SOW_-_Specs_for_Ultra_High_Pressure_Waterjet_(b).doc

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Ultra High Pressure Water Jet Systems Federal contract opportunity
Solicitation number
FA8132-17-R-0005
Issued by
Department of the Air Force Materiel Command Lifecycle Management Center Tinker Air Force Base

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Statement of Work

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Appendix_B_-_Reliability_Centered_Maintenance.pdf PDF
Appendix_A_-_Water_Jet_Parts_List.pdf PDF
Attachment_2_-_Addendum_to_FAR_52.212-2_Water_Jet_.docx DOCX document
Attachment_1_-_Addendum_to_FAR_52.212-1_WaterJ_et.docx DOCX document
Appendix_C_-_Safety.pdf PDF
FA8132-17-R-0005.docx DOCX document

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STATEMENT OF WORK (SOW) / SPECIFICATIONS

BB-16-001

Articulated Arm 55,000 PSI Ultra High Pressure Waterjet System and Accessory Equipment

BUILDING 3001 TAFB, OK

Purchase Request # F3YCFP6305AG01 Reference CCaR # OC 1526 and CSN H7WP21

Prepared by Bronson Bolvin

76 PMXG/MXDEKA

August 15, 2016 Revised March 21, 2017

Oklahoma City Air Logistics Center Tinker Air Force Base I. Description of Services

Contractor Provided Material

The contractor shall provide all labor, tools, parts, facilities, travel, transportation and incidentals to deliver and install Two (2) new ultra high pressure articulated arm waterjet systems in accordance with this Statement of Work (SOW) and manufacturer’s specifications at Tinker AFB, OK; with an option of adding Two (2) additional new ultra high pressure water jets at a later date at the Government's discretion.

Purchased Equipment Design Specifications

The Contractor shall standardize the equipment utilized to maintain configuration control with existing equipment utilized by the Government in recent equipment upgrades. 76 PMXG Engineering will approve all equipment selections.

Design of the system shall be in accordance to manufacturer’s installation recommendations, current commercial industry codes, standards (American National Standards Institute (ANSI), American Petroleum Institute (API), American Society of Mechanical Engineers (ASME), Environmental Protection Agency (EPA), the Instrumentation, Systems, and Automation Society (ISA), National Fire Protection Association (NFPA), Occupational Safety and Health Administration (OSHA), and recommended practices shall also be observed. For equipment and installation of said equipment not covered by existing standards and codes, Contractor shall provide recommendations to 76 PMXG Engineering for approval.

The new 55,000 PSI ultra high-pressure articulated arm waterjet systems shall be designed to meet the requirements given in SPOP 750 – Ultra- High Pressure (20,000psi – 55,000psi) Water Jet Stripping General Procedure, SPOP 322 - Ultra-High Pressure (20,000psi – 55,000psi) Water Jet Stripping General Procedure, SWP 006 33 – High Pressure Water Jet Stripping and the specifications given in this statement of work.

The contractor must have a minimum of TEN (10) working 55,000psi ultra high pressure articulated arm waterjet stripping systems currently in service. A list of these systems must be provided for review by PMXG Engineering. PMXG is not a research facility, so this requirement will show that the vendor has a working knowledge of building water jet stripping systems and has the infrastructure to support the systems that are provided. Note: water jet cutting systems are not the same as coating stripping systems.

Waterjet Cabinet Assembly

The waterjet system shall include one waterjet cabinet assembly which shall meet the following specifications:

The Waterjet Cabinet Module shall include all the products necessary to effectively contain the water mist as well as sound.

The cabinet shall be constructed of minimum 4" (102mm) thick walls. The walls shall incorporate heavy gauge steel on each side of a core of sound deadening material in between. Interior surfaces must be stainless steel. The enclosure shall be a minimum of 10’W x 13’D x 13’H. The enclosure must incorporate a part with a maximum size of 6.5’W x 5’D x 8’H. See reference drawing in Appendix A.

Work doors shall provide an opening for loading and unloading a part with a maximum size of 6.5’W x 5’D x 8’H (See reference drawing contained in Appendix A). A second door shall be included for access of personnel and shall be a 36"W x 84"H hinged door with viewing window.

An interlocked safety switch shall be used on all doors. The safety switch shall stop all processing if the door(s) is opened during a cycle. It must also prevent a cycle from starting unless the door is closed.

