Purchase Description Shot Peen.pdf

PURCHASE DESCRIPTION FOR THE ACQUISITION OF TWO

AUTOMATED SHOT PEEN BOOTHS

SCOPE.

The content of this specification describes the minimum requirements for two individual automated shot peen booths.

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 specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

Government Documents.

The following specifications, standards and handbooks form a part of this document to the extent specified herein. Refer to the latest revisions.

2.1.1 Code of Federal Regulations (CFR)

2.1.1.1 29 CFR 1910 – Occupational Safety and Health Standards, General Industry

2.1.1.2 40 CFR 761 – Environmental Protection Agency, Polychlorinated Biphenyls Manufacturing, Processing, Distribution in Commerce, and Use Prohibitions

2.1.2 Federal Standards

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

2.1.3 American National Standards Insitute (ANSI)

2.1.3.1 ANSI B11.25-2015 Safety Requirements for Large Machines

2.1.3.1 ANSI/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

2.1.4 International Organization for Standardization (ISO)

2.1.4.1 ISO 4413 – Hydraulic Fluid Power – General rules and Safety Requirements for Systems and their Components

2.1.4.2 ISO 4414 – Pneumatic Fluid Power – General Rules and Safety Requirements for Systems and their Components

2.1.5 National Fire Protection Association (NFPA)

2.1.5.1 NFPA 70 – National Electrical Code

2.1.5.2 NFPA 79 – Electrical Standards for Industrial Machinery

2.1.6 National Electrical Manufacturers Association (NEMA)

2.1.6.1 NEMA MG-1 – Motors and Generators

2.1.6.2 NEMA ICS 1

2.1.6.3 NEMA ICS 6 – Industrial Control and Systems

2.1.7 Military Standards

2.1.7.1 MIL-STD-130N – Identification Marking of U.S. Military Property

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.

2.1.2.1 Government Drawing 1: B794 Overview

2.1.2.2 Government Drawing 2: Fixture Base Plate

2.1.2.3 Government Drawing 3: Aisleway Travel

2.1.2.4 Government Drawing 4: Compressor Distance Overview

2.1.2.5 Government Drawing 5: Current Shop Layout

2.1.2.6 Government Drawing 6: Proposed New Locations

2.1.2.7 Enclosure (1) – FRCSE Work Restrictions

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.

2.2.1 AMS2430Automatic Shot Peening (SAE, https://www.sae.org/standards/content/ams2430

2.2.2 AMS2432 Computer Monitored Shot Peening (SAE, https://www.sae.org/standards/content/ams2432d/)

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

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.

REQUIREMENTS.

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. The machines shall be capable of peening in accordance with (IAW) applicable AMS standards using media IAW AMS 2431/4 sizes AWS 14 through 28.

Measuring and Indicating Device Graduations. All measuring and indicating devices on the machine shall be graduated in inch-pound.

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

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.

Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11.25-2015 Safety Requirements for Large Machines. 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.

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.

Mercury Restriction. The machine shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture with the exception of fluorescent lighting where required.

Asbestos Restriction. Asbestos and materials containing asbestos shall not be used on or in the machine.

Lead. Lead and materials containing lead shall not be used on or in the machine with the exception to radiation cladding and lead solder in circuits.

Use of Polychlorinated Biphenyl (PCB). The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited. The machine shall be considered PCB free providing certification to be verified containing less than 5 parts per million (<5ppm) in accordance with 40 CFR part 761.

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.

Lubrication. The machine shall be equipped with a system that provides lubrication (oil, grease, coolant, etc.) for all moving parts in accordance with manufacturer requirements. Recirculating lubrication systems shall include a filter that is cleanable or replaceable. Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low 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. All oil holes, grease fittings, and filler caps shall be easily accessible.

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.

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.

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.

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.

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.

Gears. All gears of axis drive trains shall conform to or exceed all provisions of ANSI/AGMA ISO 1328-1-B14 (PESO). 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.

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 standard commercial practice.

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.

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

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.

Components Machine One. Machine One shall consist of not less than the following components and be in full compliance with both AMS2430 and AMS2432:

Location. The machine must be entirely located, along with clearance space for maintenance within the allowable space shown in the Proposed New Locations drawing.

Turntable and Work Surface.

3.3.2.1 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, with capability to mount existing fixture provided in Government Drawing 2. The turntable shall be capable of exiting the booth on a track to be lowered by a lift in order for ergonomic loading of parts. The turntable will meet the following minimum specifications:

0.3-30 RPM range 600 pound capacity

3.3.2.2 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.

