Scope Of Work 01-22-3424 Final.pdf

Specification for New

Electrochemical Machine for Rifling

– ECM 2

Spec. # 01-22-3424

Manufacturing Engineering Work Group Watervliet Arsenal

Watervliet, New York 12189 09/30/2022

Department of the Army

TACOM

U.S. ARMY

Watervliet Arsenal Watervliet, NY Equip. Eng. Spec #01-22-3424 Date: 30 September 2022

New Electrochemical Machine for Rifling –ECM 2

Table of Contents

Contents

1. Scope

2. Applicable Standards and Publications

3. General Requirements

4. Machine Installation and Startup

5. Machine Specification Requirements

6. Requirements for Demonstration of Conformance

7. Quality Assurance Provisions

8. General Requirements and Information

9. Appendix A - Acceptable Lubricants, Hydraulic Fluids, Oils, and Coolants

10. Appendix B – Class I Ozone Depleting Substances

11. Appendix C – Electrical Survey

12. Appendix D – Environmental Protections Requirements

13. Appendix E – Drawings

1. Scope:

1.1. Abbreviated Description: The equipment covered by this specification shall be an industry standard production duty Computer Numerical Control (CNC) controlled two axis machine capable of electrochemically cutting internal splines on long tubular workpieces. The machine shall have the capability to cut straight grooves and constant/progressive twist left or right-hand splines. The machine shall be complete with all supporting components necessary to conduct electrochemical machining on the tube surface. The actual cutting head is not part of this scope of work.

2. Applicable Standards and Publications: All work performed, and procedures followed in association with this project shall meet or exceed all applicable and current Watervliet Arsenal (WVA), Occupational Safety and Health Administration (OSHA), local, state, and federal government codes and laws relative to fire, safety, environmental, and electrical issues. These standards include, but are not limited to, ANSI, NFPA, NEC, ISO, and ASME. The quality of all work performed and material provided shall meet or exceed the most recent revision of applicable industry standards and engineering practices for this type of equipment and its intended function. In all instances material, quality, and workmanship shall meet or exceed OEM specifications.

3. General Requirements: All requirements are mandatory from the standpoint of intended function. Wherever a specific requirement would force an offeror to depart from his standard practice or configuration, the Arsenal will accept, for evaluation, alternative offers for achieving the intended function. Any such alternative offers must be accompanied by sufficient technical information to allow the evaluator to reach a definite conclusion that the alternative is equal to or better than that specified. The equipment specified in this document shall be a standard product of the manufacturer and shall require either no design changes, or if required, minor design changes to meet the requirements of this specification. Therefore, ownership of the design shall remain with the manufacturer. Equipment incorporating new or unproven technology is subject to rejection at the discretion of the Contracting Officer.

3.1. Design and Engineering: The equipment specified in this document shall be designed and engineered in accordance with the most current version of each standard, recognized by the Association for Manufacturing Technology.

3.2. Materials and Components: Materials and components incorporated in the construction of the equipment specified herein shall be new, free from defects, and conform to the specifications and standards included within this specification.

3.3. Construction: All parts of the equipment specified in this document shall be new, unused, and constructed to be capable of withstanding all forces encountered during operations to the equipment's maximum factor of safety rated capacity. The structure and assembly of the machine and its components shall be sufficiently rigid that workpiece finish and accuracy are not impaired by machine vibrations.

3.3.1. Alignment Retention: Non-integral machine components, heads and ways, which are separately assembled and whose alignments determine the squareness and parallelism of machine geometry shall utilize a positive means for retaining alignments and regaining them in the event of unintentional dislocation.

3.3.2. Slideway Design and Construction: All precision ways which guide and bear the rated design loads shall adhere to the hardness criteria shown in the following examples of acceptable way systems. Please state in your proposal details of the way system being offered if applicable. Hardness tests other than Rockwell C shall be subject to approval by the designated

POC.

A. Integral cast iron ways shall be hardened from RC 50 to RC 54 to a depth of 0.100 inches or more.

B. Hardened and ground steel ways for mating with Turcite, Rulon, or other such low friction forgiving materials shall be hardened within the range of RC 55 to RC 62. Actual hardness within this range shall not vary more than 5 RC points.

C. Hardened and ground steel ways for use with anti-friction roller bearings shall be to a hardness of RC 62 to RC 65 to a depth of 0.125 inches or more.

Slideway systems other than the ones referred to above may be offered provided that their design is consistent with all specified performance characteristics of the machine. All slideway systems having less than a 60-degree incline to the horizontal shall be protected by way covers unless it can be substantiated that covers will interfere with the functions of the machine.