The switch must comply with regulations requiring “positive break normally closed” contacts. The switch shall change state when an actuator turns a positive mechanical linkage within the switch. This design eliminates false signals that could otherwise be caused by broken springs or welded contacts. The switch shall be tamper resistant and mounted with tamper resistant screws.

The cabinet shall also have a viewing window located on a side of the enclosure approximately 30" (762mm) high by 36" (914mm) wide viewing opening. The window shall be replaceable and constructed of clear safety glass.

A window wash shall be included to clear fog and mist from the viewing window for a clear view of the waterjet process. The window wash shall be composed of a series of low pressure waterjets which rinse the window when a control push-button is pressed.

The cabinet floor shall be a fabricated floor that allows all process water and contaminants to be drained to a sump well. The cabinet floor shall be lined with 10 ga. (3.3mm) thick stainless steel. A working floor above the drain floor shall allow process waste to fall through to the cabinet floor.

A stainless steel angle channel track 69 inches (5.75ft) on center shall be incorporated into the water jet floor. This track system shall be able to accommodate a fixture and part weighing 1200 lbs. This channel track must have the turntable centered between the 2 tracks.

High output marine grade fluorescent lights shall be used to provide illumination for the interior of the cabinet. The lighting shall produce a well lit cabinet interior with a minimum 80 foot-candles (861 lux) of light intensity. A switch shall be provided at the operator control station to control the light.

An emergency stop switch shall be located on an interior wall of the process cabinet. When activated this switch shall disables the equipment and puts it into an "E-stop" condition.

Steps shall be provided to allow the operator access to the personnel door and the interior of the cabinet. The steps shall meet all applicable

O.S.H.A. specifications.

Manual blow off nozzles shall be placed on the back of the cabinet and one inside the cabinet to assist in part cleaning. A lever operated hand valve and a self-coiling air hose shall be provided at each location.

A Manual Rinse hose consisting of a 15' (4.6m) of water hose and a pistol grip nozzle shall be provided inside the cabinet. The rinse hose shall provide low pressure rinsing of equipment and parts. A hose hanger shall be provided for storing the hose when it is not in use.

A pressure switch shall be provided to monitor the air supply to the machine. It shall have an adjustable range of 12 to 150 psig, (127 - 1585 KPa). It’s purpose will be to signal the operator, and stop the machine cycle if the air pressure drops too low.

The waterjet must have a single air drop that supplies air to the entire system. A supply shutoff valve shall be provided to allow quick removal of air pressure for maintenance purposes. It must be located at operator height from the floor and meet all applicable OSHA and JIC codes.

All wireway used on the machine shall be NEMA 12 (IP 65) rated against oil and dirt. The wireway shall be of the top-opening, lay-in design for easy assembly and disassembly. Dividers shall be used to isolate low power and noise sensitive cabling where required.

The Spindle Positioning System shall be used to manipulate the turntable and parts. Machine processing shall stop if actual values deviate from the program value. Should shaft rotation unexpectedly stop during a cycle, part processing must immediately stop, and a fault message shall be displayed.

The Spindle shall be housed in a framework mounted centrally in the cabinet and totally enclosing all drive components. A shaft seal shall be provided to prevent contaminants from entering its sealed bearings. Specifications for the spindle shall be: Speed range of 0.1-24.0 rpm; positioning Accuracy of +/-2.0 deg; positioning repeatability of +/-1.0 deg; max capacity of 1000 lbs (454kg).

The Spindle Table Top shall be a minimum of 48" (1219mm) diameter stainless steel disk used in conjunction with the spindle drive to support and rotate a part. A round center bung shall be provided to accurately locate parts. The spindle table top must support a maximum part size of 80" (2032mm) OD.
Four T-slotted spokes shall be mounted to the table top, which extend out from the table top to accommodate an 80” (2032mm) diameter part. Adjustable blocks and clamps shall be provided to hold and secure parts to the spokes. Each spoke shall have numbered markings to help in centering parts on the fixture. The spokes, blocks, and clamps shall be constructed from stainless steel to withstand the wet environment.

Robot

The waterjet system shall include one FANUC robot or equivalent which shall meet or exceed the following specifications:

A Fanuc M-710i six-axis or equivalent, electric-servo driven robot shall be used.

