81073699-00345-81073699revSOW_74INCH_BULLARD_VTL_2018-03-29.docx

Statement of Work (SOW) retrofit of 74” Bullard Retrofit Vertical Lathe

JML 8107-3699

Funding Document# N4523A18RC44381 (Request for Contractual Procurement (RCP) required for services over $2500 or services with terms and conditions.) – Received from Funds Administrator Ship/Activity: Puget Sound Naval Shipyard Place of Performance: Puget Sound Naval Shipyard Bld. 431 Period of Performance: 9/01/2018-8/31/2019

NOTES

Preparation for Delivery. The supplies shall be prepared for shipment in accordance with the provisions identified herein. Yellow packaging, packing, preservation and marking, in any form or manner, regardless of the method of preparation specified, is prohibited. The Shipyard uses the colors magenta, yellow, red, and blue to identify specially controlled materials. The Contractor is specifically prohibited from using magenta, yellow, red, or blue colored plastic wrapping materials, bags, tape, or other covering materials.

Special Delivery Instructions. The Contractor shall notify the receiving activity of the scheduled arrival date of the equipment and any special handling requirements. The contractor shall notify Nicole Martinez, Puget Sound Naval Shipyard at Area Code (360) 476-8264 or E-mail: nicole.martinez2@navy.mil of the scheduled arrival date of the equipment. The notification shall be made not less than 10 working days prior to the delivery date. All arrivals must be scheduled between the hours of 7:00 AM and 12:00 PM. If proper notification is not given, the Government will not be responsible for any delays caused by the inability to off-load the supplies upon delivery.

Applications and Issue of Security Badges. Contractor personnel shall comply with all current badging and security procedure requirements for gaining access to Department of Defense (DoD) Installations/Government Sites. Access to Navy Installations or Sites may only be gained by obtaining a badge (either permanent or temporary) from the Visitor Control Center (VCC) in building 981 (Pass & ID). It is the contractor’s responsibility to check for, and obtain changes and updated information from the VCC on a continual basis.

1. Contractor employees are required to have an individual identification badge as well as one (1) of the four (4) credentials listed below in their possession to gain access to job sites:

1.1 Common Access Card (CAC): Contractors who have a need to access a government computer system may be eligible for a contractor CAC; most contractors are not eligible for a CAC. Contact the Contracting Officer’s Representative (COR) or Contracting Officer’s Security Officer for assistance as needed.

1.2 Single Day Pass: Visiting vendors/contractors requiring infrequent access may obtain daily passes directly from the individual Navy Installation by submitting identification credentials for verification and undergoing a criminal screening/background check. A new pass is required to gain access each day. Passes are issued by Naval Base Kitsap (NBK). The Federal Bureau of Investigation’s (FBI) National Crime Information Center (NCIC) criminal database and FBI Terrorist Watch List will be checked daily prior to entry. In addition, NBK must check the Navy’s Consolidated Law Enforcement Operations Center (CLEOC) database to ensure an unescorted visitor has no objectionable criminal record, is not on the Terrorist Watch List and has not been previously debarred from entry onto any Navy Installation.

1.3 Defense Biometric Identification System (DBIDS) Program: Commander, Navy Installations Command (CNIC) has established the Defense Biometric Identification System (DBIDS) for access control to CNIC Installations via Entry Control Points (ECP). DBIDS is an enterprise identity management and perimeter installation access control solution in which Contractor personnel who enroll, and are approved, are subsequently granted access to the installation for a period up to three years, or the length of the contract, whichever is less, and are not required to obtain a new pass from the Base Pass and Identification Office for each visit. There are no fees associated with obtaining a DBIDS credential.

1.3.1 The Government performs background screening and credentialing. Throughout the year the Contractor employee must continue to meet background screening standards. Periodic background screenings are conducted to verify continued DBIDS participation and installation access privileges. DBIDS access privileges will be immediately suspended or revoked if at any time a Contractor employee becomes ineligible.

1.3.2 Access to Installation. All Contractor personnel shall obtain access to the installation through enrollment and registration into the Defense Biometric Identification System (DBIDS). Once enrolled, the Contractor must provide the DBIDS Registrar with an approved employee list and then direct their employees to register into DBIDS.

1.3.3 DBIDS Credentials. Contractor employees shall furnish a completed copy of the SECNAV 5512/1 form to obtain the required background check and visit the local Navy Installation Visitor Control Center to obtain a DBIDS credential once approved. The SECNAV 5512/1 form and additional information about DBIDS can be found at: https://www.cnic.navy.mil/om/dbids.html.

1.3.4 The Contractor may initiate the adjudication process when a background screen failure results in disqualification from participation in DBIDS and the Contractor employees do not agree with the reason for disqualification. The Contractor may also apply for a waiver when a background screening failure results in disqualification from participation in DBIDS.

1.3.5 The Contractor shall immediately collect employee DBIDS credentials:

1.3.5.1 When an employee has departed the company without having properly returned or surrendered their DBIDS credentials.

1.3.5.2 When there is a reasonable basis to conclude that an employee, or former employee, might pose a risk, compromise, or threat to the safety or security of the installation or anyone therein.

