PD_Pipe Bender 22-25-1004.pdf

VIBB 22-25-1004

January 25, 2023

PURCHASE DESCRIPTION FOR THE ACQUISITION OF A COMPUTER

NUMERICALLY CONTROLLED (CNC) ELECTRIC PIPE BENDER

1. SCOPE

1.1. Scope. The purchase description set forth below describes the minimum requirements of the Government for a CNC Electric Pipe Bender. The bender shall be rotary draw for making precision cold bends in 1/2 inch through 5 inch pipe. The bending machine shall bend using ambidextrous (right and left hand) bending motion and shall include single stack tooling, ancillary equipment, leveling pads, quality assurance testing, installation, and training. 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.

2. APPLICABLE DOCUMENTS

2.1. General. The documents listed in this section are cited in sections 3 and 4 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 and 4 of this specification, whether or not they are listed. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

2.2. Government Documents.

2.2.1. 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 shall be the current edition at time of solicitation.

FEDERAL STANDARDS

FED-STD-H28------------------------------ Screw Thread Standards for Federal Service

FED-STD-313 ------------------------------ Material Safety Data, Transportation Data and Disposal Data for Hazardous Materials Furnished To Government Activities

(Copies available online at http://quicksearch.dla.mil/)

MILITARY STANDARDS

MIL-STD-130N w/ Change 1 ------------ Identification Marking of U.S. Military Property

MIL-STD-1627C -------------------------- Department of Defense Design Criteria: Bending of Pipe or Tube for Ship Piping Systems

(Copies available online at http://quicksearch.dla.mil/) http://quicksearch.dla.mil/ http://quicksearch.dla.mil/

NAVSEA

OSHECM Chapter 250 Rev 1 ------------ NAVSEA Occupational Safety, Health and Environment Control Manual for Naval Shipyards Chapter 250

(Copies available online at http://www.navsea.navy.mil/Home/Shipyards/Norfolk.aspx)

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 --------------------------------- Safety and Health Requirements Manual

(Copies available online at http://www.usace.army.mil/Safety-and-Occupational- Health/Safety-and-Health-Requirements-Manual/)

UNIFIED FACILITIES CRITERIA (UFC)

UFC 3-301-01 w/ Change 3 -------------- Structural Engineering

(Copies available online at https://www.wbdg.org/ffc/dod/unified-facilities-criteria-ufc/ufc- 3-301-01)

2.2.2. 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.

COMBINED FEDERAL REGULATIONS

29 CFR 1910 -------------------------------- General Industry, OSHA Safety and Health Standards

29 CFR 1915 -------------------------------- Occupational Safety and Health Standards for Shipyard Employment

40 CFR 82 ----------------------------------- Protection of Stratospheric Ozone

(Copies available online at http://www.gpo.gov/fdsys)

LOCAL ATTACHMENTS

Attachment A ------------------------------- Site Specific Regulations

Attachment B ------------------------------- Installation Location Drawing

(Copies attached to the solicitation)

2.3. 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.

http://www.navsea.navy.mil/Home/Shipyards/Norfolk.aspx http://www.usace.army.mil/Safety-and-Occupational-Health/Safety-and-Health-Requirements-Manual/ http://www.usace.army.mil/Safety-and-Occupational-Health/Safety-and-Health-Requirements-Manual/ https://www.wbdg.org/ffc/dod/unified-facilities-criteria-ufc/ufc-3-301-01 https://www.wbdg.org/ffc/dod/unified-facilities-criteria-ufc/ufc-3-301-01 http://www.gpo.gov/fdsys

AMERICAN NATIONAL STANDARDS INSTITUTE

ANSI/AGMA ISO 1328-1-B14 ---------- Cylindrical Gears - ISO System of Flank Tolerance Classification -Part 1: Definitions and Allowable Values of Deviations Relevant to Flanks of Gear Teeth

(Copies available at http://webstore.ansi.org/ or ANSI Attn: Customer Service Department, 25 W 43rd Street, 4th Floor, New York, NY 10036)

B11 STANDARDS

ANSI B11.15 – Machine Tools-Safety Requirements for Pipe, Tube, and Shape Bending Machines (2001, R2007)

(Copies available from B11 Standards Inc, 7901 Westpark Dr, McLean, VA 22102)

AMERICAN SOCIETY FOR TESTING MATERIALS (ASTM)

ASTM A53/A53M-12: Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

(Applications for copies should be addressed to ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION

ISO 4414------------------------------------- Pneumatic Fluid Power - General Rules and Safety Requirements for Systems and Their Components

