Stament_of_Work_-_Intaglio_Presses.pdf

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SECTION C – DESCRIPTION/SPECIFICATION/WORK STATEMENT

C.1 SCOPE OF WORK

The Contractor shall design, fabricate, assemble/integrate, test, install, and startup two (2) Sheet– fed water-wipe multi-color indirect-inking Intaglio printing presses (Presses) capable of printing U.S. currency denominations using existing Bureau supplied materials. The Contractor shall provide materials and services to deliver, install, test, and start-up the presses and supporting equipment at the installation site within the Bureau’s Fort Worth, Texas Facility; and train Bureau personnel in the operation and maintenance of the equipment to meet the specified requirements. Options for additional presses are included. The Contractor shall furnish information, technical specification and/or samples of any other consumable materials required for the utilization of the presses.

The presses may be delivered with an in-line inspection system and data collection system included with each press.

All presses shall be ordered and installed in pairs, one to print the backs and one to print the faces. All presses shall be capable of printing the backs and the faces of all denominations. The press pair shall be installed within the same production area.

C.2 APPLICABLE DOCUMENTS

The presses and related equipment shall meet all current U. S. commercial codes and U. S.

industry standards or equally stringent foreign standards for the manufacture of this type of equipment. At a minimum, all equipment shall conform to National Electric Code, NEC, standards.

The following documents are provided as attachments. Some documents require a Non- Disclosure Agreement (NDA) prior to a copy being provided by the Contracting Officer (CO) due to documents containing proprietary information or sensitive information. Documents requiring a NDA are noted by an Asterisk (*).

Note some attachments may be redacted due to proprietary or confidential information. Request to the CO for un-redacted versions shall be considered pending review of vendors needs for information.

A. U.S. Currency Paper Specifications*

a. P: CDT5-1C, Paper, Currency, Type V b.P: CDT4-1B, Paper, Currency, Type IV

c. P: CDT1-B, Paper, Currency, Type I d.P: NDBT5A, Paper, NonDistinctive Banknote, Type V

e. P: NDBT4A, Paper, NonDistinctive Banknote, Type IV

f. P: NDBT1A, Paper, NonDistinctive Banknote, Type I g.P: S-1F, Paper, Safety with Watermark

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B. U.S. Currency Ink Specifications*

a. ICWC-1D: Magnetic Black and Regular Green Ink

b. ICWNM-1A: Non-Magnetic Black Ink with Specification Change Notice #1

c. I-METINK-1: Metallic Ink

d. ICWIR-1A: IR Green Ink with SCN3 with Specification Change Notice #3

e. I -CSI-2D: Optically Variable Ink

C. Bureau 32-Subject Intaglio Printing Plate Drawings, Drawing #3000304 D. Bureau 50-Subject Intaglio Printing Plate Drawings, Drawing #3000527 E. Bureau Sample prints of 32-Subject and 50-Subject layout of offset color bars and intaglio registration marks F. Bureau Installation Site Drawings:

a. Base Quantity Presses 1 & 2 Installation Site, Between Column P & Q on Drawing # PE-105

b. Base Quantity Presses 3 & 4 Installation Site, Between Column U & U.3 on Drawing # PE-105

c. Plating Line and Roller Covering Machines Installation Site, Drawing # PE- 100*

G. Information Technology Documents:

a. Federal Information Processing Standards

b. NIST Special Publication 800-53

c. US Government Security Baseline (USGCB)

d. Department of Justice Reference

H. BEP Stack-n-Rack Boards and Carts

a. BEP Stack-n-Rack boards

b. BEP Stack-n-Rack carts

I. Plating line chemistry for nickel and chrome tanks J. Suppressant system chemistry for nickel plating

C.3 GOVERNMENT FURNISHED MATERIALS:

The following items shall be supplied by the BEP for utilization under this contract. Any other materials required for successful performance of the contract or utilization of the press shall be specified and provided by the contractor. The contractor shall be required to provide a listing of all materials required and provide an initial supply of any items not provided by the government with the press. The initial supply shall be sufficient for the BEP to operate the press for 6 months at 3 shifts per day, 5 days per week.

A. Currency sheets: The press shall accept BEP currency sheets. The BEP presently prints currency in either 32-subject or 50-subject format. 32-subject format utilizes sheets that are

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582 ± 1 mm long by 657 ± 1 mm wide (22.91 ± 0.04 inches by 25.87 ± 0.04 inches). 32-subject sheets are printed with four notes across the sheet by eight notes down the sheet. 50-subject format utilizes sheets that are 818 ± 1 mm long by 700 ± 1 mm wide (32.20 ± 0.04 inches by 27.56 ± 0.04 inches. 50-subject sheets are printed with five notes across the sheet by ten notes down the sheet. Both sheet formats have specific color bars and alignment marks which vary by denomination. The size of the color bars, take-off bars, their relative position on the sheet and location of the registration/alignment marks are specifically optimized for each denomination. Attachment E is an example.

The specification for the substrate and skids are available after signature of the NDA with the government.

Sheets will be supplied in loads of up to a total of 20,000 sheets on two skids with each skid holding up to 10,000 sheets. The two skids are processed as one load.

