PD cylinder head mill Draft W911N2-22-Q-0010.pdf

DRAFT

LETTERKENNY ARMY DEPOT

PURCHASE DESCRIPTION

CYLINDER HEAD RESURFACING MILL FOR

GENERATOR ENGINE REMANUFACTURING

1.0 General Information:

1.1 Scope: Request the purchase of one (1) resurfacing mill for cylinder heads and blocks. This specification establishes the minimum requirements for the purchase of contractor installed resurfacing mill at Letterkenny Army Depot (LEAD). The contractor shall provide all professional architectural, engineering and construction services for the preparation of all necessary drawings, specifications, calculations, cost estimates and related design, permits, fabrication, construction, installation and testing services for the completion of this project. The resurfacing mill shall be installed by the government in accordance with Original Equipment Manufacturer specification and standards.

Specifications are based upon commercially available products and shall meet or exceed the minimum requirements specified in section 4.0 Specifications.

1.2 Place and Performance of Installation: All work shall be performed between the hours of 6:00 AM and 3:30 PM, Monday thru Thursday, exclusive of Federal Holidays and special depot closures (typically the Monday before or Thursday after Federal Holidays that fall on a Saturday, Sunday, Tuesday or Thursday).

Other hours, weekend, and holiday work will be considered separately as requested by the contractor with adequate advanced notice and approved by the Contracting Officer.

1.3 Security Requirements: Contractor and all associated sub-contractor’s employees shall comply with applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative). The contractor shall also provide all information required for background checks to meet installation access requirements to be accomplished by installation Provost Marshal Office, Director of Risk Management or Security Office. Contractor workforce shall comply with all personal identity verification requirements as directed by DOD, HQDA and/or local policy. Should the Force Protection Condition (FPCON) change, the Government may require changes in contractor security matters or processes.

The contractor and all associated subcontractor employees shall also comply with adjudication standards and processes using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (TSDB) (Army Directive 2014-05/AR 190-13), applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative), or, at OCONUS locations, in accordance with status of forces agreements and other theater regulations.

1.3.1 Security, Safety and Fire Protection: All work shall comply with LEAD Regulation 385-1 and Pamphlet 385-1. The equipment and the installation shall also meet all the safety criteria set forth in OSHA 1926.501 and ANSI/ASSE Z359.

1.3.2 Media Devices: All pictures shall be taken by LEAD representative and approved before release.

1.3.3 AT Level I Awareness Training: All contractor employees, to included subcontractor employees, requiring access to Army Installations, facilities, and controlled access areas shall complete AT Level 1 awareness training within 30 calendar days after contract start date and within 30 calendar days of new employees commencing performance. The contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee, to the COR or to the contracting officer, if a COR is not assigned, within 15 calendar days after completion of training. AT level 1 awareness training is available on the Letterkenny Army Depot homepage – www.lead.army.mil.

1.3.4 Physical Security: The contractor shall safeguard all Government property provided for contractor use. At the close of each work period, Government facilities, equipment and materials shall be secured.

1.3.5 iWATCH Training: The contractor and all associated sub-contractors with an area of performance within an Army-controlled installation, facilities or area shall brief all employees on the local iWATCH program. This local developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the COR or contracting officer.

This training shall be completed within 30 calendar days of contract award and within 30 calendar days of new employees commencing performance. The contractor shall report completion for each affected contractor employee and subcontractor employee, to the COR or to the contracting officer, if a COR is not assigned, within 15 calendar days after completion of training. iWATCH training is available on the Letterkenny Army Depot homepage – www.lead.army.mil.

1.3.6 OPSEC Training: Per AR 530-1, Operations Security, new contractor employees and associated sub-contractor employees shall complete Level I OPSEC training within 30 calendar days of their reporting for duty and annually thereafter. The contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee, to the COR or to the contracting officer, if a COR is not assigned, within 15 calendar days after completion of training.

Level 1 OPSEC training is available on the Letterkenny Army Depot homepage – www.lead.army.mil.

