Attachment 0001 - RIPD E4000-24-3-14 .pdf

ROCK ISLAND ARSENAL RIPD: E4000-24-3-14

PURCHASE DESCRIPTION DATE: 28-SEPT-23

RIPD E4000-24-3-14 DEEP HOLE DRILLING MACHINE (GUN DRILL)

1. GENERAL SYSTEM DESCRIPTION

2. STANDARDS AND PUBLICATIONS

2.1 Clarification

2.2 National Standards and Specifications

3. DESIGN

3.1 Ownership

3.2 General Design Standards

3.3 Safety, Security and Environmental

3.4 Responsibilities

4. COMPONENT SPECIFICATION

4.1 Dimensions:

4.2 Construction:

4.3 Capacities:

4.4 Control

5. INFORMATION TECHNOLOGY SYSTEMS AND SUPPORT

5.1 Installation IT Support:

5.2 INSPECTION/FINAL ACCEPTANCE:

5.3 Media/ Devices

5.3 INFORMATION ASSURANCE AND ACCREDITATION:

6. APPROVAL/SHIPPING

6.1 Shipping

6.2 Installation

6.3 Completion

7. TRAINING

7.1 Schedule

7.2 Location

7.3 Type

8. SERVICE

8.1 Service/Support Requirements

1. GENERAL SYSTEM DESCRIPTION

This project is to procure a deep hole drilling machine. A drilling machine is considered a deep hole drilling machine by its depth- to- diameter ratio where the length of the drilling operation exceeds the diameter by up to 100-200 times. Deep hole drills allow for smooth manufacturing process with adequate chip removal while maintaining accuracy and surface finish. In addition to being a deep hole drilling machine, the machine shall be capable of utilizing Gun Drill tooling in order to perform gun drill drilling processes. The contractor is responsible for the provision and installation of the deep hole drilling machine as well as any additional auxiliary equipment necessary to create a “turn-key” solution. The contractor is responsible for all necessary materials/ consumables/ and equipment needed to provide start-up for the equipment.

2. STANDARDS AND PUBLICATIONS

2.1 Clarification

Any ambiguities, questions, requests for clarification or discrepancies between sections of this purchase description, drawings, national or industry standards discovered by the contractor in reviewing this purchase description shall be reported by the bidder in writing to the contracting officer BEFORE THE DATE SCHEDULED FOR CLOSE OF BIDDING/receipt of proposal.

Submission of a proposal or bid shall be construed as evidence that such examination has been made. Therefore, later claims for labor, material, or equipment required, or for difficulties encountered, which could have been foreseen had such reasonable examination been made, may be denied.

2.2 National Standards and Specifications

The following specifications in effect on the Date of Invitation for Bid/Request for Proposal form a part of this purchase description. In the case of conflicting requirements, the more stringent shall apply.

2.2.1 Occupational Safety and Health Act of 1970 (OSHA).

2.2.2 American Society of Testing and Materials (ASTM).

2.2.3 American Society of Mechanical Engineers (ASME).

2.2.4 American National Standards Institute (ANSI).

2.2.5 National Electrical Manufacturers Association Standards (NEMA).

2.2.6 Electronic Industries Association (EIA).

2.2.7 Institute of Electrical and Electronics Engineers (IEEE).

2.2.8 American Code for Information Exchange (ASCII).

2.2.9 American Welding Society (AWS).

2.2.10 American Gear Manufacturers Association (AGMA).

2.2.11 National Fire Protection Association (NFPA).

2.2.11.1 NFPA-70 National Electrical Code

2.2.11.2 NFPA-79 Electrical Standard for Industrial Machinery.

2.2.12 International Standards Organization (ISO).

3. DESIGN

3.1 Ownership

3.1.1 This equipment is a standard product of the manufacturer and shall require either no change or minor design changes to meet requirements of these specifications. Therefore, ownership of the design will remain with the manufacturer.

3.2 General Design Standards

3.2.1 DEVIATION FROM PRODUCT: Modifications to the manufacturer’s standard design to achieve requirements as specified in this document are only permissible as dictated by good design practice. For example, mounting a 20-hp motor in a power train designed and normally using a 10-hp motor would not be acceptable.

3.2.2 UNITS OF MEASURE: Dimensions and capacities in this purchase description are given in the English-US (in-lb) system. All dials, gauges, and drawings shall be in the English-

US system or both the English-US and the metric systems, unless otherwise specified in this document.

3.2.3 ID DATA PLATE: The equipment shall include a main data plate which will include the following data as a minimum requirement (additional information is acceptable):

Manufacturer Name, Manufacturer’s Dunns and Bradstreet Number, Manufacturer’s Model

Number, Manufacturer’s Serial Number, Year of Manufacture, Contract Number, Machine

Weight. This information is necessary for compliance with the governments Unique

Identification Program (UID).

3.2.4 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.

3.2.5 ITEM UNIQUE IDENTIFICATION (IUID) REGISTRATION: The contractor shall register the equipment in the IUID Registry (as one single system). IUID registration requires the contractor to input Cage Code, Model Number, and Serial Number into a Government

Database to allow for asset and inventory tracking. IUID Registry of the equipment shall be performed at http://dodprocurementtoolbox.com/site/uidregistry/. Training for IUID is available in https://wawftraining.eb.mil. IUID registration of this equipment is required prior to final payment in the Wide Area Work Flow (WAWF). The contractor shall also affix a machine readable 2-dimensional (2-D) matrix representing the IUID registry to the machine. The IUID

2-D matrix may be included on the ID Data Plate outlined in paragraph 3.2.4.

