Attachment 0001- Internal Grinder Specification Rev A 04-22-3415.pdf

Specification for Internal Grinder

Revision A

Spec. # 04-22-3415

Manufacturing Engineering Work Group

Watervliet Arsenal

Watervliet, New York 12189

01/17/2023

Department of the Army

TACOM

1. Scope: The dedicated function of this specification is the acquisition of a machine tool equipped as herein described. All sections are specific in their intent and are not to be misconstrued as requests for options. The machine system described by this specification shall be provided with all required equipment whether stated requirements are standard or optional with the machine tool builder/supplier. This project is classified as a “turn-key” system with the contractor being responsible for all costs and work associated with the installation unless otherwise stated. In this specification requirements and terminology are oriented toward the purchase of a single machine tool. However, in many cases, two or more identical machine tools will be procured in accordance with this specification. In such cases, the term "the machine" means "each machine".

1.1. Abbreviated Description: This specification defines the requirements for a New

Internal Grinder with the option for a second machine. The machine shall be a CNC controlled, horizontal, hollow spindle, precision, contour grinding machine capable of rough and finish grinding on Watervliet Arsenal cannon tubes. Cannon tube material will be refractory metal applied on 4340 alloy steel hardened to RC 38-42. Cannon tubes may be up to 13.5” in outer diameter, 20’ in length, weigh up to 5,000 lbs., and have internal grinding depths of up to

60”. The machine shall be capable of grinding cannon tubes while their centerline is offset by up to 0.270”. This procurement shall be a complete turn-key project with the contractor providing all options, accessories, and other equipment as described in this specification. This machine shall not require a special foundation to be installed and shall fully function on the floor at the

Watervliet Arsenal without any modifications. More information on foundation requirements can be found in section 3.30.

2. Applicable Standards and Publications: All work performed, and procedures followed in association with this project shall meet or exceed all applicable and current Watervliet Arsenal

(WVA), Occupational Safety and Health Administration (OSHA), local, state, and federal government codes and laws relative to fire, safety, environmental, and electrical issues. These standards include, but are not limited to, ANSI, NFPA, ISO, and ASME. The quality of all work performed, and material provided shall meet or exceed the most recent revision of applicable industry standards and engineering practices for this type of equipment and its intended function.

In all instances material, quality, and workmanship shall meet or exceed OEM specifications.

3. General Requirements: All requirements are mandatory from the standpoint of intended function. Wherever a specific requirement would force an offeror to depart from his standard practice or configuration, the Arsenal will accept, for evaluation and approval, alternative offers for achieving the intended function. Any such alternative offers must be accompanied by sufficient technical information to allow the evaluator to reach a definite conclusion that the alternative is equal to or better than the criteria specified in this document. The equipment specified in this document shall be a standard product of the manufacturer and shall require either no design changes, or if required, minor design changes to meet the requirements of this specification. Therefore, ownership of the design shall remain with the manufacturer. Equipment incorporating new or unproven technology is subject to rejection at the discretion of the

Contracting Officer.

NOTE: Not all general requirements listed in section 3 shall be applicable to every machine. If a section is non-applicable, the offer is still in compliance. Please note in the attached Offeror's

Statement of Compliance if a section does not apply with the offered machine.

3.1. Design and Engineering: The equipment specified in this document shall be designed and engineered in accordance with the most recent revision of each standard, recognized by the

Association for Manufacturing Technology.

3.2. Materials and Components: Materials and components incorporated in the construction of the equipment specified herein shall be new, free from defects, and conform to the specifications and standards included within this document.

3.3. Construction: All parts of the equipment specified in this document shall be new, unused, and constructed to be capable of withstanding all forces encountered during operations to the equipment's maximum factor of safety rated capacity. The structure and assembly of the machine and its components shall be sufficiently rigid that workpiece finish and accuracy are not impaired by machine vibrations.

3.3.1. Alignment Retention: Non-integral machine components, heads and ways, which are separately assembled and whose alignments determine the squareness and parallelism of machine geometry shall utilize a positive means for retaining alignments and regaining them in the event of accidental dislocation.

3.3.2. Slideway Design and Construction: All precision ways which guide and bear the rated design loads shall adhere to the hardness criteria shown in the following examples of acceptable way systems. Hardness tests other than Rockwell shall be subject to approval by the

Watervliet Government Representative.

A. Integral cast iron ways shall be hardened from RC 50 to RC 54 to a depth of .100 inches or more.

B. Hardened and ground steel ways for mating with Turcite, Rulon, or other such low friction forgiving materials shall be hardened within the range of RC 55 to RC 62. Actual hardness within this range shall not vary more than 5 RC points.

C. Hardened and ground steel ways for use with anti-friction roller bearings shall be to a hardness of RC 62 to RC 65 to a depth of 1/8 inch or more.

Slideway systems other than the ones referred to above may be offered provided that their design is consistent with all specified performance characteristics of the machine. All slideway systems having less than a 60-degree incline to the horizontal shall be protected by way covers unless it can be substantiated that covers will interfere with the functions of the machine.

