Amendment docs.pdf

VIBB 19-20-1600

30 November 2020

PURCHASE DESCRIPTION FOR THE SOLE SOURCE ACQUISITION

OF THREE (3) COMPUTERIZED NUMERICALLY CONTROLLED

(CNC) HIGH-SPEED GRINDERS

1.0. SCOPE.

1.1. Scope. The content of this specification describes the sole source minimum requirements for the procurement of three (3) Reform HSG 800 Computerized Numerically Controlled (CNC) High Speed Blade Tip Grinders manufactured by Reform Grinding Technologies for cylindrically grinding outer tips of compressor and turbine blades. The contractor shall be responsible for installation of the High Speed Blade Tip Grinders (HSG) on the existing foundations including but not limited to all facility connections including mechanical and electrical. Two (2) grinders shall be procured and shipped to Fleet Readiness Center South-East (FRCSE), Jacksonville, Florida and one (1) grinder shall be procured and shipped to Fleet Readiness Center South-West (FRCSW), Coronado, California. All of the requirements as presented herein shall be met to be considered acceptable. This includes technical manuals and personnel training for the operation and maintenance of the machine. The contractor shall provide design, fabrication, and installation of all equipment, materials, labor, transportation, unloading, moving into place, start-up and testing.

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. The following Government documents and publications form a part of this specification to the extent herein.

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 cited in the solicitation or contract.

STANDARDS - FEDERAL

FED-STD-H28B: Screw Thread Standards for Federal Service (2019 Ed.)

FED-STD-313F: Material Safety Data, Transportation Data, and Disposal Data for Hazardous Materials Furnished to Government Activities (2018 Ed.)

SPE4A820Q0065

Amendment 1 Page 1 of 29

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

29 CFR 1910: General Industry, OSHA Safety and Health Standards (2018 Ed.)

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

Environmental Protection Agency (EPA)

40 CFR part 761: Polychlorinated Biphenyls (PCBs) Manufacturing, Processing, Distribution in Commerce, and Use Prohibitions (2018 Ed.)

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

DEPARTMENT OF DEFENSE

MILITARY STANDARDS

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

2.3. Non-Government Publications. The following documents form a part of this document to the extent herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

2.3.1. Specifications, Standards, and Handbooks.

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.)

Amendment 1 Page 2 of 29

(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 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.)

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

American National Standards Institute, Inc. (ANSI)

B11/STD B11.9: Machine Tools – Safety Requirements for Grinding Machines (2015 Rev.)

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

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 is obtained.

3.0. REQUIREMENTS.

3.1. Design. The machines offered shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model, which on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the

Amendment 1 Page 3 of 29 requirements specified herein. The machines shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair. The equipment shall be completed so that when connected to the utilities identified herein, it can be used for any function for which it is designed and constructed. All major components of the machines shall use high quality close grain meehanite cast iron or steel and shall be of rigid box section design. All major castings shall be stress relieved both after casting and after pre-machining. The machines shall be constructed on one-piece base casting or equal. The machines shall be equipped with a unit for measuring blade length of the rotor while spinning at machining speeds. The machines shall incorporate in its design the best technology available in operating and drive mechanisms. The machines shall be constructed in such a way that each machine has an overall footprint that shall fit within a twenty-five (25)-feet × twenty-eight (28)-feet area at FRCSE and twenty-five (25)-feet × thirty-five (35)-feet area at FRCSW.

3.1.1. Energy Efficiency. The HSGs and their components that directly consume energy in normal operation shall be designed and constructed for energy efficiency as governed by the developments available within the industry.

3.1.2. Measuring and Indicating Devices Graduations. All measuring and indicating devices such as scales, dial indicators, pressure gages, temperature indicators and other similar devices used on each machine shall be graduated in dual imperial and metric units. Marking on all measuring and indicating devices shall be permanently and legibly engraved or etched on a non-glare background. All dials and other type indicating devices shall be securely mounted in place.

Such devices shall be located to allow reading from the operator’s normal workstation.

3.1.3. Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's work station(s). The machines shall be ergonomically designed as to reduce or eliminate injury to the operator while performing each machine’s functions.

