonstrate the ability of storing programs for convenient rework of future parts in accordance with AMS 2432.

3.3.12.2 Software. The machines must be equipped with software and demonstrate the ability of recording saturation curves.

3.3.13 Motors. Motors shall be rated for continuous duty. 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 shall meet the requirements of NEMA MG-1 or current equivalent ISO/EN/DIN/JIS/IEC standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

Each motor shall have an identification plate in accordance with paragraph 3.12.2 to identify manufacturer, model number, serial number, voltage, amperage, horsepower, phase, frequency, and frame number. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

3.3.14 Work light. Both machines shall have a work light, whether built-in or added on, shall be provided. The light shall have a protective shield and provide maximum light to the work area.

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

3.3.16 Hour Meter. The machines shall be equipped with a non-resetting type, hour meter to display accumulated operating time of the drive motor(s), mounted on the main electrical panel visible from the outside, sealed to prevent the entrance of dust and moisture, and shall be mounted to withstand shock and vibration generated by the machine.

The meter shall have a range of 0 to 99,999.9 hours in increments of one (1) tenth of one

(1) hour. A CNC control that tracks and displays total machine on time (a non-resetting type), controller on, program runtime, and run time of the servo motor(s) shall be considered to meet this requirement. The meter shall be sealed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by the machine.

3.3.18 Emergency Stops. The machines must be equipped with emergency stops. The emergency stops must be highly visible and in accessible areas. There shall be emergency stops at minimum in the following locations:

a. Operator HMI Station

b. Booth Roof Access Ladder

c. Emergency Stop Cable in the Interior of the Booth.

3.4 Size and Capacity. The size and capacity of the machine (1) shall be not less than specified in Table I.

Maximum Part Diameter (1) 57 Inches Maximum Part Length (1) 24 Inches Maximum Part Weight (1) 110 pounds

Root Peen Blade (1) 3 inches wide, 2.5 inches tall, slanted 30 degrees

Maximum Part Length (2) 72 inches Maximum Part Width (2) 4 inch channel shape Maximum Part Weight (2) 35 pounds Minimum Part Length (3) 9 Inches Minimum Part Width (3) 4.5 Inches Minimum Part Weight (3) 3 pounds

3.5 Standard Tooling and Equipment. All standard tooling and equipment required for proper operation and maintenance of the machine (1) shall be provided to include:

a. 90 Degree Straight Lance. A non-rotating lance which quickly and easily attaches and detaches to the primary peening nozzle shall be provided. The lance shall be designed so that it is an extension of the nozzle, where the shot stream is deflected at a 90-degree angle, for peening within large part cavities. It shall be approximately twelve (12) inches long and the outer diameter shall be designed to fit into the primary peening nozzle securely.

b. Rotary Lance. The system shall be equipped with a removable rotary lance attachment which quickly and easily attaches to the programmable gantry positioning assembly. The rotary lance shall have its own media hose that connects to the media system. It shall accommodate a 3/16-inch lance and a 1/4-inch lance with the associated lance collets. The system shall be designed so that the rotary lance can be programmed to either spin continuously at a specific speed or remain stationary if desired. The system shall deliver media to the rotating lance and shall not oversaturate the lance with media so that peening remains constant. The lance shall rotate at a minimum range of 0-150 rpm. Electrical cords, and electrical connections between the machine and the attachment shall be designed with protection from the peening environment to prevent damage.

c. AMS2413/4, sizes AWS 14 and AWS 28 shot required

d. Media loading tank for CW14 and CW28 shot for both booths.

e. 12 inch nozzle

f. 12 inch 90 degree nozzle

g. 360 degree turning Rotary Lance

3.6 Components Machine Two. Machine Two shall consist of not less than the following components:

3.6.1 Base and Location. The base shall be a stress relieved, heavy duty, ribbed casting or steel weldment having characteristics that minimize both thermal and vibration effects, while providing the strength and size to assure maximum rigidity and support for any load within the rated capacity of the machine. Means shall be provided for accurate, ease of leveling. The machine must be entirely located, along with clearance space for maintenance within the allowable space shown in the Proposed New Locations drawing.

3.6.2 Turntable. The turntable shall be proportioned to support and withstand the maximum capacity work-piece weights and fixtures for the peening process. The turntable shall be precision fitted to operate with the booth’s robot. The top of the turntable shall be machine finished for the work mounting surface. The work mounting surface drawing is provided by the Base Shot Peen Fixture Mount drawing. The turntable will meet the following minimum specifications:

a. 0.3-30 RPM range

b. 300 pound capacity

3.6.3 Robot. The robot shall be suitable for the smaller workspace. The robot shall be programmable from the booth’s HMI. The robot shall be accessible for maintenance. All bearing, sliding, screw surfaces shall be protected from shot peen media.

