PURCHASE DESCRIPTION Fluid Cell Press 25-20-1000.pdf

PURCHASE DESCRIPTION FOR THE ACQUISITION OF A

FLUID CELL FORMING PRESS

SCOPE.

Scope. This specification describes the minimum performance requirements for the purchase, delivery, installation, and acceptance testing of a new, single load station fluid cell press. The press shall be used for forming standard sheet metals and sheet titanium parts up to 0.125 inch. The new Fluid Cell Press will be installed in Bldg. 840, Fleet Readiness Center Southeast, Jacksonville, Florida.

APPLICABLE DOCUMENTS.

General. 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.

Government Documents.

Specifications, Standards, and Handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract.

STANDARDS – FEDERAL

FED-STD-H28B: Screw Thread Standards for Federal Service (2016 Ed.)

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

(OSHA)

29 CFR 1910 Vol. 5: General Industry, OSHA Safety and Health Standards (2017 Ed.)

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

DEPARTMENT OF DEFENSE

MILITARY STANDARDS

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property (2012 Ed.) 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)

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 issues of these documents are those listed in the solicitation or contract.

LOCAL FACILITY DOCUMENTS

ATTACHMENT A: Shop Floor Layout

ATTACHMENT B: B840 Floor Plan

ATTACHMENT C: Installation Responsibilities

ATTACHMENT D: Environmental Guide Specification for Contracts

(Applications for these documents should be addressed to the contracting officer)

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 issues of these documents are those listed in the solicitation or contract.

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 (2014 Ed.)

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

American National Standards Institute, Inc. (ANSI)

ANSI B5.1M: T-Slots, their Bolts, Nuts, and Tongues, Revision of ANSI B5.1- 1975 (1985 Ed. 2014R)

(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 B5.48: Ball Screws (1977 Ed. 2013R)

ASME Y14.100: Engineering Drawing Practices (2017 Ed.)

(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 (2010 Ed.)

ISO 4414: Pneumatic power-General rules and safety requirements for systems and their components (2010 Ed.)

(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) (2018 Ed.)

NEMA ICS 1: Industrial Control and Systems General Requirements (2000 Ed.

2015R)

NEMA ICS 6: Industrial Control and Systems: Enclosures (1993 Ed. 2016R)

NEMA MG 1: Motors and Generators (2018 Ed.)

NEMA Z535.4: Product Safety Signs and Labels (2011 Ed. 2017R)

(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 (2018 Ed.)

NFPA 79: Electrical Standard for Industrial Machinery (2018 Ed.)

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

TECHAMERICA

TIA-232-F: Interface between Data Terminal Equipment and Data Circuit- Terminating Equipment Employing Serial Binary Data Interchange (1997 Ed.

2012R)

(Application for copies should be addressed to: TECHAMERICA, 601 Pennsylvania Ave., NW, North Building Suite 600 Washington D.C. 20004-2650)

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.

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

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 on the machine. 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 an average of 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter or equivalent, at the operator’s station. The average level shall be measured over one full cycle of the machine. Noise generated by the work place 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. Means shall be provided to ensure adequate lubrication (oil, grease, coolant, etc.) for all moving parts. Recirculating lubrication systems shall include a filter that is cleanable or replaceable. Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low 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 and the operator shall refill the lubrication reservoirs according to machine manuals. Low lubrication alarm shall prevent the machine from starting and can only be overridden at PLC level. All oil holes, grease fittings, and filler caps shall be easily accessible without removing enclosure panel (for example doors or small access covers) and shall have identification.

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-H28A 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. 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 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 painted in accordance with the manufacturer’s 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. The machine shall consist of not less than the following components:

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.

Enclosure. The machine shall be housed within an enclosure that provides containment of any hazardous conditions for operator safety in the event of a mechanical failure or hydraulic leak. The enclosure shall be equipped with a sliding door or doors that enable the operators and mechanics easy access to the machine. The enclosure shall have a work light with an on/off switch. The enclosure shall be open on the top.

Main Chamber. The main chamber shall be a stress relieved, heavy duty forging of high strength iron, or iron alloy, internally ribbed and proportioned to support and withstand the maximum capacity work-piece weights and loads.

Cylinder. A cylinder shall be provided that meets the forming pressure requirements in accordance with table I paragraph 3.4. All the necessary inserts, press plate with oil channels, refill valves, and flanges serving as the press feet and foot plate shall be provided as needed per the manufacturer design. A cylinder composed of layers of high strength steel wire wound around the cell shall be acceptable.

