SOW Explosive Lathe - 7.8.26 Harriott.docx

STATEMENT OF WORK

1.0 Scope of Work

The work to be performed by the contractor is described as follows:

Produce and deliver to NSWC Indian Head an explosion-proof CNC lathe for machining processes.

The term "machine" as used in this specification comprises the machine tool, the control stations, the operating system, electric, hydraulic, and/or pneumatic equipment, as well as all sealed interconnections between such items to form a complete functional machining center. The lathe described in CNC Lathe Description will be used for shaping explosive chargers from energetic materials. The nature of energetic material requires special physical enclosures, such as National Electrical Manufacturers Association (NEMA) 7, NEMA 9 and NEMA 4X rated electrical equipment, two separate control stations (local and remote) and safety alarming applications incorporated into the machine/control stations.

The overall machines shall be certified to be safely operable and controlled from a Local Control Station proximate to the machine frame. The overall machines shall also be certified to be safely operable and controlled from a Remote-Control Station location in the same bay as the location of the lathe frame. Both control stations are to be in a hazardous location where explosives are to be processed. The National Electric Code (NEC) designates this location as Class I, Division 1, Group D, and Class II, Division 1, Groups E, F, and G. Methods that can be used to permit safe operation of this equipment in this location include: explosion-proofing (NFPA 70, Article 500), purging or pressurizing (NFPA 496) and intrinsic safety (NFPA 70, Article 504). Electrical equipment used in hazardous environments shall be Factory Mutual (FM) or Underwriters Laboratory (UL) approved. Each piece of equipment/hardware shall be provided with a plate that designates the authorized hazardous environments the machine may be subjected to which is NEC Class I, Division 1, Group D requiring NEMA 7 and NEMA 4X rated enclosures and Class II, Division 1, Groups E, F, and G requiring NEMA 9 and NEMA 4X rated enclosures. In addition, each piece of the machines, wherever located, shall be connected to the secondary grounding girdle.

The explosion-proof CNC lathe will include the following tasks:

· Process and Instrumentation Drawings of the lathe system and controls

· Drawings of the lathe system and control parts

· Bill of Materials of the lathe system and control parts

· Manual for operation and maintenance of the lathe and auxiliary parts

· Explosion proof and intrinsically safe lathe capable of holding Class 1 Division 1 Group D explosives with both local and remote control

· Training for operation of and maintenance of the lathe

2.0 General Specifications

The Government requires all materials, equipment, operating systems and personnel to design, fabricate, assemble, inspect, test, deliver, install, operate, and educate Government personnel to operate the machine. The contractor shall design, deliver and install the machine that meets all the specifications herein and/or not stated that qualify them for safe operation in NEC defined Class I, Division 1, Group D and Class II, Division I, Groups E, F, and G hazardous environments, per National Fire Protection Association (NFPA) 70 Article 500. In addition, each piece of the machine, wherever located, shall be connected to the secondary grounding girdle.

2.1 Delivered Supplies

· The contractor shall supply a label on each of the electrical control stations stating that the control station is a control station for hazardous locations.

· The contractor shall connect the machine to Government supplied safety and interlocks such as fire protection on, flashing warning lights, blast doors closed, live explosives being worked, etc., and provide 25% additional spare circuits for future features.

2.2 CDRLs

The contractor shall provide legible drawings (hard and Solidworks readable digital), wiring, pneumatic, vacuum, lubrication and hydraulic diagrams, inspection test reports, operating manuals, maintenance plans, recommended spare parts and other documentation all written in English in accordance with MIL-STD-1916 Department of Defense Preferred Methods for Acceptance of Product.

2.3 Pre-Existing Building Plans

The Government shall provide the appropriate information as required. All Government provided information is considered the property of the Government and shall be used for no other purpose except as identified herein or in an applicable technical instruction.

If electrical and building plans are required for design and installation, the contractor may use electrical and building plans of NSWC Indian Head. When the contractor is finished, they shall either return the electrical and building plans of NSWC Indian Head or shred them.

2.4 Conflicting Document Requirements

If there are any conflicts between specifications, drawings, or requirements listed herein, the contractor shall notify the Contracting Officer (KO) and the Technical Point of Contact (TPOC), in writing for interpretation, clarification, and resolution.

CNC Lathe Description

3.0 Lathe Description

The Contractor shall manufacture, inspect, test, and deliver components in accordance with the applicable drawing and specifications. The Contractor shall provide, design, and fabricate all necessary tooling to manufacture and dimensionally inspect all components and provide data as detailed herein in adherence with DoD MIL-STD-1916.