3.3.3. Replaceable Ways: If the machine being offered is portrayed as having replaceable ways, the assembly of the way bars to the machine frame shall be such that finished ground ways are fastened to a precision ground or scraped surface to permit field replacement without additional grinding.

3.3.4. Way Wipers: All way systems shall be equipped with wipers designed to prevent intrusion of foreign material. Wipers shall be adjustable to compensate for wear. Wipers shall be easily removable and replaceable.

3.3.5. Shims and Spacers: Shims that do not appear on engineering drawings shall not be incorporated in the machine. Spacers that do appear on engineering drawings are permissible.

3.3.6. Castings and Forgings: All castings and forgings shall be free of defects, scale, and mismatching. Weldments, if used, shall be braced, ribbed and gusseted to obtain strength equal to or better than the strength of castings, and shall be properly stressed relieved.

3.4. Workmanship: Workmanship throughout the construction and assembly equipment specified herein shall be free from irregularities or defects that could adversely affect performance or durability.

3.5. Maintainability: All equipment components offered that are subject to wear, distortion or failure and all parts which require periodic adjustment shall be accessible for replacement or adjustment. Instructions for the maintenance and adjustment of these parts shall be clear, concise and definitive.

3.6. Interchangeability: All parts offered that bear the same part number shall be interchangeable.

3.7. Applicable Power Source: The power source to which the machine will be connected to furnishes a nominal 480 volts, 3 phase, 60 Hz AC. However, the machine shall be tolerant enough of line fluctuations to operate normally at source voltages ranging from 432 to 504 volts.

3.7.1. Electrical Safety Devices: The machine and its equipment shall be protected by circuit breakers which comply with NEMA standards for thermal magnetic types and shall have a minimum interrupting capacity of 25,000 RMS symmetrical amperes for 480 volt, 3-phase system. Breaker terminals shall be UL listed as suitable for the type of conductors provided. Plug in circuit breakers or current limiting fuses are not acceptable.

3.7.2. Conversion Equipment: If DC or reduced voltage AC is required to meet any specified requirement, the necessary conversion or transformation equipment shall be provided by the contractor. All transformers must meet efficiency levels specified in CFR Title 10 Chapter II Part 431 (also known as DOE 2016 Efficiency Levels). Equipment which requires a high-quality constant power source shall have proper isolation and/or power conditioning equipment for the power service designated in this description. All electrical equipment shall have a power factor (ratio of real power to apparent power) of no less than 80%, as read at the equipment main disconnect. Equipment with a power factor of less than 80% shall be fitted with suitable power factor correction capacitance, sized on the basis of the equipment’s inductive AC load.

3.7.3. Operator Control Voltage: All electrical controls meant for use by the operator of the machine shall carry 120 volts AC maximum.

3.7.4. Utility Outlet: The machine shall be provided with a 120 VAC, 20 amp, single phase, industrial rated, GFI, covered dual receptacle externally mounted onto the operator control panel.

3.7.5. Cabinet Enclosure for Electronic Equipment: All separate electrical hardware/circuitry are to be housed in a NEMA 12 rated enclosure/cabinet. Should forced ventilation be necessary to maintain the interior of the enclosure at a temperature to ensure good product reliability, filtered air shall be forced into the cabinet to maintain an over pressure condition in the cabinet. Cabinet shall not inhibit operator access to the controls and/or adjustments.

3.7.6. Interconnecting Wiring: All control functions shall be pre-wired by the contractor at their manufacturing facility. This includes wiring from the CNC/PLC to the interface and from the interface to the machine tool. If any disassembly of the machine tool and associated control wiring is necessary for shipment from the contractor's plant, the contractor shall rewire the system at the Arsenal unless a clearly labeled plug and socket system is employed. The Arsenal will not perform detailed control wiring. All wiring shall comply with accepted Joint Industry

Code (JIC), National Machine Tool Builders Association (NMTBA), and National Fire Protection Association (NFPA) Standards.

3.8. Motors: All motors provided shall be of the type and horsepower rating to meet the specified requirements based on all applicable engineering practices and standards. All motors shall be rated for continuous duty. Motors shall not operate in an overload condition during normal operation of the equipment and shall be equipped with thermal overload protection.

Motor starters and controls shall operate at 24 VDC. Motor starters shall provide drop out protection (no auto-reset). This means that in the event of power loss, the equipment shall be re-energized only by deliberate action of the operator or maintenance personnel. Manual or mechanical motor starters are not acceptable. All motors shall be housed in enclosures of the appropriate NEMA type for class and severity of service. All AC unidirectional motor housing shall bear a directional arrow to indicate proper rotation direction when correctly wired. All AC motors rated at 25 horsepower or greater shall be equipped with a “soft start” device which provides for reduced voltage starting. All polyphase AC motors rated at one horsepower or greater shall be tested per IEEE Standard 112-Method B and must meet premium efficiency requirements per NEMA MG 1-2006 Table 12-12 or IE3 9IEC 60034-30:2008. All motors are to be permanently lubricated and sealed.