3.2.6 UTILITY CONNECTION: Equipment supplied to the Rock Island Arsenal will have single point shut-off for each utility supplied to a system. This means that equipment constituting a single system shall be wired to a single main electrical disconnect point, plumbed to a single pneumatic shut-off valve, etc… This will be referred to as the “point of first connection”. Each type of power source may have only one point of first connection. E.g. (1) http://dodprocurementtoolbox.com/site/uidregistry/ https://wawftraining.eb.mil/ pneumatic shut-off valve, (1) water supply shut-off valve, (1) electrical disconnect, etc… Each point of first connection shall be clearly labeled on the system and shown in the safety lockout portion of the documentation package. These points must be located on a stationary component and positioned such that they will not create a hazard to personnel during normal operation of the system. The first connection points shall be accessible from the shop floor without the use of ladders, steps, or stools. Access cannot be hampered by operation of the system.

3.2.7 UTILITY CONNECTION LABOR: Rock Island Arsenal shall provide only such labor and materials as will be needed to connect facility utilities to each point of first connection of the system. The supplier will be responsible for all connections beyond the point of first connection for each utility.

3.2.8 UTILITIES AVAILABLE: Rock Island Arsenal shall be responsible for providing the following:

3.2.8.1 Connection of 460-V, 60-Hz, 3-Ph AC electrical power to the fused or breaker type disconnect switch required in the ELECTRICAL DISCONNECT paragraph of this purchase description. Connection does not include filters, surge protection, or any peripheral equipment necessary to make the equipment functional.

3.2.8.2 Connection of approximately 80-psi compressed air to a single point for each system, if needed. Connection does not include filters, dryers, or any peripheral equipment necessary to make the equipment functional.

3.2.8.3 Connection of approximately 65-psi water to a single point for each system, if needed. Connection does not include filters or any peripheral equipment necessary to make the equipment functional. If water is required, the contractor shall be responsible for installing a back-flow limiting device sufficient to prevent possible contamination of the water system. This is necessary to maintain IEPA compliance.

3.2.8.4 Connection of 1.5-in diameter natural gas pipe to a single point for each system, if needed. Connection does not include filters or any peripheral equipment necessary to make the equipment functional.

3.2.8.5 If, due to contractor caused problems, the equipment or components of the equipment must be moved or removed and replaced, by RIA after initial placement, the contractor shall be billed for such work at current RIA labor and overhead rates.

3.2.9 ELECTRICAL DISCONNECT: The equipment shall be equipped with a manual, fused or breaker type disconnect switch, readily accessible to the operator, which will deactivate the entire equipment. It shall be located no more than 6-ft 7-in from the floor to the highest point the control device. It shall be capable of being locked in the de-energized state (OFF) only.

3.2.10 CONDUIT: Flexible conduit is not permitted in exposed areas. All wires, cables, and hoses will be enclosed by rigid, oil-proof protection, except where flexibility is necessary for operation of the equipment. Flexible wires, cables and hoses shall be arranged to prevent draping or tripping hazards.

3.2.11 SERVICE ACCESS: Components subject to periodic adjustment, replacement, or servicing shall be readily accessible. Meaning that experienced personnel can access the part after no more than 30-min of labor. If any special tools or equipment are necessary to access these components, said equipment will be supplied as part of the system and provided with a proper storage location within the system.

3.2.12 DEFLECTION: The system shall recover from distortion and deflection at no load. The machine and its components shall be sufficiently rigid that work piece finish and tolerances are not impaired by machine vibration.

3.2.13 NEW EQUIPMENT: The equipment furnished under this purchase description shall be new and unused.

3.2.14 COMPONENT ENVIRONMENT: Under no circumstances shall a component be used in an application not recommended by the component manufacturer. Components shall not be subjected to conditions of operation beyond the recommendations of the manufacturer, such as excessive heat, lack of lubrication, over-loading.

3.2.15 REPLACEMENT COMPONENTS: All replaceable components shall be manufactured to definite standards for tolerance, clearance, and finish, enabling components to be field installed without further machining.

3.2.16 CASTINGS AND FORGINGS: All castings and forgings shall be free of defects, scale, and mismatching. No process such as welding, peening, plugging, or filling shall be used for reclaiming any defective part for use in this equipment without the prior written consent of the contracting officer.

3.2.17 SURFACE BUILDING AND COATINGS: Welding, brazing, soldering, coating or plating shall be employed only where specified in the original design. These operations may not be employed as a means of reclaiming a defective part.

3.2.18 FASTENING DEVICES: All screws, pins, bolts, and similar parts shall be installed in such a manner as to prevent change in tightness. Those devices subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently deformed. They shall not be installed using permanent bonding adhesives.

3.2.19 CLEANING AND DEBURRING: All surfaces of castings, forgings, molded parts, stampings, and welded components shall be cleaned and free from sand, dirt, fins, flash, scale, flux, and other harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. Except as specified herein, the condition and finish of all surfaces shall be commensurate with the manufacturer’s commercial practice.

3.2.20 PAINTING: All unfinished surfaces of the equipment shall be painted with a lead free and chromium free commercial grade of metal primer and a minimum of one finish coat. The color shall be in accordance with the manufacturer’s standard commercial practice, or as necessary to maintain compliance with OSHA regulations, as applicable.

3.2.21 LUBRICATION: Components specified as requiring lubrication by the original manufacturer shall have an appropriate means of providing said lubrication included in the design of the machine.