The robot/water jet system must be capable of processing one side of a part with a maximum size of 6.5’W x 5’D x 8’H that is centered on the channel track. See reference drawing contained in Appendix A for area to be stripped.

The robot shall be capable of stripping the complete inside diameter of a part that is centered on the turntable, from top to bottom, with a diameter of 3 feet and a height of 5 feet, without the need to flip the part.
A graphical demonstration must be presented for review by 76 PMXG Engineering showing how the requirements given in

2.3.1.1 and 2.3.1.2 will be met.

The Robot shall be controlled by a SYSTEM RJ-3iB Controller or equivalent. The controller shall be used to program and operate the M- 710i or equivalent robot. The controller shall be fully RIA compliant. Robot servo parameters shall be monitored and adapted in milliseconds. The controller shall also have a built-in diagnostics that test electrical and electronic functions at start-up.

Programming the Robot shall be done using a Teach Pendant Editor, and the Karel RJ-3 control system or equivalent system.

M-710i or equivalent shall meet the following specifications:

2.3.4.1.

Repeatability +/-0.15mm (+/- 0.006 in) 2.3.4.2.

Mechanical Brakes:

All axes

Working Range and Axis Speed shall meet the following specifications:

Movement

Working

Type

Axis Range Max Speed Base Rotation

320 deg 160 deg/sec Waist Bend

260 deg 120 deg/sec Shoulder Bend

420 deg 150 deg/sec Arm Roll

540 deg 240 deg/sec Wrist Pitch

250 deg 240 deg/sec Wrist Roll

720 deg 340 deg/sec

SYSTEM CONTROLLER

The SYSTEM controller will be a R-J3iB Controller or equivalent and shall incorporate the most advanced, proven technology.

SYSTEM R-J3iB or equivalent Controller shall incorporate the following features:

Ergonomically designed lightweight teach pendant with large, easy-to-read backlit LCD display.
High-speed, high-precision control of up to 16 axes of motion.
Multi-tasking operating system allows execution of up to four concurrent user programs.
Auxiliary axes options that can support up to three separate motion groups, each with their own control program and simple kinematic models.
Advanced sensing and vision capabilities.
Advanced communications and networking capabilities.
Extensive use of surface mount components, custom VLSI IC’s and 3D packaging results in fewer components for increased reliability.
More powerful 32 bit main CPU and math coprocessor allow faster calculations, shorter execution times and more accurate paths.
Fast teach pendant response time. 2.3.6.2.10.RJ3iB Handling Tool Software or equivalent
KAREL software or equivalent will be included for advanced programming.
Collision Guard software limits damage to robot in the event of a collision.
Win OLPC software for program transfer with PC 2.3.6.2.14.Memory Included:1MB SRAM (CMOS), 8MB FROM,

8MB DRAM

A Waterjet Gun Holder shall be used to support the waterjet cleaning head. The Holder shall be corrosion resistant and suited for operating in the waterjet cleaning environment.

A Machine Alignment print shall be provided which illustrates the procedures required to setup/align the gun manipulation devices and the part manipulation devices with respect to each other.

After the machine components are aligned, the proper orientation and position of the different manipulators in their home positions shall be set and documented. The Machine Homing Procedure print shall show these positions and the proper technique for home position setup. This documentation shall make resetting home positions after maintenance much easier.

A Tooling Envelope print shall be provided that illustrates the gun manipulation (robot) and part manipulation (turntable) ranges of motion, and their relationship to each other. This print shall be provided so a quick check can then be made to determine the feasibility of running different size parts.

Mist Collector

The waterjet system shall include one mist collector which shall meet the following specifications:

A Mist Collector shall be used to remove the mist and water vapor from the process cabinet while the machine is in cycle and after the machine cycle is complete. The unit shall be designed for continuous operation.

The Mist Collector shall be furnished complete with fan, motor, housing, and 3-stage filter. The system shall allow the exhaust to be returned to the plant environment. Accumulated water shall be removed from the collector via a drain. A differential pressure switch shall continuously monitor the pressure drop across the filters. The machine control system shall alert the operator if the pressure drop exceeds preset limits. The unit shall have a minimum 4000 CFM (113.2 CMM) capacity.

55,000 psi, 150 Horsepower Waterjet Pumps

The waterjet system shall include two (2) new Jet Edge 55,000 psi, 150 Horsepower Waterjet Pumps which meet the following specifications:

They shall be dual intensifier ultra-high pressure pumps. Each pump shall have its own power drop.