3.8.1. Motor Identification Plates: Each motor shall bear an identification plate containing the identity of the manufacturer, model number, serial number, input voltage, amperage, horsepower, phase, frequency, duty cycle, and frame size or mounting identification.

No identification plate shall be painted.

3.9. Safety and Environmental Requirements: The contractor shall review the environmental requirements documented in Appendix D of this document and comply as required.

3.9.1. Protection of Machine Operator: Protection of the machine operator and other personnel shall be accomplished in accordance with all pertinent Arsenal, State, Federal, and local regulations, OSHA and NEC in particular.

3.9.2. Protection of the Machine: The machine shall be designed and equipped in accordance with all applicable standards to prevent self-damage in the event of component malfunctions, power failures, expended consumables, incorrect consumables, and operator errors.

3.9.3. Noise Levels: Noise levels at a distance not exceeding one meter from the nearest point on the machine shall, under no circumstances, exceed a maximum of 85 dBA when measured by a calibrated sound level meter set for "A" weighting and slow response. Any shields, baffles, enclosures or other devices required to bring the machine into conformance with this noise level requirement shall be provided by the contractor. Any such devices shall not interfere with the operation of the machine and shall be designed to preserve the visibility needed for safe operation and ease of maintenance.

3.9.4. Ozone Depleting Substances: Section 326 of Public Law 102-484 precludes the Department of Defense (DoD) from awarding any contract that directly or indirectly requires the use of a Class I ozone depleting substance within the Government specification or standards set forth in the contract. Appendix B is a list of the restricted Class I CFCs and Halons. All shall be replaced by new functionally equivalent substances or systems that are approved for use by the Environmental Protection Agency (EPA) and have an "Ozone Depletion Potential" (ODP) rating of zero. ODP is defined as the relative capacity of a substance, per unit weight, for destroying the earth's stratospheric ozone layer, in comparison with CFC 11, CFC 12 and CFC 114, each having been assigned an ODP of 1.00.

NOTE: Offerors are responsible to obtain and adhere to the most current list of prohibited substances as of the date of the submission of bids or proposals.

3.9.5. Asbestos and Mercury Free Certification: All materials utilized in the system shall be certified as asbestos and mercury free unless substitute materials do not exist. This certification shall be provided prior to machine delivery IAW CDRL A001.

3.9.6. Material Safety Data Sheets: The offeror shall provide Watervliet Arsenal with all material safety data sheets at the time of proposal submission IAW CDRL A014.

3.9.7. Lead Free and Chromium Free Paint Certification: All paints and primers applied to the system shall be certified as lead free and chromium free. Lead based paint is paint that contains more than six one hundredths of one percent (0.06%) lead by weight. This certification shall be provided prior to machine delivery IAW CDRL A002.

3.9.8. PCB Free Certification: To the extent that the machine is charged with lubricant or hydraulic fluids at the contractor's plant for preliminary acceptance inspection, these fluids shall not contain Polychlorinated Biphenyl’s (PCBs). The machine and its equipment shall be certified as PCB free and certification shall be provided prior to machine delivery IAW CDRL A003.

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

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

A. Manufacturer's name B. Model C. WV# (Please contact the POC to receive this number)

D. Manufacturer's Serial Number E. Power Input (voltage, phase, frequency, and full load amps) F. Government Contract Number G. Date of Manufacture

3.11. Data Plates: All instruction, data, and identification plates and labels attached to this equipment and its controls shall be manufactured of corrosion and oil resistant metal or plastic material. All wording shall be in the English language using plain, bold face lettering. Lettering shall be permanent and have a contrasting background.

3.12. Utility Connections: Equipment supplied to the Watervliet Arsenal shall have a single point shut off for each utility supplied to the system. This will be referred to as the “point of first connection.” Electric utilities shall have only one point of first connection, including sub systems. Each point of first connection shall be clearly labeled on the system and shown in the safety Lockout/Tagout portion of the documentation package. These points shall be located on a stationary component and positioned so that they will not create a hazard to personnel during normal operation of the system. The point of first connection shall be accessible from the shop floor without the use of ladders, steps, or stools. Access cannot be hampered by operation of the system. Specific to electrical connections, all Arc-Flash protocols per NEC codes shall be implemented.

3.13. Utility Connection Labor and Requirements: WVA will provide a utility connection between point of first connection on the equipment, and the facility. Only one connection per utility type (air, water, electrical, etc.) will be provided. All other work shall be provided by the Contractor.