3.2.21.1 The lubrication points will be labeled on the lubrication drawing provided as part of the maintenance documentation and will also be labeled on the machine at the lubrication point and on any access panel covering the lubrication point. These labels will include as a minimum standard, the specific type of lubricant, the quantity to be used, the frequency for change, and the maintenance manual reference for detailed instructions. The lettering shall be

English and the units shall be English standard (i.e. pints, quarts, and gallons)

3.2.21.2 If an automatic circulation system is used, it shall be complete, including, but not limited to the following: reservoir, valves, nozzles, filters, pumps, sight gages, and other components as necessary to make the system completely functional.

3.2.21.2.1 A system allowing blockages or inadequacies to go undetected is unacceptable. The system shall be interlocked to the machine control, providing an alarm that lubrication failure has occurred. The system shall not initiate immediate shutdown of the affected function during a cutting cycle. It shall allow completion of the cycle and shutdown in an orderly sequence.

3.2.21.2.2 The reservoir shall be sized to allow no less than 80-hrs of machine run time before requiring refill. It shall also have a means provided for draining and cleaning. A means shall be provided to enable the operator to determine the fluid level.

3.2.21.2.3 All filters shall be either cleanable or replaceable.

3.2.21.2.4 All pumps shall be self-priming.

3.2.22 FILTRATION/REGULATION: Equipment requiring filtered or regulated energy sources shall be supplied with the components necessary to perform this function. E.g. the equipment shall be supplied with a Filter, Regulator, Lubricator (FRL) device, if filtered, lubricated, regulated pressurized air is required for the efficient, proper operation of the equipment. These devices shall be located on the equipment side of the lockout devices at the points of first connections.

3.2.22.1 Equipment which requires compressed air 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, and capable of supplying air to the rated standard cubic feet per minute (SCFM) of the equipment. The unit shall purge condensate automatically. In the case of the latter, the refrigerant used shall not be a Class I or Class II, ozone depleting substance. The air dryer shall be connected and/or piped to the equipment by the contractor.

3.2.22.2 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.

3.2.23 HYDRAULICS: The machine will be equipped with a hydraulic system and the system shall be complete with, but not limited to, pump, valves, piping, cylinders, pressure controls, filter, and reservoir. All components necessary to make the system completely functional shall be provided.

3.2.23.1 If the duty cycle of the system under maximum usage will cause the hydraulic fluid to exceed 120°F in temperature, a suitable air-cooled heat exchanger shall be provided to maintain fluid temperature at or below that temperature. The exchanger shall be equipped with changeable fiberglass filter(s), unless permanent type filters are supplied.

3.2.23.2 The system shall have adequate capacity to provide sufficient pressure and flow to perform all hydraulic operations under all normal machine operating conditions.

3.2.23.3 Protection shall be provided to prevent damage to components.

3.2.23.4 Safeguards shall be provided to alert the operator of temperatures and pressures above/below design limits. If safe limits (within design limits) are exceeded, the system shall automatically shut down.

3.2.23.5 Anti-surge devices or circuits shall be incorporated to ensure uniformity of motion under varying loads.

3.2.23.6 The hydraulic reservoir shall be provided with means for draining and cleaning.

3.2.23.7 Means shall be provided to enable the operator to determine fluid level.

3.2.23.8 Each hydraulic system shall include a filter, which shall be either cleanable or replaceable.

3.2.23.9 All pumps shall be self-priming.

3.2.24 COOLANT: The machine will be equipped with a coolant system and it shall be equipped with external flood coolant capabilities, as a minimum. Machines using cutting tools shall be equipped with both through the tool and external flood coolant capabilities. Coolant on/off shall be a machine control function.

3.2.24.1 The coolant systems shall include all necessary components necessary to provide completely functional systems, with sufficient capacity to give satisfactory service and provide adequate pressure and flow under normal operating conditions.

3.2.24.2 Coolant troughs and chip screens shall be provided around the machine table base to trap, direct, and return the coolant to the reservoir. An easily removable strainer shall be provided in the return line to the reservoir. "Easily removable" is defined as being removable after no more than 5-min of work by experienced personnel.

3.2.24.3 All machine coolant systems and their components shall provide drip-proof coolant delivery to the coolant point of discharge. In addition, the machine shall be designed and constructed to prevent coolant from escaping the confines of the machine or leaking to the floor when producing work-pieces of a size within the dimensions of the machine table.

3.2.25 CHIP REMOVAL: A chip conveyor is required and it shall be an automatic, reversible chip removal unit shall be provided, by the contractor, capable of conveying various types of ferrous and nonferrous chips from the entire work area of the machine to a suitable container outside of the machine without manual aid.

3.2.25.1 The unit shall be of watertight construction.

3.2.25.2 The conveyor belt shall be equipped with a master link, easily disconnected, allowing the belt to be removed for maintenance purposes. All pillow block bearings shall be mounted for ease of replacement. Pillow block bearings shall be fitted with external lubrication fittings. The system shall allow manual movement of the conveyor belt for maintenance.

3.2.25.3 The conveyor shall facilitate draining of excess coolant back to the sump before chips are discharged.

3.2.25.4 The height of the discharge chute from the floor shall be not less than 49.5-in.

3.2.25.5 The chip removal unit shall be installed in a manner facilitating collection of chips from the entire work area without interfering with normal operation of the machine.

3.2.25.6 As a minimum, the chip removal unit shall be provided with an on/off switch or buttons, stop button, and reversing switch.

3.2.25.7 The machine shall be equipped with a wash-down hose and nozzle assembly with sufficient reach to wash chips from the entire inside of the work area.