The Contractor shall maintain and control processes to inspect and test components as described in this SOW. This process should cover all phases from the ordering of the material to the Government acceptance of the finished product.

The Government requires an explosion proof CNC Lathe with CNC control both remote and local and the following key features:

3.1 Electrical components shall meet the NEC requirements for Class I, Division 1, Groups D, and Class II, Division 1, Groups E, F, and G hazardous locations per NFPA 70 Article 500 where applicable.

3.2 Explosion Sealers: All solid and flexible electrical conduits shall include explosion proof sealers at every connection of electrical enclosures and motors.

3.3 Motors: All sealed and/or purged per electric code.

3.4 Liquid Coolant: Supply means for liquid coolant flow control with electrical interlock to prevent operation of the machine without coolant flow and flow adjustment feature at the machine. Supply an articulated grounded metal fixture for directing coolant flow. Supply a wet pan to collect coolant run off. The Government will supply the liquid coolant at a single point.

3.5 Air Coolant: Supply means for compressed air coolant flow control with electrical interlock with machine electrical power to prevent operation of the machine without coolant flow. Supply pressure gage and adjustment feature at the machine. Supply an articulated grounded metal fixture for directing coolant flow. The Government will supply the compressed air coolant at a single point.

3.6 Clamping Vacuum: Vacuum clamping control with electrical interlock to monitor pressure and alarm when clamping pressure is lost or changes. An absolute pressure gauge of 0-760 mmHg and adjustment feature at the machine. Automatic feed hold and spindle stop when pressure thresholds are reached. Supply a vacuum rated rotary union connected to the hollow spindle in the head stock. The Government will supply the clamping vacuum at a single point.

3.7 Chip and dust collection Vacuum: Vacuum chip and dust collection control with electrical interlock to monitor pressure and alarm when chip and dust collection pressure is lost or changes. Dwyer Instruments 0-100” H2O pressure gage and adjustment feature at the machine. Automatic feed hold and spindle stop when pressure thresholds are reached. Supply an articulated grounded metal fixture for collecting vacuum flow. The Government will supply the chip and dust collection vacuum at a single point.

3.8 Lubrication: Full automatic lubrication throughout.

3.9 Laser verification: verification for +/- 0.0001” positioning accuracy over the full X and Z axes travel before shipped.

3.10 Adjacent Control Station key features: The overall machine shall be certified to be safely operable and controlled by the Adjacent Control Station in the control room

3.11 Electrical components shall meet the NEC requirements for Class I, Division 1, Groups D, and Class II, Division 1, Groups E, F, and G hazardous locations per NFPA 70 Article 500 where applicable.

3.12 Explosion Sealers: All solid and flexible electrical conduits shall include explosion proof sealers at every connection of electrical enclosures and motors.

3.13 Motors: All sealed and/or purged per electric code.

3.14 Liquid Coolant: Supply means for liquid coolant flow control with electrical interlock to prevent operation of the machine without coolant flow and flow adjustment feature at the machine. Supply an articulated grounded metal fixture for directing coolant flow. Supply a wet pan to collect coolant run off. The Government will supply the liquid coolant at a single point.

3.15 Air Coolant: Supply means for compressed air coolant flow control with electrical interlock with machine electrical power to prevent operation of the machine without coolant flow. Supply pressure gage and adjustment feature at the machine. Supply an articulated grounded metal fixture for directing coolant flow. The Government will supply the compressed air coolant at a single point.

3.16 Clamping Vacuum: Vacuum clamping control with electrical interlock to monitor pressure and alarm when clamping pressure is lost or changes. An absolute pressure gauge reading 0-760 mmHg and adjustment feature at the machine. Automatic feed hold and spindle stop when pressure thresholds are reached. Supply a vacuum rated rotary union connected to the hollow spindle in the head stock. The Government will supply the clamping vacuum at a single point.

3.17 Chip and dust collection Vacuum: Vacuum chip and dust collection control with electrical interlock to monitor pressure and alarm when chip and dust collection pressure is lost or changes. Dwyer Instruments 0-100” H2O pressure gage and adjustment feature at the machine. Automatic feed hold and spindle stop when pressure thresholds are reached. Supply an articulated grounded metal fixture for collecting vacuum flow. The Government will supply the chip and dust collection vacuum at a single point.

3.18 Lubrication: Full automatic lubrication throughout.

3.19 Laser verification: verification for +/- 0.0001” positioning accuracy over the full X and Z axes travel before shipped.