(Copies available at http://webstore.ansi.org/ or American National Standards Institute, Dept. 969, 1430 Broadway, New York, NY 10018)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION

NEMA MG 1 ------------------------------- Motors and Generators

NEMA Z535.4 ------------------------------ Product Safety Signs and Labels

NEMA 250 ---------------------------------- Enclosures for Electrical Equipment (1000 Volts Maximum)

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

NATIONAL FIRE PROTECTION ASSOCIATION

NFPA 70 ------------------------------------- National Electrical Code

NFPA 79 ------------------------------------- Electrical Standard for Industrial Machinery http://webstore.ansi.org/ http://webstore.ansi.org/ http://www.nema.org/

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

2.4. 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.

2.5. Acronym Definitions Not Explicitly Listed in Text. The following acronyms not explicitly listed in each section text are defined as follows:

a. JIS- Japanese Industrial Standards

b. DIN- German Institute for Standardization

c. EN- European Standard

3. REQUIREMENTS

3.1. Design. The item offered shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

3.1.1. Measuring and Indicating Device Graduations. All measuring and indicating devices on the CNC Electric Pipe Bender shall be graduated in the inch/pound or both inch/pound and metric.

3.1.2. Controls. All electrical, mechanical, and pneumatic operating controls shall be located convenient to the operator's workstation(s).

3.1.3. OSHA Compliance. The equipment installation and its component parts shall be in compliance with 29 CFR 1910, NFPA 70 and NFPA 79. Approval shall be as specified under the “Approval” and “Acceptance” criteria in the OSHA regulations Subpart “O”, Machinery and Machine Guarding paragraph 1910.212 and Subpart “S” Electrical, paragraph 1910.303 and paragraph 1910.399.

3.1.4. Safety Signs and Labels. Safety signs and labels in accordance with NEMA Z535.4 shall be securely attached to the equipment in visible locations, at the point of hazard(s), with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the signs.

3.1.5. Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11.15 or equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall http://www.nfpa.org/ indicate which document they will utilize for compliance to the requirements. The safety devices shall not interfere with the operation of the CNC Electric Pipe Bender. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

3.1.6. Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment.

Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

3.1.7. Hazardous Material Exclusions. Supplies or materials being provided as part of the equipment shall be free of known hazardous materials. Hazardous materials shall not be brought on site without prior approval of the Government Point of Contract and cognizant shipyard personnel. Hazardous materials not needed for this project are prohibited.

Definitions of hazardous materials are specified in the latest version, including revisions adopted during the term of the contract, of FED-STD-313. 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, lithium, methylene chloride, lead (= or >0.06%), or polychlorinated biphenyls (PCB’s) 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, for consideration, not later than 60 calendar days after effective date of contract and prior to any work being performed.

3.1.7.1. PCB Certification. Written certification from the manufacturer that the equipment contains no detectable PCBs (less than two (2) parts-per-million) shall be provided. The certification shall be on manufacturer’s letterhead, and signed by a company official who is empowered to provide same. A PCB label plate stating the PCB compliance certification shall be supplied and attached to the equipment.

3.1.8. Environmental protection. Under the operating, service, transportation, and storage conditions described herein, the CNC Electric Pipe Bender shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

3.1.9. Lubrication. Means shall be provided to ensure adequate lubrication for all moving parts. Recirculating lubrication systems shall include a filter that is cleanable or replaceable.

Each lubricant reservoir shall have at least a 24-hour capacity. When a low lubricant level condition occurs, the machine shall complete the current operation and come to a complete stop. When a low oil pressure condition occurs in a continuously pressurized system, the machine shall enter an emergency stop condition. The machine shall indicate that oil or lubrication is required. All oil holes, grease fittings, and filler caps shall be accessible. A lubrication plate shall be securely attached to the equipment, see 3.7.1.

3.1.10. Replacement Parts. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts. Foreign-sourced replacement parts shall be interchangeable with domestically supplied components or be readily available from a domestic source.

3.2. Construction. The CNC Electric Pipe Bender shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the CNC Electric Pipe Bender to its maximum rating and capacity without distortion.

3.2.1. Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, or filling with solder or paste shall be used for reclaiming any defective part.

3.2.2. Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

3.2.3. Threads. All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28 and the applicable “Detailed Standard” section referenced therein or equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

3.2.4. Gears. All gears of axis drive trains shall conform to or exceed all provisions of flank tolerance ISO 1328-1: class 7 in accordance with ANSI/AGMA ISO 1328-1-B14. The gears shall be of proper width and size to transmit full-rated torque and horsepower without failure for the expected service life of the machine. Gears in drive trains shall be hardened not less than Rockwell C48.

