Lathes_CSSB2_CSRB_SOW_Rev 7.docx

STATEMENT OF WORK (SOW)

for Two Lathes

1.0 BACKGROUND

1.1 U.S. Army Combat Capabilities Development Command (DEVCOM) is advancing technology for use on cannon tubes manufactured within the at the Watervliet Arsenal. This process is being used to eliminate the carcinogenic hexavalent chromium plating from the Defense Industrial Base (DIB). U.S. Army Tank-Automotive & Armaments Command (TACOM)'s Watervliet Arsenal (WVA) is supporting and transitioning new processes for reduction of environmental hazards in the manufacture cannon tubes while eliminating hazards that can affect human health and the environment. These lathes will be a component in this overall process.

2.0 PURPOSE

2.1 This Statement of Work is to define the requirements and deliverables to be used in the selection and procurement of (2) identical lathes for new technological process of manufacturing cannon tubes utilizing environmental alternatives to be installed at WVA. Labor and equipment required for move-in, installation, leveling, and training of the lathes shall be provided and performed by the system manufacturer.

3.0 REQUIREMENTS

3.1 The contractor shall provide two (2) identical lathes with the following required minimum specifications:

0. Capacities

0. Center height: 600mm (23.6 in.)

0. Swing over bed: 1,200mm (47.2 in.)

0. Distance between headstock and ring steady rest max: 12,500 mm (41 ft.). Note: this provides the accommodation for the required max. and min. component sizes in ring steady rest. There shall be at least a left self-centering steady rest (SS-L), a right self-centering steady rest (SS-R) and a ring steady rest provided.

0. Distance between headstock and ring steady rest min: 5,450 mm (17.88 ft.). Note: this provides the accommodation for the required max. and min. component sizes in ring steady rest. There shall be at least a left self-centering steady rest (SS-L), a right self-centering steady rest (SS-R) and a ring steady rest provided.

0. Max. tube diameter accepted: 508mm (20 in.)

0. Max. weight of components (in headstock, one intermediate steady rest and ring steady rest): 10,000 kg (22,000 lbs.)

0. Technical Specifications

1. Main Headstock

0. Range of spindle speeds: 0-500 RPM

0. Range of spindle speeds at constant torque: 5.4-500 RPM

0. Range of spindle speeds at constant power: 54-500 RPM

0. Number of speed ranges: 3

0. Standard speed range shifting: automatic by M function

0. Driving power of AC brushless main motor in S1: 51 kW (68 HP)

0. Max torque: 9,000 N*m (6,496 ft.*lbs.)

0. Spindle nose DIN 55027: 15 in. size

0. Spindle hole: 160 mm (6 3/10 in.)

0. Dia. of 4-jaw independent chuck (steel): 800 mm (31 1/2 in.)

0. Min clamping Dia.: 100 mm (3 15/16 in.)

0. Max clamping Dia.: 508 mm (20 in.)

1. Bed

1. Width of bed at guideways: 520mm (20 ½ in.)

1. Width of bed at base: 620 mm (24 2/5 in.)

1. Height of the bed: 650 mm (25 3/5 in.)

1. Total bed length: 27,330 mm (89.6 ft.)

1. Number of bed sections: 3

1. Saddle

2. Main dimensions (LxW): 850mm x 850 mm

2. Rapid traverse: 4000 mm/min

2. Stepless variable working feeds: 1-4000 mm/min

2. Maximum Z-axis working stroke: 19,550 mm

2. Maximum Z-axis working+extra stroke: 22,000 mm

2. Motor size: 50 N*m (36.88 ft.*lbs.)

4.0 TECHNICAL DESCRIPTION OF REQUIREMENTS – Each of the two lathes will have the following:

4.1 Bed with (4) flat guideways in cast iron and hardened ways:

4.1.1 The bed rests on the floor along its entire length.

4.1.2 Clamping and leveling points are arranged with a short distance between them.

4.1.3 The bed is to be case from an electric arc furnace in an alloy cast iron with 1-1.5% of copper. It shall be stress relieved to eliminate any tensile residual stresses and risk of deformation.

4.1.4 The cross section of the bed shall be heavily ribbed and shall contain phenolic resins in order to damper vibration and increase machine stability.

4.1.5 The slideways shall be induction hardened up to ~50 HRC and precision ground to a high standard of accuracy.

4.1.6 The sidewalls of the bed shall contain helical racks for longitudinal transmission of steady rests.

4.1.7 The total bed is to be divided into three (3) sections.

4.2 Headstock (cast iron):

4.2.1 The spindle rotation of the headstock is to be controlled by a brushless motor and shall be fitted on a base anchored to the foundation and separate from the bed in order to eliminate vibrations from the bed to the lathe.

4.2.2 A digital drive shall be provided for gradual acceleration, deceleration, and braking.

4.2.3 The headstock shall be provided with a three-speed gearbox, which allows for maximum power of the motor over a wide speed range.