3.20 Adjacent Control Station key features: The overall machine shall be certified to be safely operable and controlled by the Adjacent Control Station in the control room approximately 25 feet away. Conventional “non-explosive-proof” electrical wiring and apparatus are permissible in the Adjacent Control Room but shall not compromise the safe operation of the machine. Intrinsically safe barriers shall be used if applicable. Machining operations and job progress will be monitored by Government supplied video cameras (color). The contractor shall also supply the following features in the Adjacent Control Station:

3.21 Supply means for full control of the machining operation including but not limited to programming, operator messaging, alarm monitoring, emergency stop and key interlock switches and shall supply means for the lead operator in the Adjacent Control Station to enable the Adjacent Control Station via a key inserted in a two-position key switch. Only one unique key shall be allowed for this machine removable only in the OFF position. When the Adjacent Control Station is selected by the lead operator to be the active control station, a LED indicator labeled “ADJACENT CONTROL STATION IS ACTIVE” shall be illuminated on the Adjacent Control Station.

3.22 Supply means for the Adjacent Control Station to receive a 20 psi pneumatic “ENABLE MACHINE OPERATION” signal sent by the Government-supplied blast door control system. The machine shall interpret this signal as a command to enable operation of the machine by activating the control, drive transformers, sensors and displays of the machine. The machine shall also echo this pneumatic signal back to the blast door control system thru a three port solenoid whenever the equipment is operating. The blast door control system shall then prevent the operating personnel from opening the blast doors when the machine is machining explosives. For additional information, see Appendix A. When this signal is received, a LED indicator labeled “MACHINE IS ENABLED” shall be illuminated on the Adjacent Control Station. The contractor shall also supply the following features on the Adjacent Control Station:

3.23 Color LCD display

3.24 E-STOP push button

3.25 Off / Adjacent key switch and key whose function is described above

3.26 External RS-232 ports for uploading and downloading programs

3.27 Liquid Coolant ON/OFF switch

3.28 Air Coolant ON/OFF switch

3.29 Liquid coolant interlock/bypass switch

3.30 Air coolant interlock/bypass switch

3.31 Clamping Vacuum ON/OFF switch

3.32 Clamping Vacuum Interlock/bypass switch

3.33 Chip and dust collection Vacuum ON/OFF switch

3.34 Chip and dust collection Vacuum Interlock/bypass switch

3.35 Cycle Start push button

3.36 Block by Block push button

3.37 Feed hold (cycle stop)

3.38 Feed rate Over-ride control (0-100%)

3.39 Spindle OFF/ON push button

3.40 Spindle Speed Override (50-100%) switch

3.41 FAULT CLEAR push button

3.42 SD memory card and hard drives

3.43 Learn mode so the machine shall record the manual movements of the handwheels and switches by the operator to permit the machine to automatically control and produce reproductions of the recorded part.

3.44 Supply the switches and controls for the following features: E-STOP push button, Cycle Start push button, Block/Block push button, Feedrate Override (0-100%) switch, X&Z axis Jog incremental >.001, .010, .100, 1.000, Spindle Jog ON/OFF switches.

3.45 Local Control Station key features: The overall machine shall be certified to be safely operable and controlled by the Local Control Station proximate to the machine frame. All electric components shall meet the NEC requirements for Class I, Division 1, Group D, and Class II, Division 1, Groups E, F, and G hazardous locations per NFPA 70 Article 500. Also supply means for the lead operator in the Local Control Station to enable the Local Control Station via a key inserted in a two position key switch. Only one unique key shall be allowed for this machine removable only in the OFF position. When the Local Control Station is selected by the lead operator to be the active control station, a LED indicator labeled “LOCAL CONTROL STATION IS ACTIVE” shall be illuminated on the Local Control Station. Local machine operations shall be at least controlled by E-STOP push button, Cycle Start push button, Block/Block push button, Feedrate Override (0-100%) switch, X-Z axis Jog incremental >.001, .010, .100, 1.000 and Spindle Jog ON/OFF switches mounted on the Local Control Station.

3.46 Hand wheels for carriage and cross slide movement features at the carriage shall be supplied on the machine for manual positioning for initial set-up and also to cut parts manually.

3.47 Supply box with an axis selector switch, a hand wheel increment selector switch, an E-stop mushroom button and a machine ON light.

3.48 Remote Control Station: The overall machine shall also be certified to be safely operable and controlled by the Remote Control Station in a control house approximately 600 feet away. Conventional “non-explosive-proof” electrical wiring and apparatus are permissible in the control house, but shall not compromise the safe operation of the machine. Intrinsically safe barriers shall be used if applicable.