Loading Station. The press shall be equipped with one loading stations. One load station shall be configured for multi-depth, forming of sheet or thin plate material. Load station shall be complete with a part-feeding tray, driving mechanisms, and automatic tray pad roll‐up device or equivalent. The pad roll-up device shall be designed to automatically lay the pad down when the tray enters the press and automatically pick up the pad upon exiting the press. The drive mechanisms for the load station and the pad roll-up devices shall be either electrically driven or hydraulic motor with chain drives. The press shall be supplied with two (2) tray roll-up pads, one pad installed on automatic roll-up unit, and one

(1) spare pad. Automatic roll unit shall have an independent low lubrication alarm on the bearings and shall prevent the press from starting but will allow the ongoing process to complete.

Feed Tray. The press shall be equipped with a feed tray. The feed tray shall be high strength cast iron, or iron alloy, internally ribbed and proportioned to support and withstand the maximum capacity work-piece weights (up to 10,000 pounds) and loads.

Tray shall accommodate standard forming processes and shall meet the minimum usable forming area as indicated in Table I, paragraph 3.4. The forming tray shall be fitted with and include a removable filler plate that permits variable forming depths, see paragraph 3.4 Table I. The forming tray shall also be fitted with a set of urethane side moldings. The forming tray shall be provided with sufficient fill rubber to fully fill the tray.

Fluid Cell Unit/Cassette. The machine shall be provided with a kit that contains all necessary diaphragms, spacers, seals, and equipment for changing the fluid cell unit. The press shall be provided with two (2) units. One (1) installed in the press and a spare unit supplied in a steel container for storage and a diaphragm exchange fixture to aid in replacement of the unit. Diaphragm exchange fixture shall be mounted to storage rack with wheels, mechanism for easy removal and rigging, and total weight visibly stamped on the side. Fluid cell replacement shall take no more than five (5) hours. The contractor shall provide a video and visual aids for performing the replacement. The fluid cell diaphragm shall be made of natural rubber with excellent elongation and relaxation properties. The rubber diaphragm shall be repairable by cold or hot (vulcanize) method.

Forming Capacities. The press forming pressure shall be in accordance with paragraph 3.4, table I. The press shall have a pressure set point that is programmable via the user interface in increments of at least ten (10) pounds per square inch (psi). The press shall have a nominal forming capacity of 51,000 tons at the filler plate level. During high pressure forming the press shall reach ± 0.5% of operator defined set-point.

Forming Cycle. The contractor shall demonstrate the ability of the tray to travel a full cycle under a maximum loaded condition (100%) without stoppage, misalignment, or damage to drive system components. A maximum tray loaded condition (100%) is defined as the maximum usable tray area occupied with either fill rubber or other incompressible material. The contractor shall demonstrate the tray cycle operation in a timed trial. The maximum cycle time for steps a-g (see below) under any tray loading condition shall not exceed 145 second at maximum pressure. Press shall have the capability to perform manual forming cycle for service, repair, or troubleshooting. Manual forming cycle shall be able to perform at the control screen and at service pendant.

Tray starts at load/unload station

Tray travels into main chamber

Low pressure pre-fill

High pressure forming

Decompression

Evacuation

Tray travels out to load/unload station

Controller Features. The machine controller shall consist of a FANUC programmable logic control (PLC) incorporating all standard features with programmable cycle parameters. The control shall include a built-in 22-inch flat color touch screen for various functions and a digital trim pot for setting variable program parameters. The PLC unit shall provide programmable automatic control of machine functions, operating modes, and other part program directed functions for the machine. Control features shall include Manual Data Input (MDI), simultaneous control of all movements, programmable interface, part program edit, part program storage, fixed cycles, and control diagnostics.

The controller shall incorporate an on/off selector key switch with removable key, motor on illuminated push button, Emergency stop (E-stop) palm button, and E-stop reset push button. The PLC 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.

Operator’s Console. The machine shall be equipped with an operator’s console at the loading station. The console shall be equipped with but not limited to, the following items: Emergency Stop, Machine Start/Stop, and a ten (10) inch flat color touch screen display.

Safety Stops. All machine motions shall be equipped with a means of over-travel protection to prevent damage to the machine’s power feed mechanisms in the event the machine is inadvertently fed or rapidly traversed into an over-travel limit switch.

Tray Tracks. The tracks on which the part trays move on shall be either hardened steel or high grade roller tracks positioned on top of the tray track. The tray itself shall be made of a hardened steel or other suitable material that contacts with the roller tracks or tray tracks. The tray shall be moved into the press on the roller tracks positioned on top of the tray track or on the tray tracks themselves by another means.