The press shall be capable of printing, using the intaglio printing process, on sheet sizes ranging from a minimum of 631 mm wide by 561 mm long (24.84 x 22.08 inch) to a maximum of 820 mm wide by 700 mm long (32.28 x 27.56 inch) with an image area at least 800 mm wide by 666 mm long (31.49 x 25.98 inch).

The press shall have the capability of accommodating currency printed on a wide range of substrates, including polymers in addition to the existing substrate. The manufacturer shall specify the range of materials, including thicknesses, allowable on the press.

During the term of this contract, the size, format and/or substrate of currency sheets for specific denominations may change.

B. Printing Plates: The press shall utilize the existing BEP chrome coated electrolytic nickel printing plates for intaglio printing. The drawings of the plates shall be made available after signature of the NDA with the government.

Printing plates are 860 mm x 850 mm x 0.75 mm.

C. Inks: The press shall successfully utilize BEP inks for the application of the intaglio images onto the paper. The specification for the inks can be made available after signature of the NDA with the government.

D. Inking Plate (Chablon): The press shall utilize BEP produced photopolymer plates for selective inking of the plates. The specification and drawings of the plates can be made available after signature of the NDA with the government.

The BEP produced inking plates are 2.3 mm thick. A packing of 0.5 mm by Tschudi is used.

E. Packing and Blankets: The press shall utilize the BEP’s packing and blanket materials. The specification for the packing and blanket can be made available after signature of the NDA with the government.

• Impression Cylinder Blanket: 1100 mm x 870 mm x 0.50 mm, ITG

• Impression Cylinder Rigging Boards: One (1) 1.5 mm thick board and one (1) 0.5 mm thick boards made by Tschudi

• Inking Cylinder Blanket: 960 mm x 850 mm x 1.65 mm, ITG

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C.4 PERFORMANCE REQUIREMENTS

C.4.1 PRODUCTIVITY

A minimum of 60,000 sheets free of printing defects attributable to press operation (acceptable quality) within a 6½ hour period. The maximum printing speed shall be 10,000 impressions per hour (IPH). The press shall have an idle speed matching the minimum running speed of 2,000

IPH.

Print quality, print registration and spoilage shall be consistent over the entire press operating speed range. The press shall meet the above productivity requirements using no more than two contractor trained Bureau press operators during normal operation.

C.4.2 RELIABILITY/MAINTAINABILITY

The Mean Time Between Failure (MTBF) for any unscheduled corrective maintenance required shall average less than one (1) event per 100 hours of operation. An unscheduled corrective maintenance event is considered any time maintenance personnel must be called by the operators or when the press is unable to operate within conformance to the product, functional or performance requirements for more than fifteen (15) minutes.

The Mean Time To Repair (MTTR) for any unscheduled corrective maintenance event shall average less than three (3) hours for corrective actions to be made and the press returned to production.

The yearly average for time utilized for preventative maintenance on the press shall not exceed 3% of the operational time for the press. All Preventative Maintenance work shall be detailed within the Maintenance Manual, including all check-lists, procedures and recommendation for the time to perform.

The system shall be available for operation no less than 95% of the time with no more than 5% downtime for maintenance or repairs on the system.

C.4.3 SPOILAGE

Spoilage is any equipment error, fault or adjustment limitation that results in printing of sheets which do not meet the existing Bureau print quality standards. Spoilage attributable to the press shall be less than 1.5% of the number of sheets fed per shift.

C.5 FUNCTIONALITY REQUIREMENTS

C.5.1 FUNCTIONAL ELEMENTS

The components of the press, which are listed herein, shall be capable of printing BEP designs matching existing print quality with Government Furnished Materials while performing the following functions:

A. Feeder: The press shall be equipped with an automatic sheet feeder capable of performing the following functions:

• Accommodate a vertical pile of at least 10,000 currency sheets over the specified sheet size range on a skid.

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• Allow for the insertion of at least 10,000 currency sheet pile, including skid, from the bottom while a minimum of 2,500 sheets of the previous skid continues to be fed automatically into the press without slowing or stopping the press.

• Maintain continuous feeding of sheets by elevating the pile synchronously with the speed of the press, over the entire specified press speed range.

• Allow for the insertion of the skids with commercially available hand operated hydraulic lift trucks.

• Maintain alignment of pile edges within +/- 0.25 mm (0.010 inch).

• A transparent optical window or clear viewing area shall exist along the feed-board to enable the future scanning of informational printing along the edge of the sheets. The viewing area shall be along the operator side of the press and shall allow viewing of either side of the sheets. The viewing area shall have a width of no less than 0.5 inch (12.7 mm) from the sheet edge into the printing area and shall be at least 1.0 inch (25.4

mm) along the edge of the sheet. The window shall be adjustable for the entire range of paper sizes printable on the press.

The design features of feeder shall include the following:

• Lifting mechanism with a minimum 0.906 metric-tons (2000 pounds) load capacity.

• Access platforms, with railings, around both sides of the press and around the open end of the feeder. All access platforms, guardrails and stairs, including stair handrails, shall comply with Occupational Safety and Health Administration (OSHA) standard 29 CFR 1910, subpart D.