3.2.5. Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

3.2.6. Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

3.2.7. Corrosion Control. All system components shall be protected against corrosion and deterioration by appropriate material selection, application of coatings and sealants. The system and its parts shall be painted on all sides, prior to assembly, except mating surfaces such as mounting flanges and motor shafts. 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. Exposed ferrous parts such as screws, bolts, nuts, washers shall be treated to resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as chrome plating, galvanizing or other electrical/chemical process, or stainless steel is acceptable. Stainless steel parts shall be passivated. 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. All paint shall be lead and chromate free.

3.2.8. Workmanship. Workmanship of the CNC Electric Pipe Bender shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

3.3. Components. The CNC Electric Pipe Bender shall consist of not less than the following components.

3.3.1. Base. The base shall be either cast iron, cast steel or fabricated steel weldments of a mass that will support all components of the bending machine, without permanent distortion, while operating at its maximum rated capacity. Mounting bolt holes shall be provided for fastening the machine to the foundation. Means shall be provided for accurate leveling.

3.3.2. Clamping Mechanism. The clamping mechanism shall clamp the pipe to the bending form enclosing the periphery without deformation of the work piece. The clamping mechanism shall be designed to provide self-alignment and uniform clamping pressure over the entire clamping area to prevent the pipe from moving while it is being bent. Clamping surfaces shall be non-deforming to pipe and tubing surfaces. All clamping mechanisms utilizing replaceable inserts shall be provided with one (1) set of additional replacement clamp inserts for all pipe sizes in paragraph 3.4, Table I.

3.3.3. Degree Of Bend Selector. A digital degree-of-bend selector with at least 30 programmable pre-sets and the ability to add spring-back compensation values shall be provided. The amount of bending and the resulting angle shall be easily determined from the operator’s workstation.

3.3.4. Pressure/Clamping Die Assembly. The machine shall be provided with one (1) each pressure die, and clamp die for each size of pipe listed in Table I. All clamping dies shall be smooth and be of sufficient length to prevent slippage of listed pipe sizes and materials. An electric servo driven pressure die assembly shall be provided to apply pressure during the bending operation. The pressure die holder, slide, and ways shall be designed to provide and control pressure die force at the tangent point of the bend and on the vertical centerline of the pipe to obtain maximum bend quality with minimum die deflections. The die holder shall accept pressure dies for all radii within the capacity of the machine. The pressure die assembly shall have programmable position and pressure control. Readout, indicating the controlled die pressure, shall be visible at the operator’s station. Pressure dies shall also operate independently of the clamping mechanism. Pressure die assembly shall have automatic setup with no tools required to adjust position or pressure. The machine shall be provided with one

(1) each pressure die for each size of pipe’s centerline radius (CLR) of bends, as required, IAW paragraph 3.4, Table I.

3.3.5. Pressure Die Assist. An electric servo driven pressure die assist shall be provided with automatic setup requiring no manual adjustments, after initial setup, by the operator. Profiling of the pressure die to advance or retard during the bend shall be accomplished by the control system.

3.3.6. Carriage Y Axis. An electric servo driven, distance between bend carriage shall be supplied and designed to eliminate debris and/or metal chips from collecting in or on the gear track. Carriage shall allow closed or open collet bending of all diameters in this specification.

A Y axis boost shall be supplied. Carriage boost force shall be controllable during the bend cycle.

3.3.7. X Axis Tool Centerline Radius (CLR) Shift. A servo driven, gear rack shall accomplish all linear moves of the X axis and shall be fully programmable for each bend die CLR radius.

3.3.8. C Axis Bending Arm. An electric servo driven bending arm shall be provided with an all steel frame and no castings. A removable bend die mounting surface shall be provided for replacement or different tool mountings. A direct acting electric servo clamp shall have programmable position and clamping pressure control. No tools shall be needed to adjust clamp die position or pressure. C Axis bending arm shall meet the requirements of paragraph 3.4, Table I.

3.3.9. B Axis Plane of Bend. The plane of bend B axis shall have 360-degree bi-directional rotation and have programmable speed. Carriage alignment shall have the ability to be modified for various centerline heights. Collet(s) shall be provided for all pipe sizes outlined in paragraph 3.4, Table I and shall have interchangeable pads. Collet pads shall be grit blasted or serrated. Carriage/collet alignment to center line of radius shall be automatic with no mechanical adjustment required. The pressure actuator on the clamping device shall be electronic or pneumatic.