4.2.4 The shifting between the gear steps shall be carried out by M function.

4.2.5 All gears and shafts shall be manufactured out of Ni-Cr-Mo steel, heat treated, and ground.

4.2.6 Both helical and straight gears shall have proper involute correction to enable a smooth rolling motion.

4.2.7 All gears shall be lubricated through an independent pump through a drip and mist system.

4.2.8 A safety interlock shall be provided to prevent spindle rotation in the event of a pressure drop in the lubrication circuit.

4.2.9 Push buttons shall be provided to enable intermittent rotation of the spindle in order to facilitate loading and setup operations.

4.2.10 The main headstock shall be provided with an interlocked spindle location pin to prevent rotation when loading and fixturing components.

4.3 Main spindle:

4.3.1 The main spindle shall be manufactured out of Ni-Cr-Mo steel and heat treated, hardened, and precisely machined.

4.3.2 The main spindle shall be supported on multiple positions to appropriate rigidity.

4.3.3 Appropriate cylindrical roller bearing/s shall be provided in order to enable a fine radial setting and a perfect axial backlash adjustment.

4.3.4 All bearings provided shall be individually force lubricated with adjustable flow.

4.4 Travelling ring steady rest w/pass-through hole of 508 mm Dia.:

4.4.1 One (1) 4 –jaw chuck travelling steady rest shall be provided.

4.4.2 This ring shall slide on the bed by means of an independent gear motor.

4.4.3 This steady rest shall consist of a wide dimensioned and high rigidity body which is fitted to a ring having a wide bore.

4.4.4 This ring shall rotate on precision bearings and has the ability to be finely adjusted to 0.01 mm (0.0004 in.)

4.4.5 The steady rest shall be equipped with a pump to provide forced lubrication of the bearings as well as time lubrication of the slideways.

4.4.6 The steady rest shall be fitted with an automatic clamping system with the following requirements:

4.4.6.1 Hollow spindle hole: 508 mm (20 in.)

4.4.6.2 Min. & max. clamping capacity: 508mm (3.93 in. – 20 in.)

4.4.6.3 Weight admitted on the steady rest: 6,000 kg (13,227 lbs.)

4.4.6.4 Dia. of 4-jaw chuck: 800 mm (31.5 in.)

4.5 Two (2) self-centering steady rests w/75-508 mm Dia.:

4.5.1 Each self-centering steady rest shall consist of:

4.5.1.1 Sliding base positioned along the base by a motor.

4.5.1.2 Unit holding the roller arms, mounted on the base slide. Movement of the base shall occur through an independent motor and a rack and pinion system, the same as with the C-type steady rest.

4.5.2 The top unit shall include a cam-and-lever mechanism to enable good clamping accuracy and repeatability.

4.5.3 The C-type steady rest, sliding base shall be provided with automatic clamping and automatic lubrication of the slideways.

4.5.4 The requirements are:

4.5.4.1 Capacity: 75-508 mm (2.95 in. – 20 in.)

4.5.4.2 Max admitted weight: 3,000 kg (6,600 lbs.)

4.5.4.3 Diameter of rollers: 90 mm (3.54 in.)

4.5.4.4 Width of rollers: 50 mm (2 in.)

4.6 Saddle:

4.6.1 The saddle shall be freely moving along the bed section, as defined between the ring steady and the bed right end side. This will have a max. working stroke of 19,550 mm and an extra stroke of 22,000 mm

4.6.2 The saddle shall consist of a large cast base and shall provide maximum rigidity during travel.

4.6.3 The counterways of the saddle shall be lined with anti-friction and self-lubricating fiber strips to prevent stick slip, even at slow speed rates.

4.6.4 An independent electro pump and tank shall be provided to monitor lubrication of the ways.

4.6.5 A flashing light indicator shall be provided to warn of low oil levels.

4.6.6 Transmission of the saddle shall be performed by two pinions working on two opposed helical racks.

4.6.7 A brushless servomotor shall be provided with an encoder. This shall be driven by digital drives to provide both feed and rapid traverse along the longitudinal axis in both directions. Positional precision shall be on the order of 0.1mm (0.00394 in.)

4.6.8 Quality wipers shall be fitted on the saddle to prevent penetration of impurities.

4.6.9 A flat top plate (850mm x 850 mm) shall be provided and bolted to the saddle. This should include T-slots for easier positioning and locking of additional devices.

4.7 Main operator control panel:

4.7.1 The lathe shall be provided with a remote-control panel housing all of the control required to operation the lathe from the NC unit in automatic mode, m.d.i., and jog.

4.7.2 The panel shall be fitted with an electronic handwheel to operation the spindle in manual mode.

4.7.3 The panel shall be mount on a support separate from the lathe at a position that is mutually agreed upon.

4.8 Control panel for headstock:

4.8.1 The lathe shall be equipped with a push-button panel fitted on the headstock.

4.9 Hydraulic power pack:

4.9.1 The lathe shall be equipped with a sole hydraulic power pack near the main headstock.

4.9.2 All necessary servo-controls and malfunction alarms shall be provided.

4.9.3 A separate “open circuit” power pack shall be provided to provide lubrication for the slideways for the steady rests and “ring steady”.