1.3.6 DBIDS Paper Passes. In the event that a visitor, vendor, or Contractor employee elects not to participate in DBIDS, the individual will be issued DBIDS paper pass from the Base Pass and Identification Office in order to access to the installation. The time standard for the validity of a pass to access an installation will be not more than thirty (30) days and may be further restricted based on local policy or by Federal, DOD, Navy, and CNIC guidance. The Government will not be responsible for any cost or lost time associated with obtaining paper passes or added vetting or inspections incurred by non-participants in the DBIDS credentialing process.

1.4 Transportation Workers Identification Credential (TWIC): Trucking and Longshoremen industry, to include Military Sealift Command (MSC) personnel are authorized to use this credential for unescorted access so long as the holder also has in his/her possession an original Bill Of Lading indicating that the delivery of goods is within the perimeter of the host installation, or in the case of MSC personnel, the holder has in his/her possession, a current Merchant Mariner identification card.

2. Contractor employees must be U.S. citizens to access PSNS & IMF owned or controlled spaces unescorted, to include ship's engineering spaces. Foreign Nationals will be issued "Escort Required" white badges only. Additionally, an approved special security plan indicating the proposed visit locations and route to and from the location must be utilized. This requirement adds 3 working days to the visit request process. U.S. citizens working for Foreign Owned or Controlled Companies requiring access, unless they fall under a Defense Security Service (DSS) security clearance, will be issued Green badges only suitable for general CIA access. Access by U.S. citizens working for Foreign Owned or Controlled Companies into more stringently controlled areas such as Nuclear Work Areas (NWA) require a security plan and escorts. Ensure personnel employed by Foreign Owned or Controlled Companies are clearly identified in Visit Request documents.

2.1 Badges will be picked up at the Naval Base Kitsap Visitor Control Center (VCC) in building 981. Each Contractor employee is REQUIRED to present proof of citizenship for on-site verification (not retention) at the VCC prior to obtaining a badge. This is a requirement for access into the CIA at PSNS&IMF, Bremerton, WA. All contractor employees requesting access shall be U.S. citizens. Acceptable proof of citizenship includes Original Birth Certificate (not a copy) or Current U.S. Passport.

2.2 Lack of a proper ID badge will result in denial of access to the Naval Installation, facility and/or the ship, resulting in a delay at the Contractor’s expense. If Contractor employees are providing a document with no photo, they shall also be required to present a current authorized official issue photo ID.

2.3 Badges must be displayed on the outermost garment above the waist at all times. The only exception would be while the contractor personnel are engaged in work which could cause a safety hazard if the badge were worn while performing the work.

2.4 Contractor personnel are authorized to retain temporary badges until the badge expiration date or termination of employment. Upon badge expiration date, termination of employment, or completion of contract, the Contractor is required to immediately return all badges.

3. To grant Contractor Vehicle Access to the PSNS & IMF CIA, a list of vehicles, a copy of each vehicle registration and a justification for access shall be submitted for processing via PSNS & IMF Form 5530/25. Contractors are required to stop at PSNS & IMF Pass & ID Office with proof of valid, current Driver’s License, vehicle registration and proof of insurance, prior to receiving access.

4. Contractor owned computers must be inspected by Code 109 prior to bringing them into the CIA and shall have a PSNS&IMF AIS Security Survey for Visitor Computer Equipment Form PSNS&IMF 5239/49 (Rev. 8-07), approved by Code 109, on site at all times.

5. Contractor Employees shall adhere to PSNS&IMF NOTICE 5239.6 PORTABLE ELECTRONIC DEVICE (PED) GUIDANCE.

5.1 Lap-top Computers and/or cell phones equipped with cameras are STRICTLY PROHIBITED inside all PSNS & IMF owned or controlled spaces or property (the CIA, DMF & YOKO Enclaves, etc.) and subject to seizure by Installation Police and Shipyard Security Personnel.

5.2 ALL portable electronic devices are STRICTLY PROHIBITED onboard submarines (e.g. phones, mp3 devices, computing devices, recording equipment, removable storage media, etc.).

Preservation, Packaging and Packing. Material shall be packed for shipment in such a manner to insure acceptance by common carrier and safe delivery at destination. Containers and closures shall comply with Interstate Commerce Commission regulations, Uniform Freight Classification Rules or regulations of other carriers as applicable to the mode of transportation. Use of shredded paper, whether newspaper, office scrap, computer sheets, or wax paper, in packing materials for shipment to Navy activities, is prohibited. Shipments shall be marked in accordance with ASTM-D-3951. In addition to the requirements of ASTM-D-3951, marking shall further indicate "NOT FOR OUTSIDE STORAGE."

SHIP TO:

Receiving Officer Puget Sound Naval Shipyard and IMF, Bremerton Site (N4523A) Bldg. 431 1400 Farragut Ave.