2.0 Government Responsibilities:

2.1 Government Furnished Property and Materials: The Government will provide the facilities, equipment, materials and/or services listed below:

2.1.1 Facilities: The Government will provide clear access to all working areas necessary for the contractor to perform the installation outlined, during the specified hours listed in section 1.2.

2.1.2 Equipment: none

2.1.3 Materials: Stock material for testing.

2.1.4 Services: none

2.2 Site Preparation: Letterkenny Army Depot will provide a clear area for installation of the equipment.

2.3 Utilities: LEAD will provide adequate utilities for the installation and operation of the machines in a disconnect. LEAD will also provide temporary utilities for the operation of equipment required for the installation of the industrial equipment.

2.4 Delivery and Storage: The Government will unload equipment but there will not be any extended storage. The contractor will be required to be present for unloading and installing the equipment. The contractor will oversee and aid in unloading, and installing of equipment.

3.0 Contractor Responsibilities: The contractor shall be responsible to inform all of his workers, direct or contracted, and ensure they follow the information within this specification. The contractor shall also have a representative onsite to manage the project and be the point of contact (POC) to communicate and coordinate with Letterkenny’s POC.

3.1 Post Processor: If the control is capable of being programmed offline (other than on the control with HMI), the contractor shall verify their machine is compatible with Mastercam 20 and newer software. If not, the contractor must supply a post for their machine that is compatible with Mastercam 20 and current version software.

3.2 Project Schedule: A project schedule shall be submitted by the contractor, within

30 days after receipt of the purchase order, to include a timeline for material delivery, installation, testing and training.

3.3 Utility Requirements: The contractor shall provide certified utility requirements within 15 days after receipt of the purchase order. They shall include type, number of connections, and requirements.

3.4 Field Verification: It shall be the responsibility of the contractor to verify, in the field, all measurements, locations of structures and utilities, and any other physical conditions which would affect the progress, or quantity of work. Any errors by the contractor, due to omission of field verification, shall not be the basis for any increase in contract price. Where existing utilities or other obstructions interfere with the progress of the contract, the contractor shall provide all materials and labor to relocate all obstructions as required and approved by the Contracting Officer.

3.5 Foundation: The mill must operate properly and accurately on a 6 inch thick concrete slab floor. If the 6 inch slab isn’t sufficient for proper operation, the contractor is responsible to design and install an adequate foundation.

3.6 Utility Installation: Utilities are to be run overhead.

3.7 Disposal Of Materials And Equipment: All salvageable materials and equipment removed by the contractor shall be delivered to the Depot Property Disposal Yard, Facilities Engineering Division warehouse, or other sites as directed by the Contracting Officer, or his representative and shall remain the property of the Government. Delivery shall be made during normal operating hours of the receiving activity. No Government materials or equipment shall be removed from the reservation by the contractor. All packing, packaging, and scrap material accumulated during the performance of the contract shall be removed and disposed of properly by the contractor.

3.8 Dust Control: None. Install done by government.

3.9 Protection of Existing Structures and Equipment: none.

3.10 Installation of New Equipment: The government will off-load, install, and connect utilities to the equipment. However, the contractor will have a representative present during off-loading, install, utility connection, and startup and will oversee these operations. The contractor will be responsible to bring any special tools needed specifically for the installation of the equipment. The contractor shall remove all packaging and preservative material. Removed components shall not be taken from the Depot property. Removed components shall be placed in a location designated by the TPOC.

3.11 Wiring: All electrical work and materials shall be in compliance with the National

Electrical Code and National Electrical Manufacturers Association. All electrical installations shall be inspected and accepted by a certified electrician. All work shall be subject to inspection by LEAD electricians.

3.12 Pipe: Schedule 40 (minimum) black steel pipe, valves, and all materials necessary, shall be supplied and installed to provide the equipment with required adequate air and water supplies.

3.13 Fluids: The contractor shall provide all necessary fluids and chemical additives required for the start-up and proper operation of the equipment. The contractor shall supply LEAD with MSDSs for all the necessary fluids within 30 days after award of contract.