Machining operations and job progress will be monitored by Government supplied video cameras (color). The machine shall supply means for the lead operator in the Remote Control Station to enable the Remote Control Station via a key inserted in a two position key switch. Only one unique key shall be allowed for this machine removable only in the OFF position. When the Remote Control Station is selected by the lead operator to be the active control station, a LED indicator labeled “REMOTE CONTROL STATION IS ACTIVE” shall be illuminated on the Remote Control Station. Remote machine operations shall be at least controlled by E-STOP push button, Cycle Start push button, Block/Block push button, Feedrate Override (0-100%) switch, X-Z axis Jog incremental >.001, .010, .100, 1.000 and Spindle Jog ON/OFF switches mounted on the Remote Control Station.

4.0 MACHINE TOOL OPTIONS REQUIRED

4.1 Handwheels for carriage and cross slide movement.

4.2 Vacuum gauges and control switches at the machine.

4.3 Tool post with at least 8 tools in the magazine

4.4 Chuck to safely machine high-explosive billets weighing up to 500 pounds with an outer diameter up to 18 inches.

4.5 Tailstock with detachable connection to cross slide.

4.6 Wet pan to collect coolant and slurry runoff.

5.0 Machine Specifications

*Note - It is mandatory to limit the feedrate and rapid traverse to 30 ipm for all axis when machining explosives.

6.0 PHYSICAL SEALING

6.1 Special physical sealing is necessary to prevent explosive dust from building up or entering potential pinch point mechanisms or moving parts on the machine. Physical sealing shall include covers of ways & slides to positively prevent water/explosives from entering moving parts and covers or protectors over all potential pinch points where explosive dust has the potential to accumulate.

7.0 WATERTIGHT CONFORMANCE

7.1 To prevent the entry of washdown water into electrical components and enclosures, all equipment on the machine and control stations shall be watertight (NEMA 4X or equivalent). This includes position feedback devices (encoders, etc.), control enclosures, limit switches, junction boxes, and all other electrical components and devices on the machine and control stations. In addition, all exposed components of the machine shall at least be corrosion resistant. The press and all supporting equipment will be in a non-humidity/temperature-controlled environment.

8.0 SPECIAL APPLICATIONS SOFTWARE AND INTERLOCKS

Special applications programming shall include customized safety interlocks necessary for explosive pressing. Safety monitoring and alarms to include:

8.1 Vacuum pressure loss

8.2 Electrical power loss

8.3 Unintended vault entry

8.4 Fire protection on

8.5 Flashing lights on

8.6 Blast doors closed

8.7 Spares for future needs (25%)

9.0 LATHE CONTROL SYSTEM

The lathe control system shall have the capability to manage unusual situations relative to power and, or process failure for emergency stops, alarming and error messaging to alert operator of unsafe conditions and respond to unsafe conditions. As a minimum, the control system shall include:

9.1 Processor

9.2 USB port for downloading data

9.3 Shall not contain operable wireless LAN, Blue Tooth, 802.11 or WIFI options.

10.0 SPLASH/WASHDOWN COOLANT PROTECTION

10.1 All moving, rotating and/or sliding mechanical components on the lathe shall be designed, covered, or assembled to positively prevent the entry or accumulation of the water and machining slurry. Slurry is defined as the liquid coolant/cutting residue mixture. This applies to parts of the machine that are not wetted during machining as well as all wetted areas. Splashing and washdown will occur that could potentially cause slurry contamination on/in parts of the machine such as: Slides, Ways, Lead Screws, Spindle, Wet Pan, Electrical Equipment, and other locations.

11.0 COOLANT OUTLET

11.1 The wet pan shall contain a single outlet for liquid coolant and machining slurry. The outlet shall be placed so that all water and slurry will gravity drain from the wet pan both during and after machining operation.

12.0 LUBRICATION COLLECTION

12.1 All once through way/slide lubrication shall be collected in the wet pan area such that the waste oil is maximized and the potential oil drip into the wet pan area is minimized. The spent lubrication shall be directed out of the wet pan and installed so that liquid coolant/machining slurry do not contaminate it.

13.0 SPINDLE VACUUM PORT

13.1 Workpieces shall be held in place on the spindle using vacuum. The Government shall provide adapter plates, chucking fixtures and vacuum system to integrate into the machine and control unit. The vacuum system may be determined through subsequent collaboration with the contractor. Machine requirements for the vacuum system shall include:

13.2 Vacuum through spindle hole

13.3 Vacuum Rotary Union rated for explosion proof service

13.4 Vacuum Solenoid: A vacuum solenoid valve shall be provided in the piping that acts as an “ON/OFF” switch located on the local control enclosure.

13.5 Vacuum Switch and Interlock: A vacuum switch shall be provided in the piping downstream from the solenoid. The switch shall be normally closed, but will cause a secondary interlock violation if the vacuum BYPASS/INTERLOCK switch is in the interlock position and the vacuum falls below the switch setting.