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 per B11/STD B11.9. The safety devices shall not interfere with the operation of the CNC High Speed Blade Tip Grinders. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

3.1.4.2. Safety Features. The machines shall be equipped with the following safety features and devices.

Amendment 1 Page 4 of 29

a. Switches and Limits: Each machine shall have electronic switches and limits.

b. Auto Select: Protection shall be provided so that all machine references have to be completed before the selection of auto is possible.

c. Diamond Roll Reset: Manual movement of the diamond roll shall force a re-set of the diamond roll position with respect to the wheel before a dress cycle can be run.

d. Air Pressure Monitor: A low air pressure monitoring system shall be provided.

e. Vibration Monitor: A vibration monitor shall be fitted to each of the bearing pedestals. The amount of vibration shall be displayed on the control panel. The machines shall abort the cycle if the vibration exceeds a set limit.

f. Bearing Temperature: The spindle bearings temperature shall be monitored and be displayed on control panel. Each machine’s cycle shall be stopped if the bearing temperature exceeds limits.

3.1.5. Audible Noise Levels. Audible noise emitted by the equipment shall not exceed eighty-four (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 eighty-four (84) dB requirements.

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

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

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

3.1.9. Use of Polychlorinated Biphenyl (PCB). The use of PCB on or in the equipment is prohibited. The machines shall be considered PCB free providing certification to be verified containing less than five (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 CNC High Speed Blade Tip Grinders 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 (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 twenty-four (24)-hour capacity. Means shall be provided to indicate a low lubrication condition. When a low

Amendment 1 Page 5 of 29 lubrication condition occurs, the machines shall complete the current operation and come to a complete stop. The machines shall indicate that lubrication is required and the operator shall refill the lubrication reservoirs according to machine manuals. All oil holes, grease fittings, and filler caps shall be easily 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 provided as standard items shall also be considered replacement parts.

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

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

3.2.2. Fastening Devices. All screws, pins, bolts and similar parts shall be installed in such a manner as to prevent change of tightness. Those subject to removal or adjustment shall not be swaged, peened, staked or otherwise permanently deformed. The contractors design criteria shall dictate these requirements.

3.2.3. Threads. All threaded parts used on the HSGs and its related attachments and accessories shall conform to FED-STD-H28B and the applicable “Detailed Standard” section referenced therein.

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

3.2.5. Ventilation. Adequate cooling or ventilation shall be provided on the equipment to preclude premature deterioration of the equipment or any component thereof when utilized under the ambient and operating conditions specified herein.

3.2.6. Ferrous Parts. Exposed ferrous parts such as screws, bolts, nuts, washers, etc., shall resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as cadmium or chrome plating, galvanizing or other electrical/chemical process, or stainless steel is acceptable.

Amendment 1 Page 6 of 29

3.2.7. Aluminum Parts. Aluminum parts for use outdoors (if applicable) shall be anodized or chemically treated followed by two (2) coats of weather-resistant exterior paint.

3.2.8. Dissimilar Metals. Dissimilar metals shall not be used in direct contact with each other without suitable means for preventing electrolytic corrosion.

3.2.9. 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.

3.2.10. Welding, Brazing and 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.

3.2.10.1. Soldering. Solder connections shall show evidence of good bonding in metal-to-metal contact. Cold solder joints, incomplete joining of solder and metal, excess or insufficient solder or damaged insulation shall be considered reason for rejection of the equipment.

3.2.10.2. Cleaning. Any loose, spattered solder, flux, metal chips, insulation scrap or other foreign material shall be removed from the equipment.

3.2.10.3. Flux and Cleaning Agents. Flux for soldering shall be rosin or rosin and alcohol. No acid, acid salts or acid core solder shall be used in preparation for soldering of electrical connections.

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

3.2.12. Workmanship. Workmanship of the HSGs 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.

3.2.13. Maintainability. The equipment shall permit maintenance personnel easy and effective service to the equipment using a minimal number of tools. Consistent with required maintenance and design of the equipment, the contractor shall provide any “special” or “custom” tools required to service the unit. Additionally, the equipment shall be equipped with access covers to facilitate inspection, cleaning and repair or replacement of parts.

3.3. Components. The machines shall consist of not less than the following components:

Amendment 1 Page 7 of 29

3.3.1. Drive Pedestal. The drive pedestal shall be permanently bolted to each machine’s base to support the rotor assembly.

3.3.2. Aft Pedestal. The aft pedestal shall have automatic axially positioning to adjust for length of an item being ground. The aft pedestal shall have automatic clamping in order to secure the position of the aft. Interlocks are to be provided to ensure that the aft pedestal is clamped in position before the cycle can be started.