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

NOTE: Offeror is to state required power/electrical requirements for offered machine. See Appendix C and include in the proposal.

3.13.2. Pneumatics/Air: If air is required for any machine operation or function, the machine shall be fully equipped with all required components, fully installed to the point of connection of WVA shop air. Shop air at the Arsenal is 85 PSI with above normal moisture and contaminant levels. If higher or lower pressure is required at the machine or a different air flow rate is needed, the machine shall be fully equipped to modify the supply pressure and volume.

The machine shall also be equipped to remove the above normal moisture and contaminant levels. Normal moisture is defined as that moisture produced when air at a relative humidity of 75% has been compressed to 85 PSI. The equipment’s nominal and maximum compressed air usage rates in CFM shall be provided to the POC.

3.13.2.1. Air Booster Unit: If the equipment offered requires more than 85 psi at the volume for operation of the equipment, then an air booster unit shall be provided with the machine. If operation of the equipment requires an accumulator tank, it shall be provided with the booster. Please state in your proposal what the machine requirements shall be and if a booster and tank will be required. Installation shall be provided by the contractor. If the use of an air booster is not possible and an air compressor is required, the contractor must state this in their proposal and provide justification detailing CFM, psi, application, and duration of air usage.

Power requirements of the air booster or compressor shall be provided to the POC.

3.13.2.2. Air Dryers/Filtration: If the offeror determines that on machine air dryers are required to maintain moisture levels, the air dryers shall have a regenerative type desiccant or refrigerated compressed air dryer capable of drying air down to 35°F pressure dew point, minimum, from air entering the equipment at 110°F. The air dryer shall supply air at the required standard cubic feet per minute (SCFM) of the equipment. The unit shall purge condensate automatically. In the case of a refrigerated air dryer, the refrigerant used shall not be a Class I ozone depleting substance. The air dryer shall be connected and piped to the equipment by the contractor. All air dryer designs are to be supplied by manufacturers participating in the CAGI Refrigerated Dryer Performance Verification Program and have been tested and rated in accordance with CAGI ADF 100. Power for the refrigerated air dryer unit shall be 110 volts and shall be wired and powered through the machine electrical system.

NOTE: Common industrial air dryers that are used at the Watervliet Arsenal include the ZEKS HSE and Ingersoll Rand D31NC models.

3.14. Lubrication: The machine shall be equipped to provide lubrication to every moving part where lubrication is essential to prevent damage. Slideways shall be lubricated by an automatically cycled distribution system such as that manufactured by Trabon or approved equivalent. Gearboxes and transmission cases shall be lubricated by the wet sump splash method.

Spindle bearings shall be lubricated by recirculating pressure spray systems. Automatic lubrication systems shall be equipped to be fail safe to the maximum extent possible. All sensors and devices used to detect the presence or absence of lubrication shall be accessible for test or replacement without major disassembly. Manual lubrication methods are permissible for lubrication points not practically served by automatic systems. For non-recirculating automatic systems, such as slideway lubrication, the reservoirs shall be sized to provide lubrication reserve equivalent to 80 operating hours and shall be located at floor level. For recirculating automatic systems, cleanable or replaceable filtration devices shall be provided. Wet sump type systems shall be equipped with a means to confirm proper oil level. Sight gauges shall be of the external standing tube type rather than the flush mounted porthole type. Standing tube sight gages shall be protected against accidental breakage.

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

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

CDRL A007.

3.14.3. Control of Cutting Fluids: If the machine is equipped with a coolant system, the contractor shall ensure that the machine is designed and equipped to prevent coolant from escaping the confines of the machine and leaking to the floor when producing workpieces of a size within the machine's normal working range. If the coolant reservoir is part of the foundation, the coolant shall be contained in a leak proof metallic or nonmetallic liner.

3.15. Hydraulic System: Hydraulic systems provided shall be sized and powered for the intended application and shall conform to industry standards. The system shall incorporate cleanable or replaceable filtration devices to insure fluid cleanliness. Reservoirs shall be equipped with easily visible gauges to indicate fluid level. If duty cycle of the system under maximum usage will cause the hydraulic fluid to exceed 120°F in temperature, a suitable heat exchanger shall be provided to maintain fluid temperature at or below this level. The system shall be protected against overpressure as well as under pressure. System pressure in any hydraulic device shall be as low as is practical for the intended application but shall not exceed 3000 PSI in any case unless approved under special justifiable circumstances. In any system which utilizes hydraulics to produce thrust or direct linear motion, anti-surge devices or circuits shall be incorporated to ensure uniformity of motion under varying loads. These devices or circuits shall be adjustable. All reservoirs shall be easily accessible for cleaning and flushing and shall be located at floor level.