3.3.3. Replaceable Ways: If the machine being offered is portrayed as having replaceable ways, the assembly of the way bars to the machine frame shall be such that finish ground ways are fastened to a precision ground or scraped surface to permit field replacement without additional grinding.

3.3.4. Way Wipers: All way systems shall be equipped with wipers designed to prevent intrusion of foreign material. Wipers shall be adjustable to compensate for wear. Wipers shall be easily removable and replaceable.

3.3.5. Shims and Spacers: Shims that do not appear on engineering drawings shall not be incorporated in the machine. Spacers that do appear on engineering drawings are permissible.

3.3.6. Castings and Forgings: All castings and forgings shall be free of defects, scale, and mismatching. Weldments, if used, shall be braced, ribbed and gusseted to obtain strength equal to or better than the strength of castings, and shall be properly stressed relieved.

3.4. Workmanship: Workmanship throughout the construction and assembly equipment specified herein shall be free from irregularities or defects that could adversely affect performance or durability.

3.5. Maintainability: All equipment components offered that are subject to wear, distortion or failure and all parts which require periodic adjustment shall be accessible for replacement or adjustment. The contractor shall provide Instructions for the Maintenance and Adjustment of

Equipment Components Instructions for the preventative maintenance and adjustment of these parts shall be clear, concise, and definitive in accordance with (IAW) Contract Data Item List

(CDRL) A001.

3.6. Interchangeability: All parts offered that bear the same part number shall be interchangeable.

3.7. Applicable Power Source: The power source to which the machine will be connected furnishes a nominal 480 volts, 3 phase, 60 Hz AC. However, the machine shall be tolerant of line fluctuations ranging from 432 to 504 volts AC.

3.7.1. Electrical Safety Devices: The machine and its equipment shall be protected by circuit breakers which comply with National Electrical Manufacturer’s Association (NEMA) standards for thermal magnetic types and shall have a minimum interrupting capacity of 25,000

Root Mean Square (RMS) symmetrical amperes for 480 volt, 3-phase system. Breaker terminals shall be UL listed as suitable for the type of conductors provided. Plug in circuit breakers or current limiting fuses are not acceptable.

3.7.2. Conversion Equipment: If DC or reduced voltage AC is required to meet any specified requirement, the necessary conversion or transformation equipment shall be provided by the contractor. All transformers must meet efficiency levels specified in CFR Title 10 Chapter

II Part 431 (also known as DOE 2016 Efficiency Levels). Equipment which requires a high-quality constant power source shall have proper isolation and/or power conditioning equipment for the power service designated in this description. All electrical equipment shall have a power factor (ratio of real power to apparent power) of no less than 80%, as read at the equipment main disconnect. Equipment with a power factor of less than 80% shall be fitted with suitable power factor correction capacitance, sized based on the equipment’s inductive AC load.

3.7.3. Operator Control Voltage: All electrical controls meant for use by the operator of the machine shall carry 120 volts AC maximum.

3.7.4. Utility Outlet: The machine shall be provided with a 120 volt, single phase, spec grade 20 ampere, single duty receptacle, weatherproof bi-metallic box, “in-use cover”, dual receptacle, and 3 wire utility outlet. This outlet shall be protected by a ground fault interrupter and shall be externally mounted on the operator control panel. A noise suppression device for this circuit shall be provided.

3.7.5. Cabinet Enclosure for Electronic Equipment: All separate electrical hardware/circuitry are to be housed in a NEMA rated enclosure/cabinet. Should forced ventilation be necessary to maintain the interior of the enclosure at a temperature to ensure good product reliability, filtered air shall be forced into the cabinet to maintain an over pressure condition in the cabinet. Cabinet shall not inhibit operator access to the controls and/or adjustments.

3.7.6. Interconnecting Wiring: All control functions shall be pre-wired by the contractor. This includes wiring from the computer numerical control (CNC) to the interface and from the interface to the machine tool. If any disassembly of the machine tool and associated control wiring is necessary for shipment from the contractor's plant, the contractor shall rewire the system at the Arsenal unless a clearly labeled plug and socket system is employed. The

Arsenal will not perform detailed control wiring. All wiring shall comply with accepted Joint

Industry Code (JIC), National Machine Tool Builders Association (NMTBA), and National Fire

Protection Association (NFPA) Standards.

3.8. Motors: All motors provided shall be of the type and horsepower rating to meet the specified requirements based on all applicable engineering practices and standards. All motors shall be rated for continuous duty. Motors shall not operate in an overload condition during normal operation of the equipment and shall be equipped with thermal overload protection.

Motor starters and controls shall operate at 24 VDC. Motor starters shall provide drop out protection. This means that in the event of power loss, the equipment shall be re-energized only by deliberate action of the operator or maintenance personnel. Manual or mechanical motor starters are not acceptable. All motors shall be housed in enclosures of the appropriate NEMA type for class and severity of service. All AC unidirectional motor housing shall bear a directional arrow to indicate proper rotation direction when correctly wired. All AC motors rated at 25 horsepower or greater shall be equipped with a “soft start” device which provides for reduced voltage starting. All polyphase AC motors rated at 1 horsepower or greater shall be tested per IEEE Standard 112-Method B and must meet premium efficiency requirements per

NEMA MG 1-2006 Table 12-12 or IE3 9IEC 60034-30:2008. All motors are to be permanently lubricated and sealed.