4.9.3.1 Warning lights shall be provided to alert the operator to lack of lubrication.

4.9.3.2 A float indicator shall be provided in order to display lack of lubrication.

4.10 Safety guarding:

4.10.1 The lathe shall be provided with a working area that has appropriate protections, including:

4.10.1.1 Sliding guard on the chuck with a suitable interlock

4.10.1.2 Rear protection wall

4.10.1.3 Side fences with interlocked gates

4.10.1.4 Photo sensors on operator side of lathe

4.11 Electrical equipment:

4.11.1 All electrical equipment shall be enclosed in a separate cabinet.

4.11.2 Divided in section including power, PLC, and auxiliary functions.

4.11.3 Digital drive for the main motor in order to provide gradual accelerations, decelerations, and braking.

4.11.4 A programmable PLC unit, integrated into the CNC, which operates as an interface between the lathe and the control unit and external production devices.

4.11.5 The following safety devices shall be provided at a minimum:

4.11.5.1 Micro-switches monitoring the correct meshing of speed ranges.

4.11.5.2 Warning light/s for hydraulic power pack.

4.11.5.3 Warning light/s for slideways lubrication system.

4.11.6 The CNC screen shall show clear messages and/or alarm/s if anomalies are detected.

4.11.7 A diagnostic system shall be provided to facilitate troubleshooting and minimize downtime.

4.11.8 The electrical cabinet shall be provided with air conditioning.

4.11.9 The operating voltage shall be 480 V +/-10%.

4.11.10 The operating frequency shall be 60 Hz +/- 2%.

4.12 Control Unit – Siemens Sinumerik “One”:

4.12.1 The lathe shall be equipped with a modular 32-bit microprocessor CNC Siemens Sinumerik “One” continuous path control for turning operations with PLC and operating system on PC-card.

4.12.2 The CNC unit shall be fitted with one (1) remote control panel to be positioned near the lathe in a mutually agreed upon location.

4.13 Operation and displays:

4.13.1 The language and displays shall be in English.

4.13.2 The display shall provide information such as:

4.13.2.1 Actual block

4.13.2.2 Spindle revolutions

4.13.2.3 G functions

4.13.2.4 Auxiliary functions

4.13.2.5 All setting data such as part programs, user data, and machine data

4.13.2.6 Alarms and messages

4.13.2.7 Program running

4.13.3 The lathe shall display what operating mode it is in (i.e. “Automatic”, “Jog”, or “MDA”).

4.14 Programming:

4.14.1 The vendor shall provide a Siemens programming language editor to DIN 66025 with a comprehensive range of high-level language elements.

4.14.2 The programming shall provide extensive parameter technology, program generation parallel to machining, DRT (Differential-Resolver-Function), constant cutting speed (G96), and minimum (G25) and maximum (G26) programmable limitation of the spindle revolutions.

4.14.3 The NC user memory shall be approximately 3 MB for part-programs and technology cycles.

4.15 Communications:

4.15.1 Two (2) Ethernet 10/100 Mbit/s (RJ45)

4.15.2 Four (4) USB 2.0

4.15.3 One (1) PROFIBUS/MPI interface

4.15.4 Extensive archiving procedures

4.16 Operating modes:

4.16.1 The operating modes shall include “Automatic”, “Jog”, and “MDA”.

4.17 Operating Components:

4.17.1 An OP015 flat operator panel with 15 in. color display (or better) shall be provided.

4.17.2 A 19 in. machine control panel shall be provided.

4.17.3 A PCU 50.5 with Win7 EmbSys (64 bit) operating system, 80 GB hard disk, 4096 MB RAM, and software OPERATE shall be provided.

4.18 Run-off and acceptance testing of the lathe:

4.18.1 A runoff and acceptable testing shall be planned at the vendor factory in the presence of Benet/WVA representatives. This testing shall include:

4.18.1.1 A geometrical test according to ISO 1708 standards.

4.18.1.2 2 hours of operational testing (DRY RUN)

4.18.1.3 Check out of contractual specifications.

4.18.2 At the end of the run-off test, the Gov’t shall issue written (PRELIMINARY) acceptance.

4.18.3 The final run-off testing, consisting of the same parameters listed in Section 4.18, will be performed at the WVA. When all testing has been completed and standards are proven to be met, the Government shall issue a written (FINAL) acceptance once.

5.0 FOUNDATION – the following applies to each lathe:

6.0 DELIVERY REQUIREMENTS

6.1 Unless otherwise specified, the lathes shall be delivered to:

W15BW9

1 Buffington St.

7.0 INSTALLATION

8.0 WRITTEN DELIVERABLES – The following written deliverables will be supplied utilizing the English language.

8.1 Operation Manuals for each lathe

8.2 Training manuals, materials, documentation for each lathe

8.3 Foundation drawings/blueprints as specified in Section 5 for each lathe

8.4 Dimensional drawings/blueprints regarding for each lathe supplied via a 3D model in STEP (Standard for the Exchange of Product model data) or equivalent programming format.

8.5 Maintainability: All equipment components offered that are subject to wear, distortion or failure and all parts which require periodic adjustment shall be accessible for replacement or adjustment. The contractor shall provide Instructions for the Maintenance and Adjustment of Equipment Components Instructions for the preventative maintenance and adjustment of these parts shall be clear, concise, and definitive in accordance with (IAW) Contract Data Item List (CDRL) A001.