3.14 Permits: None.

4.0 Requirements:

4.1 Machine Features:

4.1.1 Capacities: The mill shall have the necessary minimum options to machine cylinder heads and engine blocks. The machine will mill the head cylinder deck (fire deck), valve cover deck, intake and exhaust faces, engine block top and pain rail surfaces, and any other milling necessary for the remanufacturing process of a large number of different sized cylinder heads with the following capacity requirements (All dimensions are in inches):

Cylinder head length range of 9” – 42”, Cylinder head width range of 12” – 15”, Cylinder head height range of 2.5” – 4.5”,

4.1.2 Features: The machine shall include, but not limited to the following items:

Proper guarding (see paragraph 4.6.5) Dry milling (no coolant) Infinitely variable spindle speeds from 350-1,800 RPM Infinitely variable travel feeds of 0.001”-0.080” per cutter revolution Max work head travel is at least 50 inches Rapid traverse rate 200 inches per minute 16 inch cutterhead 2 radially and axially adjustable cutting insert tool holders for 3/8”IC round or square inserts Cutterhead guard Roll out chip bin work light 12” color touch screen display Enclosed, guarded work area per OSHA requirements (see para 4.6.5) Depth dial indicator At least 3 T slots for universal fixture mounting Max floor space required 87” wide x 69” deep

4.2 Machine Control System:

4.2.1 Control Features: The cylinder head mill shall have a CNC style, Windows based control, or equivalent. All machine functions shall be controlled and monitored through the operator’s control panel/interface; shall be capable of being set through conversational machine code input into the control, Human Manual Interface (HMI). Machines that are network capable must have an Ethernet connection where part programs can be downloaded via the network.

4.2.2 The machine control shall have the following features at a minimum:

Touch screen with conversational programming language

Depth of cut, multiple passes, total removed material, rough and finish speeds and feeds programming

Programmable rapid touch off set points Cutterhead end of cycle auto home return

4.2.3 Control Software Compatibility: The control shall be a windows style control or equivalent. If the cylinder head machining center is network capable, the control software must be Win10 compliant and shall be compatible with Mastercam 20 and current version software.

4.3 Machine Tooling: The machine will include the following tooling and measuring devices at a minimum:

Inch unit setting dial indicator for cutterhead PCD round insert, 3/8” IC for aluminum CBN round insert, 3/8” IC for cast iron CBN octagonal inserts (qty of 5)

4.4 General Requirements:

4.4.1 Painting: All surfaces to be painted shall be cleaned of all foreign matter. The equipment shall be painted IAW standard commercial practice that shall not be less than one coat of primer and one coat of finish color.

4.4.2 Lubrication: Means shall be provided to ensure adequate lubrication to all moving parts. All oil holes, grease fittings and filler caps shall be easily accessible.

4.4.3 Power Requirements: All power requirements shall be 480V 3ph. If any requirement is not, the contractor shall supply all required transformers.

4.4.4 Automatic Lubrication: The system shall include a centralized lubrication system to automatically provide lubricant to critical components.

4.4.5 Energy Efficiency: All equipment that directly consumes energy in normal operation shall be designed and constructed for the highest degree of energy efficiency as governed by the latest developments available within industry.

4.4.6 Documentation: Two sets (each) of paper and one (each) CD of operator instruction manuals, maintenance service manuals, and parts listing manuals shall be provided for the furnished systems. These manuals shall be written in the English language.

4.4.7 Preservation, Packaging and Delivery: The contractor shall utilize standard commercial methods for preservation and packaging appropriate for each unit and acceptable to commercial carriers. As a minimum, all areas susceptible to damage from exposure to the elements shall be preserved and/or packed to prevent damage. The contractor shall be responsible for ensuring the equipment is delivered to LEAD in good condition.

4.4.8 Warranty: The contractor shall furnish with the equipment a standard commercial warranty or full one year warranty (parts, labor, and shipping, at minimum), whichever is greater. The contractor shall provide commercial warranties for any subcontracted components that will be underwritten. The contractor shall supply all corresponding warranty contact names and phone numbers before the end of the project. The warranty shall be effective beginning immediately after final acceptance of the equipment and not before that time.

