Extrusion Press Refurbishment and Upgrades Salient Characteristics.docx

Extrusion Press Refurbishment and Upgrades Salient Characteristics

1.0 General Requirements

The objective of the project is to overhaul three 15-inch, 1070 tons extrusion presses, and one 15-in blocking press. The presses have not had any significant refurbishment since their installation at NSWC IHD in 1948. The presses were manufactured by R.D. Wood Company or Watson-Stillman Company.

1.1 Rebuild 1070 Ton Presses and Blocking Press

1.1.1 Press Removal, Crating and Transportation

1.1.2 Disassemble all components of the press, clean and document sizing of parts and wear. Generate report of findings.

1.1.3 Rework of Main Hydraulic Cylinder Section

1.1.3.1 Undercut corroded areas and weld with 316 stainless steel overlay.

1.1.3.2 Spot weld (tig) areas in bores that have been damaged from pitting and assembly/disassembly.

1.1.3.3 Set up in vertical boring mill and machine true all critical faces and flange fits. Machine welded areas in bore to original size.

1.1.3.4 Check all mounting holes, pipe tapped holes and clean/repair as necessary.

1.1.3.5 Hone main cylinder bores to 16 rms finish.

1.1.3.6 Machine new groove in flange face per revised drawing and provide viton o-ring.

1.1.4 Rework Piston

1.1.4.1 Clean piston, check dimensions and polish.

1.1.4.2 Supply new set of (8) 34" diameter step seal piston rings and o-ring

1.1.5 New Piston Rod

1.1.5.1 Provide 4340 HT material and machine complete.

1.1.5.2 Re-cut existing piston rod nut true per print.

1.1.5.3 Use existing US Navy plunger head to check 5”-8 thread in rod end

1.1.6 Rework Cylinder Head

1.1.6.1 Clean, polish and machine true surfaces.

1.1.6.2 Re-tap/repair all threads.

1.1.6.3 Machine area for 14” Chevron packing 7/16” deeper to allow for 1-3-1 chevron

1.1.6.4 Cut ¼” groove on O.D. to allow for new 34” o-ring

1.1.7 Rework Lock Plate Ring

1.1.7.1 Clean, check for size and flatness, re-machine as necessary.

1.1.8 Rework Lock Plates

1.1.8.1 Clean, check for size and flatness, re-machine as necessary.

1.1.9 Rework Blowout Head

1.1.9.1 Clean, check all diameters for size and concentricity, polish and square faces.

1.1.9.2 Re-tap/repair all threads.

1.1.9.3 Provide new blowout head bushing and machine complete.

1.1.9.4 Install bushing in head and hone for proper clearance

1.1.9.5 Provide new chevron packing

1.1.10 Rework Blowout Head Gland

1.1.10.1 Clean, polish and check to print dimensions; re-machine-replace as needed.

1.1.10.2 Supply (8) new blowout studs and nuts.

1.1.10.3 Supply new blowout head gland.

1.1.11 Seal Retainer Plate

1.1.11.1 Clean, polish and check to print dimensions; re-machine/replace as needed.

1.1.12 Rework Container Sleeve

1.1.12.1 Undercut and weld with 316 stainless steel area adjacent to seal area.

1.1.12.2 Undercut and weld area at 14-1/4” chevron w/carbon steel and machine to print

1.1.12.3 Cut ¼” groove in O.D. to allow for new 26” Dia. Viton o-ring

1.1.12.4 Re-machine welded areas back to print specification, polish all diameters and machine true all faces.

1.1.13 New Container Sleeve Bushing

1.1.13.1 Supply new bronze material and machine complete.

1.1.13.2 Install bushing in container sleeve and hone for proper clearance.

1.1.14 Rework or New Container Sleeve Gland and Bushing

1.1.14.1 Clean, inspect and machine true gland.

1.1.14.2 Provide bronze material for new gland bushing, machine complete.

1.1.14.3 Provide new chevron packing.

1.1.14.4 Provide new studs and nuts.

1.1.15 Rework Container

1.1.15.1 Clean container, blast and paint.

1.1.15.2 Set up container in vertical boring mill & undercut for 316 S.S. overlay at

1.1.15.3 Container liner cooling jacket fit.

1.1.15.4 Weld bore with 316 S.S.

1.1.15.5 Setup in Boring mill and machine all surfaces back to print tolerances.

1.1.15.6 Machine 3/8” groove in back face to allow for new 3/8” Viton o-ring.

