Hydraulic Press - SOW_FINAL_without building numbers.docx

Statement of Work

Hydraulic Press Specifications for New Explosion-Proof Press

1.0 SCOPE

The Government has a requirement for the design, supply and installation of a new explosion proof press machine at Naval Surface Warfare Center, Indian Head, MD, (NSWC IHD). The term "machine" as used in this specification comprises the machine tool, the control stations, the operating system, electric, hydraulic, and/or pneumatic equipment, as well as all sealed interconnections between such items to form a complete functional machining center. The press machine described in Hydraulic Press Description will be used for pressing explosive chargers from explosive molding powders. The nature of pressing explosive material requires special physical enclosures, such as National Electrical Manufacturers Association (NEMA) 7, NEMA 9 and NEMA 4X rated electrical equipment, two separate control stations (local and remote) and safety alarming applications incorporated into the machine/control stations.

The overall machines shall be certified to be safely operable and controlled from a Local Control Station proximate to the machine frame. The overall machines shall also be certified to be safely operable and controlled from a Remote-Control Station location ~15 feet away from the location of the press frame. Both control stations are to be in a hazardous location where explosives are to be processed. The National Electric Code (NEC) designates this location as Class I, Division 1, Group D, and Class II, Division 1, Groups E, F, and G. Methods that can be used to permit safe operation of this equipment in this location include: explosion-proofing (NFPA 70, Article 500), purging or pressurizing (NFPA 496) and intrinsic safety (NFPA 70, Article 504). Electrical equipment used in hazardous environments shall be Factory Mutual (FM) or Underwriters Laboratory (UL) approved. Each piece of equipment/hardware shall be provided with a plate that designates the authorized hazardous environments the machine may be subjected to which is NEC Class I, Division 1, Group D requiring NEMA 7 and NEMA 4X rated enclosures and Class II, Division 1, Groups E, F, and G requiring NEMA 9 and NEMA 4X rated enclosures. In addition, each piece of the machines, wherever located, shall be connected to the secondary grounding girdle.

2.0 REQUIREMENTS

The Government requires all materials, equipment, operating systems and personnel to design, fabricate, assemble, inspect, test, deliver, install, operate, and educate Government personnel to operate the machine. The contractor shall design, deliver and install the machine that meets all the specifications herein and/or not stated that qualify them for safe operation in NEC defined Class I, Division 1, Group D and Class II, Division I, Groups E, F, and G hazardous environments, per National Fire Protection Association (NFPA) 70 Article 500. In addition, each piece of the machine, wherever located, shall be connected to the secondary grounding girdle.

2.2 Delivered Supplies

· The contractor shall supply a label on each of the electrical control stations stating that the control station is a control station for hazardous locations.

· The contractor shall connect the machine to Government supplied safeties and interlocks such as fire protection on, flashing warning lights, blast doors closed, live explosives being worked, etc., and provide 25% additional spare circuits for future features.

· The contractor shall provide an Allen Bradley programmable logic controller for the press, as defined in this specification.

2.3 CDRLs

The contractor shall provide legible drawings (hard and Solidworks readable digital), wiring, pneumatic, vacuum, lubrication and hydraulic diagrams, inspection test reports, operating manuals, maintenance plans, recommended spare parts and other documentation all written in English.

Hydraulic Press Description

3.0 PRESS DESCRIPTION

The Government requires an explosion proof Press with Allen Bradley Programmable Logic Controller and with these key features to be included:

3.5 Electrical components shall meet the NEC requirements for Class I, Division 1, Groups D, and Class II, Division 1, Groups E, F, and G hazardous locations per NFPA 70 Article 500 where applicable.

3.11 Supply means for full control of the machining operation including but not limited to programming, operator messaging, alarm monitoring, emergency stop and key interlock switches and shall supply means for the lead operator in the Remote-Control Station to enable the Remote-Control Station via a key inserted in a two-position key switch. Only one unique key shall be allowed for this machine to be removable only in the OFF position. When the Remote-Control Station is selected by the lead operator to be the active control station, a LED indicator labeled “REMOTE CONTROL STATION IS ACTIVE” shall be illuminated on the Remote-Control Station.