• In addition to the normal top and bottom stopping safeties on the pile, a second set of redundant micro-switches shall be installed to ensure that the stack stops repetitively at the appropriate height.

• The feeder side rail shall be movable on both sides, in such a way that it can be moved or lifted out of the way on a hinged mount to accommodate stacks that may have shifted or are inclined.

• The feeder shall be capable of controlling the stack height from the lead edge of the pile or the trailing edge of the feeder pile.

• The feeder shall be capable of consistently feeding all types of substrates consistently without causing misfed sheets to the infeed section.

B. Sheet Transfer: The sheet transfer mechanism shall transfer the sheets to maintain print-to-edge registration of the sheets regardless of the printing segment or operational speed of the press, over the entire specified press speed range. Provisions shall be made at the sheet transfer mechanism to prevent build-up of static electricity.

The press shall automatically stop the feeder and throw off the impression when any of the following conditions occur:

• Two or more sheets are fed at the same time.

• Inverted sheet detection

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• No sheet is present at the front guides.

• A sheet arrived earlier or later than required.

• Sheet is misaligned during feeding.

• No sheet is present at the impression cylinder.

• Wrapping of a cylinder by the paper occurs.

• Foreign material, metallic or nonmetallic, is fed into the press.

• A sheet is folded over or deformed from its original layout.

The detecting and tripping mechanisms shall operate at speeds designated to prevent jams, damage to the press or plates, and the printing of images on rigging boards, draw sheets or other non-substrate materials. All fault detecting devices shall indicate operational status of the fault detectors. All sensors shall have provisions for recalibration. A graphic panel with indicators to display fault detector status shall be provided. Error codes shall flash on the console and remote displays when errors are detected.

If the feeder does not stop when a side lay fault occurs, an alarm shall sound and the sheet shall be diverted to the delivery designated by the operator for side lay faults.

C. Printing Unit: The press shall be equipped with printing unit capable of performing the following functions:

• The press shall be equipped with a sheet registration system capable of controlling and maintaining sheet registration in lateral and circumferential directions, for the entire specified press speed range and plate cylinder segments. The tolerance from the leading edge of the paper to a referenced printed point in the circumferential direction shall be constant within +/- 0.38 mm (0.015 inch) on each. The tolerance from the edge of the sheet in the lateral direction to a referenced printed point shall be constant within +/- 0.38 mm (0.015 inch).

“Side Lay” Lateral

“Front Lay” Circumferential

“Front Lay” Circumferential

Targets

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The minimum circumferential adjustment range shall be +/- 1.5 mm with an independent ability to adjust each side by +/- 0.75 mm. Registration shall be validated by measuring printed sheets, measurements to occur at the registration positions on the sheets, and all measurements having a three standard deviation (3σ) less than or equal to the registration tolerance (i.e. 3σ < 0.38 mm).

The press shall be equipped with all plate mounting hardware and controls to register the plates and maintain registration while the press is in operation. Currently, for sheets previously printed via offset printing, the registration points are four tic marks centered along the edges of the sheets.

• The press shall use BEP supplied printing plates and if optioned those produced via the plate manufacturing line to be furnished under this contract. The printing unit shall utilize BEP packing, draw-sheets and blankets.

• The press shall be designed and configured for the packing thicknesses utilized by the BEP. The BEP typically utilizes the following:

o Impression cylinder typically utilizes 2 mm packing with a 0.5 mm blanket.

o Printing plate is 0.75 mm.

• The gap between the plate and impression cylinders shall be settable between 2.25 mm to

2.50 mm. The operator shall be capable of adjusting the gap -0.5 mm to + 0.3 mm from the set (zero) point. The operator shall be capable of adjusting the printing press remotely and independently for each side.

Electronic monitoring and display of the printing pressure between the plate cylinder and impression cylinder shall be provided. The pressure shall be displayed for each side. A pressure measurement in Newton/meter2 or similar measurement units shall be acceptable. The printing pressure must be available through the DCS described in section C.5.4 (For each plate)

• The system shall have means for calibration to ensure accuracy and press to press consistency. An alarm shall alert the operator when the pressure is out of acceptable range.

• Plate, Impression and Ink Collector cylinders shall be protected to prevent fretting or damage over the entire life of the press.

• All cylinder bearings design and selection shall be with consideration for full intaglio pressure over the design life expectancy of the press.

• Printing unit shall be designed to support a minimum plate life of at least one million impressions.

• Plate, Impression and Ink Collector cylinders shall resist corrosion, erosion, etching and pitting when contacted by 13 +/- 0.25 pH wiping solution, printing inks, cleaning solution(s) and subjected to wiping conditions.

• Impression and Ink Collector cylinders shall maintain the surface speed of the Plate Cylinder.

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• Plate cylinder shall automatically take up the plate stretch by fitting the plates with effective and positive leading and trailing edge plate clamps.

• Plate cylinder shall have provisions to enable repeatedly accurate hanging of the printing plates on the segments to ensure printing in registration.

• Impression and Ink Collector cylinders shall be equipped with devices to stretch the rigging and blankets flat.

• Plate cylinder shall be designed and equipped with temperature control devices to maintain the dimensional characteristics.