1.1.15.7 Check all diameters, polish/hone as necessary.

1.1.16 New Container Liner

1.1.16.1 Remove old liner from container and discard

1.1.16.2 Provide new 4340 Quenched & Tempered forging w/ 6” additional length for

1.1.16.3 Integral basket extension

1.1.16.4 Hard Chrome plate water jacket supply surfaces

1.1.16.5 Machine complete per revised drawing with US Navy providing final bore size

1.1.16.6 Provide new copper caulking strip and install.

1.1.16.7 Provide new liner packing (neoprene) and install.

1.1.16.8 Provide (1) new molded seal packing.

1.1.17 New Die Plate

1.1.17.1 Remove existing Die plate and discard.

1.1.17.2 Provide new 4340 Quenched & Tempered forging

1.1.17.3 Machine complete per drawing B-44945

1.1.17.4 Insure full contact between Die plate & Container Liner threads by lapping

1.1.18 Rework Die Plate Nut

1.1.18.1 Clean, check internal threads and machine cut all surfaces true and perpendicular if required.

1.1.19 Rework Die Holder Nut

1.1.19.1 Clean, check internal threads and machine cut all surfaces true and perpendicular if required

1.1.20 New Shear Ring Plate

1.1.20.1 Provide a new shear ring plate for each press

1.1.20.2 Provide two shear ring plates spares per press.

1.1.21 New Cam Plates

1.1.21.1 Provide 660 Bronze material and machine complete.

1.1.21.2 Provide (16) new brass socket head cap screws.

1.1.22 New Cams

1.1.22.1 Provide 660 Bronze material and machine complete

1.1.22.2 Provide (16) new brass socket head cap screws.

1.1.23 Rework Door and evaluate alternative closure design for improved seal

1.1.23.1 Dismantle door assembly, clean all parts and check all dimensions, machine true and polish surfaces.

1.1.23.2 Re-tap/repair all threaded holes.

1.1.23.3 Provide all new bearings, bushings, seal and bolting hardware for door assembly.

1.1.23.4 Evaluate alternative designs that will improve seal between press tooling and propellant container.

1.1.23.4.1 Provide white paper with design alternatives (CDRL A003)

1.1.24 New Door Hinge Pin

1.1.24.1 Provide 4140 HT bar and machine complete new hinge pin per drawing.

1.1.24.2 Provide new castle nut.

1.1.25 Rework Door Frame

1.1.25.1 Check bore size and hone as necessary

1.1.25.2 Clean, re-tap all bolt holes and true all machine surfaces.

1.1.26 Rework Latch Assembly

1.1.26.1 Clean, inspect cam latch bracket and provide new cam latch spindle as needed.

1.1.26.2 Provide new socket head cap screws and dowels for assembly.

1.1.26.3 Provide new latch handle.

1.1.27 Rework Trunion

1.1.27.1 Clean, inspect and machine to drawing specifications trunion plate (Item 136).

1.1.27.2 Clean, inspect and prepare trunion pillow blocks.

1.1.27.3 Provide new cylinder to trunion cross pin.

1.1.27.4 Provide all new hardware and dowels.

1.1.28 Rework Trunion

1.1.28.1 Clean, inspect and machine to drawing specifications trunion plate.

1.1.28.2 Clean, inspect and prepare trunion pillow blocks.

1.1.28.3 Provide new cylinder to trunion cross pin.

1.1.28.4 Provide all new hardware and dowels.

1.1.29 Rework Hydraulic Breech Cylinder

1.1.29.1 Clean, dismantle, hone and rebuild Hanna HP-17 cylinder.

1.1.29.2 Undercut, hard chrome plate and grind existing piston rod

1.1.29.3 Provide all new packing, seals, piston rings & hardware to rebuild cylinder.

1.1.29.4 If cylinder is beyond repair, a new cylinder will be substituted.

1.1.30 Final Assembly

1.1.30.1 Complete assembly of entire press per drawings and customer specifications.

1.1.30.2 Provide materials and install catch pan on hydraulic end of press

1.1.30.3 Test operation of breech lock assembly and piston travel

1.1.30.4 Paint all non-machine exterior surfaces with 2-part epoxy

1.1.30.5 Hydrotest cylinder to 2500 psi for leak free operation.

1.1.30.6 Customer to witness hydrotest and test operation at Fulton plant.

1.1.30.7 Prepare as-built drawings and deliver package along with hydrotest results and parts certifications to NSWC-IHD.

