26-35-1001 SAM PD.pdf

PURCHASE DESCRIPTION FOR WATERJETS

1.0 SCOPE.

1.1 Scope. This specification describes the minimum requirements for the procurement of one (1) waterjet used primarily to cut part outlines from aluminum, steel, titanium, and composite sheet and plate stock. It is the intent of this specification for complete installation services to include equipment, qualified personnel, material for installation, training, and quality assurance testing at origin and destination that shall provide a fully functional machine that satisfies all the requirements of this specification.

2.0 APPLICABLE DOCUMENTS.

2.1 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.

2.2 Government Documents.

2.2.1 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-H28A: Screw Thread Standards for Federal Service (2001 Ed.)

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

(OSHA)

29 CFR 1910: General Industry, OSHA Safety and Health Standards (2015 Ed.)

40 CFR 761: Polychlorinated Biphenyls (PCBs) Manufacturing, Processing, Distribution in Commerce, and Use Prohibitions (2015 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://assist.daps.dla.mil/quicksearch)

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

LOCAL FACILITY DOCUMENTS

Attachment A: B140 Sheet Metal Shop Drawing

Attachment B: Waterjet Test Plate (Accuracy Test)

Attachment C: Separation Wall and Trench Layout Drawing

Attachment D: B140 Water Utility Plan As-Built

Attachment E: B140 Drain Plan As-Built

THESE ATTACHMENTS ARE NOT YET AVAILABLE FOR PUBLIC

RELEASE – THE CURRENT GOAL ON THIS SOURCES SOUGHT IS TO

IDENTIFY MACHINE CAPABLE OF MEETING THE GOV

REQUIREMENT

2.3 Non-Government Publications.

2.3.1 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 Society for Testing and Materials (ASTM)

ASTM D3951-10 - Standard Practice for Commercial Packaging (2010 edition) https://assist.daps.dla.mil/quicksearch

Application for copies should be addressed to the American Society for Testing and Materials, ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959

International Organization for Standardization (ISO)

ISO 4413: Hydraulic fluid 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 Volts Maximum) (2014 Ed.)

NEMA ICS 1: Industrial Control and Systems General Requirements (2015 Rev.)

NEMA ICS 6: Industrial Control and Systems: Enclosures (2011 Rev.)

NEMA MG 1: Motors and Generators (2014 Rev.)

(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 (2014 Ed.)

NFPA 79: Electrical Standard for Industrial Machinery (2015 Ed.)

NFPA T2.24.1: Hydraulic Fluid Power – Systems Standard for Stationary Industrial Machinery

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

2.4 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 regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS.

3.1 Design. The equipment offered shall be new and of current, commercially available models. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold, or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

3.1.1 New Developments. The contractor shall identify any new developments that would improve the efficiency, accuracy or productivity of the equipment or would decrease its operating costs. The contractor shall notify the Contracting Officer in order that the new developments may, at the Government's option, be included in the equipment. Reports of such developments shall be addressed to the Contracting Officer.

3.1.2 Measuring and Indicating Device Graduations. All measuring and indicating devices on the machine shall be graduated in the inch/pound system. Markings on all measuring and indicating devices shall be legibly and permanently engraved or etched on a non-glare surface. All indicating devices shall be securely mounted in place and shall be located to allow reading from the operator’s workstation.

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

3.1.4 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.

3.1.4.1 Safety Guarding. Covers, guards, or other safety devices shall be provided for all parts of the machine that present safety hazards. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded parts and shall be easily removable to facilitate inspection, maintenance, and repair of the parts.

3.1.5 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.

3.1.6 Mercury Restriction. The machine shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture.

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

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

3.1.9 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.

3.1.10 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.

3.1.11 Lubrication. Means shall be provided to ensure adequate lubrication 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 oil condition. When a low oil condition occurs, the machine shall enter an emergency stop condition upon completion of the current operation. All oil holes, grease fittings, and filler caps shall be accessible.

3.1.12 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.

A spare parts list shall be provided and shall contain part and serial numbers for all components of the system.