Bremerton, WA 98314-5001 Attn: Nicole Martinez (360) 476-8264 E-Mail: nicole.marinez2@navy.mil

SCOPE

SCOPE. The specification set forth below describes the minimum requirements of the Government for services to retrofit a 74 inch Bullard vertical lathe, C. O. Hoffacker Co. retrofit S.O. 6429 in 1992, serial #22757, replacing current control with a Fanuc 0i-TF control including CNC software with Open Vision Lathe, documentation, and training. The equipment is currently outfitted with a GE Fanuc 15-T control. Components, not included in section 3.3 herein, if found to be defective or inoperative shall be reported to the government for determination of corrective action. The machine is located in building 431 Puget Sound Naval Shipyard and Intermediate Maintenance Facility (PSNSY & IMF), Bremerton site. It is the Government’s intent that a single primary contractor be awarded this contract and be responsible for the provision of equipment, and the accomplishment of all work detailed by this specification.

APPLICABLE DOCUMENTS

GENERAL. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

GOVERNMENT DOCUMENTS.

SPECIFICATIONS, STANDARDS, AND HANDBOOKS. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

FEDERAL STANDARDS

(Copies available online at https://assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

OTHER GOVERNMENT PUBLICATIONS. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

CODE OF FEDERAL REGULATIONS

(Copies available online at http://www.gpo.gov/fdsys/) NON-GOVERNMENT PUBLICATIONS. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

ASTM INTERNATIONAL

ASTM-D3951 Standard Practice for Commercial Packaging (Copies are available from www.astm.org or ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959)

ELECTRONIC INDUSTRIES ALLIANCE / TECHAMERICA

(Copies available at http://www.techstreet.com/techamgate.html or TechAmerica, 601 NW Pennsylvania Ave, North Building, Suite 600, Washington, DC 20004)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

(Copies available at http://www.nema.org/stds/ or National Electrical Manufacturers Association, 1300 North 17th Street, Suite 1752, Rosslyn, VA 22209)

NATIONAL FIRE PROTECTION AGENCY

(Copies available at http://www.nfpa.org or NFPA, 1 Batterymarch Park, Quincy, MA 02169)

TELECOMMUNICATIONS INDUSTRY ASSOCIATION

TIA/EIA-232-F Interface between Data Terminal Equipment and Data Circuit-Terminating Equipment Employing Serial Binary Data Interchange (1997, R2002) (Copies available at http://www.tiaonline.org or TIA Standards and Technology Department, 2500 Wilson Boulevard, Arlington, VA 22201)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION

ISO 13041-6 Test Conditions for Numerically Controlled Turning Machines and Turning Centres - Part 6: Accuracy of a Finished Test Piece (2009) (Copies available at http://webstore.ansi.org/ or American National Standards Institute, Dept. 969, 1430 Broadway, New York, NY 10018) ORDER OF PRECEDENCE. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

REQUIREMENTS

DESIGN. As applicable only to new parts and materials, or any existing items impacted by the installation of new materials, the finished CNC Vertical Lathe system shall exhibit the following design characteristics.

USE OF ENGLISH. Wording on all new components and new sub-components such as electrical motors, diagrams, hydraulic components, coolant components, safety and informational charts/plates shall be written in American English. All installation diagrams, operator/users manuals, brochures and any other data supplied, as part of this purchase specification shall also be written in the English language.

CASTING AND FORGINGS. Any new castings and forgings shall be free from defects, scale and mismatching. Processes such as welding, peening, plugging, or filling with cold solders or metallic pastes shall not be used on castings or forgings for reclaiming any parts of the equipment.

WELDING, BRAZING AND SOLDERING. Welding, brazing or soldering shall be employed only where those operations are included in fabrication of the original design. These operations shall not be employed as repair measures for defective parts. Solder connections shall show evidence of good bonding in metal-to-metal contact. Cold solder joints, incomplete joining of solder and metal, excess or insufficient solder or damaged insulation shall be considered reason for rejection of the equipment. Any loose, spattered solder, flux, metal chips, insulation scrap or other foreign material shall be removed from the equipment. Flux for soldering shall be rosin or rosin and alcohol. No acid, acid salts or acid core solder shall be used in preparation for soldering of electrical connections.

FASTENING DEVICES. Screws, pins, bolts, and similar internal and external parts shall be installed with means for preventing change of tightness. Parts subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently installed. Fastening devices shall be tightened to torque limits as established by the manufacturer's standard for tightening to preclude loosening by normal operation or vibration. Threaded parts shall conform to FED-STD-H28A.

CORROSION CONTROL. All new system components shall be protected against corrosion and deterioration by appropriate material selection, application of coatings and sealants. Lead based or chromium based paints are prohibited. Additions to the system and its parts shall be painted on all sides, prior to assembly. All surfaces, except mating surfaces such as mounting flanges and motor shafts, shall be painted in conformance with the manufacturer's standard practices and good workmanship. Painting shall result in a highly wear-resistant finish, which guarantees continued protection to the surfaces covered against the specified environment under all service conditions. The manufacturer's standard color shall be provided. Exposed ferrous parts such as screws, bolts, nuts, washers, etc., shall resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as cadmium or chrome plating, galvanizing or other electrical/chemical process, or stainless steel is acceptable. Aluminum parts shall be anodized or chemically treated followed by two coats of weather-resistant exterior paint. Dissimilar metals shall not be used in direct contact with each other without suitable means for preventing electrolytic corrosion.

