Statement of Work for 0213-2005.pdf

SOW / LAPPING MACHINE, 24 INCH

The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issue in effect on the date of an invitation for bids or a request for proposals shall apply.

THE CODE OF FEDERAL REGULATIONS

• 29 CFR 1910 Occupational Safety and Health Standards

• 29 CFR 1926 Safety and Health Regulations for Construction

• 40 CFR 261 Identification and Listing of Hazardous Waste

(Application for copies should be addressed to Superintendent of Documents, Government Printing Office, Washington, DC 20402)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

• NFPA 70 National Electric Code

• NFPA 79 Electrical Standards for Industrial Equipment

(Application for copies should be addressed to National Fire Protection Association, 470 Atlantic Ave., Boston, MA 02210)

NATIONAL ELECTRICAL MANUFACTURERS’ ASSOCIATION (NEMA)

• ICS Industrial Controls and Systems

• MGI Motors and Generators

(Application for copies should be addressed to the National Electrical Manufacturers’ Association, 2101 L Street, NW, Washington, DC 20037)

AMERICAN NATIONAL STANDARDS INSTITUTE, INC. (ANSI)

• ANSI Z535.4 Product Safety Signs and Labels (Copies available at: http://webstore.ansi.org or ANSI Attn: Customer Service Department, 25 W 43rd Street, 4th Floor, New York, NY 10036)

PSNS&IMF OCCUPATIONAL SAFETY AND HEALTH MANUAL

• OSH-II-9 Hazardous Energy Control, Lock Out/Tags Plus

(LOTP)

(Copies available, to be provided by Government Point of Contact as required) http://webstore.ansi.org/

1. General Equipment Requirements:

Specifications and Required Features for Lapping Machine, 24 Inch: (Lapmaster Model 24 or equivalent) shall have the minimum salient characteristics:

Characteristic Specification Input Power 230 Volts, 3 Phase, 60 Hertz Operating Capacity 3.0 cubic feet

Maximum 4.5 cubic feet Motor 2 HP # Conditioning Rings 3 Conditioning Ring ID: .25 inches Conditioning Ring OD: 9.5 inches Plate Diameter: 24 inches Load Pressure (4 bar supply)

33 lbs to 187 lbs.

Variable Speed Drive with Tachometer

20–90 rpm

Additional Required Components:

• Three (3) cartridge peristaltic pump type slurry delivery system with, tank, agitator, three slurry feed lines and return drain container.

• One (1) Set heavy duty wrenches

• One (1) High density cast alloy, radially serrated, precision machining plate, flex type, 4-1/2" inside diameter x 24" outside diameter x 1-1/2" thick

• Three (3) High density cast alloy, serrated, in-process flatness control type conditioning/retainer rings, 9-3/4" inside diameter x 11-1/4" outside diameter x 2- 3/4" thick

• Three (3) Micarta workholder discs, 9-11/16" diameter x 1/8" thick

• Three (3) Sponge rubber pads, plain back, 9-11/16" diameter x 1/2" thick

• Lap Plate Flatness Inspection gauge

• Five (5) gallons lapping oil

• Five (5) pounds 14 micron aluminum oxide lapping abrasive

1.1 Electrical Components. All electrical components including motors, starters, relays, switches, and wiring shall conform to and be located in accordance with the applicable NFPA, NEMA, and ANSI standards for the intended application.

1.2 Motors. Motors shall be rated for continuous duty. Motors shall be equipped with ball bearings of the sealed and permanently lubricated type. All electrical motors shall meet NEMA-MG1 requirements.

1.3 Bearings. All bearings contained within this machine and the entire system must be U.S. or Canadian manufactured. If they are not U.S. or Canadian manufactured bearings, the vendor must provide a list of exact U.S. or Canadian made equivalent bearings that can be used for replacement of each bearing within this equipment or system. This requirement is in accordance with Defense Federal Acquisition Regulation Supplement (DFARS 252.225-7016).

1.4 Electrical System. Electrical components including motors, starters, relays, switches, and wiring shall conform to and be located in accordance with NFPA 79.

Electricity available at the installation site is 460 VAC, 3 Phase, 60 Hz. The equipment shall be designed to operate on the available electric utilities. The electrical system shall be complete including any electrical transformer(s) required to modify the existing source voltage to the proper operating voltage of the equipment. All electrical components shall conform to applicable NEMA ICS 1 standards.

1.5 Electric Power Disconnect. A single supply circuit disconnect device shall be provided and installed on the equipment, which controls all electrical power. All electrical components shall be fused or circuit breaker protected in each phase conductor for AC circuits. Overloads, fuses, and circuit breakers shall be coordinated for maximum component protection and minimum circuit disruption. The device shall be either a fusible motor circuit switch or circuit breaker.

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

1.7 Electrical Connections. Electrical connections within the equipment shall be complete and shall be made via terminals on the components, terminals, or circuit boards and bussing. Splices between terminations are not permitted. Connections and terminals shall be supported and spaced without the dependence upon the wiring in the components and braced as necessary to assure withstanding the distortion forces associated with available short-circuit currents. Proper identification of wiring, bussing, terminals and circuits for function, polarity, phasing, etc., shall be adhered to throughout the equipment.