8.6 Motors: All motors provided shall be of the type and horsepower rating to meet the specified requirements based on all applicable engineering practices and standards. All motors shall be rated for continuous duty. Motors shall not operate in an overload condition during normal operation of the equipment and shall be equipped with thermal overload protection. Motor starters and controls shall operate at 24 VDC. Motor starters shall provide drop out protection. This means that in the event of power loss, the equipment shall be re-energized only by deliberate action of the operator. Manual or mechanical motor starters are not acceptable. All motors shall be housed in enclosures of the appropriate NEMA type for class and severity of service. All AC unidirectional motor housing shall bear a directional arrow to indicate proper rotation direction when correctly wired. All AC motors rated at 25 horsepower or greater shall be equipped with a “soft start” mechanism which provides for reduced voltage starting. All polyphase AC motors rated at 1 horsepower or greater shall be tested per IEEE Standard 112-Method B and must meet premium efficiency requirements per NEMA MG 1-2006 Table 12-12 or IE3 9IEC 60034-30:2008. All motors are to be permanently lubricated and sealed.

8.6.1 Motor I.D. Plates: Each motor shall bear an identification plate containing the identity of the manufacturer, model number, serial number, input voltage, amperage, horsepower, phase, frequency, duty cycle, and frame size or mounting identification in accordance with IAW CDRL A002. No I.D. plates shall be printed.

8.7 Asbestos and Mercury Free Certification: All materials utilized in the system shall be certified as asbestos and mercury free unless substitute materials do not exist. This certification shall be provided prior to machine delivery in accordance with IAW CDRL A003.

8.8 Material Safety Data Sheets: The offeror shall provide Watervliet Arsenal with all material safety data sheets at the time of proposal submission in accordance with IAW CDRL A004.

8.9 Lead Free and Chromium Free Paint Certification: All paints and primers applied to the system shall be certified as lead free and chromium free. Lead based paint is paint that contains more than six one hundredths of one percent (0.06%) lead by weight. This certification shall be provided prior to machine delivery in accordance with IAW CDRL A005.

8.10 PCB Free Certification: To the extent that the machine is charged with lubricant or hydraulic fluids at the contractor's plant for preliminary acceptance inspection, these fluids shall not contain Polychlorinated Biphenyl’s (PCBs). The machine and its equipment shall be certified as PCB free, and certification shall be provided prior to machine delivery in accordance with IAW CDRL A006.

8.11 Lockout/Tagout Procedures: The manufacturer shall provide the control of hazardous energy (lockout/tagout) per OSHA 29 CFR 1910.147 in accordance with IAW CDRL A007. This information shall be incorporated into the maintenance manual. Contractor shall ensure employees are trained so they know, understand, and follow the applicable provisions of the hazardous energy control procedures. The control of hazardous energy sources includes but is not limited to electrical, pneumatic, hydraulic, chemical, mechanical, UV, electromagnetic and thermal energy.

8.12 Utility Connections: Equipment supplied to the Watervliet Arsenal shall have a single point shut off for each utility supplied to the system. This single point shut off will be referred to as the “point of first connection”. Each type of power source shall have only one point of first connection. Each point of first connection shall be clearly labeled on the system and shown in the safety Lockout/Tagout Procedures in accordance with IAW CDRL A007. These points of first connection shall be located on a stationary component and positioned so that they shall not create a hazard to personnel during normal operation of the system. The first connection point shall be accessible from the shop floor without the use of ladders, steps, or stools. Access to this first connection point cannot be obstructed or hampered by operation of the system, in the event of a safety incident requiring the main power to the machine to be shut off in an emergency.

8.13 Identification Plate: A corrosion resistant metal plate shall be securely attached to the machine in a location visible to the operator's workstation. This plate shall bear, as a minimum, the information called for below, with space at the bottom of the plate for the addition of one line of information to be applied by the government in accordance with IAW CDRL A008.

A. Nomenclature B. Manufacturer's name C. Model D. WV# (Please contact the Watervliet Arsenal Representative to receive this number) E. Manufacturer's Serial Number F. Power Input (voltage, phase, frequency, and full load amps) G. Government Contract Number H. Date of Manufacture

8.14 Utility Connection Labor and Requirements: Watervliet Arsenal will provide a utility connection between first point of connection for all utilities (electrical, air, water, etc.) on the equipment, and the facility. Only one “facility side” connection per utility type will be provided. All other additional or ancillary utility connections shall be provided by the contractor.

8.14.1 Electrical: The WVA power source that the specified equipment will be connected to will be a nominal 480 volts, 3 phase, 60 Hz AC voltage. However, the machine shall be able to operate normally at source voltages ranging from 432 to 504 volts. The WVA power source does not include sub-panels, filters, surge protection, or any peripheral equipment necessary to make the equipment functional. All electric requirements shall be routed to a single point of connection, including sub systems or 120V connections.

NOTE: Contractor shall state required power/electrical requirements for offered machine. See Enclosure C – Electrical Survey and complete in accordance with IAW CDRL A009.