3.3.10. Mandrel Extractor. A servo driven mandrel extractor, with automatic lubrication and sufficient in stroke to extract the entire mandrel from the bent section of pipe shall be furnished. The extractor shall be supplied with an automatic mandrel lubricator using a paste or oil type pump. The pump shall be compatible with Irmco Gel 980-000 and Irmco Extreme 460-87A lubricants. Mandrel early withdrawal, lube time, and axis tangent position shall be operator programmable. The extractor shall have means for lateral adjustment to allow alignment of the mandrel for minimum and maximum bend die radii. Longitudinal adjustment shall be provided for mandrel tangent positioning. Provision shall be made to prevent accidental rotation of the mandrel rod during operation.

3.3.11. Mandrels. All mandrels and rods shall have “quick change” capability with the use of pins or equal means. Rods shall be provided for through mandrel lubrication. All mandrels provided shall be aluminum bronze for bending CRES and heat-treated tool steel or chrome plated carbon steel for bending all other metal alloys. The rubbing surfaces of the mandrels shall be ground and polished to provide a smooth finish. The machine shall be provided with the mandrels listed below:

Required Mandrels Type Quantity Size Material

Plug Mandrel One

0.84 inch x 0.065 inch

See Paragraph 3.3.11

1.050 inches x 0.065 inch

1.050 inches x 0.083 inch

1.050 inches x 0.120 inch

1.315 inches x 0.065 inch

1.315 inches x 0.095 inch

1.660 inches x 0.120 inch

1.900 inches x 0.109 inch

1.900 inches x 0.120 inch

1.900 inches x 0.134 inch

2.375 inches x 0.120 inch

2.375 inches x 0.165 inch

3.500 inches x 0.216 inch

3.500 inches x 0.237 inch

5.563 inches x 0.300 inch

2 Ball Mandrel One

2.375 inches x 0.083 inch

See Paragraph 3.3.11

2.875 inches x 0.120 inch

3.500 inches x 0.083inch

3.500 inches x 0.120 inch

4.500 inches x 0.120 inch

5.563 inches x.0 083 inch

3.3.12. Mandrel Rods. Mandrel rods shall be provided to support each size mandrel, without duplication of mandrel rod sizes. The mandrel rod lengths shall support 8 feet over mandrel bending operations. The mandrel rods shall be sized to prevent deformation of the mandrel rod when used in worst case pipe size/wall thickness scenarios. A laminated chart shall be provided, identifying mandrel and mandrel rod combinations.

3.3.13. Pipe Dies. Dies shall be manufactured from heat treated tool steel. Contractor shall provide a 5/8-11UNC-2B RI-I tapped hole(s), 1-1/8 inches deep, on all dies over forty-five pounds and a 3/4-10UNC-2B tapped hole 1-1/8 inches deep, if it is over 4000 lbs. as a means for safely lifting, using customer supplied swivel hoist ring(s). The tapped holes shall be vertical and arranged about the center of gravity in non-contact surfaces for balanced lifting in the working position of the die. The equipment shall be furnished with the following tooling:

quantity of one (1) each 2D, one (1) each 3D, and one (1) each 5D for 1/2 inch, 3/4 inch, 1 inch, 1-1/4 inches, 1-1/2 inches, 2 inches, 2-1/2 inches, 3 inches, 4 inches, and 5 inches NPS.

All bend die radii shall be based on nominal pipe size. All tooling shall be permanently stamped or engraved with its tool size and weight on non-contact surfaces.

3.3.14. Wiper Die. The machine shall be provided with one (1) each wiper die for each size of pipe for 2D and 3D only. Wiper Die provided shall be all steel weldment or machined design complete with adjustment slides. Wiper holders shall have independent positioning. Wiper die system shall accept both insert tips or square back wipers.

3.3.15. Overhead Tie Bars. All overhead tie bars shall be provided with quick disconnect to the swing arm or equivalent, pressure die arm, and wiper post.

3.3.16. Safety Devices. The pipe bender shall include at a minimum the following safety device:

a. Safety sensor plate on inside of swing arm, or equivalent, to prevent pinching.

b. Guard covers on B-axis drive, protecting the operator and machine during change out of mandrel

c. Laser floor scanners, with all controllers and safety relays, to prevent operator entry in a safety zone

d. Safety Warning labels on all pinch points

3.3.17. Pipe Support. A servo driven pipe support to maintain pipe alignment in the die groove shall be supplied. Support axis positioning shall be programmable, with no manual setup being required.