3.6.4 Doors

3.6.4.1 Work Door. The booth must have a side access door in order to accommodate part loading. The door shall demonstrate loading the maximum size part.

The door must be electrically interlocked to the safety system of the booth and provide sufficient sealing to prevent escape of peening media during normal operation.

3.6.5 Reclaim System. The booth shall have a media reclamation system. The reclamation system shall separate bad media from reusable AMS 2431/4 size AWS 14 and& 28 media. Reusable media shall demonstrate the ability of recirculating the reused media in the peening process. The goal is a closed-loop media system.

3.6.6 Compressor. The booth shall have a compressor suitable to meet the air pressure demands of both booths under continuous operation for one hour. The compressor shall be equipped with an air dryer and oil-separator system to ensure dry and oil-free air is used with the shot.

3.6.6.1 Solid-State Components. Electrical devices used to power electrical servo and spindle motors of control voltage delivered to solid-state electrical components shall be solid-state devices. Such devices shall be equipped to handle the electrical load imposed by operation of the machine to its maximum potential. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

3.6.7 Controller Features and Software.

3.6.7.1 Controller Features. The machines controllers shall consist of a CNC Control incorporating all standard features. The CNC unit shall provide programmable automatic control of machine functions, operating modes, axis movement and other part program directed functions for the machine. Movement in all axes shall be both synchronous and independent positioning. Control features shall include Manual Data Input (MDI), simultaneous control of all axes, programmable interface, part program edit, buffer edit capability, part program storage, fixed cycles, and control diagnostics. The CNC shall direct machine functions from command data stored in memory. The data stored in memory shall be input by the media specified herein. The control shall initiate a halt and error signal should a fault condition occur in the control. The control shall automatically shut down when internal operating temperatures exceed safe operating limits in accordance with AMS 2432.

3.6.7.2 Software. The machines shall be equipped with software that can demonstrate the recording of saturation curves.

3.6.7.3 Axes Overtravel Limits. The machines shall include axes over travel limits on gantry axes to keep the machine within the working envelope in case of programming errors or machine malfunction. The over travel limits shall be designed to meet or exceed the following:

a. X and Z axes shall have both programmed and hard stops so that the axis will stop if it travels beyond the range specified in Table I.

b. The system shall not allow the axes to extend beyond the hard stops, unless the machine is under repair.

c. Only forces external to the machine can move it past the hard stops.

d. The machine shall have a way to move the robot back into the working envelope from the operator control panel if it has traveled past programmed stops, either by jogging the robot or having an overtravel override button.

3.6.7.4 Operator Control Pendant. An operator control jog/teach pendant shall be incorporated into the system to allow the operator to perform all jogging functions on the control system. The pendant shall have an illuminated display for ease of viewing. The pendant shall be located in an optimum location for allowing the programmer to view the part and access to the operator interface for programming. The machine shall demonstrate jogging only when the system in in “Jog Mode” which shall be a separate option selection and shall demonstrate the use of jogging when in this mode. This pendant shall include at a minimum the following:

a. Jogging of all axes in both Positive and Negative directions

b. Selection of High, Medium, and Low jog speed

c. Incremental jog speeds

d. Homing of all axes

e. Cycle Pause button for program execution

f. Cycle Run button for program execution

g. Store button to Insert the current position into the motion program

h. Jog pendant cord 15 feet long and located near the programming area

i. Separate button selection for each axis

j. Pendant shall display the axis position of the axis being jogged

k. Separate button selection for separate jogging modes

l. Holder on side of machine to house pendant

m. Emergency Stop button

n. Incremental positioning wheel for precise robot positioning

3.6.8 Work light. A work light, whether built-in or added on, shall be provided. The light shall comply with NFPA 79 requirements, have a protective shield, and provide maximum light to the booth enclosure.

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

3.7 Hour Meter. The machine shall be equipped with a non-resetting type, analog hour meter to display accumulated operating time of the drive motor(s), mounted on the main electrical panel visible from the outside, sealed to prevent the entrance of dust and moisture, and shall be mounted to withstand shock and vibration generated by the machine.

The meter shall have a range of 0 to 99,999.9 hours in increments of one (1) tenth of one

(1) hour. A CNC control that tracks and displays total machine on time (a non-resetting type), controller on, program runtime, and run time of the servo motor(s) run time shall be considered to meet this requirement. The meter shall be sealed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by the machine

3.8 Size and Capacity of Machine Two The size and capacity of Machine Two shall be not less than specified below:

Maximum Part Diameter (1) 57 Inches Maximum Part Length (1) 24 Inches Maximum Part Weight (1) 110 pounds Root Peen Blade (1) 3 inches wide x 2.5 inches tall at 30 degrees Minimum Part Length (3) 9 Inches Minimum Part Width 4.5 Inches Minimum Part Weight 3 Pounds

3.9 Standard Tooling and Equipment. All standard tooling and equipment required for proper operation of the machines (such as special tools needed for maintenance) shall be furnished. A list of these items shall be furnished at time of proposal.