3.8.1. Motor I.D. Plates: Each motor shall bear an identification plate containing the identity of the manufacturer, model number, serial number, input voltage, amperage, horsepower, phase, frequency, duty cycle, and frame size or mounting identification in accordance with IAW CDRL A002. No I.D. plates shall be painted.

3.9. Safety and Environmental Requirements: The contractor shall review the environmental requirements documented in Enclosure D of this document and comply as required.

3.9.1. Protection of Machine Operator: Protection of the machine operator and other personnel shall be accomplished in accordance with all pertinent Arsenal, State, Federal, and local regulations.

3.9.2. Protection of the Machine: The machine shall be designed and equipped in accordance with all applicable standards to prevent self-damage in the event of component malfunctions, power failures, expended consumables, incorrect consumables, and operator errors.

3.9.3. Noise Levels: Noise levels at a distance not exceeding one meter from the nearest point on the machine shall, under no circumstances, exceed a maximum of 85 dba when measured by a calibrated sound level meter set for "A" weighting and slow response. Any shields, baffles, enclosures or other devices required to bring the machine into conformance with this noise level requirement shall be provided by the contractor. Any such devices shall not interfere with the operation of the machine and shall be designed to preserve the visibility needed for safe operation and ease of maintenance.

3.9.4. Ozone Depleting Substances: Section 326 of Public Law 102-484 precludes the

Dept. of Defense from awarding any contract that directly or indirectly requires the use of a class

I ozone depleting substance within the Government specification or standards set forth in the contract. Enclosure B is a list of the restricted Class I CFCs and Halons. All shall be replaced by new functionally equivalent substances or systems that are approved for use by the

Environmental Protection Agency (EPA) and have an "Ozone Depletion Potential" (ODP) rating of zero. Ozone Depletion Potential (ODP) is defined as the relative capacity of a substance, per unit weight, for destroying the earth's stratospheric ozone layer, in comparison with CFC 11, CFC 12 and CFC 114, each having been assigned an ODP of 1.00.

NOTE: Offerors are responsible to obtain and adhere to the most current list of prohibited substances as of the date of the submission of bids or proposals.

3.9.5. Asbestos and Mercury Free Certification: All materials utilized in the system shall be certified as asbestos and mercury free unless substitute materials do not exist. This certification shall be provided prior to machine delivery in accordance with IAW CDRL A003.

3.9.6. Material Safety Data Sheets: The offeror shall provide Watervliet Arsenal with all material safety data sheets at the time of proposal submission in accordance with IAW CDRL

A004.

3.9.7. Lead Free and Chromium Free Paint Certification: All paints and primers applied to the system shall be certified as lead free and chromium free. Lead based paint is paint that contains more than six one hundredths of one percent (0.06%) lead by weight. This certification shall be provided prior to machine delivery in accordance with IAW CDRL A005.

3.9.8. PCB Free Certification: To the extent that the machine is charged with lubricant or hydraulic fluids at the contractor's plant for preliminary acceptance inspection, these fluids shall not contain Polychlorinated Biphenyl’s (PCBs). The machine and its equipment shall be certified as PCB free, and certification shall be provided prior to machine delivery in accordance with IAW CDRL A006.

3.9.9. Lockout/Tagout Procedures: The manufacturer shall provide the control of hazardous energy (lockout/tagout) per OSHA 29 CFR 1910.147 in accordance with IAW CDRL

A007. This information shall be incorporated into the maintenance manual. Contractor shall ensure employees are trained so they know, understand, and follow the applicable provisions of the hazardous energy control procedures. The control of hazardous energy sources includes but is not limited to electrical, pneumatic, hydraulic, chemical, mechanical, UV, electromagnetic and thermal energy.

3.10. Data Plates: All instruction, data, and identification plates and labels attached to this equipment and its controls shall be manufactured of corrosion and oil resistant metal or plastic material. All wording shall be in the English language using plain, bold face lettering. Lettering shall be permanent and have a contrasting background.

3.11. Identification Plate: A corrosion resistant metal plate shall be securely attached to the machine in a location visible to the operator's workstation. This plate shall bear, as a minimum, the information called for below, with space at the bottom of the plate for the addition of one line of information to be applied by the government in accordance with IAW CDRL A008.

A. Nomenclature

B. Manufacturer's name

C. Model

D. WV# (Please contact the Watervliet Government Representative to receive this number)

E. Manufacturer's Serial Number

F. Power Input (voltage, phase, frequency, and full load amps)

G. Government Contract Number

H. Date of Manufacture

3.12. Utility Connections: Equipment supplied to the Watervliet Arsenal shall have a single point shut off for each utility supplied to the system. This single point shut off will be referred to as the “point of first connection”. Each type of power source shall have only one point of first connection. Each point of first connection shall be clearly labeled on the system and shown in the safety Lockout/Tagout Procedures (IAW CDRL A007). These points of first connection shall be located on a stationary component and positioned so that they shall not create a hazard to personnel during normal operation of the system. The first connection point shall be accessible from the shop floor without the use of ladders, steps, or stools. Access to this first connection point cannot be obstructed or hampered by operation of the system, in the event of a safety incident requiring the main power to the machine to be shut off in an emergency.