4.4.9 Inspection and Acceptance: The equipment shall be examined for design, construction, materials, components, and workmanship to determine compliance with the contract and this specification. Any deviation from these requirements shall be cause for rejection.

4.5 Environmental Requirements:

4.5.1 Mercury Restriction: The equipment shall not contain mercury compounds nor be exposed to free mercury during manufacture.

4.5.2 Asbestos Restriction: Asbestos and materials containing asbestos shall not be used in or on the equipment.

4.5.3 PCB Restriction: Equipment and materials containing Polychlorinated Biphenyl

(PCB) shall not be shipped to Letterkenny Army Depot.

4.6 Safety Requirements:

4.6.1 Equipment Hazards: All hazards inside the machinery shall be guarded against unauthorized access. Clearly visible signs and symbols shall warn personnel in the area, and interlocks, safety mats and redundant deactivation systems shall guard against accidental access to the tooling and moving parts. Guards shall be easily removable to facilitate inspection, maintenance, or repair.

4.6.5 Safety Guarding: The grinder design must meet OSHA standards for safety and guarding of the machine. This is addressed in OSHA subpart O, paragraphs 1910.211-1910.219. The machine must meet applicable requirements.

4.7 Installation Requirements:

4.7.1 Design and Installation: The contractor shall provide all parts, labor, and services for the design and fabrication of the cylinder head milling machine. The contractor shall provide competent English speaking personnel to place the system in operation and to conduct the acceptance tests and training of depot personnel.

The contractor, through his service personnel, shall oversee and aid in the offloading and installation of the equipment. The contractor or their service personnel will be fully responsible for the activation and testing of the system and the service personnel shall remain until system activation and testing has successfully been completed.

4.7.2 Badges: Identification badges will be issued for admittance of personnel before performing work or service on this contract. The identification badge is the property of the US Government and must be returned upon termination or demand. The contractor/vendor agrees that he will ensure all badges issued to employees are returned to the Badge and Identification Section, Security Division, Letterkenny Army Depot promptly on termination of need or on expiration, which occurs first. The badge room is located in Bldg 2, phone # 717-267-5301. Hours of operation are 7:30 AM to 3:30 PM, Monday thru Friday, exclusive of Federal Holidays.

4.7.3 Fire Extinguishers: The LEAD R 385-1 designates the type and number of fire extinguishers required to perform the contracted work. The LEAD Fire Department will not provide any extinguisher support. The contractor can gain the above information through a pre-construction conference, visiting the fire department, or phone 717-267-8108.

4.7.4 Use of Portable Gas or Arc Equipment: The contractor shall obtain a permit, from the LEAD Fire Department, to use portable gas or arc equipment for cutting, welding or open flame operations. The Fire Department will require one day advance notice to permit necessary inspection before actually starting work, and notification when work is finished to allow for re-inspection. The Fire Department can be notified by calling 717-267-8108. The contractor shall take necessary precautions to prevent fires IAW NFPA Standard No. 51B and LEAD R 420-13.

4.7.5 Spills: Any spills or releases of materials or wastes must be reported immediately to the site supervisor, the LEAD Fire Department, and the LEAD Environmental Office per the LEAD Installation spill Contingency Plan (ISCP). Any such spills or releases generated by the contractor shall be contained, cleaned and disposed of by the contractor per the direction of the LEAD on-scene coordinator.

5.0 Applicable Documents:

OSHA Safety and Health Standards 29 CFR 1910 Occupational Safety and Health Standards (copies may be obtained at www.osha.gov)

Letterkenny Army Depot (LEAD) Publications:

LEAD Regulation 385-1: LEAD Safety and Occupational Health Program LEAD Pamphlet 385-1 – Safety Requirements for Security, Safety, and Fire Prevention for Contractors Performing Work on LEAD (Copies may be obtained at LEAD Directorate of Contracting, Bldg 2)

National Fire Protection Association NFPA Standard 70 – National Electric Code NFPA Standard 79 – Electrical Standard for Industrial Machinery (copies may be obtained from www.nfpa.org)

Unified Facilities Criteria UFC 3-600-01 – Fire Protection Engineering for Facilities

(copies may be obtained from www.wbdg.org)

6.0 Quality Assurance:

6.1 Quality Conformance Inspection: The machining center and all accessory components shall be subject to a quality conformance inspection, performed by a designated Depot representative, to determine compliance with this specification.