3.3.3. Reference Block. A reference block for the blade tip gauge shall be mounted on both pedestals for blade tip gauge calibration and pedestal alignment checking. Automatic pedestal alignment/compensation shall be furnished to adjust out misalignment.

3.3.4. Work Spindles. Work spindles shall be removable from both pedestals. For the FRCSE spindles, they shall fit the current chucks on machines 7602 and 7566.

3.3.5. Vibration Detectors. The pedestals shall be fitted with vibration detectors and be able to operate with an out-of-balance of up to two (2) ounces per forty (40) ounces of rotor mass. Out-of- balance shall result in the termination of the auto cycle.

3.3.6. Part Mounting. The machines shall provide a system to mount the part directly to the spindles without an intermediate independent loading table. The part loading system shall provide accurate means to adjust the part centerline to the work spindles.

3.3.7. Work Drive. A variable speed work drive motor shall be mounted on the machine to drive the work spindle. The work speed shall be controlled by each machine’s control and programmable from the component program. Speed range shall be from one hundred (100) to six thousand revolutions per minute (6,000 rpm) and the rpm deviation shall not exceed five percent (5 %) when at operating speed. The work drive shall rotate in either direction clockwise (CW) or counter clockwise (CCW). Work spindle lubrication shall be a sealed grease packed system.

3.3.8. Work Spindle Assemblies. The work spindle assemblies shall consist of a drive (forward) and non-drive (aft) end units. These units fit in the work pedestals mounted on the table of the HSGs and provide high-speed rotation for the rotors being ground. Each spindle unit shall be made from hardened and ground steel. Accurate rotation of the spindle shall be achieved by pre-loaded high precision bearings. The nose of the spindle shall provide a location for a changeable clamping chuck allowing the accommodation of the different rotors.

Temperature sensors shall be provided on each work spindle assembly. Work spindle assembly lubrication shall be sealed, grease packed system.

3.3.9. Wheel Head. The wheel head assembly shall provide means for precise, programmable location of the wheel grind surface through control of wheel infeed, wheel angular orientation

Amendment 1 Page 8 of 29 relative to rotor centerline, wheel axial location relative to the rotor, infeed compensation to account for wheel size changes and wheel rotational speed. The grinder must be able to memorize the grinding wheel data according a code numbers on the grinding wheel flange. The latest data shall be memorized by the control, after every dressing. The current grinding wheel data shall be memorized with the chosen grinding wheel number. The control must recognize the grinding wheel data by the entered number (e.g. current diameter, width and so on) and the tool data is activated. With the latest dressing data from the wheel activated it will not be necessary to measure the grinding wheel manually.

3.3.10. Angle Axis. The wheel head assembly angle axis shall be motor driven and CNC controlled. This motor shall drive the angle axis directly or use of belt driven and precision worm gear to ensure accuracy and rigidity in accordance with paragraph 3.5, Table II. The angle shall be programmed in degrees, minutes and seconds or in degrees and thousandth of a degree.

3.3.11. Guarding. Wheel guarding shall conform to OSHA standard (29 CFR 1910). The housing shall include whatever dust extraction system needed to maximize extraction of grinding wheel material.

3.3.12. Wheel Head Spindle. The wheel shall be rotated by a variable speed alternating-current (AC) motor. Wheel surface speed shall be programmed up to twelve thousand (12,000) surface feet per minute (SFM). The spindle shall provide a constant wheel speed controlled from the CNC. The wheel head spindle shall incorporate grease packed high precision parallel roller bearings for optimum operating conditions.

3.3.13. Wheel Balancing. An automatic wheel-balancing unit shall be fitted in the wheel spindle unit to automatically balance the wheel during a non-grinding part of the cycle.

3.3.14. Wheel Dresser. The machines shall have a system for quickly and accurately removing the outermost surface of the grind wheel in order to maintain a proper grinding surface. The wheel dresser shall be an integral part of the machine wheel head. Wheel dressing shall be part of the automatic grind part programs for the machine and shall be performed concurrently with blade tip grinding. Machine software shall allow manual initiation of a dress cycle at any point during machine operating.

3.3.15. Deburring Unit. The machines shall have a system for deburring blade tips after grinding. Deburring shall be accomplished by an abrasive impregnated nylon brush or equal.

The deburring brush shall be rotated in both directions. The deburring cycle shall be controlled automatically.