The two (2) intensifier pumps shall be identical units.

The second 55,000psi intensifier pump shall serve as a back-up to the first. If one intensifier pump goes down and requires maintenance, the waterjet shall easily be switched over to the second intensifier pump to allow production to continue. The switch from one intensifier pump to the other shall be made from the machine control panel with no manual valves needing to be opened or closed.

Features of the Intensifier Pumps shall include the following:

Rated at 3 GPM at 55,000 PSI
150 horsepower, high efficiency, TEFC electric motor
Dual mechanically shifted intensifiers
High pressure attenuator, to stabilize operating pressure
Automatic shutdown for low hydraulic oil level, high hydraulic oil temperature, and low inlet water pressure
Thermostatically controlled cooling system to minimize cooling water usage
Automatic high pressure bleed down valve (safety feature) to relieve pressure from system at shutdown
Programmable Logic Controller based control system with built-in network interface. Control start/stop, set pressure, and get pump status over the network
Alpha-numericoperatorinterfacedisplaysalltheprocess parameters, and pump status information
Integrated power distribution panel with system disconnect, and power factor correction capacitors
Wye-delta electric motor soft start package
Water prefilter and pressure booster system
Completely enclosed steel framed metal cabinet to insure safety and provide ease of maintenance
A special high pressure monitor shall be provided to measure the pressure in the system. It shall be capable of measuring pressures up to 60,000 psi and shall send information to the machine control system. It shall be designed to be used in a high pressure water jet application, and guaranteed by the manufacturer for 1 million pressure cycles of 0-60,000 PSIG.

Specifications of the high pressure monitor shall include:

2.5.4.15.1.

Pressure Range 6000-60,000 PSIG (408-4080 Bar) 2.5.4.15.2.

Proof Pressure 90,000 PSIG (6120 Bar) 2.5.4.15.3.

Burst Pressure >150,000 PSIG (10200 Bar) 2.5.4.15.4.

Accuracy 0.25% of full scale 2.5.4.15.5.

Calibration NIST traceable 13 point 2.5.4.15.6.

Process Port F-250-C connection 2.5.4.15.7.

Wetted Material 316 Stainless steel A Water Flow Monitor shall be provided. It shall be an in-line type flow sensor for monitoring the water flow into the waterjet pump. It shall be interfaced to the machine control system via analog input, so the system can monitor the actual flow, and alarm on abnormal conditions.

Water Flow Monitor Specifications shall include:

2.5.6.1.

Flow Range

0.12 - 3.0 gpm (0.48-11.4 l/m) 2.5.6.2.

Accuracy 2% of full scale

Waterjet Pump Chillers

The waterjet system shall include a waterjet pump chiller which meets the following specifications.

A Chiller shall be used to cool each Jet Edge Intensifier Pump.

The unit shall use a non-ozone depleting refrigerant. It shall be used to cool the High Pressure Waterjet Intensifier Pump hydraulic system in a closed-loop configuration, eliminating the discharge of cooling water to drain. The units shall include the following features and capabilities:

126,000 BTU/Hr providing an exit water temperature of 65oF.
Air cooled, UL and O.S.H.A approved fans with guards.
460VAC, 3 phase, 60 Hz
Stainless steel tank which serves as a thermal stabilizing reservoir.
Integral pump for recirculating cooling media.

Rotating Nozzle Drive

The waterjet system shall include a rotating nozzle drive which meets the following specifications.

The rotary drive shall consist of a high-pressure swivel and an air motor drive. Waterjet cleaning nozzles shall attach to one end of the rotary drive, and the high pressure water line shall attach to the other end. An external oil reservoir shall be included that supplies oil to the air motor via the air that is powering the motor.

The rotary drive shall be specifically designed for the harsh waterjet environment. All components shall be constructed from stainless steel, anodized aluminum and/or brass.
The swivel shaft shall extend all the way through the body of the unit and shall include the nozzle attachment fitting. This will insure that the swivel always rotates concentrically with the rotary drive and is not subject to excessive vibrations.

The rotary drive shall be capable of rotating at controlled speeds of 500 to 1800 rpm. Speed shall be closed-loop controlled by a digital speed display/controller. The nozzle speed must be displayed on a monitoring system.