3.16. Painting: All exterior machine surfaces shall be painted except where bright metal is required for machine function or to otherwise adhere to the requirements of this specification.

Paint shall be chromium-free and lead-free. Quality and manner of application shall afford protection throughout the normal life of the machine. Paint shall be "semi-gloss", and selected by the Government, from a list of standard colors supplied by the offeror with their proposal. This selection shall be made after contract award. Danger areas shall be painted red and caution areas shall be painted yellow in accordance with OSHA Standard 1910.144. Appropriate warning signs, tags or emblems shall be affixed to respective areas of the machine in accordance with OSHA Standard 1910.145.

3.17. Machine Hold Down and Leveling: The machine base shall be provided with a mounting hole quantity and location for positive hold down when operating at full rated capacity.

In addition, for each hole in the machine base, the contractor shall provide a set of recommended hold down and leveling hardware. If grouting is required, it shall be provided by the contractor.

NOTE: All hold down and leveling hardware shall be delivered 30 days prior to the scheduled delivery of the machine.

3.18. Gears: All gears used in the machine and its components shall meet or exceed the standards recommended by the American Gear Manufacturers Association for the type and severity of service required.

3.19. Handwheels: Where power feed and rapid traverse of a machine component is provided or specified, associated handwheels or cranks, shall not rotate when power feed or rapid traverse is engaged.

3.20. Technical Data: All data shall be in the English language and shall be furnished in accordance with the quantities, formats and delivery dates below. All data shall be packaged and delivered separately from the machine itself marked to the attention of the Technical POC. The contractor shall provide full documentation in the form of “as built” drawings and manuals.

Drawings shall not be generic or sub-assembly prints. A “hardcopy” refers to a reproducible printed, paper copy. An “electronic copy” refers to a document saved on CD. All AutoCAD drawings shall be provided in AutoCAD version 2014 or later, shall be of one-to-one scale, shall be dimensioned in English units, and shall not utilize the color yellow. “On-line” technical data shall not be acceptable as the sole means of providing technical data for any of the systems provided. The Government contract number and the Watervliet WV# shall be printed in a conspicuous place on the covers of every manual, on each drawing/schematic, and on all disks/CDs provided.

3.20.1. Foundation Drawings, Standard or Special: Shall be complete in all construction detail to permit pricing and construction by a general contractor and shall be furnished as soon as possible after contract award and no later than 30 days after award. All drawings shall be dimensioned in English units and text shall be in the English language. One reproducible hardcopy and one electronic copy on CD in AutoCAD .dwg or .dxf format shall be provided. AutoCAD drawings shall not utilize yellow or any other colors that cannot be made readily visible when plotted out in color. When drawings are finalized the contractor shall certify the accuracy of the drawings by providing a stamped and signed hard copy of the drawings to the Watervliet Contracting Office IAW CDRL A004. If a special foundation (see Section 8.7) is required and the vendor/contractor refuses to provide the detailed drawings required then this shall be grounds for disqualification from further consideration in the machine tool procurement.

A. At least one drawing shall depict an over-lay top view of the machine foundation outline, machine general arrangement drawing (including all ancillary equipment) and the anchor bolt hole pattern.

B. The foundation drawing(s) shall be provided as 100% complete and constructible. Provide all necessary information for bid and award of the foundation work by others. This information shall include, but is not limited to, complete foundation dimensions, rebar locations, rebar size, rebar pattern, concrete PSI requirements, and load bearing specs, etc. The submitted drawings and specifications are suggested to be stamped by a Professional Engineer registered to practice in the State of New York.

Typical floor thickness at Watervliet is 8 inches to10 inches. A special foundation is one which exceeds thickness, load bearing capability and vibration isolation of Watervliet Arsenal's standard monolithic concrete flooring of 1,000 pounds per square foot (psf) load rating and/or one which requires a specific thickness, uniquely shaped excavations for coolant housings, chip conveyors, electrical circuits and conductors, etc. The soil (substrate) for a foundation is assumed to be medium dense gravel or medium dense gravel /sand with a minimum bearing capacity of 4,000 psf. Although 4,000 psf is the assumed minimum bearing capacity, there may be variations depending on the exact location of the machine. The contractor shall contact the POC to ensure that the minimum psf and other requirements are accurate. If the contractor states no foundation is required and does not ensure the minimum psf in the area and the machine causes damage to floor and requires a foundation after initial installation is attempted, the contractor shall be responsible for all costs associated with floor repair, relocation of the machine, and reinstallation of the machine. Should the contractor disturb the soil below the yet to be constructed concrete foundation then the contractor shall compact the disturbed soil to achieve at least 2,000 psf bearing capacity. See instructions in section 8.5. Drawings shall be provided IAW CDRL A004.