Hydraulic System. The hydraulic system and all components shall conform to ISO 4413. The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls. Contractor shall provide the oil needed for the operation and shall be run through filtration system prior to transferring into the oil tank. Hydraulic oil required cleanliness shall be as per machine design (for example ISO codes 16/14/11).

Diaphragm Exchange System. Diaphragm exchange system shall be automatic with manual provision, level control, and safety interlocks.

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. The equipment shall conform to NFPA 79. The existing source power available at the facility is 480 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. Each disconnect shall comply with NFPA 79.

Electrical Enclosures. Construction of the electrical enclosures shall conform to NEMA ICS 6 standards. The enclosure shall be a NEMA 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 electrical panel shall be equipped with a window to allow for a technician to scan the enclosure for “hot spots” using a forward looking infrared (FLIR) camera as part of the reliability centered maintenance. 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 motor control voltage delivered to solid-state electrical components shall be solid-state devices.

Such devices shall handle the electrical load imposed by operation of the machine to its maximum capability. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

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 either NEMA MG-1 or IE3 code standards. Each motor shall have an identification plate in accordance with paragraph 3.6 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).

Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70. Contractor shall provide all necessary components and materials needed to connect from bldg. 840 bus bars to the machine (such as the bus plug, disconnect switch, cables, circuit breakers, etc.). The contractor shall provide all cooling water requirements for the fluid cell press: pressure ranges and differentials, water quality and consumption and maximum inlet temperatures.

Cooling (Chilled) Water. Contractor shall provide the chilled water as needed for the operation of the machine. Separate chiller system shall be located outside of the building. Foundation for the chiller system shall be provided and shall comply with section

3.8.2 Foundation. Chill water status, controls, alarm, and cooling circuit shall be available at HMI. Chill water piping shall have provision to flush the system in case of chill water pump becomes air bound.

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

Table I

Characteristic Capacity/Size Operating Pressure 15,000 psi Forming Area 46 inches x 148 inches Tray Depth without Filler Plate 14.2 inches Tray Depth with Filler Plate/s 5.9 inches Maximum Filler Plate Weight (Filler plates can be combination of 1” and 2” thick plates to be safely lifted by B840 installed overhead crane, all rigging eye & U-bolts and slings shall be provided in a container). Each filler plate will have weight visibly stamped and rigging eyebolts connections.

Plate rigging eyebolts connections shall have screw in/out fillers.

10,000 lbs. (Bldg. 840 Overhead Crane Capacity)

Tray Loading Station 1 Available Floor Area (new foundation will be needed). See Attachment A.

27 ft X 56 ft

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. Any tooling, fixtures, fasteners, clamps, or other items that will come in direct contact with titanium parts shall not be made with alloys containing or plated with; tin, cadmium, lead, zinc, or bismuth.

Silver at concentrations less than or equal to 1% shall be allowed.

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 3.6.2 Nameplate.

Technical Data. Two (2) sets of electronic manuals, two (2) sets of printed technical manuals, and two (2) copies of the original computer installation and back-up/restoration software shall be provided. Documentation shall include, Operations, Maintenance, and Preventive Maintenance. A lock out/tag out (LO/TO) procedure for locking out and releasing ALL stored energy shall be provided. This instruction shall be placed on a separate sheet within the manual and located on the equipment for fast reference during maintenance of the equipment in accordance with 29 CFR 1910.147. All technical data furnished shall be written in the English language.

Machine Operation Manuals. Machine manuals shall contain technical information, specifications, instructions for the operation and maintenance of the machine, all associated accessories and sub-systems. The manuals shall provide for detailed operation of the machine and sub-systems and any operator intervention procedures required. This shall include, but not be limited to, the following.

a. Daily routine check lists, start-up procedures, and shutdown procedures.

b. Programming instructions necessary for full operation of the Fluid Cell Press, such as entering values and parameters, selecting routines, and events. The contractor shall also furnish a printout of the programming to assist personnel in understanding Fluid Cell Press operation for maintenance and troubleshooting

c. Safety precautions

d. Process and system alarm description and operator response and recovery actions

e. Step by step descriptive narrative of machine process sequences.

f. Operator inspection and maintenance procedures.