13.6 Vacuum gauge viewable by CCTV.

13.7 Vacuum Piping Connection to single point supplied by the Government.

14.0 LIQUID COOLANT SYSTEM

14.1 Water is one of the coolants utilized with explosives machining. Feeder piping to the cutting tool through the tool liquid coolant supply and auxiliary coolant lines shall contain the following components:

14.2 Liquid Coolant Solenoid. The contractor shall supply a liquid coolant solenoid valve. The control system shall incorporate a liquid coolant OFF/ON/PROGRAM control to turn the liquid coolant on or off both manually and by part program M code as specified.

14.3 Liquid Coolant Flow Switch. Downstream of the solenoid valve shall be an adjustable liquid coolant flow switch with flow indicator that will cause a SECONDARY INTERLOCK violation when the liquid coolant flow loss is detected and the liquid coolant INTERLOCK/BYPASS switch is in the INTERLOCK mode. In the BYPASS mode, no action is necessary.

14.4 The liquid coolant solenoid valve and the coolant flow switch shall be mounted at a location on the machine that is accessible and visible. One half inch piping or hose shall be installed between the flow switch and the coolant delivery connections on the machine tool.

14.5 The contractor shall supply an articulated grounded metal fixture for directing coolant flow.

15.0 AIR COOLANT SYSTEM

15.1 Air is one of the coolants utilized with explosives machining. Feeder piping to the cutting tool through the tool air coolant supply and auxiliary coolant lines shall contain the following components:

15.2 Air Coolant Solenoid. The Contractor shall supply an air coolant solenoid valve. The control system shall incorporate an air coolant OFF/ON/PROGRAM control to turn the air coolant on or off both manually and by part program M code as specified.

15.3 Air Coolant Flow Switch. Downstream of the solenoid valve shall be an adjustable air coolant flow switch with flow indicator that will cause a SECONDARY INTERLOCK violation when the air coolant flow loss is detected and the air coolant INTERLOCK/BYPASS switch is in the INTERLOCK mode. In the BYPASS mode, no action is necessary.

15.4 The air coolant solenoid valve and the coolant flow switch shall be mounted at a location on the machine that is accessible and visible. One half inch piping or hose shall be installed between the flow switch and the coolant delivery connections on the machine tool.

15.5 The contractor shall supply an articulated grounded metal fixture for directing coolant flow.

16.0 CNC CONTROL SYSTEM

The CNC control system shall be a Dynapath ® Delta 2000T CNC control that has the current processor technology for machine tool control. The control system shall have the capability to manage unusual situations relative to power and, or process failure for emergency stops, alarming and error messaging to alert operator of unsafe conditions and respond to unsafe conditions. As a minimum, the control system shall include:

16.1 Processor

16.2 16 GB Hard Drive minimum.

16.3 SD Flash memory Card and hard drives

16.4 RS-232 port for external uploading and downloading programs

16.5 Software accuracy compensation

16.6 Backlash and reversal error compensation for each axis

16.7 Control shall be capable of and configured for tool offset input

16.8 M and G Code

16.9 Shall not contain operable wireless LAN, Blue Tooth, 802.11 or WIFI options.

17.0 OPERATOR STATUS MESSAGES

In addition to the standard status indication and information displayed on the CNC control provided with the machine, the following information shall be displayed on the Adjacent Control Station:

17.1 Spindle Forward

17.2 Spindle Reverse

17.3 Spindle Speed

17.4 Local Control Station Is Active

17.5 Adjacent Control Station Is Active

17.6 Remote Control Station Is Active

17.7 Clamping Vacuum Off/On indicator

17.8 Chip and dust collection Vacuum Off/On indicator

17.9 Clamping Vacuum Interlock ON

17.10 Chip and dust collection Vacuum Interlock ON

17.11 Clamping Vacuum Interlock BYPASSED

17.12 Chip and dust collection Vacuum Interlock BYPASSED

17.13 Liquid Coolant Interlock ON

17.14 Liquid Coolant Interlock BYPASSED

17.15 Air Coolant Interlock ON

17.16 Air Coolant Interlock BYPASSED

17.17 Blast Doors Are Closed

17.18 M and G Code not defined

17.19 FeedHold indicator

17.20 Cycle Stop indication

17.21 Block by Block indication

17.22 All PRIMARY INTERLOCK faults indicators

17.23 All SECONDARY INTERLOCK faults indicators

18.0 OPERATOR ALARM MESSAGES

In addition to the standard status indication and information displayed on the CNC control provided with the machine, the following information shall be displayed on the Adjacent Control Station

18.1 Vacuum Failure

18.2 Power Failure

18.3 Coolant Failure

18.4 Tool Force Detection failure

18.5 Servo fault

19.0 CONTROL POWER-UP

19.1 Provide a key switch and master control relay that operates as follows:

The machine shall be enabled/powered up by a four position “OFF/LOCAL/ADJACENT/REMOTE” labeled key switch located on the Adjacent Control Station. The key shall only be removable in the “OFF” position.

