Attachment 0001- New Pit Tempering Furnace- WVA Spec.pdf

Specification for New Pit

Tempering Furnace

Spec. # 12-22-3424

Manufacturing Engineering Work Group

Watervliet Arsenal

Watervliet, New York 12189

12/01/2022

Department of the Army

TACOM

1. Scope:

1.0 The dedicated function of this specification is the acquisition of a heat treatment furnace equipped as herein described. All sections are specific in their intent and are not to be misconstrued as requests for options. The furnace system described by this specification shall be provided with all required equipment whether or not stated requirements are standard or optional with the furnace 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 furnace. However, in many cases, two or more identical machine tools will be procured in accordance with this specification. In such cases, the term "the furnace" means "each furnace".

The equipment covered by this specification shall be a programmable, batch type, vertical pit heat treating furnace, to be used for air tempering operations on steel production parts of various composition, and various sizes. The furnace shall be a complete “turn key” system including all controllers, and ancillary equipment necessary to install and operate the furnace in a pre-existing heat treatment facility at Watervliet Arsenal.

1.1. Abbreviated Description: The equipment covered by this specification shall be a programmable, batch type, vertical pit, electrically heated, forced convection type, heat treating furnace. This furnace shall be required to perform air tempering operations on steel and non-ferrous metal production parts as large as 33 inches in diameter. The depth of the cylindrical work zone shall be at least 36 inches. Loading and unloading of the furnace shall be facilitated via an opening located at the top of the furnace in a vertical plane using an overhead crane. The furnace shall be a “turn key” system, and shall include all of the required control system components, including a main controller, overtemperature controller, standalone process data recording system, and any other mechanical, electrical and ancillary components required to carry out the processes defined in this description. The furnace shall also include fixturing (a part loading/unloading basket with lifting bar) constructed from a heat resistant alloy such as nickel-iron-chromium or equivalent. Temperature control shall comply with temperature uniformity standard for-class 2 of Aerospace Material Specifications 2750, revision G (AMS 2750G). The instrumentation, measurement and control system shall comply with standards for

Instrumentation-class D of AMS 2750G.

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, AMS, ANSI, ASME, ISO, NFPA, OSHA, and SAE.

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, 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, as well as the Industrial Heating Equipment

Association.

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 specification.

3.3. Construction: All parts of the equipment specified in this document shall be new, unused, and constructed to be capable of withstanding all conditions encountered (static loads, thermal expansion, temperature variations, and pressure variations) during operations to the equipment's maximum factors of safety for each design criteria. The structure and assembly of the machine and its components shall be sufficiently rigid that the finished workpiece characteristics (e.g. hardness, material properties) are not impaired by machine vibrations, thermal effects, or other conditions encountered during the normal course of operation of this furnace.

3.3.1. Workmanship: Workmanship throughout the equipment specified in this document shall be free from irregularities or defects that could adversely affect performance or durability.

3.3.2. 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 stress 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 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 furnace will be connected furnishes a nominal 480 volts, 3 phase, 60 Hz AC. However, the furnace shall be tolerant enough of line fluctuations to operate normally at source voltages ranging from 432 to 504 volts.

3.7.1. Electrical Safety Devices: The furnace and its equipment shall be protected with 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 on the basis of the equipment 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 furnace electrical cabinet 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 12 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 furnace control system to the interface and from the interface to the furnace. 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. 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” mechanism 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 IAW CDRL

A002.

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 Furnace Operator: Protection of the furnace operator and other personnel shall be accomplished in accordance with the standards listed in Enclosure E.

3.9.2. Protection of the Furnace: The furnace shall be designed and equipped in accordance with the standards listed in Enclosure E to prevent self-damage in the event of malfunction and ordinary operator negligence.

3.9.3. Noise Levels: Noise levels at a distance not exceeding one meter from the nearest point on the furnace 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: The contractor is responsible for obtaining and adhering to the most current list of prohibited substances.

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 IAW CDRL A003.

3.9.6. Material Safety Data Sheets: The offeror shall provide Watervliet Arsenal with all material safety data sheets 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 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 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 IAW CDRL A007. This information shall be incorporated into the Instructions for the Maintenance and Adjustment of

Equipment Components IAW CDRL A001. 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. 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. The WVA power source does not include sub-panels, filters, surge protection, or any peripheral equipment necessary to make the equipment functional.

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

Enclosure C – Electrical Survey and complete (IAW CDRL A009).

3.13.2. Pneumatics/Air: If air is required for any furnace operation or function, the furnace 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.

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 the furnace, 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 furnace shall be equipped to provide lubrication to every moving part where lubrication is essential to prevent damage.

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

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 IAW

CDRL A011.