g. Basic equipment operations

h. Emergency shutdown

i. Terms of the equipment warranty

j. Copy of the Lockout/Tag-out Procedure

k. Basic troubleshooting

l. Calibration procedures for all items requiring calibration

Maintenance/Service Manuals. The contractor shall supply factory service manuals for the type and model of the machine being purchased. These manuals shall include but not limited to instructions for disassembly and assembly of the machine. The manuals for the machine shall include the full detailed electrical schematic and diagrams along with any pneumatic drawings. These instructions shall contain the procedures for replacing parts within the equipment, showing exploded view engineering drawings that show all fasteners with the torque values and part numbers. Procedures shall be included in the service manuals for recalibrating (if required) the part that was replaced and operational checks that ensure proper operation of the replaced part. The manuals shall include preventative maintenance task to be performed on an interval base or condition base. The manual shall include all preventative maintenance (PM) parts and have a recommended spare parts listing. The manuals shall include all disassembly and reassembly procedures to repair the machine, all associated accessories, and sub-systems. The manuals shall include detailed drawings of assemblies so as to be able to disassemble the machine and repair it, placing it back in service. The maintenance manuals shall have a comprehensive parts list as to equip the maintenance personnel to fully diagnose by part number and repair the machine back to factory operating conditions.

Preventative Maintenance Plan. A preventative maintenance plan shall be used by maintenance personnel to perform all maintenance actions not performed by equipment operators. The plans shall be sectioned by daily, weekly, biweekly, monthly, quarterly, biannual and annual actions as applicable to the specific Fluid Cell Press subsystems.

Complete with detailed illustrations.

PLC/CNC and Operator Interface Restoration Data. The contractor shall be responsible for the generation of all program logic, operator interface logic, program memory controller (PMC) program, and all data required for configuring a new control.

Any documentation necessary for machine operation and other configured and programmed electronic device shall also be provided in electronic format on read-only Verbatim Ultralife Gold optical disc and delivered with the equipment.

PLC/CNC Software. The contractor shall supply a complete licensed copy of any software required to troubleshoot and communicate with any PLC/CNC used in the control system. The contractor shall also supply a complete licensed copy of project editing software for any PLC/CNC used in the system. The HMI (Human Machine Interface) and operating controls shall be designed on a Windows 10 based operating system.

Test Plans. The manufacturer shall be responsible for the development of all test processes, procedures, and tooling necessary to form parts. Two (2) copies of the manufacturer’s test processes including machine pressure and procedures shall be submitted within thirty (30) calendar days after contract award for review/approval by the Government. The Government shall notify the contractor within ten (10) calendar days with the acceptance of the test procedures. The test procedures shall become part of the contract and Quality inspections in section 4 of this document. The manufacturer shall provide dimensioned drawings of all tooling, Form Blocks or otherwise, used in manufacturing each test part. Each drawing shall contain information to allow for the accurate reproduction of the item. Test process, procedures, and drawings shall be in the English language. Approved processes, procedures, tooling, and tool drawings shall become part of the contract for inspection testing and shall be retained by the Government.

Preliminary Installation Drawings. Preliminary Installation Drawings shall be provided within thirty (30) calendar days after contract award for review and Government approval. Contractor shall submit installation drawings which include physical dimensions of the machine, supporting equipment, and accessories with required placement dimensions in relation to the main machine components and in relation to the features of the area of the building, as well as all foundation drawings. Contractor drawings shall include all utility requirements (i.e. electrical, air, etc.). Electrical requirements provided by contractor shall include voltage, current, phase, and frequency, full load amps, and any other information applicable to connecting the machine. Minimum compressed air requirements provided by contractor shall include pressure, flow, and any other information applicable to connecting the machine. The Government shall have fifteen (15) calendar days to review and return the preliminary drawings to the contractor with comments and/or approval. If revisions are required, the contractor has ten (10) calendar days to make revisions and resubmit for a new review. Rejection of drawings does not relieve the contractor from final delivery date of contract performance period.

Final Installation Drawings. Final installation drawings shall be submitted by the contractor within fifteen (15) working days after Government approval of preliminary drawings. These final drawings shall bear a complete title block with a permanent drawing number, signature, date, and an original stamp. The Government shall notify the contractor in writing within ten (10) working days of receipt of drawing if they comply with this specification.

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 provided for Government review at least thirty (30) calendar days after contract award. 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.

Installation. The contractor shall be responsible for the complete installation of the machine and supporting equipment. Installation shall be in compliance with all applicable building codes and industry standards. This shall include, but is not limited to, foundation removal and installation, installation of all components and systems. The contractor shall provide all qualified personnel, services, materials, and material handling equipment to complete the installation including, but not limited to the following: shipping, off-load and load trucks; deliver new equipment/materials to a designated area outside/inside building;

rig equipment, install the equipment, and perform start-up and testing to ensure that the complete machine is fully operational. The premises shall be kept neat and clean, satisfactory to the receiving activity. See attached “Installation Responsibilities” sheet for clarification of Installation Responsibilities.