In the OFF position, a Master Control Relay (MCR) shall remove power to all control and drive transformers, sensors and displays. In the other three positions, the MCR shall enable all control and drive transformers, sensors and displays, but only one of the control stations input controls shall be activated at a time. The key switch shall have additional contact blocks so that input controls from specific Local, Adjacent and Remote Control Stations can be accomplished when that one station is selected.

20.0 PRIMARY INTERLOCK FAULTS

20.1 The following conditions shall be designated as “primary interlock faults”:

20.2 Each of the axis drives and spindle drives shall be deactivated upon any primary interlock fault. The control does not have to maintain part program synchronization upon activation of a primary interlock fault. The violated interlock shall be displayed as inverse/blink or flashing on the Adjacent Control Station LCD screen:

21.0 SPINDLE DRIVE FAULTS

21.1 X & Z Axis Drive Faults- Separate fault input from both of the two axis fault detects.

21.2 Extreme Travel Limit- Separate fault from the extreme travel limit switch activation.

21.3 Emergency Stop and Electrical Console Door Switches: Fault inputs from emergency stop push buttons and door switches on the local, remote and drive enclosures.

22.0 SECONDARY INTERLOCK FAULTS

22.1 The following conditions shall be designated as “secondary interlock” violations and shall cause a “feedhold” condition. A feedhold condition must cause the spindle rotation to decelerate to a stop, stop all axis movement, and allow part program synchronization to be maintained (to allow program continuation upon correction of the violation). The violated interlock shall be displayed as inverse/blink or flashing on the Adjacent Control Station LCD screen:

INTERLOCKED and sensors satisfied---Red indicator light out INTERLOCKED and sensors violated---Indicator light flashing BYPASSED---Red indicator light on continuously

23.0 VACUUM FAULT

23.1 The Vacuum interlocked/bypassed switch is in the INTERLOCK position and the vacuum loss sensing switch is activated.

24.0 COOLANT FAULT

24.1 The Coolant interlocked/bypassed switch is in the INTERLOCK position and the coolant flow loss sensor is activated. Controls shall be established to bypass the coolant flow switch and shall turn off the flood coolant regardless of the position of the Coolant Interlock/Bypassed switch and Coolant ON/OFF switch. Controls shall be established to remove the coolant flow bypassed condition and turn on the flood coolant.

Controls shall be software configured to allow the bypass condition for only one block of program execution.

25.0 TOOL FORCE DETECTION

25.1 Tool force detection means shall be incorporated into the machine tool control to monitor the force on the cutting tool. If the force exceeds a pre-set value, then the machine tool control shall go into Secondary interlock violation. The operator shall be able to correct the problem and reset control to resume operation. Excessive forces can be the result of unintended tool path travel of tooling into workpiece, vacuum holding problems that allow the workpiece to move off centerline, larger than expected raw workpiece, and/ or excessive feed rates or slow spindle speeds that allow excessive cutting forces on the workpiece.

26.0 FIRST TRAVEL LIMITS FAULTS

26.1 Contractor shall recommend limits when appropriate.

27.0 SPINDLE OPERATION AND CONTROLS

27.1 Forward/reverse spindle with the following operations and controls shall be provided:

27.2 Spindle Speed Override: Spindle speed override control (50-100%) shall be provided at both the local, adjacent and remote control stations. The adjacent and remote spindle speed override control must be deactivated in the software when the local control station is active.

27.3 Spindle Acceleration and Deceleration: The spindle acceleration and deceleration rates shall be programmed as not to exceed 1000 rad/sec/sec for all spindle start and stop conditions, including complete power loss. Spindle braking in the drive package shall not be utilized. With the machine tool powered on, and if no spindle command is active (or 0 rpm programmed speed), the spindle shall be in a free-wheeling mode (rotatable by hand) so that the machine operator can center the workpiece on the workholding fixture.

28.0 AXIS OPERATION AND CONTROLS

The following operations and controls shall be provided:

28.1 Axis Travel Ranges and Speeds: Axis travel ranges are found in Machine Description. The speed range for each axis shall be 0-30 inches per minute. Rapid movement for each axis shall be 30 inches per minute.