3.2.26 MOTORS:

3.2.26.1 All motors shall be rated for continuous duty.

3.2.26.2 Motors shall not operate in an overload condition during normal operation of the equipment and shall be equipped with overload protection.

3.2.26.3 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.

3.2.26.4 Motor starters and controls shall operate at no greater than 120-VAC. It is preferred that they operate at 24-VDC.

3.2.26.5 Motor starters shall provide drop-out protection. This means that, in the event of a loss of power, the equipment shall be re-energized only by the deliberate action of the operator. Manual or mechanical motor starters shall not be deemed acceptable.

3.2.27 DIALS AND GAUGES: All scales, dials, and gauges shall be manufactured of corrosion and oil resistant material. All wording shall be in the English language using plain, bold face lettering. Lettering shall be permanent and have a contrasting background.

3.2.28 HANDWHEELS: Hand-wheels turned in a clockwise rotation shall produce a linear motion, of the controlled component, to the right, away, or upwards. If rotary motion is produced by the hand-wheel, clockwise rotation of the hand-wheel shall produce clockwise movement of the controlled component.

3.2.29 CONTROL LEVERS: Control levers shall move in the same direction as the motion of the controlled component.

3.2.30 FOUNDATION: The requirement for a separate foundation or floor alteration is not permissible. The system shall be capable of being installed on an existing concrete floor without modification to the system or the floor, except for installation of anchor bolts.

3.3 Safety, Security and Environmental

3.3.1 SECURITY: The RIA-JMTC is an Army installation subject to Department of Defense safeguards, various precautions, and plant protection measures. All of the below requirements will be necessary of contractors visiting RIA to satisfy requirements of this purchase description; Additional requirements will be placed on contractors requiring access to the Army

Network, or Common Access Card (CAC), as specifically detailed below. At all times during the execution of this work, contractor personnel will maintain adequate plant protection devises to minimize espionage, sabotage, and other malicious destruction and damage. The contractor shall comply with all security requirements of the Rock Island Arsenal. Rock Island Arsenal island-wide Force Protection levels may be adjusted/changed at any time, which may cause possible delays and will directly affect procedures for accessing the island.

3.3.1.1 Access and General Protection/Security Policy and Procedures: The contractor and any associated subcontractor employees shall provide all information required for background checks to meet installation access requirements to be accomplished by the installation Director of Emergency Services. All contractor employees must comply with all personal identity verification requirements (IAW FAR clause 52.204-9) as directed by

Department of Defense (DoD), Headquarters Department of the Army (HQDA), and any local policy. If the Force Protection Condition (FPCON) changes, the Government may require changes in contractor installation access, security matters, or security processes.

3.3.1.1.1 Access to RIA: Contractor and all subcontractor employees performing work at

RIA shall comply with adjudication standards and procedures using the National Crime

Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening

Database (TSDB) and any applicable installation, facility access screening and local security policies and procedures. The JMTC Representative shall provide guidance to complete the Access Control Records Check request Form though the Rock Island

Arsenal Directorate of Emergency Services.

3.3.1.1.2 Random Antiterrorist Measures Program (RAMP) participation: Contractor personnel are subject to RAMP security program (i.e. vehicle searches, wearing of ID badges, etc.). Contractor shall comply with any, and all instructions issued by the Rock

Island Arsenal Police Department. The RAMP is discussed in the RIA-JMTC Anti-

Terrorism Training.

3.3.1.1.3 During FPCONs levels of Charlie or Delta, services may be discontinued/postponed due to a higher National or local security threat. Services will resume when FPCON Level is reduced to Bravo, or lower. FPCON levels are described in Anti-Terrorism Level I Training.

3.3.1.1.4 Contractor personnel shall return all Installation Badges and access passes as soon as possible prior to contract completion. RIA-JMTC electronic keys and access passes are accountable items, shad shall be returned within 24-hours of no longer being needed. Items will be returned to the JMTC Representative, or paced in a drop box at a

RIA-JMTC access point.

3.3.1.2 Security Training: The contractor shall complete the following training:

3.3.1.2.1 Anti-Terrorism, Level I: All contractor employees, including subcontractor employees, requiring access to Army installations, facilities, or controlled access areas shall complete Anti-Terrorism (AT) Level I Awareness training. The JMTC

Representative will be provided a copy of the Rock Island Arsenal –Joint Manufacturing and Technology Center (RIA-JMTC) AT Level I Awareness Training and assure that the training is complete. The contractor shall sign a memorandum of record for each contractor employees and subcontractor employee to the RIA-JMTC Operations Center prior issuing any electronic keys, or access pass being authorized.

3.3.1.2.2 iWatch (See Something, Say Something) Training: The Contractor and all associated subcontractors shall complete iWatch Training. iWatch Training shall be provided during the Anti-Terrorism Training.

3.3.1.3 For Contractors requiring Common Access Card (CAC): Before CAC issuance, the contractor employee requires a favorably adjudicated National Agency Check with Inquiries

(NACI) or an equivalent or higher investigation in accordance with Army Directive 2014-05.

The contractor employee will be issued a CAC only if duties involve one of the following:

(1) Both physical access to a DoD facility and access, via logon, to DoD networks onsite, or remotely or (2) Remote access via logon, to a DoD network using DoD-approved remote access procedures, or (3) Physical access to multiple DoD facilities or multiple Non-DoD

Federally controlled facilities on behalf of the DoD on a recurring basis for a period of 6-months, or more. At the discretion of the sponsoring activity, an initial CAC may be issued based on a favorable review of the FBI fingerprint check and a successfully scheduled NACI at the Office of Personnel Management. Contractors needing a NACI or equivalent investigation or higher investigation will coordinate this investigation through their JMTC

Representative. Contractor personnel shall turn in CAC cards upon completion of their contractual obligations, or at the request by the JMTC Representative, or at the request of the

Contracting Officer.