6.2 Tests:

6.2.1 Accuracy: If an accuracy test was performed by the OEM before the machine was shipped, the contractor shall repeat the accuracy test at LEAD after complete installation. The results of the test performed at LEAD shall be compared to those from the test at the factory. If no accuracy test was performed at the factory, the contractor shall be responsible for developing test procedures to demonstrate the accuracy and operation of the machine to be in compliance with the requirements of this specification. All test procedures shall be submitted to and approved by Depot Technical Point of Contact (TPOC) prior to the start of testing. To support the testing procedures, LEAD will provide a supply of mild steel material of various thicknesses for use during the performance tests and training. If mild steel is not available, other readily available materials may be used. The contractor shall prove out all problems.

6.2.2 Post Processing Verification: If the machine can be loaded with part programs made offline and a post is needed and the machine is operational, the contractor shall run, successfully, a proven part program through their post-processor and download to the machine. The machine shall run from the downloaded part program and then checked for accuracy of the part and program. The contractor shall prove out all problems with the post.

6.3 Technical Instruction: The contractor shall be responsible for providing technical instruction of four (4) Depot personnel in the operation of the equipment and software and four (4) Depot personnel in the maintenance of the equipment supplied under this contract. All instructions, oral and written, shall be in the English language. The project LEAD TPOC will coordinate with individuals to be trained upon successful completion of all installation and test specifications.

7.0 Information Technology (IT) Industrial System Requirements:

7.1 Operating System (OS) Specifications:

7.1.1 If applicable, the system’s OS must be Microsoft Windows 10, Windows Server

2012R2, or Red Hat Linux v6.X. Any OS supplied with the system must contain all service packs, updated patches, and hot fixes. All patching and fixes will be current as of a predefined date agreed upon by the vendor and the government.

7.1.2 Defense Information System Agency (DISA) Security Technical Implementation

Guides (STIGS) are configuration standards for the Department of Defense and contain technical guidance to lock down information systems and software applications that might otherwise be vulnerable to malicious attacks. The contractor shall be responsible for ensuring all appropriate STIGs are implemented and their software runs acceptably while secure.

7.1.3 The Army Golden Master (AGM) is a collection of security settings for Microsoft

Operating systems which must be applied to all Army computer systems. LEAD will supply the AGM to the contractor who shall ensure their software functions as intended, when installed on top of the AGM.

7.2 Programmable Logic Controllers (PLC): If a PLC is to be installed within the system, it shall be manufactured by a government approved source and shall provide an Ethernet adapter to allow for connection to the Industrial Network if required. If an Ethernet connection is used to interconnect the PLC to peripheral equipment, an additional Ethernet port shall be provided.

7.3 System Software Specifications:

7.3.1 Software Installations: If installing application code at LEAD, the contractor shall install the code within a standard container (E.g., Program Files) and located in a volume separate from the standard System Files. Interactive applications are required to run as services and daemons and any time WEB services are used, file types (E.g., XML and HTML) must be separated.

7.3.2 Software Licensing: When installed, the software licensing for computers, control units and other IT systems will be surrendered to the Information Technology Configuration Manager and will become the property of the Government upon acceptance of the system.

7.3.3 If software has been customized for LEAD’s use or is any software other than

Commercial Off The Shelf (COTS); the contractor shall provide copies of all source code, firmware and software used in the system, as well as one set of backup and configuration software for PLC’s, control and communication computers, and data acquisition. All programs shall be tested and fully operational before acceptance. All acceptance testing will adhere to common User Acceptance Testing (UAT) standards as defined by the government.

7.3.4 If any special programming software or programming software interface devices such as hardware "keys", dongles or "PIC" modules, are required to access software, these programs and devices shall be provided to LEAD along with the necessary registration information. If custom application software was written and provided, a copy of the required compiler and compiler license shall also be provided. At acceptance, all items shall become property of the government.