3.2 Construction. The equipment 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. The waterjet table and cutting axes shall be constructed of one unit.

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-H28A and the applicable "Detailed Standard" section referenced therein. Fastening devices shall be tightened to torque limits as established by the manufacturer's standard for tightening to preclude loosening by normal operation or vibration.

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. Working surface hardness shall be not less than Rockwell 48 C scale.

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. Painting shall result in a highly wear-resistant finish which guarantees continued protection to the surfaces covered against the specified environment under all service conditions. The manufacturer’s standard color shall be provided. All paint shall be lead and chromate free.

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 machines shall consist of not less than the following components.

3.3.1 Table. The table is defined as the primary structure of the equipment which includes a catching tank that supports material to be cut and holds the majority of water that has been run through the cutting head. The table shall have means for leveling the machine on a flat surface. The table shall be of a design to eliminate misalignment due to bumping or nudging the cutting head or tank by an operator’s actions during loading of material. The table shall be delivered with support slats set in the tank to support material for cutting.

Support slats shall be easily removable to allow for custom material support configurations. The combination of tank and slats shall be capable of supporting at least 400 pounds per square foot of load. The contractor shall provide the necessary anchor bolts, leveling screws, and other necessary hardware to secure the machine to the floor.

Tooling for squaring and clamping sheet metal or other material along the edge of the cutting area shall be provided.

3.3.1.1 Water Level Control. The tank shall include a system that allows the operator to adjust the water level over a range not less than 3 inches. Initiation of water level change shall be easily accessible and located, at minimum, on the primary machine controller.

3.3.2 Bridge. The bridge is defined as the structure that travels the range of the X-axis and Y-axis as necessary during operation and carries the cutting head. The bridge shall contain a motor-controlled, precision Z-axis in the direction perpendicular to the X and Y-axes. The bridge shall be supported on both ends and not be a cantilever design.

3.3.3 Pump. The system shall be consist of a 50hp direct drive crankshaft-style high pressure pump with a variable frequency drive controller. Without hydraulic assistance, the pump shall be capable of maintaining a designed operating water pressure of 60,000 psi while providing at least 1.2 gal/min of water through a 0.016” orifice. Attenuators shall not maintain operating pressure. The pump system shall be designed for no fewer than 500 operating hour intervals between maintenance cycles while running at 60,000 psi.

3.3.3.1 Hour Meter. The machine shall be equipped with a non-resetting type, analog hour meter to display accumulated operating time of the high pressure pump. The meter shall be mounted on the exterior housing of the high pressure pump assembly and easily visible. The meter shall be sealed to prevent the entrance of dust and moisture, and it shall be mounted to withstand shock and vibration generated by the machine.

3.3.4 Cutting Head. The cutting head assembly shall be carried by the bridge. The nozzle body shall be integrated with a 0.016” diamond orifice. The nozzle assembly shall be easily replaceable by a trained mechanic or operator. Cutting heads shall automatically square to the tank after nozzle rotation is no longer necessary. There shall be no cutting loss across the Z-axis. The cutting head shall be capable of both above water and underwater operation.

3.3.4.1 5-Axis Cutting Head. The contractor shall provide a single 5-axis cutting head capable of cutting angles up to at least 60 degrees from the vertical plane in addition to an ability to eliminate taper. The cutting head shall be able to continuously change its angle from vertical while cutting to follow contours as necessary for a given program.

3.3.4.2 Taper Elimination. Each cutting head shall include a rotational mechanism capable of tilt up to 10 degrees in any direction for eliminating taper on the edge of the item being cut from stock material. The taper control mechanism shall be automatically controlled by the operating software.

3.3.4.3 Contour Follower. A contour-following accessory shall be included for use on all supplied cutting heads. This accessory shall allow the head to automatically cut from material with warped surfaces without special programming. This accessory shall also contain collision-sensing features.

3.3.4.4 Edge Finder. The waterjet shall be capable of defining and finding the true edge of materials.

3.3.4.5 Composite Cutting. The cutting head shall have the ability to automatically pierce holes and continually cut brittle and composite materials without delamination.