8.15 Lubrication: The machine shall be equipped to provide lubrication to every moving part where lubrication is essential to prevent damage. Slideways shall be lubricated by an automatically cycled distribution system such as that manufactured by Trabon or approved equivalents. Gearboxes and transmission cases shall be lubricated by the wet sump splash method. Spindle bearings shall be lubricated by recirculating pressure spray systems. Automatic lubrication systems shall be equipped to be fail safe to the maximum extent possible. All sensors and devices used to detect the presence or absence of lubrication shall be accessible for test or replacement without major disassembly. Manual lubrication methods are permissible for lubrication points not practically served by automatic systems. For non-recirculating automatic systems, such as slideway lubrication, the reservoirs shall be sized to provide lubrication reserve equivalent to 80 operating hours and shall be located at floor level. For recirculating automatic systems, cleanable or replaceable filtration devices shall be provided. Wet sump type systems shall be equipped with a means to confirm proper oil level. Sight gages shall be of the external standing tube type rather than the flush mounted porthole type. Standing tube sight gages shall be protected against accidental breakage.

8.15.1 Lubrication Plate: A lubrication plate shall be permanently fastened to the machine and shall clearly indicate the type and viscosity of lubricant and the service interval for all automatic and manual lubrication reservoirs and fittings. The plate shall include a simple diagram which depicts the physical location of all lubrication points on the machine structure in accordance with IAW CDRL A010.

8.15.2 Lubricants, Hydraulic Fluids, Oils and Coolants: Watervliet Arsenal has established a standardized list of lubricants, hydraulic fluids, oils, and coolants. The contractor shall choose the required lubricants, hydraulic fluids, oils, and coolants from Enclosure A, enclosed or where there is a designated equivalent. If a substitute is required, the contractor shall provide at the time of machine delivery, a justification which shall include the manufacturer, type, and specification number as well as the reason for the substitution. A list of all fluids required to operate the machine shall be provided to the Arsenal 30 days prior to delivery in accordance with IAW CDRL A011.

8.16 Painting: All exterior machine surfaces shall be painted except where bright metal is required for machine function or to otherwise adhere to the requirements of this specification. Paint shall be chromium free and lead free. Quality and manner of application shall afford protection throughout the normal life of the machine. Paint shall be "semi gloss", and selected by the Government, from a list of standard colors supplied by the offeror with their proposal in accordance with IAW CDRL A012. This selection shall be made after contract award. Danger areas shall be painted red and caution areas shall be painted yellow in accordance with OSHA Standard 1910.144. Appropriate warning signs, tags or emblems shall be affixed to respective areas of the machine in accordance with OSHA Standard 1910.145.

8.17 Technical Data: All data shall be in the English language and shall be furnished in accordance with the quantities, formats, and delivery dates below. All data shall be packaged and delivered separately from the machine itself marked to the attention of the Watervliet Government Representative. The contractor shall provide full documentation in the form of “as built” drawings and manuals. Drawings shall not be generic or sub-assembly prints. A “hardcopy” refers to a reproducible printed, paper copy. An “electronic copy” refers to a document saved on CD. All AutoCAD drawings shall be provided in AutoCAD version 2014 or later, shall be of one-to-one scale, shall be dimensioned in English units, and shall not utilize the color yellow. “On-line” technical data shall not be acceptable as the sole means of providing technical data for any of the systems provided. The Government contract number and the Watervliet WV# shall be printed in a conspicuous place on the covers of every manual, on each drawing/schematic, and on all disks/CDs provided.

8.17.1 Foundation Drawings, Standard or Special: Shall be complete in all construction detail to permit pricing and construction by a general contractor and shall be furnished as soon as possible after contract award and no later than 30 days after award. All drawings shall be dimensioned in English units and text shall be in the English language. One reproducible hardcopy and one electronic copy on CD in AutoCAD .dwg or .dxf format shall be provided. AutoCAD drawings shall not utilize the color yellow or any other colors that cannot be made readily visible when plotted out in color. When drawings are finalized, the contractor shall certify the accuracy of the drawings by providing a stamped and signed hard copy of the drawings to the Watervliet Government Representative in accordance with IAW CDRL A013.

At least one drawing shall depict an over-lay top view of the machine foundation outline, machine general arrangement drawing (including all ancillary equipment) and the anchor bolt hole pattern. The foundation drawing(s) shall be provided as 100% complete and constructible. Provide all necessary information for bid and award of the foundation work by others. This information shall include, but is not limited to, complete foundation dimensions, rebar locations, rebar size, rebar pattern, concrete pounds per square inch (PSI) requirements, and load bearing specs, etc. All submitted drawings and specifications shall be stamped by a registered Professional Engineer (PE) or a qualified individual (through experience or alternative applicable license). The foundation package shall be delivered as such that the project can proceed straight to the construction phase without requiring additional technical review or certification by Watervliet Arsenal employees. The Watervliet Government Representative will not give approval for foundation drawings, only confirm that a design will fit location, size, and other applicable requirements. Foundation design shall be prepared in accordance with the current edition of all applicable Codes and Regulations, including but not limited to the following:

Typical floor thickness at Watervliet is 8”-10”. A special foundation is one which exceeds thickness, load bearing capability and vibration isolation of Watervliet Arsenal's standard monolithic concrete flooring of 1,000 PSI load rating and/or one which requires a specific thickness, uniquely shaped excavations for coolant housings, chip conveyors, electrical circuits, and conductors, etc. The soil (substrate) for a foundation is assumed to be medium dense gravel or medium dense gravel/sand with a minimum bearing capacity of 4,000 pounds per square foot (PSF). Although 4,000 PSF is the assumed minimum bearing capacity, there may be variations depending on the exact location of the machine. The contractor shall contact the Watervliet Government Representative to ensure that the minimum PSF and other requirements are accurate. If the contractor states no foundation is required and does not ensure the minimum PSF in the area and the machine causes damage to floor and requires a foundation after initial installation is attempted, the contractor shall be responsible for all costs associated with floor repair, relocation of the machine, and reinstallation of the machine. Should the contractor disturb the soil below the yet to be constructed concrete foundation then the contractor shall compact the disturbed soil to achieve at least 2,000 PSF bearing capacity.

8.17.2 Machine and Equipment Floor Plan: Machine and equipment floor plan AutoCAD drawings shall contain information that indicates the type, magnitude, and connection points of all plant utilities required to operate the machine. The top view AutoCAD drawing shall depict the machine, foundations, feet/anchor locations, anchor requirements, grounding, all ancillary equipment, and all necessary clearance requirements for normal use and maintenance in accordance with IAW CDRL A014.

8.17.3 Catalog of Standard Tooling and Accessories: Catalog shall be furnished 30 days after award of contract. For offers of foreign built machine tools (i.e., machines built outside the United States, its possessions or Canada), the catalog shall set forth U.S. domestic sources of supply in accordance with IAW CDRL A015.

8.17.4 Non-Standard (Special) Tooling and Accessories: To the extent that this specification requires the development of unique tooling and accessories not generally available commercially, a set of drawings and specifications to permit manufacture of such tooling and accessories shall be furnished at the time of machine delivery in accordance with IAW CDRL A016.

8.17.5 Installation Instructions and Drawings: Instructions outlining the requirements for installation of the equipment shall include a drawing containing the certified dimensioned locations of all equipment mounting/anchor holes. These documents are to be furnished 60 days prior to scheduled delivery in accordance with IAW CDRL A017.

8.17.6 Lubrication Diagram and Instructions: To be delivered to the Watervliet Government Representative at time of machine delivery in accordance with IAW CDRL A018.

8.17.7 Operating Instructions: These instructions shall be provided in separate manuals from other technical data provided. To be delivered upon machine delivery in accordance with IAW CDRL A019.

8.17.8 Maintenance and Troubleshooting Instructions: To be supplied for all machine and control systems. These instructions shall include the machine’s mechanical assembly and wiring drawings. To be delivered at time of machine delivery in accordance with IAW CDRL A020.

8.17.9 Electronic and Hydraulic Schematics: To be considered acceptable, these schematics shall clearly portray all “as built” electrical and hydraulic ties to their respective main systems. To be delivered at time of machine delivery. Wiring diagrams used to do the initial power hookup shall be furnished no later than 90 days after award in accordance with IAW CDRL A021.

NOTE: If, during installation and testing, the actual electrical and hydraulic systems are configured differently than depicted on the schematics, receipt of the revised "as built" schematics shall be a condition of final acceptance.

8.17.10 Repair Parts Catalog: This catalog shall encompass every replaceable part in the machine and shall include identification and original equipment manufacturer’s part numbers and ordering data. Items which can normally be purchased locally may be so indicated provided they are sufficiently described. The repair parts catalog shall include illustrations which clearly locate parts within larger subassemblies. To be delivered at time of machine delivery in accordance with IAW CDRL A022.

8.17.11 Program Manuals: Where a CNC machine is specified, programming manuals shall be supplied. These manuals shall include a clear summary of the control functions implemented and usable on the system specified. To be delivered at time of machine delivery in accordance with IAW CDRL A023.

8.17.12 Software Documentation: The offeror shall provide documentation of all system software and ladder logic developed to control and interface with the control/drives with the machine tool. One copy of the touchscreen software, ladder logic, operating system, Fanuc CNC software, interface software, etc. and all pertinent documentation are to be provided prior to final acceptance. If the control provided is equipped with a USB Type-A port, then a backup USB Type-A flash drive loaded with the final version of the system software (S Ram) shall be provided with the final documentation. Also, to be provided is a Fanuc CNC America bill of materials for the control and drive systems detailing all control system standard features/options (with Fanuc option numbers) and axes/spindle drive motors and drive package identifying information. Ladder logic documentation provided shall include a listing of logic error/alarm messages and a cross reference list of the full descriptive relay contact and coil names to the abbreviated names in the logic. To be delivered 30 days after delivery of the machine in accordance with IAW CDRL A024.