3.3.16. Blade Tip Measurement System. An optical or laser unit of the latest technology shall be provided which measures the radii of the individual blades during rotation. The optical measuring range must be a minimum of 0.043 inch. Blade tip measurement may be performed

Amendment 1 Page 9 of 29 as part of the grind process or separate from it. When part of the grind process, it shall provide closed-loop blade tip radius feedback to each machine for grind process control. An incremental encoder shall be linked with the rotor drive shaft to establish origin. Protection against radial collision of the sensor assembly with the revolving rotor assembly shall be accomplished by software and hardware interlocks. The optics shall be protected against grinding dust by particle traps, purging air and through sapphire windows. Deterioration of the optics, due to dust and dirt, shall be monitored. The blade tip measurement system shall handle speeds of twelve thousand (12,000) SFM or greater.

3.3.16.1. Measurements. Measurements during the grinding process shall be.

a. Largest Blade.

b. Average mean blade.

c. Median blade.

d. Smallest blade

3.3.16.2. Radius Information. Radius information of a tracked blade shall be transferred to the machine control in order to permit closed loop grinding of the blades. Each machine’s software shall be capable of continuously updated real-time graphic display of all blade tip radii on the measured stage during grind and measurement cycles.

3.3.16.3. Calibration Blocks. Calibration blocks mounted on both pedestal, shall be used for referencing axes both radial and axial.

a. Resolution: 0.0001 inch

b. Repeatability, per stage: ±0.0003 inch

c. Repeatability to master (Datum): ±0.00015 inch

3.3.17. Other Gauging Systems. The machines shall have an integrated system for work piece run out measurement and data storage. The system shall include contact probes necessary for measuring run out on appropriate work piece surfaces, tooling necessary to hold the probes securely in place during data acquisition, and any electronics required to gather and process readings from the probes for electronic data storage.

3.3.18. Dust Extraction Unit. A dust extractor for removal of the blade material and grinding wheel dust shall be provided. The unit shall be a closed loop type system and integrated into the machine enclosure. Interlocks shall be provided to ensure that the unit is operating during the machine cycle.

3.3.19. Machine Enclosure. An enclosure shall be fitted around each machine to reduce the noise level to eighty-four (84) dBA. Measuring of noise shall be at three (3) feet from the outside of each machine’s enclosure and five (5) feet above the floor. The unit shall have an

Amendment 1 Page 10 of 29 external door at the front for access and the loading of the component. The door shall also allow access above the worktable for the lowering of the component into the work area by overhead crane. Interior lighting shall be provided as part of each enclosure. Each machine’s enclosure shall contain an air-handling unit to remove heat from each machine when running. The air-handling unit shall be a closed loop type system. The temperature within the enclosures shall be controlled to seventy-two degrees (72º) ± two degrees (±2º) Fahrenheit or temperature required for processing engine part.

3.3.20. Hydraulic System. The hydraulics system shall conform to all applicable standards listed in ISO 4413 and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls. Overpressure protection shall be provided in high-pressure lines to prevent damage to components. A filter system shall be provided to ensure delivery of clean fluid. The hydraulic reservoir shall have means for determining fluid level, provisions for draining, and a clean out access plate if the reservoir is not removable.

3.3.21. Pneumatic System. The pneumatic system shall conform to all applicable standards listed in ISO 4414 and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls. Overpressure protection shall be provided in lines to prevent damage to components. A filter system shall be provided to ensure delivery of clean air.

3.3.22. Hand Held Pendant. A hand held pendant with basic machine controls shall be provided for manual operations. Manual operation of the machines for set up shall be provided by means of pushbuttons on the hand held pendant. The pendent shall have the ability to control and position all axis of the grinder and be appropriately labeled. Light-emitting diode (LED) digital readout display shall be included for axes positioning.

3.3.23. Personal Computer (PC). A personal computer shall be provided with each machine.

The PC’s shall have the following minimum specification. This PC shall run the Reform Grinding Technologies software and communicate directly with the Fanuc controller (para.

3.3.24).

a. Twenty-one (21) inch, High-resolution color liquid crystal display (LCD)

b. Pentium dual core processor

c. Two (2) gigabytes (GB) RAM

d. One-hundred-sixty (160) GB Hard Disk

e. USB ports, two (2) each

f. One (1) Ethernet 10/100 Base-T Connection

g. One (1) CD Read/writer

h. Software shall be Windows 7 professional or newer.

i. A modem link shall be furnished.

j. Optical mouse and keyboard.

Amendment 1 Page 11 of 29

3.3.23.1. Data Collection. Data from the measurement system shall be collected on the machine PC and stored in a database. Software to print the results from the database shall be provided.