28.2 Axis Power-up: Each of the axes shall be powered up by AXIS ON input from the Adjacent Control Station control station.

28.3 Axis Software Travel Limits: The software travel limits shall be established .050” beyond each of the travel ranges specified in the Machine Description for all axes.

28.4 Extreme “safety limit” travel limit switches shall be provided on each end of the axis travel. Activation of the extreme travel limit switches shall cause an Emergency Stop (Primary Interlock) condition and shall be wired in series with the E-Stop push buttons and enclosure door switches.

28.5 Axis Home Switches: Switch inputs shall be provided for X and Z home positions.

28.6 Axes Travel Limit Switches: In addition to the software travel limit switches that define the usable X-Z work area, an additional hard-switch shall be provided at each end of the X and Z axes. This limit switch shall cause a Primary Interlock violation as specified.

29.0 BLAST DOOR INTERLOCK

29.1 When operating in an adjacent or a remote-control mode, all blast doors shall be closed for personnel protection when machining explosives. The control system shall provide for an interlock/bypass switch that will indicate when the blast doors are not secure.

30.0 ELECTRICAL CONFORMANCE

30.1 The Electrical Equipment ratings of all electrical equipment on the machine tool, Local Control Station, and Remote-Control Station shall meet the NEC requirements for Class I, Division 1, Group D, and Class II, Division 1, Groups E, F, and G hazardous locations per NFPA 70 Article 500. All equipment and component parts shall be UL or FM listed for hazardous environments. All wiring and electrical equipment installations shall be in conformance with the most current editions of both NFPA 70 “National Electrical Code”, and NFPA 79, “Electrical Standard for Machine Tools…”

30.2 The machine and all the controls shall be grounded to the secondary girdle and meet the resistance requirements of OP-5, Chapter 5.

31.0 USER MANUAL(S)

31.1 All written documentation and manuals customarily provided to the public with a commercial item shall be provided. This shall include user manual(s) or equivalent as well as copies of any software, and any manuals for the software included with the system, if customarily provided. This documentation must be received at Indian Head with the system hardware, unless other arrangements are agreed to by the authorized Government representative. In addition to the above documentation, which is customarily provided, the following specific documentation is required and shall be included in the price of the equipment.

31.2 Shall include all operation and service manuals and schematics in digital and hardcopy form.

31.3 As built construction drawings and piping & instrumentation drawings shall be provided in a digital form. Electronic copies that are readable on a windows-based PC are acceptable. Both must be in accordance with MIL-STD-1916.

31.4 Suggested Preventative Maintenance Plans/Schedule shall be provided.

32.0 GOVERNMENT AND CONTRACTOR RESPONSIBILITIES BEFORE INSTALLATION OF THE MACHINE AT NSWC IHD

32.1 Upon receipt of the machine parts, the Government will provide the rigging and equipment to place the machine parts in temporary storage.

32.2 When the building is ready to receive the lathe machine, the Government will provide the rigging and equipment to move the machine frame from temporary storage to the operating location in the building, to move the machine control console from temporary storage to the Remote-Control Station and Local Control Station. The Government will also move the ancillary equipment to the utility room located outside of the building.

32.3 Contractors will support Government personnel in completing Preliminary Hazard Analysis, Systems Hazard Analysis, and Failure Modes & Effects Analysis.

32.4 The Contractor shall be responsible for packing and packaging of deliverables to prevent any potential damage during transport. The Contractor shall label completed parts packaging to include component name, quantity, contract number, drawing number, revision, and manufacturer name and date.

32.5 The Contractor shall notify the Contracting Officer 30 days in advance if the Contractor cannot meet the contract delivery schedule. The Contractor shall be responsible for coordinating and shipping all the units below to the required destination.

Table 1: Deliverables

Upon delivery of the material and Certificate of Compliance to the Government and once acceptance has been provided then the final payment will be made to the Contractor.

33.0 UPON DELIVERY OF THE MACHINE PARTS, THE CONTRACTOR SHALL PERFORM THE FOLLOWING WORK TO THE SATISFACTION OF THE GOVERNMENT TECHNICAL POINT OF CONTACT (TPOC)TO OBTAIN ACCEPTANCE:

33.1 Perform the final leveling of the machine.

33.2 Make all wiring, interlocks, pneumatic, and vacuum connections at the provided lathe system, Local Control Station, and Remote-Control Station.

33.3 Power up the machine and control system and bring into operation.

33.4 Demonstrate all interlocks that required Government hardware. Connections will be verified at this time.

33.5 Verification of all other performance, construction, and operational requirements listed in this specification, either visually or operationally.