• Plate cylinder shall be equipped with devices to maintain proper positioning of the printing plates.

• Plate cylinder shall be adequately tapered at the leading and trailing edges of the plates, to minimize the impact between the plate cylinder and all other cylinders.

• An automatic washing system shall be provided for the Plate and Ink Collector cylinders.

D. Inking System: The press shall be equipped with an inking system to permit intaglio printing with no less than five independent inks. The inking units shall employ indirect ink transfer methodology for the application of ink onto printing plates. The inking unit shall be capable of performing the following functions:

• Utilize BEP photo-polymer plates (Chablons) for the selective application of ink.

• Provide a speed dependent, programmable ink curve which minimizes the number of defective sheets at startups due to over inking.

• Each inking unit shall include modular type leak-proof ink fountain, unobstructed ink metering mechanism, and ink application device.

• Rollers and fountains shall be independently temperature controlled to facilitate ink transfer. Heating and cooling shall be maintained automatically at operator-set temperature within +/- 3 degrees Fahrenheit.

• Bearings, gears, and other related parts shall be protected from corrosion and/or damage due to the abrasive inks and cleaning solution(s).

• Permit lifting or removal of the inking fountain to enable a Bureau press operator to clean the ink fountain, printing plate and other needed items in not more than 10 minutes.

• Permit the use of one, two, three, four, or all fountains selectively. When an inking fountain is not in use, it shall not be driven.

• Permit fine and coarse metering of ink onto transfer rollers via individually adjustable keys. Each key shall be individually controllable from full open to close. At full closure, no ink film shall be transferred. At an open position sufficient ink shall flow to print any denomination of U.S. currency regardless of depth of intaglio, layout and transfer segment. Individual keys shall be no more than 38 mm (1 ½ inches) wide. Electronic controls shall be provided for the inking of each zone and shall allow for automatic compensation of the ink film requirement by press speed. The ink key control shall be

Intaglio Presses - SOW 9 of 5 3 equipped with a means of display that shows the set point and actual position of each ink key.

• For reference, the offerors are informed that the current average ink consumption rates for U.S. Federal Reserve $100 denomination notes are as follows:

o 4,800 notes per pound of U.S. Green Currency Ink o 3,136 notes per pound of U.S. Black Currency Ink

• Fountain cheeks shall not warp and shall be made out of replaceable leak-tight, longwearing, non-scoring material.

• Monitor and maintain adequate level of ink in the fountain automatically. The press shall have one (1) 24 Volt output per fountain to activate the solenoids controlling the air-actuated ink pumps.

• Minimum service life of ductor roller shall be 20 million impressions and that of fountain metering components shall be 12 million impressions.

• Lateral and circumferential control of inking-in registration shall be provided. The minimum range shall be +/- 4 mm. Controls for all press inking elements shall be provided both on press control and the remote control console and shall in no way be interrupted by other functions of the press.

• Each fountain shall be equipped with motorized ink agitators to distribute and maintain the homogeneity of the ink in the fountain and prevent it from backing up in the fountain.

Temperature gauges shall be furnished to monitor and control the fountain and ductor roller temperatures.

• A lifting/lowering mechanism shall be provided to assist the operator in the placement/removal of inking-in rollers, ink fountains and ductor rollers.

• Inking-in-rollers shall accept water-soluble, photopolymer printing plates for selective application of ink onto the blanket cylinder.

E. Wiping System: The press shall be supplied with a water wiping, counter rotation, system to wipe the printing plates prior to printing. The wiping system of the press shall meet the following requirements:

• The wiping system of the press shall remove ink from all nonprinting areas of the printing plates using BEP supplied water wiping solution. The removal of the ink from the plates shall ensure high quality printing of U.S. Currency in accordance with the established quality standards.

• The wiping system shall use no more than 4 gallon per minute (gpm) or 252 cm3 per minute of Bureau provided wiping solution to clean the wiping rollers. The Bureau’s existing wiping solution consists of the following ingredients, which are listed below according to ratio by weight:

1.0% NaOH (Caustic Soda)

0.5% Sulfonated Castor Oil or equally effective product

98.5% Softened Water

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• The wiping unit shall be designed to allow for the future use of alternative wiping solutions, including those based on Sodium Lauryl Sulfate, i.e. Standapol WAQ-LC manufactured by Cognis Corporation. An alternative wiping solution may be made up of the following: 0.1% Sodium Lauryl Sulfate, 1.0% NaOH and 98.9% Soft Water.

• Adjustments to the wiping solution flow shall be possible without removal of components.

• The force of wiping roller against the printing plates shall be maintained within the specified range by remote controls. Wiping force shall be adjustable for each side independently. A display containing the total Amperage for the wiping unit consumed shall be made available for each side and each printing plate.

• Wiping Force feedback by plate in Newton/Meters squared.

• Wiper roller shall be temperature controlled.

• All components shall operate effectively with highly corrosive wiping solutions. The wiper system shall be designed to ensure that the minimum service life of the consumable components below listed are met as follows:

Wiping roller - 150,000 impressions

Steel blade inclined against rotation of wiping roller – 180,000 impressions

Steel blade inclined with rotation of wiping cylinder – 1 million impressions

Wiping brushes – 1 million impressions

Scotch-Brite – 60,000 impressions

• The wiping system shall be designed to ensure that there is a continuous flow of waste solution out of the tank, in order to prevent obstructions in the waste solution collection lines.