1.1.30.8 Prepare final assembly for shipment and transport to NSWC-IHD.

1.2 Monthly Report - The contractor shall prepare monthly reports to include written materials (CDRL A002) and actively participate in the following:

1.2.1 The contractor shall participate in a post award kick-off meeting to be held within 3 weeks after purchase order placement at NSWC Indian Head MD

1.2.2 The contractor shall prepare a detailed project schedule which shall be updated monthly and be provided in the monthly report indicating the status of all major activities. The initial schedule shall be presented at the kick-off meeting.

1.2.3 The contractor shall host a bi-weekly telephone conference call reviewing the progress to date and maintain a list of action items.

1.2.4 The government representative will coordinate site visits with contractor to witness scheduled tasks as necessary.

1.3 Documentation Deliverables

1.3.1 The contractor shall provide a report of the “as-received” initial visual and dimensional inspection results of all parts planned for rework (CDRL A001).

1.3.2 The contractor shall provide a report of the final visual and dimensional inspection results of all new and reworked parts (CDRL A004) .

1.3.3 Provide white paper with design alternatives (CDRL A003)

1.3.4 The contractor shall provide a report with results of all test performed of parts, subassemblies and final assemblies. (CDRL A005)

2.0 CONTACT INFORMATION

POC: Robert Frederick

NSWC-IHD

Extruded Products Branch, B526 4895 McMahon Road Indian Head MD 20640 204-585-3005

3.0 SECURITY BADGES AND ON-SITE CONTRACTOR PERSONNEL

Security badges will be issued by the Government only to those Contractor personnel who require access to NAVSEA, Naval Surface Warfare Center, Indian Head division (NSWC IHD), Naval Support Activity South Potomac (NSASP) in connection with work to be performed under this contract. Approval for such issuance may only be granted by the Contracting Officer’s Representative (COR) or Contracting Officer. As contained in the DON Homeland Security Presidential Directive-12 (HSPD-12) dated 22 December 2011 policy, a National Agency Check with Inquiries (NACI) investigation with a favorable fingerprint result are the basis for the issuance of a Common Access Card (CAC). However, the Commanding Officer is the final adjudicating official for CAC issuance and will be based on OPM Final Credentialing Standards for Issuing Personal Identity Verification Cards under HSPD-12. The command, during the adjudication, has the flexibility to apply the supplemental credentialing standards delineated in OPM Final Credentialing Standards for Issuing Personal Identity Verification Cards, in addition to the six basic standards if information is developed during the credentialing process that may present an unacceptable risk to the life, safety, or health of Employees, Contractors, Vendors or Visitors.

The Contractor shall maintain a register of Employees currently authorized access to NAVSEA, NSWC IHD, NSASP. This does not include badges temporarily authorized for Contractor Visitors to NAVSEA, NSWC IHD, NSASP. Furthermore, the Contractor shall maintain a current register of Contractor personnel with full or part-time work or office space located on board the Naval Support Activity South Potomac. This register will be made available upon request of the Contracting Officer. The Contractor shall follow station security procedures in this regard.

4.7 DELIVERY TO THE WORK SITE

Contracts that require delivery of material or equipment directly to the work site require notification to the Contracting Officer’s Representative (COR) at least 24 hours in advance. Escort procedures may be required.

The Contractor is responsible for Employee’s safety and health and shall comply with OSHA regulations and comply with the NSWC IHD Instruction 5100.22H, Safety Manual, as well as all Federal, State and Local safety and security regulations. Any non-compliance with the aforementioned may be cause for Contractor expulsion from the activity. The most stringent standards will apply.