3.13. Utility Connection Labor and Requirements: Watervliet Arsenal will provide a utility connection between first point of connection for all utilities (electrical, air, water, etc.) on the equipment, and the facility. Only one “facility side” connection per utility type will be provided. All other additional or ancillary utility connections shall be provided by the contractor.

3.13.1. Electrical: The WVA power source that the specified equipment will be connected to will be a nominal 480 volts, 3 phase, 60 Hz AC voltage. However, the machine shall be able to operate normally at source voltages ranging from 432 to 504 volts AC. The

WVA power source does not include sub-panels, filters, surge protection, or any peripheral equipment necessary to make the equipment functional. All electric requirements shall be routed to a single point of connection, including sub systems or 120V connections.

NOTE: Contractor shall state required power/electrical requirements for offered machine. See

Enclosure C – Electrical Survey and complete in accordance with IAW CDRL A009.

3.13.2. Pneumatics/Air: If air is required for any machine operation or function, the machine shall be fully equipped with all required components, fully installed to the point of connection of WVA shop air. Shop air at the Arsenal is 85 psi with above normal moisture and contaminant levels. If higher or lower pressure is required at the machine or a different air flow rate is needed, the machine shall be fully equipped to modify the supply pressure and volume.

The machine shall also be equipped to remove the above normal moisture and contaminant levels. Normal moisture is defined as that moisture produced when air at a relative humidity of

75% has been compressed to 85 psig. The equipment’s nominal and maximum compressed air usage rates in CFM shall be provided to the Watervliet Government Representative as part of

Enclosure C.

3.13.2.1. Air Booster Unit: If the equipment offered requires more than 85 psi at the volume for operation of the equipment, then an air booster unit shall be provided with the machine. If operation of the equipment requires an accumulator tank, it shall be provided with the booster.

3.13.2.2. Air Dryers/Filtration: If the offeror determines that on machine air dryers are required to maintain moisture levels, the air dryers shall have a regenerative type desiccant or refrigerated compressed air dryer capable of drying air down to 35°F pressure dew point, minimum, from air entering the equipment at 110°F. The air dryer shall supply air at the required standard cubic feet per minute (SCFM) of the equipment. The air dryer shall purge condensate automatically. In the case of a refrigerated air dryer, the refrigerant used shall not be a Class I ozone depleting substance. The air dryer shall be connected and piped to the equipment by the contractor. All air dryer designs are to be supplied by manufacturers participating in the CAGI

Refrigerated Dryer Performance Verification Program and have been tested and rated in accordance with CAGI ADF 100. Power for the refrigerated air dryer unit shall be 110 Volts

Alternating Current and shall be wired and powered through the machine electrical system.

NOTE: Industrial Air dryers need to be compatible with the existing Watervliet Arsenal compressed air network. Common industrial air dryers that are used at the Watervliet Arsenal include the ZEKS brand, HSE brand, and Ingersoll Rand brand D31NC models to ensure cross compatibility with existing components on the Watervliet Arsenal’s compressed air system.

3.14. Lubrication: The machine shall be equipped to provide lubrication to every moving part where lubrication is essential to prevent damage. Slideways shall be lubricated by an automatically cycled distribution system such as that manufactured by Trabon or equal to.

Gearboxes and transmission cases shall be lubricated by the wet sump splash method. Spindle bearings shall be lubricated by recirculating pressure spray systems. Automatic lubrication systems shall be equipped to be fail safe to the maximum extent possible. All sensors and devices used to detect the presence or absence of lubrication shall be accessible for test or replacement without major disassembly. Manual lubrication methods are permissible for lubrication points not practically served by automatic systems. For non-recirculating automatic systems, such as slideway lubrication, the reservoirs shall be sized to provide lubrication reserve equivalent to 80 operating hours and shall be located at floor level. For recirculating automatic systems, cleanable or replaceable filtration devices shall be provided. Wet sump type systems shall be equipped with a means to confirm proper oil level. Sight gages shall be of the external standing tube type rather than the flush mounted porthole type. Standing tube sight gages shall be protected against accidental breakage.

3.14.1. Lubrication Plate: A lubrication plate shall be permanently fastened to the machine and shall clearly indicate the type and viscosity of lubricant and the service interval for all automatic and manual lubrication reservoirs and fittings. The plate shall include a simple diagram which depicts the physical location of all lubrication points on the machine structure in accordance with IAW CDRL A010.

3.14.2. Lubricants, Hydraulic Fluids, Oils and Coolants: Watervliet Arsenal has established a standardized list of lubricants, hydraulic fluids, oils, and coolants. The contractor shall choose the required lubricants, hydraulic fluids, oils, and coolants from Enclosure A, enclosed or where there is a designated equivalent. If a substitute is required, the contractor shall provide at the time of machine delivery, a justification which shall include the manufacturer, type, and specification number as well as the reason for the substitution. A list of all fluids required to operate the machine shall be provided to the Arsenal 30 days prior to delivery in accordance with IAW CDRL A011.