8.18 The contractor shall be responsible for providing training of WVA personnel. The type and extent of training shall depend upon whether the machine specified is equipped with numerical control. All instructions and materials, oral or written, shall be in English. "On-Site" means "At Watervliet Arsenal" and "Off-Site" means "a location within the U.S. away from Watervliet Arsenal as determined and arranged for by the contractor". If specialized formal “off-site” training is available, specify on offer, availability, and price as an option. The quality of the training shall be such that at the conclusion of the specified training time, everyone within their assigned category shall be capable of repairing or operating the machine to its productive capacity. Training shall be in accordance with the applicable areas of the schedule below, and training attendance, duration and execution shall be officially documented and submitted at the time of final acceptance by the manufacturer’s trainer in accordance with IAW CDRL A025.

NOTE: For all types of training, the associated technical data (see section 8.17) shall be on hand at the time of instruction and its use and interpretation shall be covered during the training.

8.19 Repair/Replacement Parts and Service: The offeror shall provide parts and service for the contracted equipment within 72 hours of notification of a problem. The offeror shall agree, as part of the contract, to store complete ordering data to include specifications (e.g., critical subsystem parameters and specifications), engineering drawings and other information for the contracted machine tools/parts. This data shall be stored within the U.S. or Canada and available to the Government at its request in accordance with IAW CDRL A026. The contractor shall supply a list of recommended spare machine parts (e.g., belts, filters, fluids, and wear items) in accordance with IAW CDRL A027. Watervliet Arsenal recognizes that it may be difficult to fulfill this requirement for major machine components. If the requirement cannot be adhered to, the offeror shall notify the Watervliet Government Representative within two business days and shall provide a delivery schedule to be approved by the Watervliet Government Representative.

8.20 Rigging: The contractor shall arrange for rigging services to off load the machine and contractor personnel shall be on site at Watervliet when the machine arrives and is off loaded to supervise the placement of the machine on the installation site by the rigging service. Outside rigging services shall be advised that only certified grade 8 chains are permitted to be used at the Arsenal and that all rigging slings must be tagged and certified for the weights being lifted. Only propane powered forklifts are permitted, and forklifts must also be equipped with a roll cage. Operators of forklifts shall have and be able to produce valid forklift licenses in accordance with IAW CDRL A028. The contractor shall ensure they bring all equipment and material necessary for the rigging of the machine. If necessary, the Watervliet Arsenal will provide the contractor with information for local rigging companies. Any crane truck or lifting equipment used for the installation works shall be inspected and certified as required by applicable regulations. Ensure full compliance with OSHA (CFR 1926) regulations as applicable as well as any other applicable regulation and Federal. If a partial road closure is required to offload and install the equipment, the contractor shall be responsible for traffic flaggers to direct traffic around the install site.

8.21 Certification, Drawing and Test Required: The contractor shall demonstrate the machine’s conformance to all requirements elsewhere specified in sections 3, 4, and 5 of this specification. As part of this demonstration, the contractor shall furnish at least 30 days prior to conformance testing to the Watervliet Government Representative for approval, a dimensioned and toleranced drawing workpiece, minimum 20 foot in length, exhibiting characteristics of section 5.5 in accordance with IAW CDRL A029. After approval the drawing shall be the basis for the conformance test required in section 6.1.5. The contractor shall also, as a minimum, provide the following certification and perform the following specific tests:

8.21.1 Certification of Completeness: The contractor shall provide written preliminary certification that the machine is complete, including all specified systems, accessories, markings, safety devices, geometric and accuracy requirements before and after software input correction. The certifications shall be provided to the Watervliet Government Representative 14 days prior to the scheduled preliminary testing in accordance with IAW CDRL A030.

8.21.2 Test of Conformance to Specified Characteristics: The machine shall be dry cycled at least 30 minutes, during which time the machine shall be tested for conformance to specified performance characteristics, including but not limited to, feeds, speeds, and manual as well as automatic cycling.

8.21.3 Test of Conformance to Specified Alignments and Accuracies: The machine shall be tested for conformance to the accuracies specified in sections 5.2.1 through 5.2.4. A certified factory inspection report shall be provided to the Arsenal 14 days prior to the scheduled preliminary testing in accordance with IAW CDRL A031.

8.21.3.1 Machine Reassembly Testing: Once the machine is reassembled (if disassembly is necessary to ship it to WVA) and installed at WVA, the contractor shall perform final acceptance testing on site at WVA and, on all applicable axes, perform laser positioning and repeatability testing, and develop and enter the control optimal bi-directional axes compensation values. The contractor shall also provide the laser equipment and labor for this final acceptance testing. The contractor shall deliver a final acceptance testing report containing the final compensation values/tables required to obtain conformance to the specified alignments and accuracies in accordance with IAW CDRL A032.

8.21.4 Test of Conformance to Specified Horsepower Characteristics: At the discretion of the Watervliet Government Representative, the machine may be tested for power and rigidity. The vendor shall provide a proposed test part of their choosing for this test. The test shall pull full load spindle horsepower for at least three minutes. The work piece finish and machine rigidity will be evaluated.