• The Bureau will provide the waste solution collection system including the pumps needed to transport the waste through pipes to the Bureau’s wastewater treatment plant. An interface with the wastewater pumps shall be provided on the presses that shall activate the pumps when the press is in operation, and continue to run the pumps for an adjustable time frame after all printing has ceased. Prior to shutting down the pumps, the press shall automatically cycle clean solution to minimize any buildup of waste materials within the lines.

• A lifting device shall be provided to lift the wiper tank assembly for ease of maintenance with the base pair of presses to be provided and any optional quantities if provided.

• Provisions shall be made for removal and replacement of the wiping rollers from and into the wiper tank within 5 minutes. A lifting mechanism shall be provided.

• The wiper rollers shall be recoated via the roller coating machines to be supplied with the presses. All rollers shall comply with BEP requirements for surface finish.

• At the operator’s selection, the press shall print sheet(s) without wiping the plate, e.g.

smear sheet. An alarm shall sound when the sheet(s) are printed and the number of smear

Intaglio Presses - SOW 11 of 5 3 sheets printed shall be recorded by the counters. Smear sheets shall be delivered to the delivery designated by the operator.

F. Sheet Transport Provisions System: The press shall be designed to accommodate, both electrically and mechanically, all of the following subsystems within the sheet transport arrangement. The installation and/or use of these subsystems shall not impact the operation of the press nor create additional spoilage:

• In-Line Print Inspection System: The press shall accommodate an in-line print inspection system. The In-Line inspection system shall be installed and tested on the press at the time of delivery.

• Third Party Inspection System (TPIS): TPIS is an examination or inspection system specially built by a third party or internally by the Bureau for specific detection and/or inspection of sheets. The TPIS requires an area along the transport where the sheet is stable and with a clear unobstructed view of the printed sheets. The printed side of the sheet shall be facing the TPIS. The viewing area shall cover the entire sheet width and length. The TPIS may be installed up to 775 mm away from the sheet.

• The press shall accommodate signals with the sub-systems for the diversions of sheets into specific deliveries. The press shall provide signals to communicate with the sub-systems for configuration prior to beginning a new print job. The press shall be able to turn on or off the sub-system. The press manufacturer shall provide the communication protocol for interfacing with the sub-systems.

G. Delivery Unit: The press shall be equipped with four full pile delivery units. The delivery unit shall include provisions for:

• Full pile deliveries shall be designed to receive and stack printed sheets automatically.

The full pile delivery units shall have the capabilities of stacking up to 10,000 sheets on a skid, when not using the BEP Stack-n-Rack system.

• Full pile deliveries shall be able to utilize the BEP Stack-n-Rack carts and trays. The operator shall be able to select the number of sheets to be delivered prior to changing to another delivery to minimize the amount of setoff experienced in production.

• Sheets shall be delivered printed side up onto the piles.

• The press shall allow for the switching of the delivery of sheets from one pile to another at all speeds. Changeover shall be timed to ensure proper handling of sheets.

• The sheets shall be delivered such that when the press is operating at maximum speed, the time interval between the start of impression to when the sheet is deposited onto the pile, minimum setoff shall occur.

• The piles shall be aligned within accuracy of +/- 1/32 inch (0.8 mm). Piles shall automatic descend as sheets are delivered.

• Piles shall have fast and normal speed control for up and down motion.

• Detect jam-ups and stop the press by maximum deceleration in the event that a sheet is not properly delivered.

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• Stop the press in case of presence of a jammed pile; a safety switch shall be installed on the leading edge of the delivery pile gate.

• Allow quick service accessibility to the delivery conveying arrangement.

• In addition to the normal top and bottom stopping safeties on the pile, a second set of redundant micro switches shall be installed to ensure that the stack stops repeatedly at the appropriate height.

• There shall be a slow-down zone (a reduction of lifting speed) in the up direction as the pile approaches the upper limit.

• The delivery system shall be configurable and shall be designed to allow for the separation of the work between individual pile deliveries via a simple parameter change on the operator console. The press shall allow separation of different defect types into individual deliveries. All defects may be delivered to one delivery or different defects may be delivered to individual deliveries.

• Delivery piles shall stack the paper in a clean tight stack that shall require human intervention to prepare the stack for the next printing process.

• The delivery shall have provisions to identify the total number of sheets delivered to each pile. The system shall identify the number of start-up sheets, partially printed sheets, unprinted sheets, smeared sheets, and defective sheets delivered into each delivery pile on the main press console.

• A transparent optical window or clear viewing area shall exist at each delivery pile to enable the future scanning of informational printing along the edge of the sheets. The viewing area shall be along the operator side of the press and shall allow viewing of either side of the sheets. The viewing area shall have a width of no less than 0.5 inch (12.7 mm) from the sheet edge into the printing area and shall be at least 1.0 inch (25.4

mm) along the edge of the sheet. The window shall be adjustable for the entire range of paper sizes printable on the press.