3.3.5 Water Recycling System. The water recycling system shall be self-contained and recycle the water from the catching tank for sending back to the high pressure pump for reuse. The system shall be complete with all necessary pumps, motors, filters, reservoirs, valves, piping, and flow controls. The reservoir system shall be protected from contamination. The system shall contain a settling tank, chiller, and filtering system. The waterjet shall be serviced by a single chiller and filtration system that shall be adequately sized for the specified waterjet size and water pressure.

3.3.5.1 Settling System. The settling system shall efficiently clean overflow water from the catching tank for disposal to a public drain. The tank shall be resistant to rust, and the baffles shall be easily removable. The settling system shall include a submersible sediment pump that moves sediment-laden water to a dump hopper or catching tank.

3.3.5.2 Chiller. The chiller shall cool process water prior to entering the high pressure pump. The chiller shall have capability to maintain a maximum water temperature of 60°F.

The chiller shall use R-410a, R-134a, or R-407c as a refrigerant. The chiller shall have a digital temperature control and be able to maintain a 90,000 BTU/hr cooling rate.

3.3.5.3 Filtration System. The filtration system shall remove particles, dissolved solids, and contain a bacteria elimination system. The necessary pumps and monitoring equipment shall be included in the filtration system.

3.3.6 Abrasive Garnet Delivery System. The abrasive garnet delivery system shall comprise of a hopper attached to the Z-axis near the cutting head and a bulk, pressurized tank that feeds the Z-axis hopper. An abrasive hopper shall be included on the Z-axis to supply abrasive garnet to the cutting head.

3.3.6.1 Bulk Tank. A pneumatically pressurized tank shall be provided to automatically supply garnet to the Z-axis hopper and keep it full. The bulk tank shall be capable of holding at minimum 800 pounds of garnet. It shall be designed with a maximum height of 54” and so that 50 pound bags of garnet can be easily poured inside during cutting operations. The bulk tank shall also contain a mesh screen at the top of the tank where garnet is poured into the tank by operators so that only garnet passes through during refill.

3.3.7 Garnet Removal System. The garnet removal system shall separate used abrasive garnet from water in the catching tank and return the filtered water to the catching tank.

The system shall deposit filtered abrasive garnet into a ¾ cubic yard hopper which shall include a liner to ease the removal of used garnet from the hopper. The liner shall be porous so that water may pass through, and shall have eyes or other features by which the liner can be easily removed from the hopper with a forklift. The hopper shall be easily detachable from the system and include lockable caster wheels or means by which a forklift can easily move it.

3.3.8 Water and Air Conditioning. The machine shall be supplied with equipment to condition the supply water. Filters for removal of entrained solids shall be included. An air dryer to condition incoming compressed air to the manufacturer’s specifications shall be included.

3.3.9 Consumables. The contractor shall provide three additional sets of each OEM-defined consumable part such that each item in the equipment can be operated with the expectation of maximum life after training has been completed and the government has accepted the equipment. These include all items whose wear is typically not covered by the warranty. These items include but are not limited to the typical waterjet consumable items that are listed below:

3.3.9.1 Mixing Tubes. The contractor shall provide 20 additional mixing tubes. These mixing tubes shall have an internal diameter of 0.040” and shall be 4” long.

3.3.9.2 Filters and Seals. All filters needed for the machine. These can include air filters, hydraulic filters, pump filters, calcite filters, filter bags, and final filter assemblies. All consumable seals shall also be provided.

3.3.9.3 Slats. Material support structure in the table that is usually stainless steel. A set is defined as the maximum number needed to fill the entire waterjet table.

3.3.9.4 Hopper Liners. Liners for the self-dumping solids hopper (sometimes referred to as a catcher tank) along with anything needed to secure it.

3.3.9.5 Orifices. The contractor shall provide 3 additional sets of all consumable orifices on the machine.

3.3.10 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 containing part and serial numbers shall be furnished at time of proposal.

3.3.10.1 Special Tooling. Any special tools necessary for maintenance on any equipment described in this document shall be provided. A compartmented container shall be provided for storage of all such equipment. These special tools shall be labeled with their part and serial numbers.