3.3.2 FEDERAL MARIJUANA LAWS REMAIN UNCHANGED: Note: Rock Island

Arsenal is under the exclusive federal jurisdiction of the United States. Under federal law, marijuana is still defined as a Schedule I drug, and possession and use of marijuana is still illegal. Any person using or in possession of marijuana on Rock Island Arsenal may be criminally prosecuted in federal district court. In addition, such individuals may be permanently barred from entering Rock Island Arsenal.

3.3.3 REAL ID: Starting 03-May-2023 all personnel entering Rock Island Arsenal will be required to show a Real ID form of identification.

3.3.4 FIRE PREVENTION AND PROTECTION: The contractor shall comply with all fire prevention measures prescribed in the installation Fire Regulations, a copy of which is on file in the office of the Contracting Officer. A written fire permit shall be obtained from the installation

Fire Marshall for use of open flame devices, such as torches, portable furnaces, tar kettles, or gas and electric welding and cutting equipment, in, on, or within 15-ft of the building. The contractor shall be liable for any fire loss to the Government properly attributable to negligence on the part of the contractor, including failure to comp1y with fire prevention measure described by the terms of this purchase description.

3.3.5 INDUSTRY AND REGULATIONS: The equipment shall comply with the most current of all local, state, and federal laws and regulations listed in Standards and Publications.

3.3.6 MATERIAL EXCLUSIONS: The equipment shall not contain polychlorinated biphenyl

(PCB), ozone depleting substances (Class I or Class II), or asbestos materials.

3.3.7 SAFETY REGULATION COMPLIANCE: The contractor shall comply with standard

OSHA and RIA safety standards, including conforming to confined space work requirements when applicable.

3.3.8 SAFETY LOCKOUTS: Each point of first connection shall be designed and constructed to allow the utility to be completely isolated from the equipment. This isolation shall be insured by application of a standard key locking padlock. The device(s) shall only be lockable in the de-energized (OFF) condition.

3.3.9 LOSS OF PRESSURE: Hydraulic and pneumatic circuits shall be designed such that loss of pressure, or pressure surges, shall not cause a hazard. Means shall be provided to prevent operation of the equipment with insufficient pressure, if such operation could cause a hazard.

3.3.10 TRAPPED ENERGY: Means shall be provided for the controlled release of stored energy. This energy may be in the form of, but not limited to, air and hydraulic pressure accumulators, capacitors, springs, counter balances and flywheels. When appropriate, a label shall be affixed to the stored energy source to identify the hazard.

3.3.11 WORKING RANGE: Hydraulic and pneumatic components shall be selected, which cannot be adjusted outside the safe working range of the circuit and/or equipment.

3.3.12 ACCUMULATORS: Gas charged accumulators operating above 200-psi charging pressure shall be charged with inert gas.

3.3.13 BRAKES: Braking systems shall be designed to “fail-on”. This means, energy supplied to the brake shall be used to disengage the brake. Loss of energy shall therefore cause the brake to activate.

3.3.14 EMERGENCY STOP: The system will incorporate a clearly identified, red, mushroomed, control button with a yellow backing plate at every operator work station. Upon momentary operation, any emergency stop button shall de-energize all machine motions and override all other controls without creating additional hazards. All motion stopped shall be restarted by the deliberate action of the operator (requiring manual reset). No other red mushroomed buttons shall be allowed on the equipment. It is preferred that there is no other red buttons of any type.

3.3.15 CONTROL GUARDS: Controls shall be guarded against accidental operation.

3.3.16 OPERATOR REACH: Controls shall be within reach and located such that the operator, when in the normal operating position, is not required to reach past moving parts, which may cause injury.

3.3.17 AUDIBLE NOISE: The equipment noise level during normal operation shall not exceed

85-dbs, “A” scale. Tests shall be conducted around the entire equipment 60-in to 65-in above the floor within 3-ft of any major sound source. Metal removal equipment shall comply with the standard noise requirement while making a midrange horsepower cut on rigidly clamped mild steel. The contractor shall furnish shields, baffles, enclosures, or other devices necessary to bring the equipment into conformance. Any such device shall not interfere with the proper operation of the equipment and shall be designed to preserve the visibility necessary for safe operation of the system.

3.4 Responsibilities

3.4.1 SITE INSPECTION: Any site inspections and/or measurements, which must be taken in order to determine the suitability of the proposed location or to perform the design of the system, are the sole responsibility of the contractor. This may begin prior to completing the bidding process. Rock Island Arsenal will support this function through the POC (point of contact) by guiding personnel, facilitating security registration, and providing general assistance. The contractor will be responsible for providing any and all equipment necessary for this process.

3.4.2 SITE CONDITIONS: Rock Island Arsenal will be responsible for additional costs incurred by unforeseen, but controllable manmade issues with the location of the system.

Examples would include, but are not limited to, buried sewer lines, standing water, and so forth.

The contractor will be responsible for all costs associated with correcting foreseeable conditions, including but not limited to low hanging electrical lines which are clearly visible, encountering rock during excavation, inclement weather, interference with established machines or structures by components not shown on the footprint drawing, etc.