C.5.2 CONTROL STATION REQUIREMENTS

Control stations shall have features for safe and efficient operation of the press and shall be strategically located. All electrical, electronics and computers supplied under this contract shall conform to the relevant design and construction requirements.

A. Localized Operator Stations: Normal Start/Stop buttons, speed control buttons and jog buttons shall be provided to operate and maintain the press in accordance with the specified requirements at any speed within the specified range.

Jog buttons shall be located near the front lay and inside the fountain area to enable the operator to set the conditions at the front lay and perform wash ups while inching the press in forward and reverse directions. There shall also be jog buttons located in the wiper tank area and all delivery piles. All jog and run buttons shall be interlocked with a warning horn capable of producing a minimum 95 decibels sound on the A scale at three feet from the perimeter of the press for 2 seconds.

B. Master Control Station (MCS): A free standing Master Control Station (MCS) shall be provided to allow the operator to control the operation of the press, including all subsystems

Intaglio Presses - SOW 13 of 5 3 and components to produce a quality product and maximize productivity. The operator shall be able to make adjustments from the MCS and monitor performance.

The MCS shall include the following components to display all parameters associated with operation and maintenance of the press including type and location of faults, date, load number, press speed, and counts of number of sheets printed during a production run:

1. Clock and Calendar: The system shall be equipped with a real-time, battery back-up, clock and calendar, which shall maintain time and date information even under power loss. The clock shall be accurate to within two seconds per month. This clock shall serve as the master time source for the control system and shall be able to be reset from the operator interface, with password or key switch protection.

2. Data Input: The system shall include a bar code reader(s) and standard computer 101 Keyboard to input data into the system. The bar code reader shall read Bureau operator and maintenance personnel badges, order number, job suffix load number, and seal numbers. Up to four (4) operating personnel and two (2) maintenance personnel shall be able to be logged onto the machine at a time.

The bar code readers shall be capable of reading a character string of up to nine digits printed in a medium density “3 of 9” code (10 characters/inch). This may include Identity Card (ID) card sets, which will have a “3 of 9” bar code heat press encapsulated in a polyester pouch or between Polyvinylchloride (PVC) sheets. Card thickness will be between 0.030 and 0.035 inches (0.75 - 0.90 mm).

The bar code reader system shall consist of a decoder/electronics assembly and a detachable wand. The wand shall operate with visible light and be suitable for use in an industrial environment. The wand shall be supplied with a coiled cord, with a minimum extended length of twenty-five (25) feet (8m). The wand shall be supplied with an industrial grade holder mounted in a convenient location for the operator. The decoder/electronics assembly shall be equipped with an adjustable volume audio feedback to inform the operator of a valid scan.

3. Quality Assurance Controls: Controls shall be provided to minimize the production of spoilage, number of jam ups and down time of the press. Controls shall be provided to maintain proper rigging, inking functions, and plate printing to minimize the number of defective sheets and to alert the operator if set conditions are not maintained. The MCS shall have provisions to enable wiper and ink key adjustments. The MCS shall include a light table for inspection of the printed sheets. The light table shall be in accordance with Commission Internationale de l’Eclairage (CIE) Stand D65 for daylight as specified in ASTM Standard D1729. All light fixtures and bulbs shall be in standard sizes available in the United States.

4. Sheet Accountability Controls: The MCS shall display the number of sheets fed, printed, and delivered to each delivery. All counts of number of sheets shall be accurate within +0.01%. The count of the total number of sheets printed over the life of the press shall not be able to be reset nor lost for any reason. All other counts shall be reset by key (or password) only.

5. Press Controls: The MCS shall display types and locations of all faults, speeds, main drive amperage, and all remotely controlled positions. The date, time and type of error

Intaglio Presses - SOW 14 of 5 3 shall also be displayed. The program shall provide individual and average readings of number of sheets printed per shift. Press speed feedback, calibrated for 10,000 sheets per hour shall be provided. They shall be accurate within 2% full scale and visible to the operator at the master control console. Provisions shall be made to recalibrate the tachometers when necessary.

C.5.3 HEAT TRANSFER SYSTEM REQUIREMENTS

The press shall be equipped with a heat transfer system capable of controlling the temperatures of the plate cylinder, ink fountain, ductor roller, wiper roller, and any other cylinder required to successfully print high quality work. The actual surface temperature of the following components shall be maintained constant within +/- 3 °F (+/- 2 °C) of any set point in the following ranges:

• Plate cylinders 160 – 200 °F (71.1 – 93.3 °C)

• Ductor rollers 50 – 150 °F (10 – 65.6 °C)

• Wiper rollers 64 – 95 °F (18 –35 °C) The Heat Transfer sub-system shall be capable to bring the Press to start of production temperature from standby mode in thirty (30) minutes or less.

Monitoring devices shall be provided such as flow indicators, temperature gauges, set point indicators, on off controls, and alarm indicators to indicate system problems. The information shall be delivered to the press console.

All connections from the temperature regulating system to the press and the regulating system shall be supplied as part of the press. Power for the temperature regulating system shall not be controlled by the same master switch, which controls the press. Each temperature regulated device shall be supplied by a dedicated temperature control circuit.