3.3.10.2 Operation Spray Shields. The contractor shall provide a shield kit with the waterjet system in order to reduce water spray during operation.

3.3.10.3 Garnet. The contractor shall supply 1 pallet of Barton HPX 80 Abrasive Garnet (MSN: 5350013686708, SDS: 478781). 1 pallet contains forty (40) 55lb bags of garnet.

3.3.10.4 Ozone Generator. The contractor shall provide 2 backup Ozone generators for use within the water filtration/recycling system.

3.3.10.5 Mixing Chamber Assembly Kit. The contractor shall provide 3 extra mixing chamber assembly kits.

3.3.10.6 On/Off Valve Repair Kit. The contractor shall provide 3 extra sets of on/off valve repair kits. The special tooling needed to replace the packing on these items will also be needed.

3.3.11 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.

3.3.12 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.

3.3.13 Electrical System. All electrical equipment shall comply with NFPA 79. The machine shall be designed to operate from an existing 480 volt, 3 phase, 60 hertz power source. The machine shall consist of independent electric servo drives. 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 connections made to the facility electrical system shall conform to NFPA 70.

3.3.13.1 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.

3.3.13.2 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.

3.3.13.2.1 Arc Flash Permit. The contractor shall notify the government POC if welding is required as part of the installation. The government POC shall provide the contractor with the local phone number for the Robins Air Force Base Fire Department Arc Flash Permitting Authority. The contractor shall call that number the day welding work is set to begin and every day thereafter that welding is required. Approval from the Fire Department authority shall be received prior to the start of any welding work. Arc Flash Permits are viable for 24 hours.

3.3.13.3 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 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.

3.3.14 Control System. 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, background editing function, part program storage, fixed cycles, and control diagnostics. The CNC unit shall be a fully automatic, integrated circuit, 64-bit, multiple processor-based computer integrated with CAD/CAM software and flat panel display. The CNC unit shall provide for automatic control of all machine functions. Manual adjustment of cut speed, abrasive garnet feed rate, and axis positioning shall be possible from the primary machine controller. The CNC unit shall be able to receive programs via ethernet connection and store part programs for later use. The CNC unit shall direct machine functions from command data stored in memory. The data stored in memory shall be input by the media specified herein. The CNC unit shall initiate a halt and error signal should a fault condition occur in the control. The CNC unit shall automatically shut down when internal operating temperatures exceed safe operating limits and shall initiate a halt and error signal should a fault occur at any time.

3.3.14.1 Internet Connection. The CNC unit and waterjet shall not be connected to the internet and shall not require the internet to be operated at its full capacity.

3.3.14.2 Remote Handheld Pendant. The contractor shall supply a wired USB remote handheld pendant. This handheld pendant shall allow for precise control of the waterjet’s movement operations while away from the controller. The remote pendant cable shall be at minimum 30’ long.

3.3.15 Software. Provided software shall run on the Windows 11 operating system and be specifically designed for all abrasive jet and waterjet machining functions. Software shall include a G-Code translator and be compatible with and be able to open both native and neutral file formats created in a variety of modeling software including, but not limited to, CATIA, Solidworks, and SURFCAM 4.0 for both 3-axis and 5-axis cutting operations.

Functions of the software shall include the following:

• Calculation of cut speed with material, thickness, and edge finish inputs

• Part nesting aid given desired number of parts and sheet size

• Part time estimates

• Automatic collision prediction and protection

• Taper reduction methods and cutting quality calculation

• Sample cutting program calculation before programs are sent to the machine

• User-specified home positions for the cutting head

• Creation of 3D tool paths from imported 3D solid models

• Exportable programs to machine controller

• Importing of .ORD file types

3.3.15.1 Software Licenses. The contractor shall provide unlimited licenses, with unlimited upgrades and updates, of all provided software. These shall be able to be installed on off-network computers and controllers.

3.3.16 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 (if available). Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

3.3.17 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.

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

3.3.19 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. 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. A digital CNC control meter option on the controller 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 also be provided.