Waterjet Nozzles and Extensions

The waterjet system shall include Pratt & Whitney SPOP 322 approved nozzles.

The waterjet system shall include the following nozzles and extensions:

FANJET NOZZLE, NARROW - Shall deliver a single fanjet of water. The nozzle body shall be a maximum of 5/8" (15.9mm) diameter to permit access into difficult geometry.

FANJET NOZZLE, 75 DEGREE ANGLE - Shall deliver a single fanjet of water. This nozzle shall have a 45 degree angled outlet and small size.

4 JET (ORIFICE) NOZZLE - Shall deliver four jets of water. It shall be designed to have even energy distribution of the high pressure water. The maximum diameter of this nozzle shall be

1.25 inches.

MINI 4 JET (ORIFICE) NOZZLE – Shall deliver four jets of water. It shall be designed to have even energy distribution of the high pressure water. The maximum diameter of this nozzle shall be 0.625 inches.

5 JET (ORIFICE) NOZZLE - Shall deliver five jets of water. It shall be designed to have even energy distribution of the high pressure water. The maximum diameter of this nozzle shall be

1.95 inches.

6 INCH NOZZLE EXTENSION - A 6 inch long nozzle extension shall be provided to act as a spacer between the rotating drive and the waterjet nozzle.
16 INCH NOZZLE EXTENSION - A 16 inch long nozzle extension shall be provided to act as a spacer between the rotating drive and the waterjet nozzle.

Intensifier Water Treatment System

The waterjet system shall include a water treatment system to supply clean treated water to the intensifiers which meets the following specifications.

When the intensifier demands water it shall be drawn from holding tank. As it leaves the holding tank the water shall flow through de-ionization tanks (de-ionizations tanks do not need to be provided) which are adjusted to maintain the proper level of total dissolved solids (TDS) in the water, and finally it shall pass through three successively finer cartridge filters (1 micron, 0.45 micron, and 0.2 micron) which remove particulate down to

0.2 microns in size.

The water treatment system shall be controlled by a programmable logic controller that monitors liquid level, filter condition, total dissolved solids, and overall system timing. The system shall be designed to operate at up to 3 gallons per minute.

Water Filter Skid

The waterjet system shall include an open loop water filter skid which meets the following specifications.

The water filter pumps process water through a bank of bag filters to remove contaminants from the water. The process water shall be filtered down to 5 microns prior to being sent to the drain.

The dirty water pump shall be an air operated diaphragm pump designed for passing large particles and plasma.

Stainless steel housings shall be used to hold standard size #12 filter bags. Gauges shall be provided to monitor when the filter bags are becoming loaded. In addition, a differential pressure sensor shall be provided across the entire bank of filters to alert the operator when a bag has become clogged.

Controls

The waterjet system shall include the following controls:

The control panel shall be NEMA12/IP65 rated against oil & dirt, and are built to conform to the U.S. National Electrical Code (NEC) ANSI/NFPA 70 and ANSI/NFPA 79 standards. Computer printed wire and terminal numbers shall be used for easy identification.

The processor, rack, and power supply shall include extensive diagnostic capabilities and shall be rated for operating at up to 55 degrees C.

Minimum Controller Specifications:

Memory Size 16 or 32 Kilobytes
Modular hardware style with expandable I/O rack
Battery backup of RAM memory
Built-in Data Highway Plus
Built-in RS-232 Port
PID control loop instruction
Integer and floating point math capabilities

Scan rates as low as 0.9ms per K of program Wide operating temperatures of 32 to 140 degree F.

To provide maximum reliability for the machine control system, an air conditioner shall be provided to keep the control enclosure at a constant temperature. It shall be a "non-ozone depleting" unit providing up to 4000 BTU/hr (1170 watts) of cooling and be thermostatically controlled.

A conveniently located receptacle shall be provided (120 VAC) to power test equipment or light duty tools.

Process Control System

The waterjet system shall include a process control system which meets the following specifications:

A process control system shall use an IBM PC compatible computer as the operator interface and the data recording system. The PC shall constantly communicate with the machine controls to provide and store data for the operator and process engineer.

The process control system shall be integrated with the RJ3 controller. It shall include utilities for uploading and downloading part programs to the CNC/ROBOT controller.