33.6 At the completion of the installation and demonstration of the specifications, the CONTRACTOR must provide onsite training at Indian Head for 8 people for a minimum of at least three whole days in the subject areas listed below, that is sufficient to enable them to independently program, operate, and maintain the machine:

33.6.1 Operation of the machine and control system

33.6.2 Maintenance of the machine and control system

33.6.3 Programming

33.6.4 Complete understanding of the explosive safety features

33.7 Deliver all required documentation. All deliverable documentation as specified herein or by individual technical instructions, shall be inspected and approved by the Technical Point of Contact (TPOC). All technical drawings shall be in accordance with ASME Y14.100 and ASME Y14.5, or equivalent. All documentation shall be compatible with Adobe Acrobat and Microsoft Office 365 Applications.

34.0 WARRANTY

34.1 The contractor shall offer the Government at least the same warranty terms, including offers of extended warranties, offered to the general public in customary commercial practice. These warranty terms must be included in the system price. The period of the warranty shall begin upon acceptance.

Final acceptance by the Government will occur at:

Naval Surface Warfare Center Indian Head Division 4522 McMahon Road Bldg. 116, Suite 100 Indian Head, MD 20640

35.0 SHIPPING

The Contractors price shall include the cost of shipping the complete machine to:

Naval Surface Warfare Center Indian Head Division 4522 McMahon Road Bldg. 116, Suite 100 Indian Head, MD 20640

The packaging shall prevent any damage which may occur during transit. The Contractor paperwork shall state the contract number. Transportation shall comply with Department of Transportation regulations at Title 49, Code of Federal Regulations.

36.0 Base Entry

All contractors entering NSWC IHD must be U.S. citizens and must obtain a temporary identification badge from the Pass and Identification Office upon arrival. Drivers must show two forms of identification, proof of insurance, and registration documents to obtain a temporary identification badge. All base access and arrangements must be made by the vendor prior to providing services and deliveries.

37.0 Controlled Unclassified Information (CUI)

The Contractor may be required to handle Controlled Unclassified Information (CUI). There are numerous types of CUI, e.g. documents with limited distribution statements, documents marked as For Official Use Only (FOUO), etc. The minimum level of protection for all CUI is adherence to FOUO protection standards. Distribution Statements (DS) and warning labels, such as the Arms Export Control Act Warning, identify additional protection requirements for a given document. Minimum FOUO protection requirements/controls applicable to the performance of this contract for CUI are listed below. Additional protection requirements, as marked on a given CUI document, are in addition to the standards listed.

37.1 Handling/Storage: Access to FOUO is limited to those needing it to conduct official business for the Department of Defense (DoD). FOUO information is not classified information but requires extra precautions to ensure it is not released to the public. During business hours, reasonable steps shall be taken to minimize risk of access by unauthorized personnel. After business hours, FOUO information shall be stored in unlocked containers, desks, or cabinets if Government or Government-contracted building security is provided. If it is not, store in locked desks, file cabinets, bookcases, locked rooms, or similar items.

37.2 Transporting/Transmitting/Release/Destruction: FOUO information shall be transported in a manner that prevents disclosure of the contents. FOUO information may be sent via USPS first-class mail, parcel post, or – for bulk shipments – 4th class mail. Electronic transmission of FOUO information (voice, data, or facsimile) shall be by approved secure communications systems. Transmission via unsecure fax is acceptable if an authorized person is standing by on the receiving end to take custody. All emails containing FOUO or attachments with FOUO must be digitally signed and encrypted when transmitted within a Navy network or to an approved Contractor email address. Transmission of FOUO (i.e. any CUI) to personal email accounts (e.g. AOL, Yahoo, Hotmail, Comcast, etc.) is strictly prohibited. FOUO sent out of the Contractor’s facility electronically must be encrypted (DoD FIPS 140-2 standard). FOUO material shall not be released outside the Contractor’s facility except to representatives of DoD. When no longer needed, destroy FOUO by a method that precludes its disclosure to unauthorized individuals.

37.3 Markings: Unclassified documents (paper or electronic) generated in support of this contract which contain FOUO are to be marked “For Official Use Only” at the bottom on the outside of the front cover (if any), on each page containing FOUO information, and on the outside of the back cover (if any). Each paragraph containing FOUO information shall be marked as such. Within a classified document, an individual page with both FOUO and classified information shall be marked at the top and bottom with the highest security classification of information appearing on the page. Individual paragraphs shall be marked at the appropriate classification level, as well as unclassified or FOUO, as appropriate. Within a classified document, an individual page that contains FOUO information, but no classified information shall be marked “For Official Use Only” at the top and bottom of the page, as well as each paragraph that contains FOUO information.