3.3.18. Automatic Spring-back Correction System. . Auto spring-back detection shall be laser and/or proximity sensors and be automatically read by the processor. The operator shall be given a readout on screen of degree of bend and be allowed to set spring back correction in automatic or manual. The processor software shall allow the operator access to input spring-back correction. Spring-back re-clamping shall not deform or change tangent of the pipe or its bend.

3.3.19. Tooling Storage. Tooling storage shall be provided with a minimum of seven (7) drawers or adjustable shelves, having a minimum capacity of 1,000 Lbs. Vendor shall submit drawings at time of proposal to determine space constraints.

3.3.20. Controller Features. The machine controller shall consist of a CNC Control, incorporating all standard features. The CNC unit shall provide programmable automatic control of machine functions, operating modes, axis movement and other part program directed functions for the CNC Electric Pipe Bender. Axis movement shall be independent and shall have independent positioning. Control features shall include Manual Data Input (MDI) or Graphical User Interface (GUI), simultaneous control of axis’s, programmable interface, part program and buffer edit capability, infinite part program storage in manual, step or auto cycle, and control diagnostics to at least board level. The CNC shall direct machine functions from command data stored in memory. The data stored in memory shall be input by the media specified herein. The control shall initiate a halt and error signal should a fault condition occur in the control. The control shall automatically shut down when internal operating temperatures exceed safe operating limits. The operator control station shall include incremental control of Bend Clamp (Open/Close), Pressure Die (Open/Close), Mandrel (Retract/Extend), Spindle Rotation (Return/Bend), and Master Bar (Retract/ Extend). The keypad of workstation shall be a mounted between 42 to 48 inches above foot grade. At a minimum, the control system shall also include:

a. 3D part simulation feature with collision detection

b. Windows 17” PC touch screen, Icon menu driven interface

c. Teach Mode

d. Memory stick or flash drive capability for storing and transferring data

e. No “Third Party" software to import IGES/STEP files from Solidworks, AUTOCAD or Inventor

f. Step interfaces for Solidworks, AUTOCAD, and Inventor

g. Main Cabinet, Sealed and Air Conditioned

h. Bend data entered in XYZ and/or LRB,

i. Conversion between XYZ and YBC bend data

j. line editing functions including Add, Delete, Insert, Copy, Paste, Clear, and Fill Down

k. Capable of direct communication with PCMM (Portable coordinate measuring machine) equipment and V-Tube measuring system (customer supplied)

l. 4 USB Connection Ports

m. 250G Storage Min.

n. Collision Detection or Collision Simulation

3.3.21. Pneumatic System. All pneumatic systems shall conform to ISO 4414, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls including protection from over-pressurization.

3.3.22. Energy Isolating Devices. The equipment shall be provided with energy isolation devices (e.g. power switches, safety devices, circuit breakers, valves) that protect personnel from the release of hazardous energy and are integral to the component being isolated and locked out. The devices shall be designed and manufactured such that they can be padlocked in the OFF position. This includes both mechanical and electrical devices. An energy isolation device shall be installed as the first energy control device on all major components of the system such that the component can be isolated at the component level.

3.3.23. Electrical System. The machine shall conform to NFPA 79 or equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements. The existing electrical power source available at the installation site is 480V, 3 PH, 125 Amps, 60 Hz. The machine’s electrical system shall be tolerant of voltage fluctuation of ± 10 percent. The electrical system shall be complete, including transformers required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device, controlling all electrical power to the equipment, shall be utilized on the machine with means of lockout in the off position only.

3.3.23.1. Motors. Motors shall be rated for continuous duty and shall have ball or roller bearings of the sealed and permanently lubricated type. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors 1 HP and above shall meet the requirements of NEMA MG 1 or current equivalent ISO/EN/DIN/JIS/IEC standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements. Each motor shall have an identification plate to identify manufacturer, model identification, serial number, voltage, amperage, horsepower, phase, frequency and frame number written in the English language. Servo motors are exempt from these requirements.

Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s), unless otherwise specified herein.

3.3.23.2. Solid-State Components. Solid-state design shall be employed throughout for electronic components. 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. Solid-state devices shall be capable of handling the electrical load imposed by operation of the machine to its maximum capability.