Site Preparation and Installation Plan. The contractor shall provide a clear and concise site preparation and installation plan. The plan shall include a detailed description of all installation work, a detailed site layout, interference removal, delivery route, general equipment specifications (i.e. size, weight, etc.), any required structural modification or additions, utility requirements and location, pertinent electrical details, and any other details required for site preparation and layout. As part of the site preparation and installation plan the contractor shall include facilities preparation instructions, including detailed information concerning any equipment that applies a load to a facility structure, wall, or roof. The site preparation plan shall be submitted at least sixty (60) calendar days prior to installation for review and comments. The contractor shall have ten (10) calendar days to officially respond in writing to the comments. All Government comments shall be reviewed and answered by the contractor in an acceptable manner before any work begins.

Foundation. FRCSE will provide available Bldg. 840 Foundation Plan (Attachment B) for the contractor to during the proposal. Contractor shall do the following 30 days after contract award:

A Professional Engineer license in Florida shall evaluate the existing Bldg. 840 Foundation Plan. Floor evaluation and additional investigation needed to determine suitability of the existing floor such as but not limited to geotechnical subsurface soils evaluation must be completed. Report of the evaluation and investigation must be submitted to FRCSE.

All new foundation shall be designed and signed by a Florida licensed Professional Engineer (PE). The approved design and signed foundation plan shall be delivered to FRCSE sixty (60) days prior to work.

The contractor shall provide FRCSE with samples test reports, and curing times for the concrete and epoxy. Foundation shall be completed prior to delivery of the equipment. Attachment C (Installation Responsibilities) applies.

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. The training shall be for eight (8) operators and maintenance personnel. Training shall be performed at the Government facility and shall not be less than three (3) consecutive eight (8) hour working days for the operator personnel and three (3) consecutive eight (8) hour days for maintenance personnel, between 7:00 am and 3:30 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 handson portions. All printed training aids shall be supplied for the course, be in the English language, and become the property of the Government. Training syllabus shall be provided after 30 ACA to be approved by FRCSE.

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). 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.

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. Contract quality assurance inspection (Origin) (see 4.4).

b. Final Inspection/Acceptance test (Destination) (see 4.5).

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.

Contract Quality Assurance (CQA) Inspection (Origin). CQA inspection shall be applied at the contractor’s facility prior to being offered for acceptance under the contract.

The machine and all peripheral equipment added to the machine shall be fully assembled and perform all functions in accordance with this specification. Quality conformance inspection shall consist of the examination in 4.6 and the tests in 4.7. The machine shall pass the examination, all tests, and contract quality assurance inspection to be acceptable for shipment.

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.

Alignment and Accuracy Tests. The contractor shall provide all labor, equipment, and materials necessary to insure the alignment and accuracy of the machine in accordance with manufacturer’s standard requirements provided. Contractor shall provide results including final report to the Government POC.

Operational Test. The machine shall be operated under no-load for not less than four

(4) hours. Proper operation of all controls, motors, and adjusting mechanisms shall be observed. The fluid cell bladder will be tested through the entire range of pressures at 500 psi intervals up to the maximum operational pressure limit. Any air, hydraulic, or other fluid leaks shall be repaired as they are discovered. During operational testing the control functions and machine response loading tray motions, fluid cell bladder pressurization and auxiliary functions shall be checked. The machine shall be run in each mode of operation (Manual and Automatic) to test the machine’s response to command data. Three (3) failures in a row to complete the run test may be cause for rejection of the entire system.

After successful completion of the operational test, over-travel limits (programmed stops and hard stops), emergency stop devices, and accessories shall be verified during the trial period. The safety limit stops shall be checked by attempting to exceed the limits of travel of each moving axis.

Performance Test. Testing shall consist of forming two (2) identical parts utilizing three dimensional (3D) forming templates designed by FRCSE for forming sheet metal parts and the manufacturer’s standard testing identified in the approved Test Plan (see

Paragraph 3.7.5). The Government shall provide the materials and forms at destination only, the contractor shall provide materials and forms at origin. The test at origin shall produce a part using the full depth of the machines forming capabilities. These parts will contain several compound angles, slots, and concave and convex regions. During these tests the equipment shall be operated continuously with no shutdowns for repairs or adjustments. All tests specified in the Acceptance Test Plan shall be performed.

Audible Noise Level Test. The equipment shall be tested for compliance with paragraph 3.1.4. “Audible Noise Level”. FRCSE Industrial Hygienist Specialist shall conduct the noise level test.

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 25 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.