4. COMPONENT SPECIFICATION

Equipment: The supplier shall furnish all equipment normally considered by him to be standard for his machine unless identified in this requirement to be of specific manufacture. The following equipment shall be provided in addition to the equipment specified in other sections of this purchase description, which may not be standard. The inclusion of standard equipment in this paragraph is inadvertent and should not be construed to allow duplication. The equipment shall be a Computer

Numeric Control (CNC) deep hole boring machine with gun drill capabilities. The machine shall be a unisig, Model UNI-50-1500 or equivalent. The general components of the base machine shall consist of, but not be limited to, bed, main headstock, boring saddle, oil pressure heads, tool/boring headstock, CNC control, electrical cabinet, coolant reservoir and chip removal conveyor, coolant-filter and chiller, boring bar guides, work piece steady rests, and leveling squares. The contractor shall be responsible for the provision and installation of the equipment capable of three different configurations as follows:

- Rotating Work-piece – Stationary Tool

- Stationary Work-piece – Rotating Tool

- Rotating Work-piece – Counter-rotating tool

4.1 Dimensions:

4.1.1 DOOR ACCESS: The equipment shall be shipped either assembled or disassembled to pass through a door 12-ft wide by 12-ft high.

4.1.2 COMPONENT WEIGHT: The maximum weight of any one piece shall not exceed

25,000-lbs.

4.1.3 INSTALLED FLOORSPACE: When installed complete, the equipment shall be contained in an area 12-ft wide and 30-ft long, excluding the operator’s area. Maximum height shall not exceed 6.5-ft. Width is defined as front to back from the operator’s normal operating position.

4.2 Construction:

4.2.1 MOUNTING: The bed/base may be anchored to RIAs foundation using a chemical anchoring system. (Can type anchoring shall not be considered acceptable.). The contractor is responsible for all core drilling and labor.

4.2.2 HARDWARE: All necessary leveling wedges, foundation studs/bolts, nuts, chemical adhesives and foundation hardware required for the installation shall be furnished by the contractor.

4.2.3 AXIS DEFINITION: This shall be a horizontal centerline rotational axis machine with the cutting tool aligned in the same lineal path as the work-piece. The path of the cutter is fed down the center of the work-piece to a depth defined as the Z-axis. The Main Headstock (S1) is the machine stationary and rotational capable spindle with an installed chuck holding the work-piece. The tooling/boring headstock (S2) is a stationary and counter-rotational capable spindle opposing the main headstock, which holds the boring bar and part cutter, and can also move toward and away from the Main Headstock, S1 (along the Z-Axis).

4.2.4 MACHINE BED: The machine bed shall be made of Cast Iron (or equivalent) of sufficient weight and rigidity to machine the sizable work-pieces specified herein. Construction shall be ribbed or boxed sufficiently to dampen vibrations and increase overall stability of the machine. The sideways shall be hardened to a Rockwell Hardness C Scale value of 50, and precision ground.

4.2.5 MACHINE GUARDING: Covers, guards, or other safety devices shall be provided for all parts of equipment that present safety hazards. Safety devices shall not interfere with operation of the equipment. The devices shall prevent unintentional contact with the guarded part and shall be removable to facilitate inspection, maintenance and repair of the parts.

Machine parts, components, mechanisms, and assemblies furnished on the unit shall comply with all specific requirements of "OSHA Safety and Health Standards (29 CFR 1910), General

Industry" that are applicable to the equipment itself. Additional safety and health requirements shall be as specified in other paragraphs of this specification.

4.2.6 MAIN HEADSTOCK (S1): The main headstock shall hold the workpiece, and come equipped with a 3 jaw chuck. From the operator position, it will be located on the left end of the machine bed.

4.2.6.1 Horsepower: The main headstock spindle shall be variable speed, with capability of at least 27-horsepower continuous duty. All spindle drive shafts and gearing shall be of steel or steel alloy, and ground.

4.2.6.2 Rotational Speed and Torque: The spindle shall be capable of infinitely variable speeds of from 0-revolutions per minute (rpm), and as fast as 2200-rpm.

4.2.6.3 Spindle Nose: The main headstock spindle nose shall be hardened to a minimum of

60 Rockwell C and ground. The mounting shall be at least an ISO A2-15 spindle nose.

4.2.6.4 Capacities: The Gundrill/ BTA machine shall have the following capacities.

4.2.6.4.1 Maximum Swing Over Bed shall be at least 11.8-inches.

4.2.6.4.2 Chuck Clamping Diameter Range: The headstock shall be provided with a 3-jaw chuck. The headstock chuck shall be capable of clamping parts of up to 8in.

4.2.6.4.3 Weight carrying capacity of the main headstock spindle will be at least 570lbs pounds.

4.2.6.4.4 Weight of work-piece allowed between headstock and steady rests will be at least 1700lbs (maximum weight of workpiece in chuck, plus 570 pounds/steady rest).

4.2.6.4.5 Range of Speeds: The machine will have as a minimum range between 0-3000 revolutions per minute (rpm)

4.2.6.4.6 Driving Power for the main headstock will be at least 27 horsepower.

4.2.6.4.7 Spindle through hole will be at least 1.2-inches.

4.2.6.4.8 Diameter capacity of 3-jaw chuck shall be at least 8in.

4.2.7 TOOLING/BORING HEADSTOCK (S2): The tooling/boring headstock shall be located on the right end of the bed.

4.2.7.1 The tooling/boring headstock will have a range of spindle speeds at constant power of at least 0 through 3,000 rpm.