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

This data shall be furnished with offeror’s proposal IAW CDRL A005. (One hardcopy and one AutoCAD electronic copy).

3.20.3. Catalog of Standard Tooling and Accessories: If applicable, catalog shall be furnished at time of machine delivery. For offers of foreign built machine tools (i.e., machines built outside the United States, its possessions or Canada), the catalog shall set forth U.S.

domestic sources of supply. (Two hardcopies).

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

3.20.5. Installation Instructions and Drawings: Instructions outlining the requirements for installation of the equipment shall include a drawing containing the certified dimensioned locations of all equipment mounting/anchor holes from an agreed upon facility datum. These documents are to be furnished 60 days prior to scheduled delivery IAW CDRL A006. (One hardcopy and one AutoCAD electronic copy).

3.20.6. Lubrication Diagram and Instructions: To be delivered to the technical POC at time of machine delivery IAW CDRL A007. (One hardcopy and one AutoCAD electronic copy).

3.20.7. Operating Instructions: These instructions shall be provided in separate manuals from other technical data provided. To be delivered upon machine delivery IAW CDRL A008.

(Three hardcopies and one electronic copy).

3.20.8. Maintenance and Troubleshooting Instructions: To be supplied for all machine and control systems. These instructions shall include the machine’s mechanical assembly and wiring drawings. To be delivered at time of machine delivery IAW CDRL A009. (Two hard copies and two electronic copies).

3.20.9. Electronic and Hydraulic Schematics: To be considered acceptable, these schematics shall clearly portray all “as built” electrical and hydraulic ties to their respective main systems. To be delivered at time of machine delivery. Wiring diagrams used to do the initial power hookup shall be included and furnished no later than 90 days after award IAW CDRL A010. (One hardcopy and one electronic copy).

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

3.20.10. Repair Parts Catalog: This catalog shall encompass every replaceable part in the machine and shall include identification and original equipment manufacturer’s part numbers and ordering data. Items which can normally be purchased locally may be so indicated provided they are sufficiently described. The repair parts catalog shall include illustrations which clearly locate parts within larger subassemblies. To be delivered at time of machine delivery IAW CDRL A011. (Two hardcopies and one electronic copy).

3.20.11. Program Manuals: Where a CNC machine is specified, programming manuals shall be supplied. These manuals shall include a clear summary of the control functions actually implemented and usable on the system specified. To be delivered at time of machine delivery IAW CDRL A012. (One hardcopy and one electronic copy).

3.20.12. Software Documentation: The offeror shall provide documentation of all system software and ladder logic developed to control and interface the control/drives with the machine tool. To be delivered 30 days after delivery of the machine IAW CDRL A013. (One hardcopy and one electronic copy). One copy of the system memory backup (S-Ram) shall be provided on a USB Type-A flash drive at startup of machine.

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

Type of training Number of persons When required Training location

Machine operation 4 During or after machine performance testing

On site

Mechanical maintenance

2 During startup On site

Hydraulic maintenance

(if applicable)

2 During startup On site

Electrical maintenance 2 During startup On site

Electronics (CNC) maintenance

2 During Installation On site

Spindle/Axes Drives (if applicable)

2 During Installation On site

Programming training 2 During Installation On site

NOTE: For all types of training, the associated technical data (see section 3.20) shall be on hand at the time of instruction and its use and interpretation shall be covered during the training.

3.22. Repair/Replacement Parts and Service: The offeror shall provide parts and service for the contracted equipment within 72 hours of notification of a problem. The offeror shall agree, as part of the contract, to store complete ordering data to include specifications, engineering drawings and other information for the contracted machine tools/parts. This data shall be stored within the U.S. or Canada and in detail to permit successful acquisition of the parts and associated repair service. The offeror shall supply a list of recommended spare machine parts as an option with the offer. Watervliet Arsenal recognizes that it may be difficult to fulfill this requirement for major machine components. If the requirement cannot be adhered to, the offeror shall notify Watervliet Arsenal’s POC within two business days and shall provide a delivery schedule to be approved by Watervliet Arsenal’s POC.

3.23. Special Tools: If any element of machine operation or maintenance requires the use of specially designed tools, these tools shall be provided with the machine and shall become the property of the Government.

3.24. Site Conditions: The machine covered by this specification shall be installed in a general machine shop space and there will be no environmental conditioning. Temperatures will range from 65°F to 95°F and relative humidity will range from 20% or less to 95%. On any given day, the temperature in the machine shop may change as much as 4°F per hour. These are the conditions under which the machine is expected to perform as specified, and the contractor shall be responsible for supplying what is required to meet the specified performance. The only permissible exception is positioning accuracy for numerically controlled machines. For this performance factor, allowances may be made for the effects of temperature fluctuation.