3.29 Vacuum Selector Switch (portable vacuum pump or central vacuum pump)

3.33 Local Control Station key features: The overall machine shall be certified to be safely operable and controlled by the Local Control Station proximate to the machine frame. All electric components shall meet the NEC requirements for Class I, Division 1, Group D, and Class II, Division 1, Groups E, F, and G hazardous locations per NFPA 70 Article 500. Also supply means for the lead operator in the Local Control Station to enable the Local Control Station via a key inserted in a two-position key switch. Only one unique key shall be allowed for this machine to be removable only in the OFF position. When the Local Control Station is selected by the lead operator to be the active control station, a LED indicator labeled “LOCAL CONTROL STATION IS ACTIVE” shall be illuminated on the Local Control Station.

3.34 Any non-metal components that will be in contact with explosives must be tested for compatibility with explosives to be used with the press.

3.35 All pipelines and storage tanks shall be labelled in accordance with 20 CFR 1900.1200.

4.0 MACHINE SPECIFICATIONS

4.3 Ram Pressing Speeds: 2-38 inches per minute range adjustable, each ram independent

5.0 PHYSICAL SEALING

5.1 Special physical sealing is necessary to prevent explosive dust from building up or entering potential pinch point mechanisms or moving parts on the machine. Physical sealing shall include covers of ways & slides to positively prevent water/explosives from entering moving parts and covers or protectors over all potential pinch points where explosive dust has the potential to accumulate.

6.0 WATERTIGHT CONFORMANCE

6.1 To prevent the entry of washdown water into electrical components and enclosures, all equipment on the machine and control stations shall be watertight (NEMA 4X or equivalent). This includes position feedback devices (encoders, etc.), control enclosures, limit switches, junction boxes, and all other electrical components and devices on the machine and control stations. In addition, all exposed components of the machine shall at least be corrosion resistant. The press and all supporting equipment will be in a non-humidity/temperature-controlled environment.

7.0 SPECIAL APPLICATIONS SOFTWARE AND INTERLOCKS

Special applications programming shall include customized safety interlocks necessary for explosive pressing. Safety monitoring and alarms to include:

8.0 PRESS CONTROL SYSTEM

The press control system shall be an Allen Bradley Programmable Logic Controller that has the current processor technology for press control. The control system shall have the capability to manage unusual situations relative to power and, or process failure for emergency stops, alarming and error messaging to alert operator of unsafe conditions and respond to unsafe conditions. As a minimum, the control system shall include:

8.1 Processor

8.2 USB port for downloading data

8.3 Shall not contain operable wireless LAN, Blue Tooth, 802.11 or WIFI options.

9.0 BLAST DOOR INTERLOCK

9.1 When operating in a Remote-control mode, all blast doors shall be closed for personnel protection when machining explosives. The control system shall provide for an interlock/bypass switch that will indicate when the blast doors are not secure.

10.0 ELECTRICAL CONFORMANCE

10.1 The Electrical Equipment ratings of all electrical equipment on the machine tool, Local Control Station, and Remote-Control Station shall meet the NEC requirements for Class I, Division 1, Group D, and Class II, Division 1, Groups E, F, and G hazardous locations per NFPA 70 Article 500. All equipment and component parts shall be UL or FM listed for hazardous environments. All wiring and electrical equipment installations shall be in conformance with the most current editions of both NFPA 70 “National Electrical Code”, and NFPA 79, “Electrical Standard for Machine Tools…”

10.2 The machine and all the controls shall be grounded to the secondary girdle and meet the resistance requirements of OP-5, Chapter 5.

11.0 USER MANUAL (S)

11.1 All written documentation and manuals customarily provided to the public with a commercial item shall be provided. This shall include user manual(s) or equivalent as well as copies of any software, and any manuals for the software included with the system, if customarily provided. This documentation must be received at Indian Head with the system hardware, unless other arrangements are agreed to by the authorized Government representative. In addition to the above documentation, which is customarily provided, the following specific documentation is required and shall be included in the price of the equipment.