3.3.23.3. Electrical Enclosures. Electrical components of the equipment shall be contained in enclosures of drip-proof construction and of minimum size consistent with good design practices and ventilation of components, meeting the requirements of NEMA 250 Type 12 or current equivalent ISO/EN/DIN/JIS/IEC standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

3.3.23.4. Cable and Hose Carriers. All flexible power lines, cables, conduits, and hoses necessary to connect the linear sliding, powered, assemblies to stationary utilities and controls shall be contained within a flexible cable and hose carrier arrangement. Conductors located on the cable and hose carrier shall be adequately cradled or secured at regular intervals and in an orderly manner. Cable and hose carrier design shall ensure that flexible conductors are not stretched, crimped, pinched, or scraped over the full travel of the track. A guide arrangement shall be provided to ensure straight motion of the track, parallel to slide motion, without twist or binding. Each cable and hose carrier shall be located in a position that will allow access and egress to the operator and control panel without interference as well as afford the best possible protection of the conductors. All conductors shall be of sufficient length to allow full travel of connected components and shall be connected at both ends to junction boxes and manifolds in proximity to the track ends to facilitate replacement of conductors. All conductors shall be labeled at both ends. Installation of the cable and hose carrier s in the overhead position is not allowed.

3.3.23.5. Facility Electrical Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

3.3.23.6. Hour Meter. The CNC Electric Pipe Bender shall be equipped with an analog hour meter mounted on the main electrical panel visible from the outside. A digital hour meter embedded in the controller shall be acceptable. The hour meter shall be installed to display accumulated operating time of the main drive motor. The meter shall be of the non-resetting type and shall have a range of 0 to 99,999.9 hours in increments of 0.1 hours and shall revert to zero (0) upon reaching the maximum count. All analog hour meters shall have a NEMA enclosure rating of 4X, and shall be mounted to withstand shock and vibration generated by the equipment in an accessible location.

3.4. Size and Capacity. The size and capacity of the CNC Electric Pipe Bender shall be not less than specified in Table I.

Table I Size and Capacity Max Allowable Installation Space, At Rest (L, W, H)

30 ft. x 24 ft. x 12ft. (see note in Att B)

Max Allowable Operational Space, Swing Arm Extended (L,W)

32 ft. x 30 ft. (see note in Att B)

Available Compressed Air 120 PSI Working Environment Temperature 60 – 90 Degrees Fahrenheit Relative Humidity, Non-Condensing 90 percent Max Pipe Capacity Range 1/2 inch NPS- 5 inches NPS Work piece Length Over Mandrel 8 feet Working Height From Floor To Centerline Of Pipe

50-57 inches

Degree of Bend 180 degrees + Overbend Bend Arm Speed (C-Axis) 7 degrees/second Y Axis Speed 12 inches/second B Axis Travel 360 Degrees B Axis Speed 40 degrees/second Center Line Radius(CLR) of Bends - Diameter(D)

3D, 5D (5 inch pipe acceptable @ 3D and/or 5D)

Pipe Material Carbon Steel 3/4 inch to 3 inches Sch 40 and 80 CUNi 1/2 inch to 4 inches Sch 40 and 80

Table I Size and Capacity Stainless Steel (304, 316) 3/4 inch to 5 inches Sch 40 and 80

Inconel ¾ inch to 3 inches Schedule 40 and 80 ½ inch Schedule 160

NICU 4 inches 0.120 inch wall thickness Aluminum 3 inches to 5 inches ½ inch wall thickness Copper 3 inches to 5 inches 1/4 inch wall thickness

3.5. Accuracy Tolerances. The alignment and accuracy tolerances of the CNC Electric Pipe Bender shall be as specified in Table II. For the purposes of this specification thin wall is considered wall thickness less than or equal to (≤) 0.065 inch schedule 40 for pipe as per ASTM A53/A53M Table X2.2 and thick wall is considered any wall thickness greater than (>) 0.065 inch schedule 40 for pipe as per ASTM A53/A53M Table X2.2.

Table II Accuracy/Repeatability

Bend Angles Thin Wall ± 0.25 degrees Bend Angles Thick Wall ±0.35 degrees Bend Repeatability Thin Wall ± 0.25 degrees Bend Repeatability Thick Wall ± 0.35 degrees Plane of Bend ± 0.10 degrees Out of roundness (Ovality) 5 percent (max.)

Wall thinning 25 percent (max.)

Distance Between Bends (DBB) 0.004 inch

3.6. Standard Equipment. All standard equipment required for proper operation of the CNC Electric Pipe Bender) shall be furnished. The contractor shall provide a list of these items at the time of proposal.