The heat transfer system shall use electric resistance type heaters and Bureau provided chilled water. The vendor shall provide a filtering system to remove any scale or hard water deposits from the system.

C.5.4 DATA COLLECTION SYSTEM (DCS) REQUIREMENTS

The presses shall have an automated Data Collection System (DCS) meeting the following requirements.

The DCS shall have capabilities to collect and store all information while the machine is running and sheets are being printed. Storage capacity shall be for at least 24 hours of continuous operation of the press. When the data storage system is 90% full, an alarm shall be initiated to provide sufficient time to archive data and preventing overwriting of the data. All DCS database records shall captured at the date and time of any changes within a given record.

The following subsystems of the Data Storage shall be provided: Accountability, Data Logging, Error Code, and Maintenance.

A. Accountability Subsystem: The DCS shall be equipped with a subsystem to record and track all sheets passing through the press from feeding to delivery. The following are the minimum requirements for the subsystem:

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• All data collected and stored shall be accurate within 0.005% of the number of sheets counted in each stack and fed into the press.

• The Bureau processes and accounts for all acceptable and defective sheets of paper in each load or 20,000 sheets. Upon entry of this information, the system shall automatically store it.

• Records should be generated at the end of every shift and at the end of each load. The records should contain the following:

ELEMENT TYPE LENGTH FORMAT/NUMBER

Machine Number alphanumeric 8

Order Number alphanumeric 9

Job (suffix) numeric 2

Load Number alphanumeric 6

Crew Members alphanumeric 7 Occiremnces/8-times

Date Started numeric 8 (yyyymmdd)

Time Started numeric 6 (hhmmss)

Shift Started alphanumeric 1 (D, E,M)

Begin Register numeric 10

Date Ended numeric 8 (yyyymmdd)

Time Ended numeric 6 (hhmmss)

Shift ended alphanumeric 1 (D, E, M)

Ending Register numeric 10

The following occurs once per load:

Seals removed “A” numeric 7

Seals removed “B” numeric 7

Good Sheet Count numeric 8

Bad Sheet Count numeric 8

• Any elements that are not applicable to that particular process shall have an appropriate number of space characters entered for that element.

B. Error Code Subsystem: The DCS shall be equipped with a subsystem, which shall be capable of storing error codes, machine status conditions and associated data. The error code subsystem shall store this information without the loss of data, or operator intervention if two or more error codes occur simultaneously. The system shall inform the operator when 90% of the system's memory has been used. Data generated by the equipment fault indication system shall be automatically collected with no operator attention required.

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It is required that fault analysis be extended to all components that are monitored by the machine control system.

The system shall include the time and date of each error occurrence.

C. Maintenance Management Subsystem: The DCS shall be equipped with a subsystem that provides for information to be inputted any time a non-preventative maintenance repair or replacement occurs. The system shall allow for maintenance personnel to input the following: craft code (8 digit alphanumeric), amount of time required for repair (hours:minutes), parts used (24 digit alphanumeric), list of error codes proceeding repair, and text description of repairs made to the press (up to 120 characters).

D. Operator's Daily Log Subsystem: The DCS shall be equipped with a subsystem that allows for the entry of information relative to downtime. The system shall have provisions for manual entry of data for purposes of allocation of labor to various downtime conditions. The Bureau currently maintains a log of downtime labor by manually recording the date, time, duration, and description for each occurrence. To facilitate record keeping, numerical codes have been assigned for the more frequent conditions. One approach is to establish "look up tables", in which the more frequent downtime conditions could be entered into on screen menus. Operating personnel could then quickly log the occurrence without entering a written description. The precise format will be determined during the course of the design review meetings. Allowance shall also be made for the input of consumables and wiper roller core numbers.

Shift Log visibility from Managers desks shall require equipment data to be replicated to an existing replication database in the BEP infrastructure. The contractor shall need to configure the replication.

E. Machinery Data Logging Subsystem: The DCS shall be equipped with a performance monitoring subsystem which shall provide a display of current values and conditions and the ability to electronically record those values according to a variable, operator selected scheme.

The system shall monitor all specified values and conditions whenever the equipment is running.

The DCS display shall be able to present all electro-mechanical variables that the controller regulates or monitors. Any operating parameter, which may result in a fault trip or error code condition, shall be included. Each display value shall be appended with its set point, alarm and trip limits, and its units of measurement. Values displayed shall be current with the control system logic.

Any variable machinery system information available on the DCS shall be recordable by the subsystem. Each data element shall be tagged with its units of measurement, year, month, day, shift, and time.

F. Management Information System (MIS): The machine shall be provided with the ability for the Bureau to connect to the machine to retrieve all data temporarily stored on the DCS. The configuration, layout, and data type shall be specified as where the access points to the data shall be located.

The system shall have provisions for authorized Bureau personnel to override any or all capabilities/systems. When the override function is exercised by authorized personnel, the badge number, time, date, press number, and all current counters shall be recorded. When

Intaglio Presses - SOW 17 of 5 3 reconnection occurs, the system shall record the time, data, press number, and current counters, and prompt for entry as to why the system was disconnected.