Material Handling. Material handling equipment shall be provided that handles a minimum of at least 600 pounds and shall be fully automated. The material handling equipment shall load components from the front of the machine into the enclosure. If any hydraulic systems are used in the equipment, the equipment and all components shall conform to ISO 4413. All hydraulic systems to be installed, shall be installed over a catch tray with a drain port. The material handling system shall be one complete unit.

Robot. The robot shall be a 5-axis gantry robot to make maximum use of the work space. The robot shall be programmable from the booth’s human machine interface (HMI).

The robot shall be accessible for maintenance. The robot shall meet the following minimum requirement specifications:

Stroke Lengths (Linear axes): X-axis – 48 inches Y-axis – 60 inches W-axis – 60 inches

Positioning Speeds: 400 inches/minute Positioning Repeatability and Accuracy: 0.02” for all linear axes

3.3.5 Hose Support. The machine 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 booth must have a front access door in order to accommodate part loading. The door must be capable of 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 booth 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.

Grating. The booth 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.

Reclaim System. The machine shall have a media reclamation system. The reclamation system shall separate bad media from reusable media. Reusable media shall be capable 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:

Dust Collector w/0.5 micron filters Cyclone (for media separation) Ductwork Rejected Media Barrel Mechanical Screening System Media type: AMS 2431/4, Sizes AWS 14 and 28.

3.3.9 Pressure Pot System. The machine 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:

+/- 5% for flow ranges less than 8 lbs/min +/- 3% for flow ranges between 8 and 15 lbs/min +/- 2% for flow ranges greater than 15 lbs/min

3.3.9 Manual Blow-off. The booth 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.

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-separating system to ensure dry and oil-free air is used with the shot.

Pneumatic System. The pneumatic system and all components shall conform to ISO 4414. The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

Electrical System. Machine One and Two shall conform to NFPA 79. The existing source power available at the facility is 460 Volts, 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.

Electrical Enclosures. Construction of the electrical enclosures shall conform to NEMA ICS 6 standards. The enclosure shall be a NEMA 250 type 12 and shall provide for ventilation of components and shall be designed for an indoor non-hazardous location. All electrical components shall conform to applicable NEMA ICS 1 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.

Arc Flash Protection. The machine enclosures shall be marked for arc flash in accordance with NFPA 79 Paragraph 16.2.3 “Safety Signs for Electrical Enclosures” for arc flash safety.

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.

Controller Features and Software.

3.3.13.1 Controller Features. The machine controller 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 be capable of storing programs for convenient rework of future parts.

3.3.13.2 Software. The machine must be equipped with software capable of recording saturation curves.

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. Each motor shall have an identification plate in accordance with paragraph 3.9 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).

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.

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

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 run time, 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.

3.3.18 Emergency Stops. The machine 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:

Operator HMI Station Booth Roof Access Ladder Emergency Stop Cable in the Interior of the Booth.

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

5-axes gantry robot Part maximum: 57 inch diameter, 24 inches tall, 110 pounds peening root of blade that is 3 inches deep, 2½ inches tall and slanted at 30 degrees Part maximum: 72 inches long, 4 inches wide channel shape, 35 pounds Part minimum: 9 inches long, 4½ inches wide, 3 pounds

12 inch straight and a 12 inch 90-degree nozzle/lance must be provided with Machine One AMS2413/4, sizes AWS 14 and AWS 28 shot required 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.

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

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.

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:

0.3-30 RPM range 300 pound capacity

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.

3.5.4 Doors

3.5.4.1 Work Door. The booth must have a side access door in order to accommodate part loading. The door must be capable of 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.

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 be capable of recirculating and be reused in the peening process. The goal is a closed-loop media system.

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.

Pneumatic System. The pneumatic system and all components shall conform to ISO 4414. The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

Electrical System. Machine One and Two shall conform to NFPA 79. The existing source power available at the facility is 460 Volts, 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.

Electrical Enclosures. Construction of the electrical enclosures shall conform to NEMA ICS 6 standards. The enclosure shall be a NEMA 250 type 12 and shall provide for ventilation of components and shall be designed for an indoor non-hazardous location. All electrical components shall conform to applicable NEMA ICS 1 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.

Arc Flash Protection. The machine enclosures shall be marked for arc flash in accordance with NFPA 79 Paragraph 16.2.3 “Safety Signs for Electrical Enclosures” for arc flash safety.