3.7. Marking on Instruments, Control Panels, and Plates. All words on instruments, control panels, and plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

3.7.1. Lubrication Plate. A lubrication plate shall be permanently and securely attached to each machine. The plate shall contain the following information:

Points of lubricant application Servicing interval Type of lubricant Viscosity Military or Federal Specification for each lubricant (If applicable) Size and type of each lubricant filter

3.7.2. Nameplate. A nameplate shall be permanently and securely attached to each machine.

The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

Nomenclature Manufacturer's name Manufacturer's model designation Manufacturer's serial number Power input (volts, total amps, phase, frequency) Contract Number Date of manufacture

3.7.3. Identification Marking of Military Property. An Item Unique Identification Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text.

3.8. Technical Data. Three (3) hard copies and one (1) searchable electronic copy of the following technical data shall be provided with the machine.

3.8.1. Plan of Action and Milestones (POA&M). The contractor shall provide a POA&M to identify contractor performance dates of all major events from contract award to completion of all contract requirements. The initial POA&M shall be delivered thirty (30) calendar days After Contract Award (ACA). The milestones shall be prepared using a recognized project management technique (preferably Microsoft Project). The Government and the contractor shall review the report on a monthly basis. The contractor shall notify the Government prior to making any changes to the POA&M. All changes to the POA&M shall be approved in advance by the Government. The POA&M shall detail such items as engineering, procurement of major hardware, assembly, operational debug, factory acceptance, shipment, installation, training, and final acceptance test.

3.8.2. Acceptance Test Plan (ATP). The Contractor shall prepare an Acceptance Test Plan (ATP). The ATP shall be a step-by-step written instruction on how to verify compliance during Contract Quality Assurance Inspection and the Final Inspection/Acceptance Test specified in Sections 4.4 and 4.5. The Contractor shall develop and provide dimensioned drawings of the proposed test part specified in Paragraph 4.7.3. The Manufacture’s standard testing procedures shall be included in the ATP. Any procedures necessary for compliance with Section 4, which are not covered by the Manufacturer’s standard testing procedures, shall be identified and included in the ATP. The initial ATP shall be submitted thirty (30) calendar days ACA for Government review and approval. The accepted test procedures shall become part of this contract.

3.8.3. Operating and Maintenance (O&M) Manuals. O&M Manuals shall contain technical information, specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language. Technical Data shall contain at a minimum:

a. Data shall enable an average journeyman mechanic to operate, program, maintain, and repair the equipment.

b. Complete instructions and information for all equipment, components, assemblies, subassemblies, attachments, and accessories.

c. Operating instructions including programming requirements, pre-operational checks, start up, shut down and emergency shutdown procedures.

d. Maintenance and service instructions, including all preventive maintenance schedules, and lubrication charts.

e. Trouble-shooting guides.

f. Parts list containing illustrations, part numbers, part nomenclature, original manufacturer, cross reference numbers, and recommended spare parts, including quantities.

g. Energy control procedure, in accordance with 29 CFR 1910.147, to bring equipment to a zero-energy state for maintenance.

h. All mechanical and electrical schematics with a table of contents showing discrete components, block diagrams, wiring diagrams with inputs and outputs identified, system electrical interface documents, and drawings for the specific model of all machine equipment/drives/controls supplied.

i. All final “as-built” contract drawings shall be provided at time of proposal on CD or DVD disc(s). The format of the drawing files shall be in AutoCAD version 2010 or older. Files shall have DWG or DXF extensions.

3.8.4. 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.

3.8.5. Test Data Results Used for Evaluation of Equipment to Meet Specification Requirements. The Contractor shall submit a written test report of all tests and results conducted at origin and destination. The test report shall be submitted within 10 working days after the tests are performed.

3.9. Installation. Contractor shall be responsible for attached Installation Responsibilities chart and Local Documents Attachment A for site specific facility requirements. Installation shall comply with EM 385-1-1 and UFC 3-301-01. Installation location shall be IAW Attachment B.

3.9.1. Structural Installation. The Contractor shall accurately set, align, plumb, field connect with sufficient bolts, or weld all structural steel required to make installed equipment permanent. Temporary bracing shall be provided, and subsequently removed, as necessary.

3.9.2. Mechanical Installation. The Contractor shall provide all labor, fluids, piping, interconnecting hoses, and any other materials to move, locate, set level, align, lubricate, and make ready to operate all equipment required by this contract. All machinery shall be installed to original manufacturer's tolerances.

3.9.3. Electrical Installation. The Contractor shall provide all labor, wiring, cables, disconnects, connectors, and any other materials for complete installation of any requisite electrical equipment from the government point of delivery. Installation shall include necessary power, control, and interconnecting wiring installed in conduit.