4.2.7.2 The tooling/boring headstock may have up to 3 speed ranges.

4.2.7.3 The tooling/boring headstock will have driving power of at least 38 horsepower.

4.2.7.4 The tooling/boring headstock will have a spindle hole through hole of at least 1.2-inches.

4.2.7.5 Solid Boring (with rotational work piece and counter-rotating tool): The machine will have a range to solid bore at minimum between 0.35in up to 2in.

4.2.7.6 Counter-boring: The provided and installed deep hole boring machine will have the capability to counter bore though at least up to 2.5in

4.2.7.7 Contractor shall provide tool spindle bar stops and gripper bushings/drill tube drivers needed adapt RIA boring bars to the proposed machine for the machine’s specified solid boring/counter boring range.

4.2.8 COOLANT PUMPING, COOLANT RESERVOIR, CHIP REMOVAL, COOLANT

FILTRATION SYSTEM: The contractor shall provide and install an integrated coolant reservoir, chip removal and filtration system for the deep hole boring machine. The coolant system shall include a pressure pumping system (minimum 30 horsepower pump) capable of at least flow rates up to 53 gpm, gross chip removal/straining system, a magnetic drum filter and a paper filter system for removing contaminants to 10 microns (.00039-in) in size, or less. The coolant separation system/chip conveyor shall be capable of stopping, and reversing while the machine is operating. The coolant circulation system shall have a fluid capacity of at least 700 gallons, and pressure capacity up to at least 700 pounds per square inch (psi) but up to at least

1,400 pounds per square inch (psi) when performing Gun Drill operations. The flow rate shall be programmable

4.2.8.1 The machine will also include a coolant chiller to control coolant temperature, capable of maintaining the coolant temperature between 50 and 95 degrees Fahrenheit with digital temperature control.

4.2.8.2 A hinged style belt chip conveyor shall be included with the equipment for chip evacuation.

4.2.8.3 The contractor shall provide enough coolant with the machine in order to begin operation for start up and run-off testing.

4.2.9 AIR PURGE: The system shall be designed to include an air purge feature at the spindle nose to evacuate chip nests and excess fluid.

4.2.10 BORING BAR GUIDES: If necessary for safe and accurate operation of the equipment, the system shall include all guide bars/ steady bars needed for the operations to perform.

4.2.11 PART STEADYRESTS/WORK PIECE SUPPORTS: The contractor shall provide quantity one steady rests/work-piece supports (three roller, manual) for the deep hole boring machine with a minimum diameter work-piece capacity range of at least 1-inches through 6-inches. The unit shall include hydraulic actuation and shall be removable if necessary.

4.2.11.1 The system shall include an adjustable vee support for the workpiece

4.2.12 PRESSURE HEADS/ ACCESSORIES: The contractor shall provide BTA pressure head(s) and accessories to solid bore from at least 0.5-inch through 2.0-inch diameter. The pressure head shall be provided be provided with a minimum 8-inch diameter capacity chuck.

The contractor shall provide stuffing boxes/pressure head packing glands, vibration mounting adapters, master bushings, guide bushings and centering cones/conical flanges for the machine.

4.2.12.1 Tooling, Centering Cones/Conical Flanges: The JMTC RIA currently manufactures parts with 52 different centering cones/conical flanges across three different pressure heads for RIA’s SIG _________. The contractor shall ensure that either 1) parts can be produced with RIA’s existing centering cones across the contractor’s provided pressure heads or, 2) the contractor provides new centering cones to fit their new provided pressure head(s) or, 3) the contractor provides an adapting mechanism(s) to fit RIA’s existing centering cones across the new pressure head(s) provided under this contract. Contractor shall define which alternative they will satisfy in their cost and pricing proposal. Centering cone/conical flange blueprints are available upon request from the contracting officer.

4.2.13 ALIGNMENT TOLERANCE REQUIREMENTS: Machine alignment shall conform

(and be proven out) to the following tolerances:

4.2.13.1 Main headstock radial spindle run-out (TIRr) shall be .0003-in or less.

4.2.13.2 Main headstock, axial spindle run-out (TIRa), shall be .0003-in, or less.

4.2.13.3 Boring headstock, TIRr shall be .0003-in, or less.

4.2.13.4 Boring headstock, TIRa shall be .0003-in, or less.

4.2.13.5 Z-Axis Positioning Accuracy: The deep hole boring machine shall demonstrate Z-Axis accuracy of plus or minus .003-in, or less.

4.2.13.6 Main headstock spindle parallelism to bed guideways, in vertical plane, shall be within +/-.0005-in (or less).

4.2.13.7 Main headstock spindle parallelism to bed guideways, in horizontal plane, shall be within +/-.0005-in (or less).

4.2.13.8 Boring headstock spindle parallelism to bed guideways, in vertical plane, shall be within +/-.0005-in (or less).

4.2.13.9 Boring headstock spindle parallelism to bed guideways, in horizontal plane shall be within +/-.0005-in (or less).

4.2.13.10 Pressure head housing to bed guideways:

4.2.13.10.1 Front housing vertical plane, .001-in or less.

4.2.13.10.2 Front housing horizontal plane, .001-in or less.

4.2.13.10.3 Rear housing vertical plane, .001-in or less.

4.2.13.10.4 Rear housing horizontal plane, .001-in or less.

4.2.13.11 Boring Bar guides to base guideways in vertical plane, .001-in/foot, or less.

4.2.13.12 Boring Bar guides to base guideways in horizontal plane, .001-in/foot or less.

4.2.13.13 Straightness of base guideways, .0005-in/foot or less

4.2.13.14 Flatness of base guideways, .001-in or less.

4.2.13.15 Machine positioning accuracy Z-Axis, .001-in or less.

4.2.13.16 Machine repeatability, Z-Axis + .001-in or less.

4.3 Capacities:

4.3.1 Maximum Swing Over Bed: The maximum swing over bed shall be at least 11.8in.

4.3.2 Maximum Boring Depth: The boring depth shall be at least 60in.

4.3.3 Solid Boring Range: The machine shall have the ability to bore from at least 0.5in

(smaller is acceptable) to a minimum of 2.0in.