G. Bureau ORACLE Database Interface Subsystem (DIS): The contractor shall configure the BEP provided hardware and software infrastructure necessary for interconnecting the equipment control system to the BEP's database. The BEP will use a database as the primary information storage layer between machine control system and other BEP information systems. The database will also serve specialized and localized information processing needs, like maintenance management and historical process data retrieval, for example.

The DIS shall perform the actual exchange of digital information between the machine control system and the BEP's database. The information exchanged shall take many forms.

This specification identifies the control system data that shall serve as our default configuration.

DIS should deliver “Bi-Directional Ready” data with the existing equipment event telegraphs and infrastructure. The BEP anticipates additional event telegraphs over the life cycle of the system.

The BEP desires the Control Station Requirement to have the flow as laid out in the following sketch. At a minimum all components within the blue box are to be provided by the vendor. A typical front and back press pair maybe as illustrated:

The contractor is required to provide the DIS so that the control system can be designed to accommodate information exchange with a database, and so that contractor engineers, most familiar with the specific control system used on the equipment, can provide the best communications devices between the control system and the DIS computer.

To meet the BEP's changing information demands, the contractor shall design a fully open system using commercial-off-the-shelf (COTS) U.S. software products, which maximize BEP configuration. The DIS shall be designed such that a programmer familiar with common programming languages and with the machine control system shall be able to make operationally needed configuration changes without the assistance of the contractor, example, add storage capacity to the database.

The DIS and the control system shall be designed with reasonably sufficient expansion capability to meet the BEP's communication needs over the life of the equipment.

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The vendor must support a bi-directional flow solution which shall enable the Bureau’s Manufacturing Execution Console (MEC) and the DIS to communicate across the BEP network using an Enterprise Service Bus (ESB). The key tasks that are currently enabled for bi-directional communication are Load Start, Load Stop, Assignments, and Consumable data.

The Bureau foresees additional bi-directional flows in the future. The purpose of the ESB is to enable all of the various applications within the BEP enterprise (BEN) Architectural framework to communicate with one another via web services. The ESB provides system transparency across the BEN architecture and ensures minimal message loss. The ESB solution at BEP leverages Oracle Fusion Middleware with a small amount of custom Java code. The architecture is loosely coupled. If a consumer system is unavailable the producer shall not be directly affected. Likewise, if a producer is offline the consuming systems shall have nothing to run, but they shall not directly generate errors. This modularization allows producer and consumer to interact with ESB independent of the other and creates more ease in scaling the solution.

The vendor shall support at least four (4) messages where DIS is the consumer of the message payload and two (2) messages where DIS is the producer of the message payload. If any additional messages are envisioned, the vendor shall develop the message payload. The payload shall contain at the minimum information such as facility, press name, date and time, operation, load type, jobname, denomination/series, badge name, load size and action.

The vendor shall provide an accept acknowledgement where the response includes the original message (full payload) and the transaction return status code.

Vendor shall provide error checking for transport when a table insert fails, parsing errors while parsing the XML content, syntax errors for invalid format for data element and semantic errors when items cannot be processed by the application. The vendor shall create before insert triggers to validate header and payload header information, update columns and transform data.

The vendor shall create after insert triggers to insert a job into a queue that starts JAVA.

JAVA shall read the table records for records with a new status. The JAVA job shall validate the elements, extract a CLOB XML elements into columns and insert the record into the database.

C.5.5 SAFETY REQUIREMENTS

The following safety requirements shall be met:

A. Noise Level: The noise produced by the operation of the press within specified speed range shall not exceed 85 Decibels A-weighted Sound Level (dBA) when measured at 914 mm (3 feet) distance along the plan view of the press from the press and at an elevation of 1,524 mm (5 feet) including the wiper and inking areas of the press. Note: These noise levels are desired at every location but may be relaxed at the wiper and inking areas of the press, not to exceed 90 dBA. These noise level limits do not affect the warning horn levels described in C.5.2 – Control Stations Requirements.

B. General Safety: The press shall be designed to prevent injury to operation and maintenance personnel at all times. The press shall be equipped with service access equipment; such as, catwalks, access platforms, access ladders, lifts, and other equipment for operation and maintenance. Fixed stairs shall be provided in compliance with OSHA 29CFR 1910.24, Intaglio Presses - SOW 19 of 5 3

Fixed Industrial Stairs. All catwalks, access platforms, access ladders, lifts, hoists, and any other equipment that are furnished, shall be built and tested to comply with ANSI and OSHA standards. Special attention shall be given in providing proper ‘angle of steps’ as indicated in paragraph (e) of the referenced standard. All press and service access equipment shall be guarded as required by applicable portions of OSHA Regulations.

The presses shall comply with ANSI Standard B65.1, Safety Standard-Printing Presses.

Provisions shall also be made to meet the following requirements:

1. Sharp Edges: All sharp edges and corners, which present personnel hazards, shall be guarded or padded. All covers and safety guards shall be interlocked with the press control to prevent its normal operation while any cover or guard is open or absent. Only local jogging control at a reduced speed is allowable provided no other covers are opened or removed. The location of opened switches shall be displayed on the Master Control Station. Covers and guards shall be manufactured for easy removal by Bureau personnel with tools to facilitate removing mechanical and electrical parts for repair.