Process set points and process actuals shall be displayed in an easy-to- read format on a monitor screen. Process recipes shall be easily written and modified. Should the operator enter a parameter not consistent with the process or not within the range of a particular variable, a message indicating the valid range must be displayed. The CNC/Robot controller shall specify process parameter set points, alarm limits, shutdown limits, and recipe numbers which shall be passed to the control system for immediate implementation.

Each parameter shall be protected by a multi-level security system. The process administrator shall have the option of allowing machine operators to modify some or none of the process parameters within the recipe. Recipe selection and storing shall also be protected by a security system that safeguards the recipe from accidental or unauthorized deletions or selections.

A help message shall be available for any parameters shown on the display screens. The help messages shall provide relevant information on the limits and operation of a parameter. Help information about alarms shall be specific for the displayed alarm.

Each parameter shall have programmable high and low limits. If a warning or shutdown alarm occurs, a message describing the condition and the time of occurrence shall be displayed. In addition, a diagnostic message shall be provided to assist in the rapid correction of the problem.

Machine and system alarm conditions, such as equipment malfunctions, shall also be supported by alarm and diagnostic messages.

A part identification page shall be provided to allow the operator to locate and select which part to process. The user shall be able to enter a known part number or click on a PART SELECT push button to display a sortable list of all entered/programmed parts. Along with each part recorded in the system, a part picture (entered by the customer) shall be available to aid in selecting the correct program. When the part is selected by the operator, the associated part program shall automatically be sent to the CNC and made active. Documentation such as gun selection, setup description, fixturing requirements, and user specific data shall also shown on the part identification screen. The Serial Number of the part(s) being run must be entered into this screen and stored with the part information and operation parameters in the part tracking database.
Each part program must have a minimum 16 optional motion control or process functions that can be defined. This feature shall be used when certain areas of the part need to be processed and others do not. The operator shall toggle each function on or off. This data shall then be passed to the CNC which will only perform the selected functions/areas.

The control system shall collect data during the processing of the part. The data shall be stored in a database. Reporting shall be done through an integrated database reporting utility. Reports shall be set up to provide the following: process summary reports – providing the summary of all key parameters (i.e set point, minimum, maximum and average values); alarm logs which show all alarms and shutdowns generated over a given time period; recipe prints-outs; part log reports which show all parts processed for a given time period; strip chart records which show second-by-second data. The data must be able to be reported by date, part noun, part number, serial number, or any other user specified data. Reports must be able to be exported in a wide variety of formats such as Lotus 123, Excel, Word, RTF, Text, Dbase, etc.

Tracking of preventive maintenance (PM) scheduling shall be available with the control software. The PM scheduler shall track the elapsed hours, or days on up to 100 items, tying each item to a unique on-bit for the machine. The PM system must monitor these bits each second and increments the hours, or days as required if the bits are on. This will allow maintenance to be recorded for each unique item based on it’s usage rather than on an hour basis for the complete machine. Each item shall be assigned an elapsed time/cycle for the maintenance due alarm to alert the operator. Each time maintenance is performed the system shall record the time & date information, as well as the name & ID number of the person doing the work. Each maintenance item shall have help available at the push of a button. Procedures and check lists shall be available to help get the work done.

The control system shall be housed in a floor mounted enclosure adjacent to the robot control. The enclosure shall be rated NEMA12/IP55 to provide protection against oil and dirt. The control station shall be equipped with an industrially hardened keyboard.

The control system shall be a standard “white box” computer and shall be housed inside the main control panel. This computer be a high- performance IBM compatible computer, a Pentium processor, and must use a Windows 7 operating system or newer. A 15” minimum flat panel touch screen monitor shall be mounted on the main panel.
An inkjet printer shall be provided to printout system information as described elsewhere in the specification. The printer shall be IBM PC compatible; USB communications; 120 VAC, 50/60 Hz.

Software shall be provided for the end-user to create new reports or modify the standard reports included with the system.

Screen shots must be provided to 76 PMXG Engineering showing the company’s existing running Process Control System. Displayed parameters on the control screen at a minimum must be Pressure, Water Flow Rate, Nozzle Orifice Size, Water Power, and Nozzle Rotation Speed as described in Section 2.12.3.

Screen shots must be provided to 76 PMXG Engineering showing the company’s existing running Part Selection screen. The minimum 16 optional motion controls or process functions must be included showing that the controls system can select up to 16 different surfaces of the part being stripped as described in Sections 2.12.8 and 2.12.9.