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.

Controller Features and Software.

3.5.8.1 Controller Features. The machine controller 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.

3.5.8.2 Software. The machine must be equipped with software capable of recording saturation curves.

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.

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

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.

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

Programmable robot Part Maximuim: 57 inch diameter, 24 inches tall, 110 pounds, peening root of blade that is 3 inches deep, 2½ inches tall and slanted at 30 degrees Part Minimum: Part minimum: 9 inches long, 4½ inches wide, 3 pounds AMS2431/4 sizes aws 14 and 28 shot required

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

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

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.

3.7.1 Tooling/Accessories: The following tooling/accessories shall be provided with each machine.

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

12 inch nozzle 12 inch 90 degree nozzle 360 degree turning Rotary Lance

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.

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

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

Nomenclature Manufacturer’s Name Manufacturer’s Model Designation Manufacturer’s Serial Number Power Input (Volts, Total Amps, Phase, Frequency) Contract Number Date of Manufacture

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.

Technical Data. Two hard copies and One electronic copy of technical data shall be provided with the machine. Operator manual, Maintenance manual, OSHA Certification, Test Plan, Electrical Schematics, Mechanical Schematics, Parts Listings all to be included. All copies of technical data shall be legible and written in the English language.

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.

3.11 Removal and Relocation of Existing Equipment.

3.11.1 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.

3.11.2 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.

Installation.

The primary constraint for booth installation is door sizes of the shop and B794 itself. The shop door is 12’ wide x 10’ tall. The same is true of the Building access door. The aisle way from the outside door to the shop is 11’ wide. See attached photo of aisle access to the shop. There is overhead crane availability once inside the shop, with a maximum load of

0.5 tons. The booths may be assembled inside the shop to deal with door size constraints.

Attachments A, B, and D are applicable.

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’ x 18’. 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 14’x16’. 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.

Power: 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.

Government Drawing 4 is applicable.

Contractor shall be responsible for disposal of existing automated booth. Government will be responsible for any hazardous waste removal, as well as cleaning and decontaminating the booth before removal.

See Attachment F: FRCSE Work Restrictions.

Work Stoppage. For unforeseen issues that are found during installation of the foundation, the contractor shall notify the facility point of contact (POC) and DLA immediately to determine further course of action.

Training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is an American citizen of good standing and repute and 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.

Maintenance, Operator, Programming, and Electrical Training to qualified personnel in each category is needed.

Five (5) days of eight (8) hours of training between (0600-1400) are required. Training must be conducted Monday-Friday, all federal holidays excluded.

Maintenance Personnel: 8 Operator Personnel: 4 Programming Personnel: 4 Electrical Personnel: 2 (May be included in maintenance training) 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.

QUALITY ASSURANCE.

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). 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.

Responsibility for Compliance. All items must meet all requirements of sections 3 and 4.

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

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

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.

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 4.6 and all tests in 4.7.

The machine shall pass the examination and all tests to be accepted.

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.

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.

Machine I Type of test to be performed: Contractor shall program and sucessfuly 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.

Material supplied by whom Government: F/A-18 NLG cylinder peening fixture

Test parts to peen and to what accuracies: Four areas peened. Almen strips shall show peening intensities of 0.010A±0.002A.

Almen Strips, Almen Gages, and Test Fixturing will be provided by the Government.

Almen Strips and Gages will be in compliance with AMS2430. They will be ‘A’ type

The Contractor shall test both AWS 14 and AWS 28 (AMS2431/4) shot peening media and sizes.

The contractor shall select and program the variables required to produce satisfactory peening intensity on the test fixture part.

The Government will suitably mount and mask as required. The contractor shall then peen in accordance with the parameters established above. A successful test will produce a variation of peening intensity no more than ± 0.002A from specified intensity. The variation in boundaries of areas to be peened when limited shall be -0 to +.125 inches.

Part size minimum and maximum: Approximately 6” ID/OD x 40” tall cylinder as shown in image below. Weight of part approximately 200lb. Weight of fixture approximately 200lb. Almen strip blocks (4X) are set-up in the areas of interest.

Finished Part Tolerance: Four areas peened to within ±0.002A of specified intensity.