The Contractor may be required to stop performance with no additional price or cost to the contract, when it is determined the Contractor operation site does not comply with an applicable OSHA regulation and is a threat to the safety and health of on-site personnel and/or the public. Should unforeseen hazards become evident during the performance of the work, the Contractor shall make a formal request to the Contracting Officer and COR, both verbally and in writing, to provide a resolution as soon as possible. In the interim, all necessary action shall be taken by the Contractor to restore and maintain safe working conditions in order to safeguard on site-personnel, Visitors, the public, and the environment.

4.8 Operations Security (OPSEC) Requirements: Contractor personnel are subject to applicable provisions of Department of Defense Manual 5205.02-M, Enclosure 6 and NSWC IHD 3070.3A OPSEC Program. Contractor personnel supporting this contract/task order must complete Government approved or provided OPSEC awareness training. OPSEC education and training may be accomplished through established programs within the DoD Component, using external resources such as the Interagency OPSEC Support Staff (IOSS) and the Defense Security Service Academy, or a combination (i.e. https://securityawareness.usalearning.gov/opsec/). Contractor personnel may have access to Government Critical Information (CI), Indicators and Observables that may indirectly disclose CI. CI includes, but is not limited to: Ship movements and schedules, weapons and sensor system installations, capabilities, and configurations; specific platform installations and characteristics, test schedules, deficiencies and vulnerabilities. Indicators and Observables may include, but are not limited to: Outdoors system testing; ship's external hull or superstructure modifications; shipboard equipment, ordnance, weapons, fuels, and/or stores loading/unloading operations, and/or personnel or aircraft embarkation. No CI, Indicators, or Observables may be divulged to third parties (including other company Employees who are not subject to this contract) without approval of the local command Security Officer, OPSEC Officer, or the NSWC IHD OPSEC Program Manager.

4.9 Voluntary Protection Program

4.9.1. In August 2006, Naval Surface Warfare Center Indian Head Division (NSWC IHD) was nominated to participate in the DoD Voluntary Protection Program Center of Excellence Implementation Initiative of the Defense Safety Oversight Council (DSOC). The Voluntary Protection Program (VPP) was established by the Occupational Safety and Health Administration (OSHA) in 1982 to recognize and promote effective worksite-based safety and health management systems. NSWC IHD, through the utilization of VPP, desires to be a model of safety and health excellence. VPP's emphasis on trust and cooperation between OSHA, the Employer, Employees, Employees’ Representatives, and Contractors’ complements the Agency's enforcement activity but does not take its place. All parties, including Contractors, are to work together to identify and resolve any safety and health problems that may arise, yet obtain Contracting Officer approval of any changes that would impact the terms of the contract. NSWC IHD as the VPP participant develops and implements systems to effectively identify, evaluate, prevent, and control occupational hazards so that injuries and illnesses to Employees and Contractors are prevented. Contractor and Sub-Contractor personnel are subject to occupational safety and health oversight. This oversight will be accomplished by NSWC IHD personnel and Contracting Officers. Contractors, Sub-Contractors, and their Employees, while in performance of a contractual action on-site within the geographical boundaries of Naval Support Facility (NSF) Indian Head, shall be subject to the requirements of the NSWC IHD INST 5100.22H, “Safety Manual” regardless of the type or duration of the contract. Chapter 13 of the NSWC IHD 5100.22H, “Safety Manual”, entitled “Contractor Safety” is provided as Attachment XX. Appendix 13-A, of the chapter 13 entitled “Contractor Safety Requirements When Performing Work at the Naval Support Facility (NSF) Indian Head, MD” shall be signed by the Contractor prior to commencement of services on-site at NSF Indian Head. The Contractor shall maintain one signed copy for future reference in educating its personnel and Sub-Contractors. A second signed copy shall be provided to the Contracting Officer to be maintained in the contract file. If an occupational safety or health related injury or illness occurs during the performance or as a result of this contractual action, the Contractor shall notify the Contracting Officer Representative (COR) as soon as practicable, who will notify the Safety Office and the Contracting Officer.