3.14.3. Control of Cutting Fluids: If the machine is equipped with a coolant system, the contractor shall ensure that the machine is designed and equipped to prevent coolant from escaping the confines of the machine and leaking to the floor when producing workpieces of a size within the machine's normal working range. If the coolant reservoir is part of the foundation, the coolant shall be contained in a leak proof metallic or nonmetallic liner.

3.15. Hydraulic System: Hydraulic systems provided shall be sized and powered for the intended application and shall conform industry standards. The system shall incorporate cleanable or replaceable filtration devices to insure fluid cleanliness. Reservoirs shall be equipped with easily visible gages to indicate fluid level. If duty cycle of the system under maximum usage will cause the hydraulic fluid to exceed 120°F in temperature, a suitable heat exchanger shall be provided to maintain fluid temperature at or below this level. The system shall be protected against overpressure as well as under pressure. System pressure in any hydraulic device shall be as low as is practical for the intended application but shall not exceed

3000 PSI in any case. In any system which utilizes hydraulics to produce thrust or direct linear motion, anti-surge devices or circuits shall be incorporated to insure uniformity of motion under varying loads. These devices or circuits shall be adjustable. All reservoirs shall be easily accessible for cleaning and flushing and shall be located at floor level.

3.16. Painting: All exterior machine surfaces shall be painted except where bright metal is required for machine function or to otherwise adhere to the requirements of this specification.

Paint shall be chromium-free and lead-free. Quality and manner of application shall afford protection throughout the normal life of the machine. Paint shall be "semi-gloss", and selected by the Government, from a list of standard colors supplied by the offeror with their proposal in accordance with IAW CDRL A012. This selection shall be made after contract award. Danger areas shall be painted red and caution areas shall be painted yellow in accordance with OSHA

Standard 1910.144. Appropriate warning signs, tags or emblems shall be affixed to respective areas of the machine in accordance with OSHA Standard 1910.145.

3.17. Machine Hold Down and Leveling: The machine base shall be provided with a mounting hole quantity and location for positive hold down when operating at full rated capacity.

In addition, for each hole in the machine base, the contractor shall provide a set of recommended hold down and leveling hardware. If grouting is required, it shall be provided by the contractor.

NOTE: All hold down and leveling hardware shall be delivered 30 days prior to the scheduled delivery of the machine.

3.18. Gears: All gears used in the machine and its components shall meet or exceed the standards recommended by the American Gear Manufacturers Association for the type and severity of service required.

3.19. Handwheels: Where power feed and rapid traverse of a machine component is provided or specified, associated handwheels or cranks, shall not rotate when power feed or rapid traverse is engaged.

3.20. Technical Data: All data shall be in the English language and shall be furnished in accordance with the quantities, formats, and delivery dates below. All data shall be packaged and delivered separately from the machine itself marked to the attention of the Watervliet

Government Representative. The contractor shall provide full documentation in the form of “as built” drawings and manuals. Drawings shall not be generic or sub-assembly prints. A

“hardcopy” refers to a reproducible printed, paper copy. An “electronic copy” refers to a document saved on CD. All AutoCAD drawings shall be provided in AutoCAD version 2014 or later, shall be of one-to-one scale, shall be dimensioned in English units, and shall not utilize the color yellow. “On-line” technical data shall not be acceptable as the sole means of providing technical data for any of the systems provided. The Government contract number and the

Watervliet WV# shall be printed in a conspicuous place on the covers of every manual, on each drawing/schematic, and on all disks/CDs provided. If applicable, it is preferred to receive a 3D file of the complete machine configuration that is compatible with current 3D parametric programs such as SolidWorks.

3.20.1. Foundation Drawings, Standard or Special: A special foundation for this machine shall not be permitted, and therefore no foundation drawings will be required. See section 3.30 for more information about specific foundation requirements.

3.20.2. Machine and Equipment Floor Plan: Machine and equipment floor plan

AutoCAD drawings shall contain information that indicates the type, magnitude, and connection points of all plant utilities required to operate the machine. The top view AutoCAD drawing shall depict the machine, foundations, feet/anchor locations, anchor requirements, grounding, all ancillary equipment, and all necessary clearance requirements for normal use and maintenance in accordance with IAW CDRL A013.

3.20.3. Catalog of Standard Tooling and Accessories: Catalog shall be furnished 30 days after award of contract. For offers of foreign built machine tools (i.e., machines built outside the United States, its possessions or Canada), the catalog shall set forth U.S. domestic sources of supply in accordance with IAW CDRL A014.

3.20.4. Non-Standard (Special) Tooling and Accessories: To the extent that this specification requires the development of unique tooling and accessories not generally available commercially, a set of drawings and specifications to permit manufacture of such tooling and accessories shall be furnished at the time of machine delivery in accordance with IAW CDRL

A015.