The following system parts will have to meet the corresponding tolerances to be considered acceptable:

Shot Flow (for each nozzle): +/-10% lbs/min Air Pressure (for each nozzle): if >20psi then +/-10%. If <or= 20psi then +/-20% Nozzle Translation Speed: +/-10% in/min Nozzle Shut Down Time: 1 second Turntable Speed: +/- 10% rpm Peening Cycle Time: 1 second Nozzle Position: 0.062 inches or 5 degrees Table Position: 0.062 inches or 5 degrees

Machine II Type of test to be performed: Contractor shall program and sucessfully run robotic peening operation as described below. A successful run is accomplished when machine is started, program is entered, machine executes the program, peens a minimum of 9 hole IDs (test strip in hole position 5) and the almen strip on the test fixtures achieve the specified intensity ±0.002A. Holes are approximately 1.125 inch diameter.

Material supplied by whom Government: TF34 Fan Disk peening fixture

18” Ruler

External

External

Internal

Internal

Test parts to peen and to what accuracies: Four areas peened. Almen strips shall show peening intensities of 0.008A±0.002A.

Almen Strips, Almen Gages, and Test Fixturing will be provided by the Government.

Almen Strips and Gages will be in compliance with AMS2430. They will be ‘A’ type

The Contractor shall test both AWS 14 and AWS 28 (AMS2431/4) shot peening media and sizes.

The contractor shall select and program the variables required to produce satisfactory peening intensity on the test fixture part.

The Government will suitably mount and mask as required. The contractor shall then peen in accordance with the parameters established above. A successful test will produce a variation of peening intensity no more than ± 0.002A from specified intensity. The variation in boundaries of areas to be peened when limited shall be -0 to +.125 inches.

Part size minimum and maximum: Approximately 18 inches OD x 4 inches tall Fan Disk and 1.125 inches holes as shown in image below. Weight of part approximately 50 pounds. Weight of fixture approximately 120 pounds. Almen strip block (1X) is set-up in the areas of interest.

18” Ruler

Finished Part Tolerance: Four areas peened to within ±0.002A of specified intensity.

The following system parts will have to meet the corresponding tolerances to be considered acceptable:

Shot Flow (for each nozzle): +/-10% lbs/min Air Pressure (for each nozzle): if >20 psi then +/-10%. If <or= 20 psi then +/-20% Nozzle Translation Speed: +/-10% in/min Nozzle Shut Down Time: 1 second Turntable Speed: +/- 10% rpm Peening Cycle Time: 1 second Nozzle Position: 0.062 inches or 5 degrees Table Position: 0.062 inches or 5 degrees

Alignment and Accuracy Tests. Tests shall be conducted to ensure both machines meet the alignment and accuracy tolerances specified in paragraph 3.5, Table II. The machine repeatability and accuracy for shot flow, air pressure, nozzle translation speed, nozzle shutdown, turntable speed, peening cycle time, nozzle position, and table indexing shall be checked.

Audible Noise Level Test. The equipment shall be tested for compliance with paragraph 3.1.4. “Audible Noise Level”.

INSTALLATION RESPONSIBILITIES

Government Contractor ☒ ☐ a. Provide machine foundation in accordance with the

Manufacturer’s design requirements ☐ ☒ b. Furnish labor and material handling equipment for off-loading and placing item on foundation ☐ ☒ c. Provide and install anchor bolts and nuts ☐ ☒ d. Set and rough level the machine on its foundation ☐ ☒ e. Level and align machine ☐ ☒ f. Connect machine to the provided utilities hook-up ☐ ☒ g. Provide all necessary tools, gages, and instrumentation necessary to perform the required tests ☐ ☒ h. Provide and charge all systems with fluids in accordance with manufacturer's instructions ☐ ☒ i. Material for performance testing at Government facility ☐ ☒ j. Material for performance testing at Contractor's facility ☐ ☒ k. Material handling, Rigging equipment and Qualified

Personnel for performance testing

GOVERNMENT RESPONSIBILITIES

☒ Provide utilities hook-up within 150 feet of the machine.

☐ Government will connect utilities to the machine based on the contractor's accepted site drawings.

☒ Assign one mechanic (mechanical/hydraulic) and one maintenance mechanic (electrical/electronic) to provide information and any additional materials for the contractor's representative during installation, verification, and initial start-up of the machine.

☒ No work shall be performed by customer personnel when the contractor's representative is not in the immediate work area during installation, verification, and initial start-up of the machine.

