24-13-1002_Vertical.pdf

PURCHASE DESCRIPTION FOR THE ACQUISITION OF TWO

NEW VERTICAL BALANCING MACHINES

1.0 SCOPE.

1.1 Scope. The content of this specification describes the minimum requirements for purchasing two new Vertical Balancing machines. The contractor shall provide complete installation services to include all parts, rigging equipment, qualified personnel, materials, delivery, removal of existing equipment, performance testing, and training as described in the following specification to provide two (2) fully operational machines located at Fleet Readiness Center Southwest (FRC-SW), in Building 472.

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 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.

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

a. US NAVY OPNAVINST 3960.16A: Navy Test, Measurement, and Diagnostic Equipment (TMDE), Automatic Test Systems (ATS), and Metrology and Calibration (METCAL) (2011)

FED-STD-H28A - Screw Thread Standards for Federal Services (1994 edition)

a. MIL-STD-130N – Identification Marking of U.S. Military Property (2007 edition) (Copies of Federal and military specifications, standards, and handbooks are available from the Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402-0001)

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.

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.

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

1. NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

a. NEMA ICS 6 – Industrial Control and Systems Enclosures (1993 edition) Pg. 16 (13.16.3)

b. NEMA MG-1 – Industrial Control and Systems Enclosures (1993 edition)

(Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Suite 1847, Rosslyn, VA 22209)

2. NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

a. NFPA 79 - Electrical Standards for Industrial Machinery, (2012 edition)

(Application for copies should be addressed to the National Fire Protection Association, 1 Battery march Park, Quincy, MA 02269- 9101)

3. SOCIETY OF AEROSPACE ENGINEERS (SAE)

a. SAE ARP 5323 - Balancing Machines – Description and Evaluation Vertical, Single-Plane, Hard-Bearing Type for Gas Turbine Rotors

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.

3.0 REQUIREMENTS.

3.1 Design. The two vertical balancing machines 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 has 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 two vertical balancing machines 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. Measuring and indicating device calibration shall be either in inch/pound or in both the inch/pound and the SI metric system of units.

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.

3.1.3.1 Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11. The safety devices shall not interfere with the operation of the 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 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.

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

3.1.7 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.

3.1.8 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.

3.1.9 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.

3.1.10 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.

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.

3.2.4 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.

3.2.5 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.

3.2.6 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.

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

3.2.8 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. The machine shall consist of not less than the following components:

3.3.1 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.

3.3.2 Machine Housing, The machine shall come with a machine housing that is a rigid fabricated design. It shall include a balancing spindle with a hardened mounting flange specific to SAE 5323, and a force measuring transducer system for single plane unbalance measurement.

3.3.3 Electrical Cabinet: The electrical cabinet incorporates all the controls necessary for the machine to run efficiently. Components would include PC, keyboard, electrical power, printer, connection ports and software to run the machine. The cabinet is connected to the machine but is portable between 5 and 15 feet.

3.3.4 Shroud. The machine shall come with a shroud that is interlocked to prevent drive engagement when it is open and when it is closed until the rotor has come to a complete stop.

3.3.5 Disk Clamp, The machine shall have a disk clamp for spindle locking that is interlocked into the machine drive system.

3.3.6 Leaf Table, The machine shall come with a drop leaf table, which provides easy operator access to spindle and tooling from the front of the machine. It is manually operated and electrically interlocked into the machine drive system

3.3.6 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.

3.3.7 Electrical System. The machine shall conform to NFPA 79. The existing source power available at the facility is 480 VAC, 3 phase, 60 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.

3.3.7.1 Electrical Enclosures. Construction of the electrical enclosures shall conform to NEMA ICS 6 standards. The enclosure shall be a NEMA 250 type 12, 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.

3.3.7.2 Arc Flash Protection. The electric 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.

3.3.7.3 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.

3.3.8 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 3.7 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).

3.3.9 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 work area.

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

3.3.11 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 (Shall be an optional sentence and used as desire). 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.