SURFACES. Surfaces of new castings, forgings, molded parts, stampings and welded parts shall be cleaned and free from sand, dirt, fins, sprues, flux or other harmful or extraneous materials. External surfaces shall be smooth. Edges shall be rounded or beveled unless sharpness is required to perform a function.

ELECTRICAL EQUIPMENT. Electrical components including motors, starters, relays, switches, and wiring shall conform to NFPA 70 and NFPA 79. Any existing electrical components which do not conform to NFPA 70 and NFPA 79 shall be reported to the government for determination of corrective action.

ELECTRICAL ENCLOSURE. Electrical components of the equipment shall be contained in the existing enclosures, a new display, operator’s panel and pendant will be installed in the existing pendant arm / free standing enclosure.

MOTORS. All new motors shall be Fanuc AC servomotors with high resolution absolute encoders. All axes motors will be sized with torque and speed characteristics required to meet or exceed the system currently on the machine.

CONTROL CIRCUITS. Main and auxiliary control circuits shall operate on a circuit of 120 volts or less derived from isolation transformer(s) integral with the equipment.

ELECTRICAL CONNECTIONS. Electrical connections within the equipment shall be complete and shall be made via terminals on the components, terminals, or circuit boards and bussing. Splices between terminations are not permitted. Connections and terminals shall be supported and spaced without dependence upon the wiring in the components and braced as necessary to assure withstanding the distortion forces associated with available short-circuit currents. Proper identification of wiring, bussing, terminals and circuits for function, polarity, phasing, etc., shall be adhered to throughout the equipment. Identification shall be in the form of wire markers, color coding, permanently engraved plates, and permanent markings on the devices. Adequate spacing shall be maintained throughout to avoid excessive bending of cabling and wiring, to maintain adequate separation and creepage distance between electrical potentials and between these potentials and ground, and to permit ease in disconnecting wiring and cabling during trouble-shooting and repair. In no instance shall clearances and creepage distances be less than those prescribed under NEMA ICS 1. This paragraph shall apply to both existing and new electrical connections.

GROUNDING. Exposed, non-current carrying metal parts on the equipment shall be maintained at common, zero ground potential. None of the primary circuits in the equipment shall be connected to ground. A ground stud or lug on the equipment shall provide means for grounding the equipment for safety to personnel, and be connected to an earth ground compliant with NFPA 70.

SOLID-STATE COMPONENTS. Solid-state design shall be employed throughout for electronic components. New parts and materials shall conform to the following requirements of this paragraph. Use of selenium and other similar aging devices shall be permitted only in the application of voltage surge protection to other solid-state components. Solid-state components shall not be adversely affected when subjected to power line transients and surges typically experienced in industrial environments. Series and parallel connections of solid-state devices without forced sharing circuitry for voltage and current, respectively, is not permitted.

EMERGENCY STOP DEVICES. The equipment specified herein shall be provided with emergency stop buttons at the equipment control panel, and on the remote pendant. These stop buttons shall be the mushroom type, shall be colored red, and shall be labeled as such. When activated, the emergency stop devices shall cause all operations or functions to cease immediately.

HAZARDOUS MATERIAL EXCLUSIONS. Hazardous materials shall not be brought on site without prior approval of the receiving activity’s safety department. The Government Point of Contact shall be the liaison. Hazardous materials not needed for this project are prohibited. No paint, oil, grease or other hazardous material may be turned over to the Government or left at the receiving activity site at the end of this project, to be used for maintenance. Definitions of hazardous materials are specified in the latest version, including revisions adopted during the term of the contract, of FED-STD-313D. Notwithstanding any other hazardous material usage permitted in this contract, radioactive materials or instruments capable of producing ionizing radiation as well as materials which contain asbestos, mercury, cadmium, lithium, methylene chloride, lead ≥0.06%, or polychlorinated biphenyls (PCB) are prohibited. Nickel metal hydride and lithium batteries are permissible for memory backup. Class I ozone depleting substances as defined in 40 CFR 82 shall not be used in the performance of this contract, or be provided as part of the equipment. Exceptions to the prohibition of these materials must be referred to the Contracting Officer in writing.

ENVIRONMENTAL PROTECTION. New parts and materials shall not emit materials hazardous to the ecological system, as prescribed by federal, state and local statutes in effect at point of installation, under the operating, service, transportation and storage conditions described herein.

PCB CERTIFICATION. The contractor shall provide written certification that all new materials and components contain no detectable PCBs greater than or equal to two (2) parts-per-million (PPM).

Globally Harmonized System (GHS) Safety Data Sheets (SDS). Offerors and Contractors shall submit Globally Harmonized System Safety Data Sheets (SDS), whenever the supplies being acquired or supplies used during performance are identified as hazardous materials. Hazardous Materials include any material which, by virtue of its potentially dangerous nature (e.g., toxic, flammable, corrosive, oxidizing, irritating, sensitizing, reactive), requires controls in its use, packaging, handling, storage, or stowage, to assure adequate safety to life and property. This definition is intended to apply to proprietary industrial, commercial, or locally prepared blends, mixtures, formulations, or compounds of gases, liquids, and solids intended for use at the job site. Any other material designated by a Government technical representative as potentially hazardous and requiring safety controls shall also be supplied with a SDS. SDSs shall be available at work sites where materials are being used.