Software and hardware purchased for this project shall be registered to Commander, Letterkenny Army Depot, Chambersburg, PA 17201.

7.4 System Environment Specifications:

7.4.1 All supplied software must be capable of operating in a multi-user environment and data which contains permissions information shall be hidden from view and inaccessible to those with less than administrator level access. Shared accounts shall not be used, and users shall only be authorized the minimum security rights to operate the application software. Users will not have access to system or software configuration items (e.g., Control Panel, software and hardware installation). Under no circumstances will the intended end user log in using the Administrator or Root account for routine operation of the equipment. The use of these accounts will be restricted to only administrative activities which will be carried out by LEAD Information Technology personnel. All software products shall employ a minimum of three permission based levels of access.

7.4.1.1 Administrator - Full control at root level, restricted to LEAD IT personnel and when required, the Contractor.

7.4.1.2 Maintenance - Mid-level control required to perform maintenance and alter control parameters as needed.

7.4.1.3 Operator - Minimum control necessary to perform the routine operation of software. The Operator shall not be able to alter the programming of software, make changes to executable files, or modify control parameters.

7.4.2 Application Interoperability: If an application will interfere with the operation of the industrial system, E.g., (McAfee Anti-Virus), the Contractor shall provide a written statement to the LEAD IT Directorate explaining the technical restrictions placed upon them.

7.4.3 Auditing: If applicable, the contractor shall enable audit files and data logs for access by LEAD Cybersecurity personnel to audit access and actions on the equipment.

7.4.4 User Acceptance Testing (UAT): LEAD Cyber Security Personnel will have the ability to conduct validation testing with approved security tools prior to equipment being introduced to the shop floor. This testing will also satisfy any UAT requirements. A UAT Plan will be furnished prior to testing and all equipment documentation will be made available for review during the test. If discrepancies are discovered the contractor shall remediate identified issues prior to government acceptance.

7.5 Documentation Requirements:

7.5.1 A complete set of instruction manuals containing all of the information necessary to operate, maintain, and reinstall all software and hardware contained within the system shall be provided by the Contractor. These manuals shall include step-by-step instructions which facilitate the rebuilding of the system in the event of a fatal system crash.

7.5.2 If networked, the Contractor shall provide the system’s network design drawings to the Information Technology Directorate. These drawings should include complete directional data flow diagrams that include all ports and protocols in use.

7.5.3 The Contractor shall provide to Industrial Automation at least two electronic copies of all control unit programs. These copies should include description files of the ladder logic and any cabling required to connect to the control systems. No control units will be password protected and no other form of lockout measure shall be implemented by anyone other than LEAD IT employees. The Contractor shall also provide electrical wiring diagrams for all installed control systems to this LEAD Industrial Automation group.

7.5.4 Certificate of Networthiness: Certificate of Networthiness (CoN) certification ensures Automated Information Systems (AIS) utilizing the Army Network are developed in compliance with the Clinger Cohen Act and are secure, supportable, sustainable, and compatible with the Army Enterprise Infrastructure (AEI) (as defined in AR 25-1). All new AIS capabilities and all capability modifications and upgrades must be assessed to validate their Networthiness (network security, network impact, compatibility with the infrastructure, infrastructure requirements, spectrum support, security policy compliance, Joint Technical Architecture –Army (JTA-A) standards compliance, communications and information manpower, training, logistics support, schedule, and funding). If software is installed within the system, the Contractor shall work with LEAD Directorate of Information Management (DOIM) personnel to check for CoN availability and when not available, ensure a CoN is requested and all documentation is submitted.

7.6 Proposal Deviations:

7.6.1 Proposals or specifications that deviate from those described herein shall be coordinated for specific approval or rejection by the LEAD Information Technology representatives prior to shipment, installation, or acceptance of the equipment.

8.0 Final Acceptance: Once all conditions of this contract are met, final acceptance will be after 100 hours of continuous operation without a breakdown or failure, or 14 days, whichever comes first. If the machine has a failure or breakdown and it is determined that is the fault of the machine hardware or software, the operating time and 14 days timeframe start over each time this happens. After the 100 hour operating time or 14 days have been met, final payment of this contract will be made.