ATTACHMENTS

A. B794 Overview

B. Aisle Way Travel

C. Proposed New Locations

D. Current Shop Layout

E. Compressor Distance Overview

F. FRCSE Work Restrictions

G. Fixture Base Plate

Appendix

Enclosure one (F) - Fleet Readiness Center Southeast Work Restrictions

1. GENERAL

1.1. This attachment covers the most common work restrictions for contractors working at Fleet Readiness Center Southeast (FRCSE) facilities. The contractor shall obtain the necessary passes and/or identification for entry into Naval Air Station (NAS) Jacksonville and FRCSE for all employees prior to commencement of work.

2. CONTRACTOR ACCESS AND USE OF PREMISES

2.1. NAS Jacksonville Base Regulations

2.1.1. Each contractor must identify itself as either a U.S.-owned or a Foreign Owned, Controlled or Influenced (FOCI) entity.

2.1.1.1. A company is considered to be a FOCI entity when a foreign interest has the power, either direct or indirect, whether or not exercised, to direct or decide matters affecting the management or operations of the company in a manner which may result in unauthorized access to classified information or may adversely affect the performance of a classified contract. A FOCI entity must contact the Technical Point of Contact (TPOC) or Contracting Officer’s Representative (COR) within 5 days of contract award to begin paperwork necessary to obtain base access in a timely manner. A non-U.S.

citizen employed by a FOCI entity is considered a foreign national of the foreign interest’s country. A U.S. citizen employed by FOCI entity is considered a foreign representative of the foreign interest’s country, but access will be managed the same as a foreign national.

2.1.2. The contractor shall be responsible for securing the necessary permits and base access passes for contractor personnel, vehicles, and equipment for the duration of the contract. NAS Jacksonville Security Forces reserve the right to refuse to issue a pass to an employee of the contractor for any reason deemed valid by the Government.

2.1.2.1. Non-U.S. citizen personnel of a FOCI entity will be required to provide the Security Forces at the NAS Jacksonville Pass and ID Office located at the Main Gate on Yorktown Ave with vehicle registration, proof of insurance, driver’s license, and passport in order to obtain a pass for entry onto the Base.

2.1.2.2. U.S. Citizen Personnel of a FOCI entity will be required to provide the Security Forces with vehicle registration, proof of insurance, driver’s license, and second form of picture ID.

2.1.2.3. U.S.-owned company personnel will be required to provide the Security Forces with vehicle registration, proof of insurance, and driver’s license.

2.1.2.4. The contractor shall submit Base Access Request Forms (provided by the TPOC/COR) for all contractor and subcontractor personnel, equipment and vehicles to the TPOC/COR or FRCSE Security, complete and in a timely manner, no less than 5 workdays prior to actual visit.

2.1.3. Flight Line Access: Unless otherwise stated in the main body of the Statement of Work, flight line access is not required for this job. Contractor personnel shall not, under any circumstances, enter the flight line, nor shall they solicit FRCSE personnel for tours. Personnel found on the flight line without a valid reason for being there, and personnel who do not possess a valid flight line access badge, will be detained by NAS Jacksonville security personnel and will be permanently denied further access to FRCSE and NAS Jacksonville property. The contractor shall report any such violations to the FRCSE TPOC immediately. There will be no exceptions made to this requirement.

2.1.4. Defense Biometric Identification System (DBIDS) increases installation security and communications by receiving frequent database updates on changes to personnel/credential status, law enforcement warrants, lost/stolen cards, and force protection conditions. The system provides a continuous vetting anytime the DBIDS card is scanned at an installation entry point.

2.1.5. If you currently have an Navy Commercial Access Control System (NCACS) card, the following is required to get a DBIDS credential:

2.1.6. Present your NCACS Card and a completed copy of the SECNAV FORM 5512/1 to the base Visitor Control Center (VCC) representative. The VCC will pull up your information in the computer, ensuring all information is current and correct. Once your information is validated, a temporary DBIDS credential is provided. Your temporary credential will have an expiration date, prior to which you will need to obtain your permanent DBIDS credential (~ 180 days).

For each additional U.S. Navy installation to which you need access, the first time you visit you only need to bring your DBIDS credential and statement of purpose for base access when arriving at the Visitor Control Center. The representative will enter base access authorization and then you may proceed to work.

2.1.7. If you do NOT have an NCACS Card, the following is required to obtain a DBIDS credential:

2.1.8. Present a letter or official document from my government sponsoring organization that provides the purpose for your access. Present valid identification, such as a passport or Real ID Act-compliant state driver's license.

Present a completed copy of the SECNAV 5512/1 form to obtain your background check.

Upon completion of the background check, the Visitor Control Center representative will complete the DBIDS enrollment process, which includes your…