3.20.5. Installation Instructions and Drawings: Instructions outlining the requirements for installation of the equipment shall include a drawing containing the certified dimensioned locations of all equipment mounting/anchor holes. These documents are to be furnished 60 days prior to scheduled delivery in accordance with IAW CDRL A016.

3.20.6. Lubrication Diagram and Instructions: These instructions shall be provided in separate manuals from other technical data provided. To be delivered upon machine delivery in accordance with IAW CDRL A017.

3.20.7. Operating Instructions: These instructions shall be provided in separate manuals from other technical data provided. To be delivered upon machine delivery in accordance with

IAW CDRL A018.

3.20.8. Maintenance and Troubleshooting Instructions: To be supplied for all machine and control systems. These instructions shall include the machine’s mechanical assembly and wiring drawings. To be delivered at time of machine delivery in accordance with IAW CDRL

A019.

3.20.9. Electronic and Hydraulic Schematics: To be considered acceptable, these schematics shall clearly portray all “as built” electrical and hydraulic ties to their respective main systems. To be delivered at time of machine delivery. Wiring diagrams used to do the initial power hookup shall be furnished no later than 90 days after award in accordance with IAW

CDRL A020.

NOTE: If, during installation and testing, the actual electrical and hydraulic systems are configured differently than depicted on the schematics, receipt of the revised "as built" schematics shall be a condition of final acceptance.

3.20.10. Repair Parts Catalog: This catalog shall encompass every replaceable part in the machine and shall include identification and original equipment manufacturer’s part numbers and ordering data. Items which can normally be purchased locally may be so indicated provided they are sufficiently described. The repair parts catalog shall include illustrations which clearly locate parts within larger subassemblies. To be delivered at time of machine delivery in accordance with IAW CDRL A021.

3.20.11. Program Manuals: Where a CNC machine is specified, programming manuals shall be supplied. These manuals shall include a clear summary of the control functions implemented and usable on the system specified. To be delivered at time of machine delivery in accordance with IAW CDRL A022.

3.20.12. Software Documentation: The offeror shall provide documentation of all system software and ladder logic developed to control and interface with the control/drives with the machine tool. To be delivered 30 days after delivery of the machine in accordance with IAW

CDRL A023. One copy of the system memory backup (S-Ram) shall be provided on a USB

Type-A flash drive at startup of machine.

3.21. Training Required: The contractor shall be responsible for providing training of WVA personnel. The type and extent of training shall depend upon whether the machine specified is equipped with numerical control. All instructions and materials, oral or written, shall be in

English. "On-Site" means "At Watervliet Arsenal" and "Off-Site" means "a location within the

U.S. away from Watervliet Arsenal as determined and arranged for by the contractor". If specialized formal “off-site” training is available, specify on offer, availability, and price as an option. The quality of the training shall be such that at the conclusion of the specified training time, everyone within their assigned category shall be capable of repairing or operating the machine to its productive capacity. Training shall be in accordance with the applicable areas of the schedule below, and training attendance, duration and execution shall be officially documented and submitted at the time of final acceptance by the manufacturer’s trainer in accordance with IAW CDRL A024. For all types of training, the associated technical data (see section 3.20) shall be on hand at the time of instruction and its use and interpretation shall be covered during the training. A minimum of five (5) full days training on site at WVA shall be required for the following categories.

A. Machine Operation: Four (4) persons during or after machine performance testing

B. Mechanical Maintenance: Two (2) persons during startup

C. Hydraulic Maintenance: Two (2) persons during startup (if required)

D. Electrical Maintenance: Two (2) persons during startup

E. Electronics (CNC) Maintenance: Two (2) persons during installation

F. Spindle/Axes Drives: Two (2) persons, during installation (if required)

G. Programming: Two (2) persons, during installation

3.22. Repair/Replacement Parts and Service: The offeror shall provide parts and service for the contracted equipment within 72 hours of notification of a problem. The offeror shall agree, as part of the contract, to store complete ordering data to include specifications (e.g., critical subsystem parameters and specifications), engineering drawings and other information for the contracted machine tools/parts. This data shall be stored within the U.S. or Canada and available to the Government at its request in accordance with IAW CDRL A025. The contractor shall supply a list of recommended spare machine parts (e.g., belts, filters, fluids, and wear items) in accordance with IAW CDRL A026. Watervliet Arsenal recognizes that it may be difficult to fulfill this requirement for major machine components. If the requirement cannot be adhered to, the offeror shall notify the Watervliet Government Representative within two business days and shall provide a delivery schedule to be approved by the Watervliet

Government Representative.

3.23. Special Tools: If any element of machine operation or maintenance requires the use of specially designed tools, these tools shall be provided with the machine and shall become the property of the Government.

3.24. Site Conditions: The machine covered by this specification shall be installed in general machine shop space and there will be no environmental conditioning. Temperatures will range from 65°F to 95°F and relative humidity will range from 20% or less to 95%. On any given day, the temperature in the machine shop may change as much as 4°F per hour. These are the conditions under which the machine is expected to perform as specified, and the contractor shall be responsible for supplying what is required to meet the specified performance. The only permissible exception is positioning accuracy for numerically controlled machines. For this performance factor, allowances may be made for the effects of temperature fluctuation.