3.25. Heat Exchange Equipment: Heat exchange equipment shall be provided with the machine wherever it is needed to keep operating temperatures within design or specified limits.

Any heat exchange equipment using water as the heat exchange medium shall be fully recirculating and shall not require the continuing input and discharge of Arsenal water supply.

Wastewater systems of any type are not acceptable. Furthermore, it is the Arsenal's preference to avoid heat exchange equipment making use of the refrigeration cycle, and refrigeration systems of any kind are not acceptable unless design or specified temperature limits cannot be achieved without them. If a refrigeration system is absolutely necessary, the contractor shall ensure that it operates properly using a refrigerant having an ozone depletion potential of zero. The contractor shall be responsible for identifying and providing such a refrigerant and its material safety data sheet IAW CDRL A014.

3.26. Elapsed Time Meter: The machine shall be fitted with a meter to measure operating time of the spindle drive. The time totalizing meter shall be of the non-resetting type and shall have a range of 0 to 99,999 hours in increments of one hour; one-hour being the least significant digit. Upon reaching the maximum accumulative hours the meter readout shall automatically revert to zero and continue to totalize time. The meter shall be designed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by the equipment. The meter shall be located as to be readily visible but not subject to abuse relative to the operating environment of the equipment. Time meters resident in the numerical control unit are unacceptable.

3.27. Enclosures: All new controller hardware shall be provided with new electrical enclosures. Enclosures located in explosive, high dust, paint or heavy industrial manufacturing environments shall be NEMA 4X rated. All other locations shall be NEMA-12 rated. In addition, if required, given shop environmental conditions as detailed in section 3.24, new control system enclosures for electronic circuitry shall be air conditioned and air filtered to maintain constant temperature, to reduce humidity and to prevent contamination of control boards and other critical system components. Air conditioning units shall not utilize Ozone Depleting substances. New enclosures shall be painted with a color as close to the painted color of the original machine tools as possible.

3.28. Piping: All pipe work performed by the contractor shall be to the specifications below:

A. All equipment piping shall be identified per ANSI/ASME A13.1 or equivalent.

B. Brazing filler metal shall conform to AWS A5.8/A5.8M, Type BAg-5 with AWS Type 3 flux, except Type BCuP-5 or BCuP-6 may be used for brazing copper-to-copper joints.

C. Welding work for new piping systems shall be in conformance with ASME B31.9. The welding work includes brazing procedures, brazers, brazing operators, and nondestructive examination personnel, maintenance of welding records, and examination methods for welds.

D. Pipe hangers, inserts and supports shall conform to MSS SP-58, MSS SP-69, and ASME B31.1, except as specified or indicated otherwise. Piping shall be adequately supported to eliminate sag and weak points and allowance for thermal expansion must be considered on long pipe runs.

E. All piping, tubing and fittings shall be in strict accordance with manufacturer’s requirements and recommendations to include industry standards and applicable codes (ANSI B16 and B31.3).

F. Process piping shall be ASTM 312, 304 stainless steel, seamless.

G. For pressures up to 150 psi, SCH 80, pipe shall be used where threaded connections are made. For pressures between 150 and 2000 psi, SCH 160 pipe shall be used where threaded connections are made.

H. Joints in piping systems shall be listed as complying with ASME B31.3 to include the use of welded fittings. Gaskets and sealants shall also be listed as complying with ASME B31.3.

I. Prior to acceptance and initial operation, all piping shall be inspected, and pressure and leak tested in accordance with ASME B31, Code for Pressure Piping, and Section 705 of the

IFGC.

3.29. Machine Control: If a control system is supplied with the machine, it shall be of the CNC type and the requirements specified in sections 3.30.1 through 3.30.10 shall apply.

3.29.1. Applicable Electronics Standards: The CNC system shall adhere to the most current applicable revisions of the standards of the Electronics Industries Association (EIA).

3.29.2. Input/Output Requirements: The CNC shall be equipped with at least the following:

A. A visual display having sufficient resolution to provide easily readable text of at least 80-columns and 20-rows. A color display shall be provided to provide contrast between different data types. If a monochrome display is required, it shall be subject to approval by the POC and an alternate means (inverse video, for example) shall be provided.

B. An alpha-numeric keyboard for on-site program editing, operator input, MDI and other necessary communication. This keyboard shall be an open-key, tactile feedback type. The alpha characters shall be arranged in "QWERTY" format.