8.21.5 Test of Conformance to Specified Performance on Workpiece: The contractor shall perform at their plant two preliminary tests and the standard NAS 966 run off test. The drawing provided by the Contractor specified in section 6.1 shall be used at the contractor’s facility. These tests shall demonstrate all the functions and capabilities of the machine such as straight and internal taper turning, arc contouring and left-hand and right-hand single point threading of such materials as 4340 alloy steel with a hardness of Rockwell 38-42. The drawing of this test configuration shall be furnished to the Arsenal 30 days prior to testing in accordance with IAW CDRL A029. Sizes and tolerances on this drawing shall be sufficiently stringent to demand full performance accuracy from the machine. This configuration will be compared to the drawing to ensure that the carriage has produced the proper configuration in accordance with the dimensions of the test drawing. The test part proposed shall be of a size commensurate to the size of the machine. The final test shall be a WVA production tube power chamber bore with the drawing provided by the contractor.

8.21.6 Test Workpieces: The material to be used for the performance test shall be Alloy Steel 4340 and shall have a Rockwell hardness of approximately RC 38 to 42. Dimensioned and tolerance drawing of the finished configuration of any contractor-designed and/or contractor furnished workpiece used for machine acceptance testing (see section 5.5) shall be furnished to WVA 30 days prior to preliminary acceptance testing in accordance with IAW CDRL A029.

8.22 Preliminary Acceptance Inspection: Preliminary acceptance inspection shall occur at the contractor's facility prior to machine shipment to WVA and shall consist of the certifications and tests specified in section 6. When these tests are completed successfully, the contractor shall provide no less than 14 calendar days’ notice to the Arsenal Contracting Officer that the machine is ready for the preliminary acceptance inspection. This notification shall also include for review the test results of all preliminary tests performed in accordance with IAW CDRL A033. If test results are acceptable, the Arsenal representatives will schedule a factory acceptance and the contractor shall await the arrival of the Arsenal representatives before starting the official acceptance.

8.23 Examination for Completeness: The contractor shall furnish the Watervliet Government Representative with a manufacturer’s final certification of completeness that certifies all required systems, subsystems and components are complete and in operational condition in accordance with IAW CDRL A030. The Government will reserve the right to examine the machine to ascertain the presence of all specified features, equipment, markings, and safety devices.

8.24 Warranty: Upon final acceptance of the machine a Standard Commercial Warranty shall commence for one year. This Standard Commercial Warranty shall include, at a minimum, parts and labor for the duration of the warranty at no cost to the Government. The one-year period shall commence from the date of notification by the Watervliet Government Representative of the final acceptance of the machine. Final acceptance is defined as the act of an authorized representative of the Government (the Watervliet Government Representative in this case), by which the Government assumes ownership of existing supplies/equipment and/or approves specific services rendered, as partial or complete performance of the contract (i.e. testing, training, and delivery of all required technical documentation and ancillary equipment and supplies/parts included in the original contract) in accordance with IAW CDRL A034.

9.0 TRAINING

10.0 MAINTENANCE SET

10.1 Each lathe shall be supplied with tools to enable periodic preventative maintenance including a test mandrel, test bar, and “dual use” sliding base (to serve as an optical collimator and dial gauge).

11.0 WARRANTY

11.1 The integral warranty for each lathe shall start from the signature of the final acceptance, be at least 12 months in length, and cover all defects with regard to material and workmanship.

Enclosure D - Environmental Protections Requirements

1. Compliance with Environmental Laws and Regulations: Contractor shall comply with all applicable federal, state, and local environmental laws, statutes, regulations, executive orders, permits, Army regulations (with supplements), as well as Major Subordinate Command (MSC) and installation regulation, policy, Host Tenant Agreement, Interagency Service Support Agreement, or Status-of-Forces Agreement. Contractor shall immediately report any conflicts between applicable federal, state, local environmental laws, statutes, executive orders, and provisions of Army Regulation 200-1, and any specifications within this contract to the Contracting Officer Representative (COR).

2. Compliance with Green Procurement Requirements: Contractor shall follow Federal EPA Comprehensive Procurement guidelines (www.epa.gov/cpg) and Army Contracting Command Quick Guide (https://acc.aep.army.mil/accapps/ACCMAP/Documents/Quick-Guide-for-Sustainable-Procurement.docx) for acquisition of building materials and products and select materials that have a long life cycle; the least toxic materials; recyclable materials; materials that are resource-efficient; materials with the maximum recycled content; materials harvested on a sustained yield basis; and products causing the least pollution during their manufacture, use, and reuse.

3. Compliance with License and Certification Requirements: Contractor shall obtain all license and certification required by Federal, State, and Local environmental laws and regulations necessary to adhere to the specifications of this contract. The Contractor shall submit all plans, notifications, reports, submittal documents, and fees required by Federal, State, and Local environmental laws and regulations to the appropriate Federal, State, and Local authority and/or agency as necessary to adhere to the specification of this contract. All required licenses and certifications required by Federal, State, and Local environmental laws and/or regulations shall be considered a contract deliverable in accordance with IAW CDRL A035.

4. Notification of Federal and State Regulators: Contractor shall immediately notify the Designated Government Representative (DGR) and COR of the arrival on site of any Federal, State, and/or DoD environmental regulator or enforcement agent and/or the receipt of any correspondence from a Federal or State environmental agency.

5. Inspections of Work Sites: Contractor…