4.9.2 In support of VPP and in compliance with Chapter 13 of the Safety Manual, entitled “Contractor Safety,” all Contractors performing on-site at NSF Indian Head shall comply with the following:

4.9.2.1 Public Law 91-596 (and Amendments), also known as the Occupational Safety and Health Act of 1970, establishes that all employers, including Contractors, are responsible, as far as possible, for providing every Employee a safe and healthful working environment. All employers, including Contractors, shall conform to the standards as issued by OSHA. Contractors are responsible for complying with safety requirements specified in the contract as well as all Federal, State, and local safety and security regulations. Non-compliance may be cause for the removal of a Contractor or any Contractor Employee from the activity and such non-compliance may form the basis for contractual action, up to and including termination for default.

4.9.2.2 Contractor personnel shall participate in basic safety awareness and hazard identification training offered by the Government activity at the work area they are supporting. Contractors performing on-site shall attend area weekly safety meetings and annual safety stand-downs, as determined by the COR.

4.10 The best Safety and Health Programs involve every level of the organization, instilling a safety culture that reduces accidents for workers and improves the bottom line for managers. When Safety and Health are part of the organization and a way of life, everyone wins. NSWC IHD is committed to safety excellence. The Contractor shall familiarize itself with the “Contractor Volunteer Protection Program (VPP) Fundamentals training located on the NSWC IHD intranet on the 00SA VPP page https://navsea.portal.navy.mil/wc/surinhd/a/private/sa/default.aspx.

4.11 Costs Expressly Not Allowed for Direct Charge

The costs of general purpose business expenses required for the conduct of normal business operations will not be considered allowable direct costs in the performance of the contract unless supported by DCMA as a procedure of the Contractor's accounting procedures. General purpose business expenses include but are not limited to the costs for items such as telephones (including cell phones) and telephone charges, copy machines, word processing equipment, personal computers, and other office equipment and supplies.

Required Approvals Prior written approval from the Contracting Officer (KO) shall be required for all purchases of materials under the following circumstances:

(a) If the Contractor possesses an approved purchasing system, the following applies:

(1) A purchase of materials that equals $10,000 or less per individual purchase may be executed with COR review and written approval. KO approval is not required.

(2) A purchase of materials that exceeds $10,000 per individual purchase may NOT be executed unless the COR reviews the proposed purchase and the KO issues written approval.

(b) If the Contractor does not possess an approved purchasing system, the following applies:

(1) A purchase of materials that equals $3,000 or less per individual purchase may be executed with COR review and written approval. KO approval is not required.

(2) A purchase of materials that exceeds $3,000 per individual purchase may NOT be executed unless the COR reviews the proposed purchase and the KO issues written approval.

(c) Separate multiple purchases of amounts valued below those thresholds stated in this section shall not be submitted to circumvent the COR and KO review and approval procedure. Splitting purchase requirements to defeat purchasing thresholds shall not be approved.

(d) No purchases of any amount shall be executed by a Sub-Contractor if they do not have an approved cost accounting system.

Procedure for Obtaining COR and KO Approval To obtain COR and/or KO approval, the Contractor shall do the following:

(a) Submit a written request for purchase of materials to the COR through e-mail. The COR shall review the request. If it requires KO approval, the COR shall submit the request via the Contract Specialist to the KO for review and approval.

(b) Minimum requirements for a written request for purchase are as follows:

1) Complete description of the material to be purchased

2) Quantity

3) Unit and Total Cost

4) Delivery/Freight charges

5) Any associated service charges such as assembly, configuration, packing, etc.

6) An explanation of the need for the material

7) List the competitive quotes received from potential suppliers

8) The basis for the selection of the selected supplier

9) Explanation of the determination of price reasonableness regarding the selected supplier costs

10) If the procurement is sole sourced to a particular supplier or manufacturer, include the rationale for limiting the procurement to that supplier or manufacturer.

11) You may seek the assistance of the Contract Specialist for guidance on item 10.

(c) Once the COR and/or KO have reviewed the request, the Government shall notify the Contractor of the outcome. Issues or details may be discussed with the Contract Specialist acting on behalf of the KO until a final Government determination is made as to whether to approve, modify, or reject the purchase.