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

Size and Capacity Table I.

Characteristic Capacity/Size Maximum material size 15-feet × 7.5-feet Cutting Area (X-Y Travel) 13-feet × 6.5-feet (4m x 2m) Slats 4-inches x 0.125-inch Load on Slats 400 lbs./sq.ft.

Z-Axis Travel 24-inches Transverse Rate/Speed 600 inches per minute

3.4.1 Cutting Area. “Cutting Area” in Table 1 refers to the ability to continually cut the entirety of a piece of material of this size from end to end in each axis without needing to move or adjust the material in any way.

3.5 Accuracy/Repeatability. The machines shall conform to the tolerances in Table II.

Accuracy/Repeatability Table II.

Characteristic Capacity/Size

X, Y, & Z Axis Linear Positional Accuracy +/- 0.0015”/3-feet X, Y, & Z Axis Linear Positional Repeatability +/- 0.001” 12” Ballbar Circularity +/- 0.0025”

3.6 Marking on Instruments, Control Panels, and Plates. All words on plates shall be in the English language. All units shall be in U.S. Customary Units (inch, pounds, gallons, etc). Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

3.6.1 Lubrication Plate. A lubrication plate shall be permanently and securely attached to the machine. The plate shall contain the following information:

• Points of lubricant application

• Service interval

• Type of lubricant

• Viscosity

• Military or federal specification for each lubricant (if available)

• Size and type of each lubricant filter

3.6.2 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)

• Machine Weight

• Contract number

• Date of manufacture

3.6.3 Identification Marking of Military Property. An Item Unique Identification Marking (IUID) shall be provided in accordance with MIL-STD-130N w/Change 1 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

3.7 Technical Data. One (1) electronic copy of technical data shall be provided with the machines. Data shall contain technical information, part numbers, part nomenclatures, cross reference numbers, specifications, illustrations, maintenance, service, overhaul instructions, all preventative maintenance schedules, lubrication chart, all mechanical and electrical schematics showing discrete components/block diagrams/wiring diagrams with inputs and outputs identified/system electrical interface documents and drawings for the specific model of all machine equipment/drives/controls supplied, instructions for the operation and maintenance of the machine, troubleshooting guide, and recommended spare parts list. All copies of technical data shall be legible and written in the English language.

Each binder cover shall indicate in bold type the manufacturer’s name, contract number, model number, and serial number of the unit.

3.7.1 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. 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 procurement of major hardware, assembly, operational debug, factory acceptance, shipment, installation, training, and final acceptance test.

3.8 Installation. The contractor shall be responsible for all equipment (forklifts, man lifts, etc.), materials for installation: anchors, bolts, leveling pads, wiring, piping, electrical components, temporary bracing, hoses, touch-up paint, etc., and qualified personnel required for unloading, rigging, installation, anchoring, connecting machine to utilities, and accurately leveling the machine in place. The contractor is not authorized to use Government equipment (forklifts, ladders, stools, tools, etc.) at any time. Disturbed surfaces, disconnected machinery or equipment shall be returned to original condition unless specified in installation drawings and approved by receiving activity. The contractor shall be a factory-trained field service technician for the manufacturer. The contractor shall provide completely operational systems that meet the inspection and test requirements of section 4. The contractor shall instruct the carrier that the machine shall be offloaded only under the supervision of a representative of the contractor. With the exception of water provided by the government to fill the tanks, the contractor shall provide the first fill of all liquids, refrigerants, or other similar materials necessary for equipment operation. Access to the installation site in Building 140 at Robins AFB shall be through a rollup door measuring approximately 19’ wide x 17’ high. Installation shall be scheduled in advance with the Government point of contact (POC). Installation shall be performed during normal laboratory business hours (0600-1400, Monday through Friday excluding federal holidays) unless approved by the Government POC or his/her designated representative and the Administrative Contracting Officer (ACO).

3.8.1 Existing Utilities. The contractor shall connect all equipment to the existing compressed air and city water lines within 25 feet of the installation area. Existing compressed air is 100 psi. Both utilities are located near the roof above an overhead crane.