3.3.11.1 Software. The contractor shall provide a permanently licensed programming software package. The software package shall include at a minimum the following modules:

a. Electronic Zeroing

b. Tooling Compensation (Remount Indexing)

c. Multiple Run Averaging

d. Tooling Management Software

e. Index Balancing Software

f. Custom Calibration Capability

g. Component Balancing Software

h. Rotor Memories

i. Ethernet Connectivity

j. Bode Plot Graph Display

k. SAE ARP Testing Software

l. Advanced Data Collection Software

m. Acronis software

n. Windows 11 Pro/Enterprise

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

TABLE I

Weight Range of Rotor @ 900 RPM 440 lbs Max. Rotor Diameter 57 inches

Ctr. of Spindle to back w/ shroud closed 84.0 inches Ctr. of Spindle to back w/ shroud open 79.2 inches Minimum Rotor Weight without Tooling 7 lbs Max. Spindle Height 20.3 inches Shroud Diameter 62.2 inches Shroud Height 36 inches Driving System Belt Balancing Speed 400 – 1200 rpm Power of Motor 10 HP

3.5 Alignment and Accuracy Tolerances. The alignment and accuracy tolerances of the machine shall be as specified in Table II.

TABLE II

Balancing Accuracy 50 µ inches Unbalance Reduction Ratio 90 – 95% Maximum Sensitivity <1.25 gmm/kg

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

3.7 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.

3.7.1 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

3.7.2 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

3.7.3 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.

3.8 Technical Data. Two (2) hard copies and two (2) electronic copies of technical data shall be provided with the machine. Each electronic copy shall be provided on a read-only archive grade optical disc. 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. Technical Data shall at a minimum include the following:

a. All engineering drawings.

b. Factory service and operator manuals for the type and model of the machine being purchased.

c. Diagnostic procedures for isolating and correcting faults. Procedures shall be included in the service manuals for recalibrating and performing operational checks to ensure proper operation of any replaced parts, as required.

d. Preventative and predictive maintenance tasks, including oil and vibration analysis and show recommended intervals of tasks.

e. Software manuals and registration keys/codes shall be provided, along with original software installation disks.

3.8.1 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. The Government shall approve all changes to the POA&M in advance. The POA&M shall detail such items as engineering, procurement of major hardware, assembly, operational debug, factory acceptance, shipment, installation, training, and final acceptance test.

3.8.2 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 Sections 4.4 and 4.5. The Contractor shall develop and provide dimensioned drawings of the proposed test part specified in Paragraph 4.7.3. 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.

3.9 Installation. The contractor shall be responsible for all equipment (forklifts, man lifts, etc.) and qualified personnel required for unloading, rigging, installation, anchoring, connecting machine to utilities, and leveling the machine in place. The contractor shall provide the necessary anchor bolts, leveling screws, and related hardware to secure machine components to a foundation. Contractor shall also be responsible for the Installation Responsibility sheet. Contractor shall be responsible for reading, understanding, and complying with Government facility requirements and information.

3.9.1 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.

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). Except as otherwise specified in the contract or purchase order, the contractor may use his own facility for the performance of the inspection requirements specified herein, unless disapproved by the Government 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. All items must meet all 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 4.5).

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 4.6 and all tests in 4.7.

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. The tests below shall be tailored to specific requirements desired by the customer and the type of machine.

Operational/Performance Tests should not exceed a 6-hour run (excludes alignment tests.)

The contractor will perform a SAE (Self-Assessment Examination) ARP test.

4.6.1 Alignment and Accuracy Tests. Tests shall be conducted to ensure the machine meets the alignment and accuracy tolerances specified in paragraph 3.5, Table II. The machine repeatability and accuracy for shall be checked.

4.6.2 Performance Test. A Factory Acceptance Test (FAT) shall be conducted at vendor facility in the last weeks of building out the machine by the contractor. All SAE ARP testing will be completed at vendor facility prior to FRCSW receiving new equipment.

Certification of completed testing will be provided by the contractor. FRCSW will have the opportunity to travel to the contractor’s location to attend testing phase.

- Maximum: 37.8” Dia x 4.25” tall, 150lbs Minimum: (23” Dia, 1” tall)

- Parts must be balanced below 10 gr-in.

- Tests rotors will be provided by FRCSW.

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

NOTE: The above checklist can have items removed and added based on customer/vendor needs for specific machines.

GOVERNMENT RESPONSIBILITIES

☒ Provide utilities hook-up within twenty (20) linear feet of the machine.

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 s...