INFORMATIONAL PLATES. The following informational plates shall be marked by engraving or photo imaging, on wear and corrosion resistant metal, permanently affixed to the equipment, and located as near to the hour meter as practicable.

IDENTIFICATION PLATE. The following information shall be on the plate:

Nomenclature Contractor’s Name Electrical Utilities: Volts, Full Load Amps, Frequency, Phases CNC Control Model Number CNC Control Serial Number Date of Re-Manufacture REUSE OF UNDAMAGED OR NEW COMPONENTS. The following components, if not specified in the section titled “NEW COMPONENTS”, shall be reutilized if they are undamaged. Damaged or inoperative components listed in this section shall be reported to the government for determination of corrective action. Elimination of existing components without replacement shall require prior receiving activity approval, unless otherwise specified.

Pendant Electrical enclosures, junction boxes, conduits, and wire ways Limit, proximity, and operator switches Existing motor mounts for all axes, may adapt/modify, as required.

Existing mounts for spindle motor and encoder, may adapt/modify, as required

1.1. NEW COMPONENTS. All non-existing hardware covered by this specification shall be new and unused, without defects and free of repair. Hardware associated with installation of new components including, but not limited to, gaskets, seals, bearings, keys, rings, washers, screws shall be new and unused. The following hardware items shall be added or replaced.

CONTROL. A Fanuc 0i-TF utilizing Open Vision Turn software shall be supplied. The control shall be mounted on the existing pendant. The Fanuc machine operators panel shall be angled upwards towards the operator for easier viewing. The control will include:

A PCMIA Flash memory card for backup storage of all control setting.

A machine operators panel Model A I/O modules A 15 inch Extended Graphics Array touch screen with 1024 x 768 pixels will be installed in the existing pendant Control Features.

Axis Control Digital Servo Function 1 Controlled Path Standard, 2 Paths available.

Simultaneously controlled axes: Up to maximum of 4; 3 if Contouring Spindle Configured PMC Axis Control Simple synchronous control Tandem control Serial Encoder Interface Axis Name Selected from X,Z and Y,A,B,C Spindle Up to two Spindles Least input increment 0.001mm, 0.001deg, 0.0001inch Increment system 1/10 0.0001mm, 0.0001deg, 0.00001inch Flexible feed gear Optional DMR Fine Acc & Dec control Inch/metric conversion Interlock All axes/each axis/each direction/block start/cutting block start Machine lock All axes/each axis Emergency stop Overtravel Stored stroke check 1 Stored stroke check 2, 3 Chuck and tail stock barrier Mirror image Each axis Follow-up Servo off Chamfering on/off Backlash compensation Backlash compensation for each rapid traverse and cutting feed Stored pitch error compensation Position switch Unexpected disturbance torque detection function Operation Automatic Data Backup (R641) Automatic operation (memory) DNC operation Reader/puncher interface is required.

MDI operation Schedule function Program number search Sequence number search Sequence number comparison and stop Program restart Manual intervention and return Buffer register Dry run Single block JOG feed Manual reference position return Reference position setting without DOG Reference position setting with mechanical stopper Manual handle feed Max. 2 units (requires MPG - order from IOetc Sheet) Manual handle feed rate ｘ1, ｘ10, ｘm, ｘn m: 0～127, ｎ: 0～1000 Manual handle interruption Incremental feed ｘ1, ｘ10, ｘ100, ｘ1000 Jog and handle simultaneous mode Interpolation Positioning G00 (Linear interpolation type positioning is possible) Linear interpolation Circular interpolation Multi-quadrant is possible Dwell Dwell in seconds Dwell per revolution (synchronous cutting function is required.)