3.10 Tooling/Accessories: The following tooling/accessories shall be provided with machine (2).

a. AMS2431/4 sizes aws 14 and 28 shot required b.Media loading tank for CW14 and CW28 shot for both booths.

c. 12 inch nozzle d.12 inch 90 degree nozzle

e. 360 degree turning Rotary Lance

3.11 Alignment and Accuracy Tolerances. The alignment and accuracy tolerances of both Machine One and Machine Two shall be as specified below:

a. Both machines will need to be able to provide a range of intensities from as low as 0.004N and as high as 0.018A on Almen test strips

b. All linear axes positions of the robot shall be repeatable within 0.020 inches, and all rotary axes shall be repeatable within 1.0 degree. The positional accuracy for all linear axes shall be accurate within +/- 0.020 inches, and all rotary axes shall be accurate within +/-1 degree.

c. The Robot shall have a minimum positioning speed of 500inches/minute for all linear axes, and a positioning speed of 3600 degrees/minute for all rotary axes.

d. All geometric accuracy and positions of the robot shall be tested in conformance with ISO 230-1:2012

e. A blast wear plate shall be mounted on the cabinet wall directly in front of the nozzle at the home position to absorb energy from overspray and ricochet.

3.12 Marking on Instruments, Control Panels, and Plates. All words on 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.

3.12.1 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 available)

• Size and Type of Each Lubricant Filter

3.12.2 Nameplate. A nameplate shall be permanently and securely attached to each machine. The nameplate data shall meet the requirements of NFPA 79 and 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

• CAGE Code

• Manufacturer’s Name

• Manufacturer’s Model Designation

• Manufacturer’s Serial Number

• Power Input (Volts, Total Amps, Phase, Frequency)

• Contract Number

• Date of Manufacture

• Full-load current for each supply

• Ampere rating of the largest motor or load

• Short-circuit current rating of the industrial control panel

• Max ampere rating of short-circuit and ground fault protective device, where provided

• Electrical diagram number(s) or number of the index to the electrical drawings

3.12.3 Identification Marking of Military Property. An Item Unique Identification Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text. At a minimum this tag shall contain the information listed in paragraph 3.7.2 Nameplate.

3.12.3.1 Warranty Data Plate. The Contractor shall securely attach a warranty data plate to the machine enclosure in accordance with MIL-STD-130N, the data plate shall include the statement “WARRANTIED ITEM” and the warranty expiration date.

3.13 Technical Data. Three (3) hard copies and one searchable (1) electronic copy on compact disk of technical data shall be provided with the machine. Technical data shall contain 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.

3.13.1 Plan of Action and Milestones (POA&M). The contractor shall provide a POA&M to identify contractor performance dates of all major events from contract award to completion of all contract requirements. The initial POA&M shall be delivered thirty

(30) calendar days After Contract Award (ACA). The milestones shall be prepared using a recognized project management technique (preferably Microsoft Project). The Government and the contractor shall review the report on a monthly basis. The contractor shall notify the Government prior to making any changes to the POA&M. All changes to the POA&M shall be approved in advance by the Government. The POA&M shall detail such items as system design concept, system development, software design concept, software development, engineering, procurement of major hardware, assembly, operational debug, factory acceptance, shipment, installation, training, and final acceptance test. Removal, installation, and training shall take no more than 15 months.

3.13.2 Acceptance Test Plan (ATP). The Contractor shall prepare an Acceptance Test Plan (ATP). The ATP shall be a step-by-step written instruction on how to verify compliance during Contract Quality Assurance Inspection and the Final Inspection/Acceptance Test specified in Section 4.6. The Contractor shall develop and provide dimensioned drawings of the proposed test part specified in Paragraph 4.6. The Manufacture’s standard testing procedures shall be included in the ATP. Any procedures necessary for compliance with Section 4, which are not covered by the Manufacturer’s standard testing procedures, shall be identified and included in the ATP. The initial ATP shall be submitted thirty (30) calendar days ACA for Government review and approval.

The accepted test procedures shall become part of this contract.

3.14 Removal and Relocation of Existing Equipment.

3.14.1 Removal of Fully Automated Shot Peen Booth. The Contractor shall be responsible for removal and disposal of all equipment for the existing automated shot peen booth. The Government will handle all of the decontamination process prior to contractor beginning removal. All hazardous waste will be handled by The Government.