3.14.3. Control of Heat Transfer Fluids: For any heat exchangers/ thermal regulation systems which require a working fluid, the heat exchanger/thermal regulation system shall operate in a sealed, closed loop and shall not consume water or other fluids. The contractor shall ensure that this subsystem is designed and equipped to prevent heat transfer fluids from escaping the confines of the machine and leaking to the floor during normal operation of the furnace. Any connections shall be designed to withstand the thermal expansion/contraction which is produced by the furnace during operation within its rated design temperatures. Any components of the system such as tubing, o-rings, gaskets, and heat exchangers, shall comply with the applicable

ASME/TEMA design standards e.g. applicable factors of safety for the type of heat exchanger

(e.g. Shell in Tube, etc.).

3.15. Hydraulic System: If the furnace is equipped with any hydraulic system, such as a lifting device for the furnace cover, 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 furnace surfaces shall be painted except where bright metal is required for furnace 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 color shall be “semi-gloss”, and the paint color will be selected by the Government, from a list of standard colors supplied by the contractor 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. Furnace Hold Down and Leveling: The furnace 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. Moving Parts: Any handwheels, levers, or knobs incorporated in the design and construction of the furnace shall be not impede in the safe operation of the furnace during required motions such as the opening or closing of doors, lids, etc. Any such devices shall not have sharp edges, protrusions, or grip points which could pose a hazard to the operator. Any moving or rotating parts shall conform to OSHA standards for machine guarding to protect the operator from occupational hazards such as in-running nip points on handwheels, gears, etc.

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 furnace 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.

3.20.1. Foundation Drawings, Standard or Special: If the furnace requires a special foundation, the vendor shall provide foundation drawings. These drawings shall be complete in all construction detail to permit pricing and construction by a general contractor and shall be furnished as soon as possible after contract award and no later than 30 days after award. All drawings shall be dimensioned in English units and text shall be in the English language. One reproducible hardcopy and one electronic copy on CD in AutoCAD .dwg or .dxf format shall be provided. AutoCAD drawings shall not utilize the color yellow or any other colors that cannot be made readily visible when plotted out in color. When drawings are finalized, the contractor shall certify the accuracy of the drawings by providing a stamped and signed hard copy of the drawings to the Watervliet Government Representative IAW CDRL A013.

Typical floor thickness at Watervliet is 8”-10”. A special foundation is one which exceeds thickness, load bearing capability and vibration insulation of Watervliet Arsenal's standard monolithic concrete flooring of 1,000 pounds per square foot load rating and/or one which requires a specific thickness, specifically shaped excavations for coolant housings, process piping, electrical circuits and conductors, etc. The soil (substrate) for a foundation is assumed to be medium dense gravel or medium dense gravel and sand with a minimum bearing capacity of

4,000 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 furnace 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. Should the contractor disturb the soil below the yet to be constructed concrete foundation then the contractor shall compact the disturbed soil to achieve at least 2,000 pounds per square foot (PSF) bearing capacity.

3.20.2. Furnace and Equipment Floor Plan: Offerors shall provide a floor plan which depicts the layout and locations of all required equipment to install and operate the furnace. The furnace 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 furnace. The top view AutoCAD drawing shall depict the furnace, foundations, feet/anchor locations, anchor requirements, grounding, all ancillary equipment, and all necessary clearance requirements for normal use and maintenance IAW CDRL A014.

3.20.3. Catalog of Standard Furnace Tooling and Accessories: Catalog shall be furnished 30 days after award of contract. For offers of foreign built furnaces (i.e. machines built outside the United States, its possessions or Canada), the catalog shall set forth U.S. domestic sources of supply IAW CDRL A015.

3.20.4. Non-Standard (Special) Furnace 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 IAW CDRL A016.

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 IAW CDRL A017.

3.20.6. Lubrication Diagram and Instructions: To be delivered to the Watervliet

Government Representative at time of machine delivery IAW CDRL A018.

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

IAW CDRL A019.

3.20.8. Maintenance and Troubleshooting Instructions: To be supplied for all furnace and control systems. These instructions shall include the furnance’s mechanical assembly and wiring drawings. To be delivered at time of machine delivery IAW CDRL A020.

3.20.9. Electronic and Hydraulics 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 included furnished no later than 90 days after award IAW CDRL A021.

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 manufacturers 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 IAW

CDRL A022.

3.20.11. Program Manuals: For all controllers supplied with the furnace, programming manuals shall be supplied. These manuals shall include a clear summary of the control functions actually implemented and usable on the system specified. To be delivered at time of machine delivery IAW CDRL A023.

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 furnace tool. (One hardcopy and one electronic copy) One copy of the system memory backup (S-Ram) shall be provided on compact flash drive at startup of furnace. To be delivered

30 days after delivery of the machine IAW CDRL A024.

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 furnace 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, each individual 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 IAW CDRL A025.

Type of training Number of persons When required Training location

Furnace operation 4 During or after furnace performance testing

On site

Mechanical maintenance 2 During startup On site

Hydraulic maintenance

(if applicable)

2 During startup On site

Electrical maintenance 2 During startup On site

Electronics (CNC) maintenance

2 During Installation On site

Spindle/Axes Drives (if applicable)

2 During Installation On site

Programming training 2 During Installation On site

NOTE: 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.