3.3.24. Controller Features. The CNC High Speed Blade Tip Grinders controls shall be a Fanuc 30i or newer. The control unit, drive packages, motors and all related electronics shall be Fanuc and shall have the following characteristics.

3.3.24.1. Display. A single color seventeen (17)-inch LCD monitor attached to the PC shall display all necessary component selection, machine set-up and program status information. The display shall show all the normal CNC screens as well as the special screens developed for each machine’s operations and part program generation.

3.3.24.2. Digital Displays. Digital displays shall show data in illuminated figures clearly legible at a distance of ten (10)-feet and give direct horizontal readings without requiring any calculation or interpolation. Each digit of the readout display shall be of the in-line type.

3.3.24.3. Screens. The display shall be used to show the following screens.

a. Rotor programming and rotor Database maintenance utilities

b. Process database maintenance utilities

c. Machine and process display utilities

d. Maintenance related PC screens

e. Result of applications

f. Help pages for machine operation

g. Help pages for maintenance

h. MDI Auxiliary programs

i. User Log-In Interface

j. Preventive Maintenance Utility

3.3.24.4. Operator Interface. An operator’s interface shall be provided by a PC, which is linked to the CNC unit. The PC shall be fitted with an interface for the blade tip measurement system and provide the operator with the ability to view records or print the measurement data as required.

3.3.24.5. Machine Control. The following machine control features shall be required:

a. Axis Control - All axis shall be CNC controlled.

b. Z1-axis (longitudinal axis of grinding head)

c. Z2-axis (longitudinal axis of measuring head)

d. Z3-axis (Rear pedestal movement)

e. X1-axis (In feed axis of grinding head)

f. X2-axis (In feed axis of Blade tip measuring head)

Amendment 1 Page 12 of 29

g. B-axis (swiveling head grinding device)

h. U-axis (dresser axis)

i. W-axis (dresser axis)

j. C-axis (rotor drive)

k. C1-axis (rotation brush)

l. All linear axes shall be fitted with digital A/C servo drives, Heidenhain Glass Scales and recirculating ball screws.

m. A push button panel shall be mounted adjacent to the machine with facilities for manual positioning of each machine, Cycle Start and Emergency Stop etc.

n. Leading dimensions such as target radius and stacking dimensions shall be changeable by the operator without the need to change the part program. These changes are only temporary, shall only be applicable for the component being ground, and shall be deleted when the component is completed.

o. Each machine’s operator shall be able to vary the machine’s cycle to delete out /pass over selected stages or operations, again without alteration to the part program.

p. The control shall be used to store operations performed on a component to allow the automatic return to the correct operation if a program has been stopped in mid-cycle.

3.3.24.6. Programming. The following programming features shall be incorporated. In addition, the contractor shall furnish rotor editor software, which shall include procedures allowing the operator to adjust offset values and dimensions without requiring actual editing of a stored program. This would be for developing new grinding programs.

3.3.24.7. Subroutines. Subroutines shall be provided on the Fanuc control to perform the basic grinding operations. These subroutines shall contain parameters rather than actual dimensions.

The values for the parameters for each of the operations shall be transferred from the programming system in the PC to the Fanuc control for each stage of the component process.

3.3.24.8. Program Data. Machine program data and results shall be stored on the PC in Microsoft Excel format on at least two (2) hard drives. Archiving of all data shall be possible to either a Digital Versatile Disk (DVD) or through a Universal Serial Bus (USB) port to a thumb drive.

3.3.24.9. Operator Inputs. The control shall prompt the operator for the following data at the beginning of the auto cycle:

a. Work Order Number

b. Operator Number or Name

c. Rotor Type

d. Serial Number of rotor

e. Process Required

Amendment 1 Page 13 of 29

3.3.24.10. Help Data. All the machine manuals and drawings shall be available in an online help system. The help system shall be provided on a Compact Disk (CD) Read-Only Memory (ROM) and be available on the machine screen.

3.3.25. Printer. A laser color printer shall be provided adjacent to the PC monitor for the output of reports. The printer shall be mounted in the computer desk that holds the PC control. The output report shall be formatted to the Government requirements.

3.3.26. Preventative Maintenance Prompts. Prompts shall be displayed on the control LCD.

These shall be displayed on an elapsed time basis and shall cover all regular maintenance functions to be implemented. An error log shall be displayed giving date and time of the errors.