Polar coordinate interpolation Cylindrical interpolation Threading, synchronous cutting Multiple threading Threading retract Continuous threading Variable lead threading Polygon turning Skip G31 High-speed skip Input signal is 1 point Torque limit skip Reference position return G28 Reference position return check G27 2nd reference position return 3rd/4th reference position return General purpose retract Feed Function Rapid traverse rate Max. 240m/min (1μm) Max. 100m/min (0.1μm) Rapid Traverse Feedrate Override preset value, 25%, 50%, 100% settings Feed per minute Feed per revolution Tangential speed constant control Cutting feedrate clamp Automatic acceleration/deceleration Rapid traverse: linear; Cutting feed: exponential Rapid traverse bell-shaped acceleration/deceleration Linear acceleration/deceleration after cutting feed interpolation Feedrate override 0～254% Jog override 0～655.34% Override cancel Manual per revolution feed Error detection Rapid traverse block overlap External deceleration Programming Tape code EIA RS244/ISO840 Label skip Parity check Horizontal and vertical parity Control in/out Optional block skip 9 Levels Max. programmable dimension ±8-digit Program number O4-digit External memory and sub program calling function Sequence number N5-digit Absolute/incremental programming Combined use in the same block Decimal point programming/ pocket calculator type decimal point programming Input unit 10 time multiply Diameter/radius programming (X axis) Plane selection G17, G18, G19 Rotary axis designation Rotary axis roll-over Coordinate system setting Automatic coordinate system setting Coordinate system shift Direct input of coordinate system shift Workpiece coordinate system G52～G59 Workpiece coordinate system preset Direct input of workpiece origin offset value measured Manual absolute on and off Direct drawing dimension programming G code system A/B/C Programmable data input G10 Sub program call 4 folds nested Custom macro B Addition of custom macro common variables #100～#199, #500～#999 Pattern data input Interruption type custom macro Canned cycles Multiple repetitive cycle Multiple repetitive cycle II Pocket profile Canned cycles for drilling Circular interpolation by R programming Tape format for FANUC Series 10/11 Auzxillary and Spindle Functions Auxiliary function M8-digit 2nd auxiliary function B8-digit Auxiliary function lock High-speed M/S/T/B interface Multiple command of auxiliary function 3 Spindle speed function S5-digit, binary output Spindle serial output S5-digit, serial output Constant surface speed control Spindle override 0～254% Actual spindle speed output Spindle speed fluctuation detection 1st spindle orientation 1st spindle output switching function 2nd spindle orientation 2nd spindle output switching function Spindle synchronous control Multi spindle control Spindle positioning Rigid tapping Tool Functions and Tool Compensation Functions and Tool Compensation Tool Function T7 + 1/T6 + 2 digits Tool offset pairs ±6 digits 64 Tool offset Y-axis offset Tool nose radius compensation Tool geometry/wear compensation Tool life management Tool offset value counter input Automatic tool offset Direct input of tool offset value measured Direct input of tool offset value measured B Part Program Storage & Editing Part Program Storage 512KB Number of registerable programs 400 Part program editing Program protect Background editing Extended part program editing Playback Password function Display Status display Clock function Current position display Program comment display Program name 31 characters Parameter setting and display Self-diagnosis function Alarm display Alarm history display Operator message history display Operation history display Help function Run hour and parts count display Actual cutting feedrate display Display of spindle speed and T code on all screens Directory display of floppy cassette Directory display and punch for each group Servo setting screen Display of hardware and software configuration Periodic maintenance screen Maintenance information screen Trouble diagnosis Software operator's panel Software operator's panel general purpose switch English Language Display, Multiple Languages Selectable Jap, Ger, Fr, Sp, It, Chi, Kor, Por, Dut, Swe, Hun, Cz, Pol, Rus, Tur Data protection key 4 types Erase CRT screen display Data Input/Output and Communications I/O Link Interface Punch Panel with 2m Cable A02B-0236-C192 in LCD Mount, A02B-0120-C192 in Stand Alone.

Reader/Punch Interface 1 (RS-232) 2nd Channel may be activated External I/O device control External data input: External tool offset External message External machine zero point shift External key input External program input External workpiece number search 9999 Expanded external workpiece number search External program number search 1～9999 Memory card input/output for maintenance Power Mate CNC manager Embedded Ethernet SERVO MOTORS. Axis servo system consisting of the following:

Three (3) Fanuc AC Digital Velocity Units for the X, Z & Tool changer axes utilizing a High Speed Digital Serial interface.

Three (3) Fanuc AC servomotors with high resolution absolute encoders. All axes motors will be sized with torque and speed characteristics required to meet or exceed the system currently on the machine. Absolute encoders will eliminate the need for zero return after power shut-off.

Long lasting, rechargeable batteries exceeding the minimum system recommendations for the control and servo motors.

All new power and feedback cables.

SPINDLE. Fanuc Digital Spindle System consisting of the following:

Fanuc Alphai HV 60 - 6000 RPM digital drive system providing 75/100 HP capability. Consisting of both a motor and drive.

Replacement of the resolver to encoder feedback if currently on the machine.

New power and feedback cables.

Interface to the machine tool as required.

INDUSTRIAL COMPUTER. The HMI software will run on an integrated industrial hardened Nema 4 rated computer with:

Ethernet interface capability Windows 10 64-bit Core i7-4650U 1.7GHz processor 16GB RAM memory External USB 80GB Solid State Drive REMOTE OPERATOR PENDANT. A Euchner, or equivalent, remote pendant with:

Axis select Increment select Manual Pulse Generator (MPG) Twenty (20) feet of cable Emergency stop, E-stop, button meeting requirements of paragraph 3.1.7.6.

Cycles Start and Feed Hold Six (6) operator push buttons CNC SOFTWARE. The existing CNC software shall be replaced and fully documented. The PMC ladder logic shall support all original machine functions, lubrication cycles, faults and alarms, display pages. The new CNC software shall include the following requirements.

HUMAN MACHINE INTERFACE. Open Vision™ Turn software adapted to this machine capable of emulating the standard Fanuc screen on the touch screen display.

FLOOD COOLANT. The existing coolant functionality shall be maintained.