C. A USB Type-A flash drive and USB Type-A port on the controller shall be provided. The drive shall provide formatted data capacity of at least 8 gigabytes and shall be the means of uploading to the CNC the system executive (operating system and machine-specific data) as well as part program files.

D. The CNC offered in accordance with this specification shall have included in its design both the capability and cabinet space to permit the future installation of a remote data interface so that the control may be placed online to a remote host computer. Offerors must certify that the offered control could subsequently be equipped with any of the common interfaces covered by EIA RS-422.

3.29.3. Control/Machine Interface: It is required that the control/machine interface be of the solid-state type. Electromagnetic relays are not permissible.

3.29.4. Operator's Console: The CNC console shall house everything necessary for communicating with the control and operating the machine. This shall include at least the visual display, keyboard and USB Type-A drive specified in section 3.30.2, “A” through “C”. An emergency stop button shall also be located on the console. The console shall be machine-mounted or pendant-mounted. A floor-mounted console is unacceptable. A fixed-height machine-mounted console shall place the visual display at 66-72 inches above foot level at the operator's station. A pendant-mounted console shall be adjustable to place the visual display within this same height range.

3.29.5. User Software Interface: The control's operating system shall include a software interface providing a user-friendly environment within which operating, programming and maintenance personnel can interact with the control. "User-friendly" means that the interface shall employ on-screen menus or equivalent techniques to guide the user through the process of accessing control functions and entering or modifying data. Write access to system level data such as axis calibration tables shall be protected by user-selectable passwords.

3.29.6. Control Functions and Capacities: The CNC shall include at least the following functional capabilities and capacities whether standard or optional:

A. Two-axis linear and circular interpolation. For machines of three or more axis, the plane of interpolation shall be switchable via program code.

B. The ability to program, execute and display in both inch and metric modes. Inch/metric switching shall be possible by MDI as well as from a part program. All displayable numeric information shall reflect the selected format.

C. Selectable absolute or incremental programming.

D. Automatic maintenance of the commanded feed rate when slide velocity is a vector resulting from two or more axis of motion.

E. Full floating point support for display and programming.

F. System resolution of 0.0001 inch (English) and 0.001 mm (metric). Visual display format and command increments shall also exhibit this resolution.

G. Dry run mode, which is the ability to execute a programmed tool path at an accelerated rate under non-cutting conditions.

H. The ability to program a dwell of adjustable duration.

I. Program and data editing at the machine. However, editing capability shall be protected by a user-selectable password.

J. Zero shift (i.e., the capability to establish a program origin point which differs from the machine's home position anywhere along each axis).

K. Provision for disabling the operator's ability to override programmed speeds at the machine.

L. Data format for positioning and contouring shall be in accordance with the most recent revision of EIA Standard RS-274.

M. A minimum of 4 GB of RAM shall be provided for the control system.

3.29.7. Diagnostics Capabilities: The CNC shall be equipped with diagnostic capabilities covering the control itself, the interface and the machine tool. As a minimum, diagnostic capability shall include the display of a message or other meaningful indicator to identify any fault which causes the machine to be inoperable. This includes electrical/electronic faults and any mechanical faults which result in operation of a safety interlock.

3.29.8. Crash Protection: The machine and control shall be equipped with means to sense and react to abnormal power draw at the spindle. Abnormal power draw shall be a variable assignable by the programmer on a tool-by-tool basis. A bi-level system employing two variables per tool is preferred, the first level being a warning threshold which shall display a warning and initiate feedhold upon completion of the current machining pass and the second level being an absolute threshold which shall initiate immediate feedhold. If the bi-level system is not available, a system employing at least the absolute thresholds is mandatory.

3.29.9. Temperature Control: The control shall be equipped with means to maintain electronic circuitry and devices at temperatures well within operating limits. The temperature control system shall also provide stability such that temperatures are maintained within 10°F of shop ambient temperature. Ambient temperature in the shop will range from a low of 65°F to a high of 95°F. It is preferred that temperature control be achieved without the use of refrigeration.

In the event that a refrigeration system is absolutely essential, it shall operate normally using a refrigerant having an ozone depletion potential of zero.

The machine enclosure shall be equipped with means to maintain internal cavity of the enclosure at temperatures well within operating limits. The temperature control system shall also provide stability such that temperatures are maintained within +/-10°F of 75°F.

3.29.10. Power Supply Conditioning: The AC feed to the control’s DC power supply shall incorporate transient suppression. The suppression network shall have a transient response time not greater than 6 nanoseconds and a peak ampacity of 20,000 or more.

4. Machine Installation and Startup:

4.1. Work Performed by Watervliet Arsenal:

4.1.1. Site Designation: Upon receipt of the required installation and foundation drawings (see section 3.20), Watervliet Arsenal will designate an installation…