Screen shots must be provided to 76 PMXG Engineering showing the company’s existing running Preventative Maintenance screen and an example of the onscreen help that is provided for the operator to accomplish the preventative task as described in Section 2.12.11.

Screen shots must be provided to 76 PMXG Engineering showing the company’s existing running Part Data Storage screen as described in Section 2.12.10.

At 76 PMXG Engineering’s request, a machine Runoff will be performed at the manufacturer’s plant prior to shipping of the equipment. The customer's representative will authorize shipment by approving each item on the Acceptance Criteria at the time of runoff. Runoff shall include: Overview of the equipment; Audit test results for the machine; Repeat selected tests; Demonstration of the machine functions and capabilities; Review of Machine Manuals; Machine approval sign-off.
Hydraulic and Pneumatic

Components used shall be selected based on a track record of quality, and long service. Design and construction practices shall meet the following standards: ANSI/(NFPA/JIC) T2.25.1-1986 Pneumatic Fluid Power - Systems standard for industrial machinery (21 - September - 1986); ANSI/(NFPA/JIC) T2.24.1-1991 Hydraulic Fluid Power - Systems standard for stationary industrial machinery (26 - July - 1991) The contractor/manufacture shall propose sampling points and lines in accordance with Method No.1 as recommended by the National Fluid Power Association (NFPA). Method No. 1 is published as NFPA T2.9.1-1972 titled Method for Extracting Fluid Samples from the Lines of an Operating Hydraulic Fluid Power System for Particulate Particle Contamination Analysis. The proposed modifications shall be presented to 76 PMXG Engineering for approval.

For Pressurized Systems - A ball valve shall be placed in the fully opened position with a downstream capillary tube (ID> 1.25 mm) of sufficient length to reduce downstream pressure and control flow in the desired range. The sampling point shall be located in a turbulent flow region and upstream of any filters.

For Reservoirs and Non-Pressurized Systems - A 1/8" stainless steel line and ball valve should be placed in the side of the oil sump or tank. The line shall be located as close to the midpoint of the structure as feasible. In addition, the sample line shall extend internally to and as close to the center of the tank as possible.

Spare Certified Gages

One extra NIST certified gage shall be delivered for all gages requiring NIST certification.

Safety

The waterjet shall be designed and built in conformance with O.S.H.A Code of Federal Regulations 29 part 1910.

Welding

All welding shall be done in conformance with Structural Welding Code ANSI/AWS D1.1-1998.

Sound Specification

All equipment shall be designed to operate at or below 85 dBa. Sound levels shall be tested at various locations around the perimeter of the machine, five feet (1524mm) from the floor and three feet (914mm) from the machine. Sound levels shall be measured with a calibrated sound level meter set on “A” scale and “Slow” response.

Test results will be recorded and included with the Machine Service Manual. Sound Readings Documentation will include: Floor layout (footprint) of the machine; Symbols designating each sound measurement location; Customer's sound specification; Test parameters for each test; Ambient noise levels; Process parameters; Gun/nozzle types, quantity; Chart listing sound measurements for each test
Sound measurements will be taken while the machine is operating under normal conditions and cycles; Temporary increases above 85 dBa may occur while processing certain part features, while the nozzle/gun is directed “off” the part, or while operating at certain nozzle/gun parameters. These peaks are generally short in duration, resulting in minimal impact on overall operator exposure.

Paint Specification

All machine components shall be coated with a high quality industrial epoxy paint. To ensure proper paint adhesion, machine components shall be thoroughly cleaned of grease and contaminates. The machine shall be primed and painted. The result must be an extremely tough and durable surface, resistant to marring and scratching.

Unless otherwise noted, machine components shall be painted Turbine Blue (Note: some items with a high quality OEM finish may retain their OEM finish and color).

Shipping

All items and materials purchased along with necessary equipment to complete tasks listed in this SOW shall be transported by the contractor to Tinker AFB.

All items transported to Tinker AFB shall be packaged according to commercial standards.

Warranty

A standard 1 year manufacturer’s warranty is required. This warranty does not need to cover items that would normally be consumed or require replacement due to normal wear in use. These parts shall be replaced at the sole expense of the purchaser.