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 furnaces/parts. This data shall be stored within the U.S. or Canada and available to the Government at its request IAW CDRL A026. The contractor shall supply a list of recommended spare furnace parts (e.g. belts, filters, gaskets, fluids, and wear items) IAW CDRL

A027. Watervliet Arsenal recognizes that it may be hard to fulfill this requirement for major furnace 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 furnace operation or maintenance requires the use of specially designed tools, these tools shall be provided with the furnace and shall become the property of the Government.

3.24. Site Conditions: The furnace covered by this specification shall be installed in a dedicated heat treat facility, with the presence of smoke, fumes, dust, and high temperatures. As such, there will be no environmental conditioning. Temperatures will range from 65° F to 100° F and relative humidity will range from 20% or less to 95%. On any given day, the temperature in the furnace shop may change as much as 8° F per hour. These are the conditions under which the furnace 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 furnaces. 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 furnace 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 absolutely 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. Heat Shielding: Any process heating equipment shall be provided with adequate guarding and operator protection, including the appropriate clearances, in accordance with

ASME, API, OSHA, and NFPA codes for the heating processes used.

3.27. Elapsed Time Meter: The furnace shall be fitted with a meter to measure operating time of the furnace heating elements. 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 to be located in explosive, high dust, paint or heavy industrial manufacturing environments, and 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, inserts, and supports shall conform to MSS SP-58 and MSS SP-69, except as supplemented and modified herein.

E. 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.

F. 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).

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

H. For pressure above 150 psi, SCH80, pipe shall be used where threaded connections are made.

At pressure above 2000 psi, SCH 160 pipe shall be used where threaded connections are made.

I. Joints in piping system shall comply with ASME B31.3 to include the use of welded fittings.

Gaskets and sealants shall also comply with ASME B31.3.

J. 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.

4. Furnace Installation and Startup:

4.1. Work Performed by the Arsenal:

4.1.1. Site Designation: Upon receipt of the required installation and foundation drawings (see section 3.20), IAW CDRL A013, 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 furnace 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 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 free from any defect materially affecting appearance or serviceability 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 or platform is constructed, the contractor or their designated third party shall layout the machine. Please note that the majority of the Watervliet Arsenal’s shop floor is covered with 2.5” thick wood block. The contractor shall be responsible for the removal of wood block flooring and existing concrete preparation. Contractor shall also be responsible for securing wood block flooring and install any leveling pads necessary for installation.

4.2.2. Site Visit: A site visit to the Watervliet Arsenal is highly encouraged. The purpose of the visit is to observe how the process and use of the machine is currently at the Arsenal, so that the machine can 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 IAW CDRL A028.

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. Ensure full compliance with OSHA (CFR 1926) regulations as applicable as well as any other applicable regulation and

Federal.

4.2.4. Installation: Once the furnace is positioned and rough leveled by the contractor, the contractor, through his own service personnel, shall be fully responsible for the startup and testing of the machine, conducting any acceptance tests specified, and performing the required onsite training. The contractor shall provide competent, English speaking service personnel to install the machine, rough and finish level the machine, startup, and conduct the acceptance tests.

The contractor and the service personnel shall remain until the machine activation and testing have been successfully completed. Under no circumstances shall the contractor plan on Arsenal assistance for diagnosis, troubleshooting or repair of the equipment during activation and testing.

If the contractor chooses to request Arsenal assistance in lieu of providing their own resources, the request will be reviewed by the Watervliet Government Representative who shall reserve the right to impose a charge for the assistance. Approvals, even on a charge basis, shall not be taken for granted since there is no guarantee that appropriate Arsenal personnel will be readily available. In such cases, the Arsenal will not be held responsible for delays in acceptance of the equipment resulting from non-availability of Arsenal personnel or Arsenal furnished equipment.

If the contractor requests Watervliet Arsenal to ship miscellaneous material via UPS, FedEx or by other similar carrier then the contractor shall provide their carrier account number for this purpose.

NOTE: Under normal circumstances the contractor will be allowed to work as long as is desired during normal work days. Contractor work outside Watervliet’s normal work days cannot be guaranteed. Watervliet is on a condensed work schedule. Normal work hours/days for this schedule are four 9-hour workdays (Friday off) one week and four 9-hour days, one 8-hour day

(Friday) the following week. Contractor work on the Friday off and weekends cannot be guaranteed. Contractor’s classified as foreign nationals may further restrict work hours and days available.

4.3. Project Safety: Throughout the duration of the project, the contractor must maintain a safe working environment for both the contractor’s and WVA’s personnel. This shall include, but not limited to, sections 4.3.1 and 4.3.2.

4.3.1. Safety Fencing: If applicable, the contractor shall provide temporary safety fencing around the work area within five (5) business days of work beginning at the Arsenal.

The contractor shall maintain the safety fencing for the duration of the contract work and remove the safety…