3.9.4. Installation Drawings. The drawings shall contain at least, but shall not be limited to, the following information and requirements of Attachment A:

a. Overall and principal dimensions in sufficient detail to establish limits of space in all directions required for installation, operation and servicing. See Table I for maximum allowable footprint.

b. Amount of clearance required to permit opening of doors and removal of plug-in units

c. Clearance for travel or rotation of any moving parts

d. Interface mounting and mating information, such as dimensions of location for attaching hardware, and meet the manufacturer vibration design requirement

e. Interface pipe and cable attachments required for installation and co-functioning of the item to be installed with related items

f. Mounting place details, hardware requirement lists, drilling plans and shock mounting buffers

g. Weight of each component and total unit

h. Location, type and dimensions of cable entrances, terminal boards, electrical connectors, and ducts

i. Interconnecting and cable detail

j. Peak electrical load (Amps) requirement to support all proposed equipment in its fully configured and operational state, including all accessories

3.9.4.1. Installation Drawings (Preliminary Submission). Not later than sixty (60) calendar days after effective date of contract, installation drawings shall be provided with soft metric measurements using the manufacturer’s standard format. An electronic copy shall also be provided in DWG or DXF format and download to AutoCAD 2010 version or older. The Government shall notify the contractor in writing within ten (10) working days of receipt of drawing if they comply with this specification. If revisions are required, the contractor has ten (10) working days to make revisions and resubmit for a new review.

Rejection of drawings does not relieve the contractor from final delivery date of contract performance period.

3.9.4.2. Installation Drawings (Final submission). Submission of final installation drawings shall be not later than sixty (60) calendar days of Government acceptance of preliminary drawing. These final drawings shall bear a complete title block with a permanent drawing number, signature, and date. The Government shall notify the contractor in writing within ten (10) working days of receipt of drawing if they comply with this specification. If revisions are required, the contractor has ten (10) working days to make revisions and resubmit for a new review. Rejection of drawings does not relieve the contractor from final delivery date of contract performance period.

3.10. Hazardous Energy Control (HEC) Program, Lockout/Tags-Plus (LOTP).

HEC/LOTP shall be accomplished in accordance with OSHECM Chapter 250 and 29 CFR 1915.89.

3.11. Training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is a United States citizen proficient in the English language, shall be provided for specialized training to familiarize receiving activity personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage. The training shall be performed at customer facility and shall not be less than 5 consecutive, 8 hour workdays, between 7:20 am and 3:30 pm excluding any federal holidays.

The course shall utilize as-built drawings and manuals provided under this contract and shall include both classroom and hands-on portions. All printed training aids shall be supplied at no additional cost to the government and be in the English language.

3.11.1. Operator Personnel. A minimum of three (3) days training shall be provided for up six (6) operators at a journeyman mechanic level. The trainees shall be provided instruction for all aspects of machine operation. Trainees shall be provided instruction for the care, use and safe operation of all attachments and accessories. A training manual shall be provided for each student.

3.11.2. Maintenance Personnel (Mechanical). Maintenance training shall include troubleshooting and methods of correction if the equipment malfunctions, with particular emphasis on minimizing equipment down time. Training shall be provided for two (2) mechanical maintenance personnel. A mechanical maintenance training manual shall be provided for each student. Training shall be timed for completion of the acceptance testing of equipment and shall be accomplished at the receiving activity. The training period shall not be less than one (1) eight (8) hour workday.

3.11.3. Maintenance Personnel (Electrical/Electronic). Maintenance training with respect to controls and related components shall include troubleshooting and methods of correction should the equipment malfunction, with emphasis on minimizing equipment down time.

Training shall be provided for one (1) electrical/electronic maintenance personnel. An

DGO0001

Highlight electrical/electronic maintenance training manual shall be provided for each student.

Training shall be timed for completion of the acceptance testing of equipment and shall be accomplished at the receiving activity. The training period shall not be less than one (1) eight-hour work day.

4. QUALITY ASSURANCE

4.1. Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein. Except as otherwise specified in the contract or purchase order, the contractor may use his own facility or any other facility suitable for the performance of the inspection requirements specified herein, unless disapproved by the Government. 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. The Government reserves the right to witness any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

4.1.1. Responsibility for Compliance. All items must meet all requirements of sections 3 and 4.

4.2. Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. Contract quality assurance inspection (Origin) (see 4.4).

b. Final Inspection/Acceptance test (Destination) (see 4.5).

4.3. Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient conditions of 60 degrees F to 90 degrees F and 10 percent to 90 percent relative humidity.

4.4. Contract Quality Assurance Inspection (Origin). Contract quality assurance inspection shall be applied at the contractor’s facility prior to being offered for acceptance under the contract.