3.14.2 Relocation of Manual Glove Box Peening Cabinet. The Contractor shall be responsible for relocating the manual glove box peening cabinet. The Contractor shall move the glove box to the allocated space in the adjacent Blast Shop. The Government will be responsible for setting the glove box back up in operational condition, including connecting it to utilities. The Contractors only responsibility is relocating the equipment without damage to the adjacent room’s space.

3.15 Installation. The contractor shall be responsible for all equipment (forklifts, man lifts, etc.) and qualified personnel for unloading, rigging, installation, anchoring, connecting machine to utilities, and leveling the machines in place. The contractor shall provide the necessary anchor bolts, leveling screws, and related hardware to secure the machines components to a foundation. The contractor shall follow the customers hours of operation;

6:30am to 3:00pm, Monday through Friday excluding all national holidays, unless informed otherwise. The Booths will be installed in the existing automated shot peen room. The room has a total size of 55’x 29’. See drawing for existing shop layout. All equipment related to the existing automated shot peen booth must be disposed of. All cleaning and decontamination of the booth will be handled by the Government. All equipment from the existing manual hand peening booth will be disconnected and moved to the adjacent room.

The Government will handle the booth from there. Machine One will have the larger footprint and has a maximum allowable footprint of 28.5 feet x 20 feet. This includes the space for the part loading lift. This must also include space around the booth for access.

Machine Two will have the smaller allowable footprint of 25 feet x16 feet. This is the true allowable footprint for Machine Two, and does include access space, as this was accounted for. Please see the attached drawing for the proposed location/space for the new booths. All electrical hookups are available within the same room from the existing equipment.

Attachments B, C, D, and E are applicable. Dimensions for the shop door and entrance door are 12 feet wide by 10 feet tall. Use of an overhead crane with 0.5-ton limit is available. The booths may be assembled inside of the shop to allow for size constraints.

3.15.1 Power and Air. Power will come from existing panels for the booths being replaced. Panels will be located within 15 feet of booth locations. Compressor: Located 115 feet from the Shop when ran as existing lines. Existing lines may be used that are located within the room, within 20 feet of the existing equipment. Attachment F is applicable.

3.16 Training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is proficient in the English language, shall be provided for specialized training to familiarize Government personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage.

The training shall be for eight (8) maintenance personnel, four (4) operators, four (4) programming personnel and two (2) electrical personnel. Training shall be performed at the Government facility and shall not be less than five (5) consecutive eight (8) hour workdays, between 06:00 am and 2:00 pm excluding weekends and federal holidays. The course shall utilize as-built drawings and manuals provided under this contract and shall include both classroom and hands-on portions. All printed training aids shall be supplied for the course, be in the English language, and become the property of the Government. All training may be provided onsite in the shop, with the option to train in a classroom in building 7H. For training on using the booth, the use of dummy fixtures (provided by the Government) shall be required for programming.

4.0 QUALITY ASSURANCE.

4.1 Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein and in accordance with the attached Quality

Assurance Provision (QAP) The Government reserves the right to witness any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

4.1.1 Responsibility for Compliance. The Contractor shall be responsible for ensuring all items meet the requirements of sections 3 and 4.

4.2 Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. Final Inspection/Acceptance test (Destination) (see 4.4).

4.3 Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient temperature conditions in the range of 55° F to 100° F and 10% to 95% relative humidity.

4.4 Final Inspection/Acceptance Test (Destination). Final Inspection and acceptance test shall be performed on the machine to ensure conformance with this purchase description.

The acceptance test shall be performed only after the machine is installed at its final location. The acceptance test shall consist of the examination in 4.5 and all tests in 4.6. The machine shall pass the examination and all tests to be accepted.

4.5 Examination. The equipment shall be examined for design, dimensions, construction, materials, components, electrical equipment and workmanship to determine compliance with the requirements of this specification.

4.6 Tests. Unless otherwise specified within this document, all programs, instruments, materials, material handling equipment, qualified personnel, and tools required to perform and evaluate the tests shall be furnished by the contractor. All measurement tools and indicating devices shall be calibrated in accordance with the attached QAP. If a malfunction occurs during the test, the test shall be restarted each time until all tests in 4.7 are completed without a malfunction. Three (3) consecutive failures without completion of the test may be considered cause for rejection of the system. For the purpose of this test, a “failure” is defined as any equipment malfunction which requires remedial action to restore the system to full operation in accordance with this specification.

4.6.1 Machine (1) Performance Test. Contractor shall program and successfully run robotic peening operation as described below. A successful run is accomplished when machine is started, program is entered, machine executes the program and the four almen strips on the test fixtures achieve the specified intensity ±0.002A. Test shall be completed with the following criteria.

a. Material…