3.25. Heat Exchange Equipment: Heat exchange equipment shall be provided with the machine wherever it is needed to keep operating temperatures within design or specified limits.

Any heat exchange equipment using water as the heat exchange medium shall be fully recirculating and shall not require the continuing input and discharge of Arsenal water supply.

Wastewater systems of any type are not acceptable. Furthermore, it is the Arsenal's preference to avoid heat exchange equipment making use of the refrigeration cycle, and refrigeration systems of any kind are not acceptable unless design or specified temperature limits cannot be achieved without them. If a refrigeration system is necessary, the contractor shall ensure that it operates properly using a refrigerant having an ozone depletion potential of zero. The contractor shall be responsible for identifying and providing such a refrigerant and its material safety data sheet.

3.26. Chip Removal: If applicable, an automatic chip removal unit shall be provided to convey chips of any material from the machine to an external container without manual aid. The unit shall be reversible to facilitate clearing of blockages. The unit's drive mechanism shall be equipped with an external square or hexagonal extension piece to permit use of wrenches to manually free blockages which stall the drive mechanism. The unit shall operate successfully in a variety of machining environments including dry cutting, machining with cutting oils and machining with water extendable oils. Automatic means shall be provided to return cutting fluids to the machine's coolant tank which shall be separate from the unit. The chip removal unit shall be engineered for the machine so that when fully installed in accord with instructions, the following shall be true:

A. All points subject to periodic maintenance and lubrication shall be externally accessible.

B. The unit shall be capable of being disassembled and removed without disabling the machine itself.

3.27. Elapsed Time Meter: The machine shall be fitted with a meter to measure operating time of the spindle drive. The time totalizing meter shall be of the non resetting type and shall have a range of 0 to 99,999 hours in increments of 1 hour. 1-hour being the least significant digit.

Upon reaching the maximum accumulative hours the meter readout shall automatically revert to zero and continue to totalize time. The meter shall be designed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by the equipment.

The meter shall be located as to be readily visible but not subject to abuse relative to the operating environment of the equipment. Time meters resident in the numerical control unit are unacceptable.

3.28. Enclosures: All new controller hardware shall be provided with new electrical enclosures. Enclosures located in explosive, high dust, paint, or heavy industrial manufacturing environments shall be NEMA 4X rated. All other locations shall be NEMA-12 rated. In addition, if required, given shop environmental conditions as detailed in section 3.24, new control system enclosures for electronic circuitry shall be air conditioned and air filtered to maintain constant temperature, to reduce humidity and to prevent contamination of control boards and other critical system components. Air conditioning units shall not utilize Ozone Depleting substances. New enclosures shall be painted with a color as close to the painted color of the original machine tools as possible.

3.29. Piping: All pipe work performed by the contractor shall be to the specifications below.

A. All equipment piping shall be identified per ANSI/ASME A13.1 or equivalent.

B. Brazing filler metal shall conform to AWS A5.8/A5.8M, Type BAg-5 with AWS Type 3 flux, except Type BCuP-5 or BCuP-6 may be used for brazing copper-to-copper joints.

C. Welding work for new piping systems shall be in conformance with ASME B31.9. The welding work includes brazing procedures, brazers, brazing operators, and nondestructive examination personnel, maintenance of welding records, and examination methods for welds.

D. Pipe hangers and supports shall conform to MSS SP-58, MSS SP-69, and ASME B31.1, except as specified or indicated otherwise. Piping shall be adequately supported to eliminate sag and weak points and allowance for thermal expansion must be considered on long pipe runs.

E. All piping, tubing and fittings shall be in strict accordance with manufacturer’s requirements and recommendations to include industry standards and applicable codes (ANSI B16 and

B31.3).

F. Process piping shall be ASTM 312, 304 stainless steel, seamless.

G. For pressure up to 150 psi, SCH 80 pipe shall be used where threaded connections are made.

For pressures between 150 and 2000 psi, SCH 160 pipe shall be used where threaded connections are made.

H. Joints in piping system shall be listed as complying with ASME B31.3 to include the use of welded fittings. Gaskets and sealants shall also be listed as complying with ASME B31.3.

I. Prior to acceptance and initial operation, all piping shall be inspected, and pressure and leak tested in accordance with ASME B31, Code for Pressure Piping, and Section 705 of the

IFGC.

3.30. Foundation Requirements:

3.30.1. Machine Foundation Requirements: This machine shall not require a special foundation to be installed and shall fully function on the floor at the Watervliet Arsenal without any modifications performed by the contractor or WVA. The machine shall have a granite base machined to accept the slides, work head, dressing system, and wheelhead.