Errors shall be displayed on the machine control display. All errors shall be stored in an error log, which shall be available for subsequent examination. The error log shall store the error, date and time of error. Each error text may have additional text added by the receiving facility. This shall be stored and displayed with the normal error test each time the error is generated.

3.3.27. Electrical System. The machines shall conform to NFPA 79. The existing source power available at the facility is four-hundred-sixty (460) volt, three (3)-phase, sixty (60) Hertz (Hz).

Each machine’s electrical system shall be tolerant of fluctuation of ± ten (10) percent. The electrical system shall be complete, including any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated, and fused, single disconnect device shall be utilized on the machine with means of lockout in the “Off” position only.

3.3.27.1. Electrical Enclosures. Construction of the electrical enclosures shall conform to NEMA ICS 6 standards. The enclosures 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 machines 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.

3.3.27.2. 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.

3.3.27.3. 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.

Amendment 1 Page 14 of 29

3.3.27.4. Electrical Connections. Electrical connections within the equipment shall be complete and shall be made via terminals on the components, terminals, or circuit boards and bussing.

Splices between terminations are not permitted. Connections and terminals shall be supported and spaced without dependence upon the wiring in the components and braced as necessary to assure withstanding the distortion forces associated with available short-circuit currents. Proper identification of wiring, bussing, terminals and circuits for function, polarity, phasing, etc., shall be adhered to throughout the equipment. Identification shall be in the form of wire markers, color-coded, permanently engraved plates, and permanent markings beside the devices.

Adequate spacing shall be maintained throughout to avoid excessive bending of cabling and wiring, to maintain adequate separation and creepage distance between electrical potentials and between these potentials and ground, and to permit ease in disconnecting wiring and cabling during trouble-shooting and repair. In no instance shall clearances and creepage distances be less than those prescribed under NEMA ICS, Part ICS 1-111.

3.3.27.5. Grounding. Exposed, non-current carrying metal parts on the equipment shall be maintained at common, zero (0) ground potential. None of the primary circuits in the equipment shall be connected to ground. A ground stud or lug on the equipment shall provide means for grounding the equipment for safety to personnel. A NEMA-type grounding plug that effectively grounds the equipment shall be acceptable for cord connected equipment.

3.3.27.6. Control Circuits. Main and auxiliary control circuits shall operate on a circuit of one hundred and fifteen (115) volts or less derived from isolation transformer(s) integral with the equipment.

3.3.28. Motors. Motors shall be rated for continuous duty. AC motors shall be designed to operate on sixty (60)-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG 1. Each motor shall have an identification plate in accordance with paragraph 3.7 to identify manufacturer, model number, serial number, voltage, amperage, horsepower, phase, frequency, and frame number. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

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

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

3.3.31. Hour Meter. The machines 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

Amendment 1 Page 15 of 29 shall be mounted to withstand shock and vibration generated by each machine. The meter shall have a range of zero (0) to 99,999.9 hours in increments of one (1) tenth of one (1) hour. A CNC control that tracks and displays total machine on time (a non-resetting type), controller on, program runtime, and run time of the servo motor(s) run time shall be considered to meet this requirement. The meter shall be sealed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by each machine.

3.3.32. Safety Stops. All machine motions shall be provided with a means of over-travel protection via electrical switch limits to prevent damage to the machine’s power feed mechanisms in the event the machine is inadvertently fed or rapidly traversed. Each machine shall have on all axes programmable travel limits and control-activated axes inhibit functions to prevent damage to the machine tool.

3.4. Size and Capacity. The size and capacity of the machines shall include but shall be not less than the following specifications.

Table I

Characteristic Capacity/Range Working Diameter (Minimum/Maximum) 12 inches / 36 inches Maximum Weight of Part 1,000 pounds Component Length (Minimum/Maximum) 17 inches / 59 inches Grinding Wheel Size (Minimum/Maximum) 14 inches / 20 inches Work Spindle RPM 100 – 6,000 RPM Grinder wheel head adjustment – 10 degrees to +25 degrees

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

TABLE II

Linear Accuracy

Straightness, Flatness

Squareness Parallelism

Wheel Head slide “X”

± 0.0002 inch 0.0004 inch over 16 inches

X to Z, 0.0004 inch over 10 inches

W H Traverse Slide “Z”