The utility connections shall not impede the movement nor operation of the crane. These utility connections shall be done with corrosion-resistant materials. The city water connection shall include a backflow preventer of appropriate size. If required, the drain line for the backflow preventer shall be installed and connected to the nearest available floor drain. The line shall not be ran along the ground nor impede the movement nor operation of the overhead crane.

3.8.1.1 Electrical Connection. The contractor shall connect the machine to the appropriate busbar within 45 feet to supply all equipment within this project with power. 208V and 480V busbars are available. These busbars are located near the roof above an overhead crane. The electrical connection shall not impede the movement nor operation of the crane. The contractor shall install a new switch on the busbar to supply the machine. The contractor shall install new electrical disconnect panel(s) near the machine, complete with the appropriate fuses and following all applicable safety codes. The contractor shall provide a transformer if voltage adjustment is needed.

3.8.2 Maximum Available Floor Space. The floor space available for both waterjet systems and all peripheral equipment is 18 feet wide × 20 feet long x 15 feet high. The size and form of the waterjet systems and all peripheral equipment shall allow for reasonable space for operation and maintenance of all components within the available floor space.

3.8.3 Work Area Maintenance. The contractor shall remove all packing materials and residue from the area and properly dispose of these off base. The work area shall be maintained in an uncluttered and safe condition at all times or work will be terminated until the conditions are corrected.

3.9 Training. After satisfactory completion of acceptance testing of the machine, 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. Training shall be performed at the Government facility in accordance with 3.10.1 and 3.10.2. Training shall be between normal operating hours of 6:00 am to 2:00 pm. Training shall not be scheduled on weekends or federal holidays. The course shall utilize as-built drawings and manuals provided under this contract, and shall include both classroom and hands-on portions. All printed training aids shall be supplied for the course, be in the English language, and become the property of the Government.

3.9.1 Operator/Programmer Training. The contractor shall provide a minimum of five days of onsite training for up to ten operations and programming personnel.

This training shall include, at minimum, a review and use of the operator's manual, programming in 2D and 3D with the contractor-provided software, actual hands-on production runs, and instruction with the machine and all relevant peripheral equipment. All materials, manuals, data, etc. shall be contractor furnished and become the property of the Government.

3.9.1.1 Operator Training-Translation. If available, a trainer with knowledge of American Sign Language (ASL) is requested. Otherwise, the government will require at minimum 30 days’ notice of the planned training to schedule an ASL translator.

3.9.2 Maintenance Training. The contractor shall provide a minimum of five days of onsite training for up to ten electrical, electronic, mechanical, and hydraulic maintenance personnel. This training, with respect to controls and related components, shall include, at minimum, trouble-shooting and methods of connection if equipment malfunctions, with emphasis on minimizing equipment down time. Training shall cover all provided equipment, peripherals, and accessories. Training shall include, but is not limited to, a complete preventative maintenance cycle, basic troubleshooting, review of electrical and mechanical diagrams, review of the maintenance manual, changing of cutting head assemblies, and spare parts list.

3.10 CAD Layout Model. The contractor shall provide a CAD layout drawing of the equipment within 60 days after contract award. This drawing shall either a .dwg or .dxf compatible with AutoCAD 2024. This shall be used by the government to lay out the shop floor with the new equipment.

3.11 Separation Wall. The contractor shall install a separation wall as specified in Attachment C to keep water and garnet spray from entering the adjacent area. The wall shall be at least 12’ tall and be secured to both the floor and nearby columns to where they are rigid. The wall shall be made from plexiglass. The wall shall contain a personnel access door- either hinged or sliding- at the specified location in Attachment C.

3.12 Facility Draining System. The contractor shall perform the work specified below to allow for a nearby Industrial draining location for the waterjets.

3.12.1 Draining Trench and Piping. The contractor shall dig an appropriate trench to connect the existing facility collection trench train to the Industrial Drain specified in Attachments A, D, and E. The contractor’s trench shall be utilized for underground drainage piping. The contractor shall dispose of all removed materials.