4.3.4 Counter Boring Range: The machine shall have the ability to counter bore up to 2.5in.

4.3.5 Maximum Work-Piece Weight: The machine shall have the ability to hold a part that is at least 1700lbs with the use of a steady rest, and 1100lbs without the use of a steady rest.

4.3.6 Main Headstock Carry Weight: The machines main headstock shall be able to carry up to at least 570lbs.

4.3.7 Maximum Chuck Clamping Diameter: The machine shall have be able to clamp parts of up to 8in without the steady rest. While utilizing the steady rest, the machine shall have the capacity to clamp up to 6in.

4.3.8 ADDITIONAL ACCESSORIES:

4.3.8.1 Lantern Chuck Housing: The system shall include a lantern assembly to utilize pull bore process.

4.3.8.2 Tool Drivers: The contractor shall provide (1) set of Gundrill Drivers with the equipment. This shall include any reducers/seals necessary to utilize the drivers. The tool drivers shall cover the specified drilling ranges.

4.3.8.3 Drill Tubes: The contract shall provide (1) set of BTA Drill tubes with the equipment covering the specified drilling ranges.

4.3.8.4 Bushings: The contractor shall provide (1) set of guide bushing inserts with the equipment covering the specified drilling ranges.

4.4 Control

4.4.1 CONTROL SYSTEM: The machine control shall be a CNC programming system

(Siemans Sinomerik 840D, or equivalent). The Control Processing unit shall be provided with a color flat, minimum 12.1-inch LCD screen. The control will contain port connections: quantity

2 Ethernet 10/100 MB/seconds (RJ45), quantity 4 USB 2.0, and quantity 1 PROFIBUS/MPI interface. The machine control will be provided with a complete keyboard, and multiport interface. The machine control will control the Z working axis, and other functions including:

4.4.1.1 Tool rotation speed and feed rate

4.4.1.2 Work-piece rotation speed.

4.4.1.3 Motor load amperage

4.4.1.4 Operation and stop.

4.4.1.5 Coolant pumping pressure and coolant flow rate.

4.4.1.6 Z-Axis positioning

4.4.1.7 Distance to go

4.4.1.8 Lube oil pressure.

4.4.1.9 Filter use.

4.4.1.10 Feed Rate and spindle override

4.4.1.11 Tool Feed Force

4.4.1.12 Workpiece Torque

4.4.1.13 Tool Torque

4.4.2 MT CONNECT/ IOT (Internet of Things) CAPABLE: The machine shall include capability for system monitoring and data collection/ diagnostics.

4.4.3 CONTROL CABINET: The machine cabinet will comply with NEMA Standard 12 and shall be sealed against dust and shop environmental conditions that might adversely affect performance of the system. No outside air shall be blown through the control for cooling purposes. The control shall be equipped with an industrial type air conditioner. The control cabinet shall be a separate cabinet with a modular design, and divided into sections for power, Program Logic Controller, and auxiliary functions. The power section shall include digital drives for the main motors to provide gradual accelerations, decelerations, and braking. Other drives provided will include the servo motor controlling the longitudinal axis. The PLC shall be integrated with the machine control operating as an interface between the machine and the control unit. It shall control limit switches for all machine control axis, it shall control emergency switches for all axis, and provide a warning light for slideways lubrication.

4.4.4 DIAGNOSTIC: The control shall include a diagnostic system for monitoring the control during operation and for locating malfunctions when troubleshooting. It shall bring the machine to a controlled stop should a malfunction occur during operation. The system shall give fault data in understandable code or message form on the color display, which shall identify a problem at board level in the control and identify program errors.

4.4.5 MEMORY: The control shall be provided with a minimum of 1-gigibyte (GB) of usable part program storage.

4.4.6 FILE MANAGEMENT: CNC operational characteristics shall include providing file management of more than one part program, either within the control or auxiliary file storage device. In any case, an appropriate reader shall be supplied.

4.4.7 POWER LOSS RECOVERY: The control shall recover from power outages. Upon power resumption, the control shall automatically reload/reboot the executive and bring itself back, by operator initiation, to a state where the operator can initiate part program load and restart.

4.4.8 BACKLASH BALL SCREW/RACK AND PINION COMPENSATION: The machine shall have the capability to input offsets for ball-screw/rack and pinion compensation activated through the operator manually programming those offsets for the Z-Axis through the machine control.

4.4.9 LOAD MONITOR: The control shall display the real time loads exerted by the spindle and the axis drive motor. In the event that a load exceeds the rated capacity of the system, the machine shall automatically shut-down. The recovery procedure shall be the same as for a power interruption.

4.4.10 PROGRAMMING RESOLUTION: The machine control shall have programming resolution (the smallest increment of machine control value) of .0001-in, or less.

5. INFORMATION TECHNOLOGY SYSTEMS AND SUPPORT

5.1 Installation IT Support:

5.1.1 PERSONNEL: RIA-JMTC will not provide the technician credentials to access the workstation. Access to the workstation will be provided by the RIA-JMTC IT Support Staff escort.