± 0.0002 inch 0.0004 inch over 48 inches

X to Z, 0.0004 inch over 10 inches

Wheel Dresser Slide

± 0.0002 inch 0.0004 inch over 48 inches

Traverse Slide to Workpiece Rotation

0.0004 inch over 48 inches

Amendment 1 Page 16 of 29

Gage Traverse Slides

± 0.0002 inch

Traverse Slide ± 0.0002 inch 0.0004 inch over 48

Infeed Slide ± 0.0002 inch 0.0004 inch over 10

To Traverse Slide

0.0004 inch over

10 inches

Positioning Axis Accuracy Repeatability Lost Motion Axis

All Linear Axis ±0.0001 inch / foot

±0.0002 inch 0.0001 inch All Linear Axis

Gage Infeed Axis ±0.0001 inch Gage Infeed Axis

3.6 Standard Tooling and Equipment. All standard equipment normally provided with the machines shall be furnished.

3.6.1 Tooling and Accessories. Each machine shall include the following items.

TABLE III

Description Quantity Diamond roller with diamond roller dresser unit 2 Grinding wheel flanges comprising inner and outer flanges 2 Deburring brushes 5 Sets Leveling Screws and Pads 1 Set Wheel Lifting Cradle 1 Tool Kit (comprising wrenches and Allen keys). 1

3.6.2 Master Rotor. Reform Grinding Technologies shall provide a total of two (2) master rotors, one (1) master rotor for FRCSE and one (1) master rotor for FRCSW for machine calibration.

3.6.3 Master Setting Equipment. Reform Grinding Technologies shall provide one (1) set of calibration tools for each machine to set and calibrate each machine axis. Two (2) sets of master setting equipment for machines going to FRCSE and one (1) set of master setting equipment for machine going to FRCSW, comprising.

a. One (1) master for mounting in the work spindles.

b. One (1) master wheel for mounting on the wheel spindle.

c. Zero (0) degree angle setting plate shall be controlled and monitored by a direct mounted absolute rotary encoder.

Amendment 1 Page 17 of 29

d. Twenty (20) degree angle setting plate shall be controlled and monitored by a direct mounted absolute rotary encoder.

e. Support for dial indicator for mounting on the wheel head assembly front face.

f. Master Rotor (paragraph 3.6.3)

g. Storage boxes including all documentation and calibration certificates

3.6.4 Chuck Sets. Reform Grinding Technologies shall provide a total of five (5) chuck sets (for a total of ten (10) chucks each) for FRCSE (per paragraph 3.6.5) and a total of two (2) sets of LM2500 chucks for FRCSW (one (1) set of LM2500 HPC and one (1) set of LM2500 HPT;

per paragraph 3.6.6).

3.6.5 Engine Part Tooling (FRCSE ONLY). Gage length between spindle faces shall be twenty-four (24) inches to a maximum of forty-eight (48) inches. All master setting & calibration equipment shall be provided with sturdy boxes for proper storage of the tooling.

Complete set of tooling shall be provided with each machine at the time of purchase for the following (drawings shall be submitted to the government as state in paragraph 3.8):

a. F404 HPC: (One (1) set of chucks per machine for a total of two (2) each sets)

1. Hydra – Expansion Chuck Type – MHF (for clamping F404 forward), drawing no.

30109711

2. Test ring for chuck HPC front drawing no. 30110211

3. Hydra – Expansion Chuck Type – MHF (for clamping F404 afterward) drawing

no. 10258711

4. Test ring for chuck HPC rear drawing no. 30110211

b. F414 HPC: (One (1) set of chucks per machine for a total of two (2) each sets)

1. Hydra – Expansion Chuck Type – MHF (for clamping F414 forward) drawing

no. 30110110

2. Test ring for chuck HPC forward drawing no. 30110211

3. Hydra – Expansion Chuck Type – MHF (for clamping F414 afterward) drawing no.

30110110

4. Test ring for chuck HPC afterward drawing no. 30110211

c. TF34 HPC: (One (1) total set of chucks)

1. Hydra – Expansion Chuck Type – MHF (for clamping TF 34 forward) drawing

no. 30109511

2. Test ring for chuck HPC front drawing no. 30110211

3. Hydra – Expansion Chuck Type – MHF (for clamping TF34 afterward) drawing

no. 30109611

4. Test ring for chuck HPC rear drawing no. 30110211

Amendment 1 Page 18 of 29

3.6.6 Tooling (FRCSW ONLY). A set of LM2500 high pressure compressor (HPC) and a set of LM2500 high pressure turbine (HPT) shall be included with the machine that shall be shipped to FRCSW.

a. LM2500 Compressor HPC: (One (1) total set of chucks)