3.30.2. Watervliet Floor Details: Typical floor thickness at Watervliet is 8”-10”. A special foundation is one which exceeds thickness, load bearing capability and vibration isolation of Watervliet Arsenal's standard monolithic concrete flooring of 1,000 PSI load rating and/or one which requires a specific thickness, uniquely shaped excavations for coolant housings, chip conveyors, electrical circuits, and conductors, etc. The soil (substrate) for a foundation is assumed to be medium dense gravel or medium dense gravel/sand with a minimum bearing capacity of 4,000 pounds per square foot (PSF). Although 4,000 PSF is the assumed minimum bearing capacity, there may be variations depending on the exact location of the machine. The contractor shall contact the Watervliet Government Representative to ensure that the minimum

PSF and other requirements are accurate. If the contractor states no foundation is required and does not ensure the minimum PSF in the area and the machine causes damage to floor and requires a foundation after initial installation is attempted, the contractor shall be responsible for all costs associated with floor repair, relocation of the machine, and reinstallation of the machine.

4. Machine Installation, Startup and Testing:

4.1. Work Performed by the Arsenal:

4.1.1. Site Designation: Upon receipt of the required installation drawings (see section

3.20), Watervliet Arsenal will designate an installation site and outline a general machine location on the shop floor. The Watervliet Arsenal will not perform any floor work or other work related to the machine except for ensuring the area where the machine will be installed is cleared.

4.1.2. Utilities: Once the machine is installed, positioned and rough leveled by the contractor or their designated rigging crew, Watervliet personnel will run utilities to a single first point of connection for electrical and a single first point of connection for compressed air.

Watervliet must be provided with sufficient time to accomplish these connections. Sufficient time may be up to 3 working days depending on Watervliet personnel availability. However, if the installation instructions supplied by the contractor are incomplete or insufficiently detailed, installation work will stop, and the contractor shall be required to dispatch a service engineer.

Installation shall resume upon their arrival and continue under their guidance.

NOTE: If installation instructions, electrical and hydraulic schematics are not delivered at or before the times specified (see section 3.20), the Government reserves the right to forestall delivery and/or final acceptance testing of the machine by an amount of time equal to the delay in receipt of instructions, drawings, or schematics.

4.2. Work Performed by the Contractor: This project is classified as a “turn-key” system with the contractor being responsible for all costs and work associated with the installation unless otherwise stated. The Contractor shall be solely responsible for all costs associated with skidding and shipment, rigging, and installation at WVA. Contractor personnel shall adhere to the WVA requirements to wear OSHA approved non-tinted safety glasses with side shields, to wear safety shoes, and to refrain from wearing loose clothing (i.e. “hoodies”) and jewelry while in the manufacturing shop areas. The contractor shall ensure they bring all equipment/material necessary for the installation of the machine. The contractor shall remove from WVA and dispose of all wastes (other than hazardous wastes) generated from uncrating, unpacking, and installing the machine at a permitted off-post disposal facility, in accordance with Enclosure D of this specification and the document "WATERVLIET ARSENAL (WVA) INFORMATION FOR

CONTRACTORS" which is available on the Watervliet Arsenal website. All labor for the installation of material and equipment furnished under this Contract shall be done by experienced personnel. All workmanship shall be up to commercial standards and in compliance with the specific requirements of the Scope, Drawings and Specifications. If any of the

Contractor’s services do not conform to the Contract requirements, the Government may require the Contractor to perform the services again in conformity with the contract requirements at no additional cost. The Contractor shall be responsible for the professional quality, technical accuracy, and the coordination of all construction and other services furnished under this

Contract. Contractor shall, without additional compensation, correct or revise any errors or deficiencies in its construction and other services.

4.2.1. Site Preparation: Once an installation site is identified by Watervliet personnel and if required, a foundation is constructed, the contractor or their designated third party shall layout the machine. Please note that much of the Watervliet Arsenal’s shop floor is covered with

2.5” thick wood block. The contractor is responsible for the removal and disposal of wood block flooring and existing concrete preparation if necessary. Contractor shall also be responsible for securing wood block flooring and install any leveling pads necessary for installation. This shall include informing the Watervliet Government Representative of the number and size of metal blocks required to act as a spacer where the floor was removed to prevent the machine from sitting on the concrete below the wood block flooring. These metal blocks will be provided by the Watervliet Arsenal.

4.2.2. Site Visit: A site visit to the Watervliet Arsenal is highly encouraged after contract award. The purpose of the visit is to observe the process and how a similar machine is currently used at the Arsenal, this will enable the machine to be constructed with the process in mind. It shall also allow the contractor to see the location of the machine and determine how to rig it into place.

4.2.3. Rigging: The contractor shall arrange for rigging services to off load the machine and contractor personnel shall be on site at Watervliet when the machine arrives and is off loaded to supervise the placement of the machine on the installation site by the rigging service. Outside rigging services shall be advised that only certified grade 8 chains are permitted to be used at the

Arsenal and that all rigging slings must be tagged and certified for the weights being lifted. Only propane powered forklifts are permitted, and forklifts must also be equipped with a roll cage.

Operators of forklifts shall have and be able to produce valid forklift licenses in accordance with

IAW CDRL A027. The contractor shall ensure they bring all equipment and material necessary for the rigging of the machine. If necessary, the Watervliet Arsenal will provide the contractor with information for local rigging companies. Any crane truck or lifting equipment used for the installation works shall be inspected and certified as required by applicable regulations.