The contractor shall take the appropriate steps to contain the dust while cutting concrete, including installing a temporary curtain. The trench shall be sized appropriately to adequately drain a garnet and water mixture from the existing collection trench. Upon installation of the drainage piping, the contractor shall fill the trench with concrete. The area shall be marked with caution tape during concrete pouring and curing in order to prevent accidental personnel traffic.

3.12.1.1 Concrete Work Approval. The contractor shall provide a plan for the trench work to be performed within 60 days after contract award. These plans shall include a full scope of work, materials used, and any other applicable civil engineering data. These plans shall be submitted by the government POC to the relevant Base Civil Engineering Authority for approval prior to the start of any work.

3.12.2 Drain Sump Pump. The contractor shall provide and install a sump pump to connect to the installed drainage piping listed in Section 3.12.1. The installation location is shown in Attachment C. The sump pump shall be rated appropriately to ensure that it is able to reliably pump a water/garnet mixture while being either partially or fully submerged. The sump pump shall be installed in the existing government facility collection trench drain. The sump pump specifications, part number, serial number, and manuals will be provided to the government prior to installation. The contractor shall connect the sump pump to power with conduit by means of a shallow trench shown in Attachment C. The trench shall be subject to the same requirements mentioned in Sections 3.12.1 and 3.12.1.1. The government shall provide an electrical disconnect on a nearby column marked in Attachment C upon reception of the contractor-provided electrical requirements for the sump pump. The trench shall be filled with concrete upon completion of conduit installation.

3.12.3 Sump Pump Collection Area Grating. The contractor shall install grating to cover the entire sump pump collection area marked in Attachment C. This grating shall be secure and removable. The grating shall be rated to hold at least 10,000 lbs.

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 their own facility for the performance of the Origin 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. Contract quality assurance inspection (Origin) (see 4.4).

b. 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 Contract Quality Assurance Inspection (Origin). Contract quality assurance 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.

4.5 Final Inspection/Acceptance Test (Destination). Final Inspection and acceptance test shall be performed on the machines to ensure conformance with this purchase description. The acceptance test shall be performed only after the machines are installed at their 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.

4.6 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.

4.7 Tests. Unless otherwise specified all programs, instruments, materials, and tools required to perform and evaluate the tests shall be furnished by the contractor and shall be calibrated in accordance with the attached (QAP) Quality Assurance Provision.

4.7.1 Operational Test. The machine shall be operated at no load for at least thirty

(30) consecutive minutes for an initial warm-up period. Basic operational tests shall be conducted on the primary equipment and all associated equipment to demonstrate full functionality of the equipment specified in sections three (3) and four (4) herein. Proper operation of all manual controls, motors, adjusting mechanisms and accessories shall be verified during the warm-up period. The program shall include rapid travel of the slides, independently and simultaneously. Upon completion of the initial check procedure, the system shall be cycled continually for not less than three (3) consecutive hours to demonstrate operability of the equipment and permit the machine to reach a steady operating temperature. If a malfunction occurs during the cycling period, the test shall be restarted each time until a full three (3) hour test cycle is completed without a malfunction. Three (3) failures without completion of the test period shall be considered cause for rejection of the system. For the purpose of this test, a “failure” is defined as any equipment malfunction, which requires remedial action to restore the system to full operation in accordance with this specification.

4.7.2 Performance Tests. Two performance tests will be performed in order to test the waterjet’s cutting accuracy and its 5-axis capabilities.

4.7.2.1 Accuracy Test. The machine shall cut two (2) identical parts per Attachment B. The parts chosen shall not exceed the machine’s capacity. The parts shall be measured by a coordinate measuring machine (CMM) or other process for accurately measuring the parts to determine that the machine accurately manufactures parts that are identical within 0.005-inch of each other.

4.7.2.2 5-Axis Test. The machine shall cut a cone frustrum with a 10° apex angle with a minimum apex diameter of 2” out of appropriately sized stock material.

4.7.3 Audible Noise Level Test. The equipment shall be tested for compliance with paragraph 3.1.5. “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 utility supply connection points within 35 feet of the machine.

☒ Provide a clear path and adequate openings to…