11.2 Shall include all operation and service manuals and schematics in digital form. Electronic copies on CDs that are readable on a windows-based PC are acceptable.

12.0 GOVERNMENT AND CONTRACTOR RESPONSIBILITIES BEFORE INSTALLATION OF THE MACHINE AT NSWC IHD

12.1 Upon receipt of the machine parts, the Government will provide the rigging and equipment to place the machine parts in temporary storage.

13.0 UPON DELIVERY OF THE MACHINE PARTS IN THE OPERATING BUILDING, THE CONTRACTOR SHALL PERFORM THE FOLLOWING WORK TO THE SATISFACTION OF THE GOVERNMENT TECHNICAL POINT OF CONTACT (TPOC)TO OBTAIN ACCEPTANCE:

13.3 Power up the machine and control system and bring into operation.

13.6 At the completion of the installation and demonstration of the specifications, the CONTRACTOR must provide on location training at Indian Head for 8 people for a minimum of at least three whole days in the subject areas listed below, that is sufficient to enable them to independently program, operate, and maintain the machine:

14.0 WARRANTY

14.1 The contractor shall offer the Government at least the same warranty terms, including offers of extended warranties, offered to the general public in customary commercial practice. These warranty terms must be included in the system price. The period of the warranty shall begin upon acceptance.

Final acceptance by the Government will occur at:

NAVSEA IHD

Receiving 4522 McMahan Rd. Ste. 100 Bldg. 116 Indian Head, MD 20640-5125

15.0 SHIPPING

The Contractors price shall include the cost of shipping the complete machine to:

NAVSEA IHD

Receiving 4522 McMahan Rd. Ste. 100 Bldg. 116 Indian Head, MD 20640

The packaging shall prevent any damage which may occur during transit. The Contractor paperwork shall state the contract number. Transportation shall comply with Department of Transportation regulations at Title 49, Code of Federal Regulations.

16.0 GOVERNMENT FURNISHED INFORMATION

The Government shall provide the appropriate information as required. All Government provided information is considered the property of the Government and shall be used for no other purpose except as identified herein or in an applicable technical instruction.

17.0 BASE ENTRY

All contractors entering NSWC IHD must be U.S. citizens and must obtain a temporary identification badge from the Pass and Identification Office upon arrival. Drivers must show two forms of identification, proof of insurance, and registration documents to obtain a temporary identification badge. All base access and arrangements must be done by the vendor prior to providing services and deliveries.

APPENDIX A

NARRATIVE OF THE OPERATION OF THE GOVERNMENT SUPPLIED BLAST DOOR CONTROL SYSTEM TO BE INSTALLED IN OPERATING BUILDING

A-1. The lead operator shall initialize the Blast Door Control System by applying ~ 30 psi of air from a filtered and dried regulated source to the Blast Door Control Station (Feature 1) located in the Adjacent Control Station in Operating Building, Bay 2 or 8.

A-2. The lead operator shall decide which single piece of equipment will be used to process the material and connect the signal source hose from Feature 1 to the corresponding equipment socket in the Manual Equipment Selector Signal Sending Manifold (Feature 2) accordingly. Other means may be employed to accomplish the same result.

A-3. The lead operator shall decide whether the material to be processed is inert or live explosive and position the Manual Inert/Live switch (Feature 3) accordingly.

A-4. If the Inert position is selected, the selected processing equipment shall be enabled to be operated whether the blast doors are open or closed.

A-5. If the Live position is selected, the lead operator shall ensure that all blast doors are closed. In this case, a pneumatic signal shall pass serially thru all the Blast Door Closed Limit Switches to the Equipment Selector Sending Manifold (Feature 2) and then to the selected equipment. When manufactured, the contractor shall have provided interlocks for this equipment to be enabled to be operated only when this signal is received (unless bypassed intentionally). When the equipment is operated (i.e. moving), the contractor shall have provided means to echo the received signal back to the Blast Door Control Station (Feature 1), which shall cause the blast doors to be held closed until the equipment is no longer being operated. This shall prevent unintended vault entry into the hazardous location during explosive processing operations.