1. Hydra – Expansion Chuck Type – MHF (for clamping LM2500 HPC front)

2. Test ring for chuck HPC front

3. Hydra – Expansion Chuck Type – MHF (for clamping LM2500 HPC rear)

4. Test ring for chuck HPC rear

b. LM2500 Turbine HPT: (One (1) total set of chucks)

1. Hydra – Expansion Chuck Type – MHD (for clamping LM2500 HPT front)

2. Test ring for mandrel HPT front (2 pieces)

3. Hydra – Expansion Chuck Type – MHF (for clamping LM2500 HPT rear)

4. Test ring for chuck HPT rear

3.6.7 Video Monitor System. A video camera system shall allow the operator to view the grinding operation from the outside of each machine enclosure. The system shall include a color camera, a monitor, all mounting brackets, wiring, and any other required items.

3.7 Marking on Instruments, Control Panels, and Plates. All words on plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

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

Points of Lubricant Application Servicing Interval Type of Lubricant Viscosity Military or Federal Specification for Each Lubricant (If available) Size and Type of Each Lubricant Filter

3.7.2 Nameplate. A nameplate shall be permanently and securely attached to each machine.

The nameplates shall contain the information listed below. If the machines are 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

Amendment 1 Page 19 of 29

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

3.7.3 Identification Marking of Military Property. An Item Unique Identification Marking (IUID) shall be provided in accordance with MIL-STD-130N 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.

3.8 Technical Data and Manuals. Two (2) hard copies and one (1) electronic copy, in PDF format, of technical data shall be provided with each CNC Blade Tip Grinder. Documentation shall include at a minimum drawings stated in paragraph 3.6.5, Operation, Installation, Maintenance, Lock-out/Tag-Out Procedures, Preventive Maintenance Plan, Illustrated Parts Break Down, Recommended Spare Parts List, Vendor’s Literature, all subcomponent cut sheet documentation and Manufacturer’s Software Licenses and Manuals. All original software manuals and registration keys/codes shall be provided, along with original software installation disks. All copies of technical data shall be legible and written in the English language.

3.8.1 Plan of Action and Milestones (POA&M). The contractor for each FRC shall provide a POA&M to identify contractor performance dates of all major events from contract award to completion of all contract requirements. The initial POA&M shall be delivered thirty (30) calendar days After Contract Award (ACA). The milestones shall be prepared using a recognized project management technique (preferably Microsoft Project). The Government and the contractor shall review the report on a monthly basis. The contractor shall notify the Government prior to making any changes to the POA&M. All changes to the POA&M shall be approved in advance by the Government. The POA&M shall detail such items as system design concept, system development, software design concept, software development, engineering, procurement of major hardware, assembly, operational debug, factory acceptance, shipment, installation, training, and final acceptance test.

3.8.2 Calibration Procedures. Calibration procedures for each component requiring operator calibration or verification shall be provided to the Government. One (1) copy of the calibration procedures shall be provided to the government. Tools, fixtures and/or jigs that may be required to perform calibration shall be furnished with the equipment. All calibrated systems shall have a certificate of calibration traceable to the National Institute of Standards and Technology (NIST).

3.8.3 Installation Drawings. The contractor shall provide one (1) hard copy and one (1) in PDF format no later than forty-five (45) days after effective date of contract for FRCSE and FRCSW. The contractor shall provide installation drawings in the English language. The

Amendment 1 Page 20 of 29 drawings shall contain at least, but shall not be limited to, mounting place details, hardware requirement lists, drilling plans and shock mounting buffers details. The machine layout shall be furnished in AutoCAD format.

3.8.3.1 Dimensions and Weights. Overall and principal dimensions in sufficient detail to establish limits of space in all directions required for installation, operation and servicing;

amount of clearance required to permit opening of doors and removal of plug-in units; clearance for travel or rotation of any moving parts, and interface piping and interface connections; size and location of ducts; and weight of all major components.

3.8.3.2 Utilities. Location, type and dimensions of electrical cable entrances, terminal boards and electrical connectors, full load amperage required, shop air, requirements and any other utilities needed to support the machines are required items within the drawings.

3.9 Installation. The contractor shall be responsible for the subsequent paragraphs and the attached Installation Responsibilities sheet.

3.9.1 Foundation. The existing foundations at each location, FRCSE and FRCSW, shall be utilized with the newly procured machines.

3.9.2 Existing Equipment Removal. Material handling shall be in accordance with FED-STD- 313F.