Manuals

The contractor shall provide 76 PMXG Engineering with 3 sets of commercial manuals of operation, maintenance, and calibration for the equipment provided including system wiring diagrams and schematics. Commercial manuals and drawings shall also be provided digitally. Commercial manuals shall be provided no later than 20 business days after government acceptance.

The contractor shall provide, to 76 PMXG Engineering, three paper and digital copies of each software and programming manual used in the development and maintenance phase of the application software.

Contractor shall provide, to 76 PMXG Engineering, an electronic and paper copy of the installation drawings. The electronic version shall be compatible with AutoCAD software.

Machine Run-off

Contractor shall provide a machine run-off of the purchased equipment at the manufacturer prior to shipping the equipment.

A Government representative will authorize shipment of equipment after conducting a performance checklist including the following:

Demonstration of the machine functions and capabilities

Review of Machine Manuals

Repeatability of selected tests

Personnel

Contractor shall provide a service Engineer/Technician to assist and supervise the installation of the purchased equipment.

Installation Installation of System The installation of the waterjet system is considered to be a turn key installation by the contractor. The government will provide all required ultility connections to within 50 ft. of the installation location. The contractor shall provide all labor, tools, parts, facilities, travel, transportation and incidentals to deliver and install the system.

The contractor shall install Government purchased industrial equipment and provide utility connections for all installed equipment.

Contractor shall coordinate the delivery and installation so that interim storage is held to a minimum.

Contractor shall coordinate with 76 PMXG Engineering on the exact equipment layouts before installation. The coordination with 76 PMXG Engineering is at the time when the contractor will be placing the equipment.

Contractor shall run new utility connections to the new equipment from existing sources. The Government will provide utilities within 50 feet of the desired installation location. The contractor shall provide complete installation drawings to 76 PMXG Engineering for review at least 30 calendar days before the scheduled installation of the equipment. No major electrical system upgrade or buss duct system extension is included.

The contractor shall supply all services needed to ensure proper installation of equipment.

Installation and construction work shall be in accordance with OC-ALC Design Standards and Guidelines, provided upon request. Manufacturer’s installation recommendations, current commercial industry codes, standards (American National Standards Institute (ANSI), American Petroleum Institute (API), American Society of Mechanical Engineers (ASME), Environmental Protection Agency (EPA), the Instrumentation, Systems, and Automation Society (ISA), National Fire Protection Association (NFPA), Occupational Safety and Health Administration (OSHA) and recommended practices shall also be observed. For equipment and installation of said equipment not covered by existing standards and codes, Contractor shall provide recommendations to 76 PMXG Engineering for approval.

All equipment shall be identified and labeled with permanent tags consistent with the electrical and hydro-mechanical schematic drawings provided by contractor.

All questions concerning the proper way to install the equipment shall be direct to the manufacturer’s expert.
Operational Set-Up and Checkout

The contractor shall power up the control and instrumentation systems after installation. The contractor shall perform a checkout of all systems with assistance from a technical expert provided by the manufacturer to verify correct installation.

The contractor shall make all necessary set-up changes for correct operation of the system.

Government Acceptance. Upon completion of Installation of all equipment, 76 PMXG Engineering will accomplish inspection and acceptance of services performed based on requirements of the SOW.

Training

The Contractor shall provide operator and maintenance on-the-job-training on site at Tinker AFB. Operator on-the-job-training shall include the equipment, safety systems, and related procedures. Maintenance on-the- job-training shall include software upkeep and maintenance, calibration, electrical and electronic, and mechanical on-the-job-training. On-the-job- training shall be concurrent with or immediately following installation, set-up, and acceptance of the systems at Tinker AFB.

Maintenance training shall include a system overview of all hardware components, fault isolation, troubleshooting techniques, component repair and replacement, and system calibration.
Software and programming training shall include data input source code editing, parameter selection, compiling and linking, back-up procedures, and system and network diagnostics and troubleshooting.
Up to 6 government employees will attend the maintenance and operating training concurrent with or immediately following installation, set-up, and acceptance of the systems. Up to 6 government employees will attend the software training session.
Training will be up to 8 hours for each section (Section 1: maintenance and operation and Section 2: Software Training) of 6 employees and will take place on a Monday to Friday between the hours of 7:00am to 4:00pm, excluding government holidays.

APPENDIX A

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File details come from the government source that posted it. Updated .