PROGRAM INPUT.

Maximum programmable dimension: +/-9999.9999 Decimal point programming Inch and metric modes Interpolation functions shall include rapid traverse positioning, linear interpolation, multi-quadrant circular interpolation, polar coordinate interpolation, and cylindrical interpolation.

Feed modes shall include feed per minute, feed per revolution, inverse time, and rapid traverse.

Program input shall be feasible via keyboard input from the operator panel, USB port, RS-232 port conforming to TIA/EIA-232-F.

MAINTENANCE DIAGNOSTIC SYSTEM. Maintenance diagnostics software shall be furnished either in the control as nonvolatile memory or as a separate program that is compatible with the input media specified herein. The diagnostic software shall test, and display failures. The system shall monitor operating conditions, and have an automatic means of rapidly stopping operations to prevent damage when potentially harmful malfunctions are detected.

OTHER FUNCTIONALITY. The following functionality shall be provided by the new CNC software and PMC ladder logic.

Eliminate the need to manually home the tool changer. The tool changer magazine shall home itself, if required, on the first tool change following a machine cold start.

Allow bidirectional jog while in “HOME” mode.

Axis selection buttons shall illuminate when respective axis is at home position while in “HOME” mode.

Allow feed hold while in “HOME” mode.

Rapid override selector, versus the federate override, shall control axis velocity while referencing the axes in the “HOME” mode.

Allow feed hold during M06 tool changes.

ELECTRICAL AND ELECTRONIC SERVICES.

INPUT AND OUTPUT DEVICES. All input and output devices, including but not limited to, limit switches, proximity switches, and solenoids shall be inspected. Faulty devices shall be reported to the government for determination of corrective action.

FEEDBACK LOOP. The feedback loop for each axis shall be tested, and deficiencies shall be corrected to make the feedback loop fully operational, providing full integration of the linear and rotary axes.

SYSTEM TUNING. All spindle drives, servo drives, and feedback devices shall be tuned for optimal system operation.

LABELING AND MARKING. All wiring connections, junction boxes, input/output devices, fuses, motors, and drives shall be identified with labels or wire markers. Numerous placards for input/output devices exist on the equipment. Existing placards, labels and markers shall be validated, and erroneous identifiers shall be corrected.

ELECTRICAL INSTALLATION. The final installation of all new components covered by this statement of work shall comply with the requirements of NFPA 70 and NFPA 79.

COMMERCIAL TECHNICAL DATA. The following technical data, written in the English language, shall be furnished not less than two (2) weeks prior to the commencement of training. Each technical data element shall be labeled in bold type the manufacturer's name, contract number, model number, and serial number of the unit. Technical Data shall include, as a minimum, the following:

Operating instructions including start up, shut down and emergency shutdown procedures Programming requirements including, but not limited to, a complete listing of G and M codes, subroutine and macro calls, variable assignment, and listing of parameters where tool and fixture offsets are stored Electrical service manuals shall include electronic documentation which accurately reflects the new configuration. The new electronic documentation shall include a table of contents with device functions, feedback interface, electrical schematics with wiring and device numbers, PMC ladder diagrams including the device numbers shown on placards and labels, parameter list including latest values. The documentation shall identify each junction box, terminal block, terminal number, switch, and cannon plug pin-out.

Fanuc maintenance manuals.

Parts list containing: illustrations, part numbers, part nomenclature, original manufacturer, cross reference numbers, and recommended spare parts including quantities Energy control summary, in accordance with 29 CFR 1910.147, OSHA Energy Control Standard to bring equipment to a zero energy state for maintenance

1. TECHNICAL MANUALS. Three (3) sets of documentation consisting of the following will be provided on CD, Fanuc Operator Manual and Control Maintenance Manual.

ENGINEERING DOCUMENTATION. Three (3) sets of documentation will be provided on CD and one (1) printed set of documents consisting of the following:

Electrical schematics Mechanical assembly drawings PLC schematics Parameter list Operator Addendum OSHA Approved Certification. The equipment and its installation specified herein shall be inspected, approved as defined in 29 CFR 1910.399, and labeled by a Nationally Recognized Testing Laboratory (NRTL) as defined in 29 CFR 1910.7. A satisfactory NRTL Field Evaluation Report shall be provided to the receiving activity after equipment delivery and installation, and prior to destination testing.

TRAINING. All training shall take place at the receiving activity. The contractor shall schedule and tailor training by mutual agreement between the contractor and the receiving activity. Initial on-site operator and maintenance training shall be timed for machine acceptance testing and shall be completed prior to final acceptance at destination. Instructor(s) shall comply with security clearance instructions specified herein and in Attachment A. At least two (2) weeks prior to the start of any training, the contractor shall provide a course outline for Government review and comment. Training shall stress the importance of system interactions, troubleshooting, and long-term preventative maintenance and operation. The core of this training will be based on manufacturer's recommendations and the operation and maintenance information provided. A review of environmentally-related aspects of the operation and maintenance shall be included. The PSNSY & IMF will provide classroom space in proximity to the equipment, as necessary. Include within the training plan the following elements:

a. Equipment included in training.

b. Intended audience.

c. Location of training.

d. Objectives.

e. Subjects covered including description.

f. Duration of training on each subject.

g. Methods (classroom lecture, video, site walk-through, actual operational demonstrations, written handouts, etc.).

h. Instructor and instructor qualifications for each subject.

OPERATOR / PROGRAMMER ON-SITE TRAINING. Operator training shall be provided at the receiving activity. Training shall include preparation of part programs and preparation of equipment for safe operation of the equipment. The operator shall be provided instruction for the care, use and operation of all attachments and accessories. Training shall be provided for four (4) operators / programmers. The training period shall not be less than one (1) eight (8) hour work day.

MAINTENANCE PERSONNEL (ELECTRONIC). Maintenance training with respect to controls and related components shall include trouble-shooting and methods of correction should equipment malfunction, with emphasis on minimizing equipment down time. Training shall be provided for four (4) electronic maintenance personnel. The training period shall not be less than one (1) four (4) hour work day.

ON-SITE WORK RESTRICTIONS. The following requirements apply to working on the receiving activity’s site. Additional requirements may be found in attachments to this document.

CONTROL OF HAZARDOUS ENERGY (LOCKOUT /TAGS-PLUS) PROGRAM. The Government will provide the Contractor with a copy of the lockout and tag out controls used by the Government facility where the equipment is to be installed. The Contractor shall meet with the Government Point of Contact to discuss Lockout/tags-plus interface. The Contractor shall use the Receiving Activity's Lockout/tags-plus procedures in accordance with 29 CFR 1915.89. Lockout/Tags-plus procedures IAW 29 CFR 1915.89 shall be followed, where applicable. Contractors shall train their employees to Vol. II Chapter 9 of the Government Occupational Safety and Health (OSH) manual or as directed by technical guidance from the Receiving Activity. Audits, surveillances and incident investigations shall be performed per 29 CFR 1915.89 and the Receiving Activity's OSH Manual Vol. II Chapter 9 requirements.

STORAGE AND DEBRIS. During the process of the work, the contractor shall confine his apparatus, storage of materials, and the operation of his personnel within reasonable limits as specified by the receiving activity. The receiving activity will designate a suitable storage area. The contractor shall be responsible for security of their own property. Upon completion of each day’s work, the contractor shall clean, remove, and properly dispose of the resultant dirt and debris. All equipment and unused materials shall be removed from the premises upon completion of work. The premises shall be kept satisfactory to the receiving activity. The receiving activity is responsible for testing and disposal of hazardous material. Upon testing approval of nonhazardous debris, the contractor shall be responsible for the disposal of the debris.

Contractor Hazardous Material Inventory Request (CHMI). Hazardous materials to be used in the performance of this contract require advance approval by the Government and monthly reporting by the Contractor. Prior to arrival and use at NBK or PSNS & IMF, the Contractor shall provide an inventory of all hazardous materials anticipated to be used during the performance of the contract. Hazardous materials shall be listed on a Contractor Hazardous Material Inventory (CHMI) form. The CHMI form can be obtained from the Receiving Activity’s Point of Contact.

The Contractor shall provide, in electronic format, the completed CHMI form and the Globally Harmonized System Safety Data Sheet (SDS) for each item listed on the CHMI. The SDS shall be not older than five (5) years.

CHMI submittal shall be no less than 14 business days prior to hazardous material being brought on PSNS & IMF to allow review and approval by the Environmental, Safety and Health office. A Receipt and Monthly Usage Form will be issued for all approved hazardous materials.

The Receipt and Monthly Usage Form shall be completed and returned to the Receiving Activity’s Point of Contact within five (5) business days of the following month.

ACCURACY AND PRECISION. The equipment shall meet the accuracy and precision requirements listed in Table I under continuous operation in the specified work environment.

TABLE I ACCURACY AND PRECISION

SIZES AND CAPACITIES. The equipment supplied under the requirements of this specification shall conform to the dimensions, sizes, and capacities stated in Table II. Unless otherwise specified all dimensions are in inches. Unless otherwise specified, listed values are minimum requirements. Where a range is shown, the required performance is from the smaller figure, or less, to the larger figure, or more.

TABLE II SIZES AND CAPACITIES

Working Environment

Machine Capacities

QUALITY ASSURANCE.

RESPONSIBILITY FOR COMPLIANCE. All items offered for inspection shall meet all requirements of sections 3 and 4. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of assuring that all products or supplies submitted to the Government for acceptance comply with all requirements of the proposal.

RESPONSIBILITY FOR INSPECTION. The contractor is responsible for performance of all inspection requirements specified herein. The Government reserves the right to perform any of the inspections set forth in the specification where such inspections are deemed necessary to assure that supplies and services conform to the prescribed requirements. Only supplies that totally conform to the specifications shall be offered for inspection and test. The contractor's test schedule shall allow consecutive inspection and test of the supplies offered.

MEASURING AND TESTING EQUIPMENT. The contractor shall provide and maintain gauges and other measuring and testing devices necessary to assure that supplies conform to the technical requirements.