Identification shall be in the form of wire markers, color coding, permanently engraved plates, and permanent markings on the devices. Adequate spacing shall be maintained throughout to avoid excessive bending of cabling and wiring, to maintain adequate separation and creepage distance between electrical potentials and between these potentials and ground, and to permit ease in disconnecting wiring and cabling during trouble-shooting and repair. In no instance shall clearances and creepage distances be less than those described under NEMA ICS, Part ICS 1-111.

1.8 Grounding. Exposed, non-current carrying metal parts shall be maintained at common, zero ground potential. A grounding stud/lug shall be provided as a means for grounding the equipment. For cord connected equipment, a NEMA type grounding plug which effectively grounds the equipment for the safety of personnel shall be acceptable in lieu of a ground stud or lug on the equipment.

1.9 Over-current Protection. All electrical components shall be fuse or circuit breaker protected in each phase conductor for AC circuits. Overloads, fuses and circuit breakers shall be coordinated for maximum component protection and minimum circuit disruption.

1.10 Electrical Enclosure. Electrical components of the equipment shall be contained in an enclosure(s) of structural and sheet steel. Provisions shall be made for power cable entrance. The enclosure(s) shall be of drip-proof construction and of minimum size consistent with good design practices and ventilation of components. meeting the requirements of NEMA Type 12,

1.11 Emergency Stop Buttons. The equipment specified herein shall be provided with emergency stop buttons (switches) at the equipment control panel. These stop buttons shall be colored red with a yellow background, and shall be labeled as such.

When activated, the emergency stop buttons shall disconnect all electrical power to the equipment such that all operations or functions will immediately stop or cease.

1.12 Painting. All surfaces shall be painted in conformance with the manufacturer’s standard practices and good workmanship. Painting shall result in a highly wear-resistant finish that guarantees continued protection to surfaces in an indoor environment with a temperature range of 15° to 110° F, up to 100% Non-condensing relative humidity. The manufacturer’s standard color shall be provided. Lead or chromium base paints are prohibited.

1.13 Controls and Instrumentation. Operator controls, instrumentation and indicators shall be mounted convenient to operating personnel. Such devices shall be clearly and legibly marked in English for function and identification. Controls shall be fitted with suitable handles, pushbuttons, or control knobs, as applicable. Gauges and instruments shall be designed for recalibration. Pressure gauges shall be calibrated in the U.S. system of measurement.

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

1.15 Hour Meter. The Pneumatic Pressure Disc Type, Precision Loose Abrasive Processing Machine shall be equipped with a digital hour meter mounted on the main electrical panel visible from the outside. The hour meter shall be installed to display accumulated operating time of the main drive motor. The meter shall be of the non-resetting type and shall have a range of 0.1 to 999.9 hours in increments of 0.1 hours, and shall revert to zero (0) upon reaching the maximum count. The meter shall have a

NEMA enclosure rating of 4X, and shall be mounted to withstand shock and vibration generated by the equipment in an accessible location.

1.16 Safety devices. All machine parts, components, mechanisms, and assemblies furnished on the unit shall comply with all specific requirements of “OSHA Safety and Health Standard (29 CFR 1910), General Industry” that are applicable to the equipment itself.

1.17 Safety signs and labels. Safety signs and labels in accordance with ANSI Z535.4 shall be securely attached to the equipment in visible locations, with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the signs.

1.18 Informational Plates. The following informational plates shall be marked by engraving or photo imaging on wear and corrosion resistant metal and permanently affixed to the equipment.

1.18.1 Identification Plate. The following information shall be securely attached to the equipment on an identification plate: Nomenclature, Contractor’s name, manufacturers name, equipment model number, equipment serial number, electrical utilities (Volts, Full Load Amps, Frequency, Phases, and Short Circuit Current Rating {SCCR}), date of manufacture, contract number and any other pertinent information for identifying the part as a unique component of the system.

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

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

1.19 Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11. The safety devices shall not interfere with the operation of the Pneumatic Pressure Disc Type, Precision Loose Abrasive Processing Machine. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

1.20 Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 dB(A) as measured on the "A" scale and 92 dB(C) as measured on the "C" scale, at any point three feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment.

1.21 Lubrication. Means shall be provided to ensure adequate lubrication for all moving parts. Recirculating lubrication systems shall include a filter that is cleanable or replaceable. Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low oil condition. When a low oil pressure condition occurs, the machine shall enter an emergency stop condition. All oil holes, grease fittings, and filler caps s shall be accessible. A lubrication plate shall be securely attached to the equipment.

1.22 Standard, Off The Shelf Components – All materials and parts comprising this system shall be new, of current design and manufacture and shall not have been in prior service except as required for factory testing. Standard, off the shelf components with proven reliability shall be used whenever possible to increase performance reliability and reduce costs. The equipment shall be one of the manufacturer’s current production models which has been designed, engineered and sold, or is being offered for sale through advertisements or manufacturer’s published catalogs or brochures. Products such as a prototype unit, pre-production model, or experimental unit DO NOT qualify as meeting this requirement. The equipment shall be complete, so that when connected to power, it can be used for the function for which it was designed and constructed.

1.23 Warranty. Supplies and services furnished shall be covered by warranty from defects in design, materials and workmanship. The warranty shall be the manufacturer’s standard commercial warranty which shall conform to all the requirements of the contract. Acceptance of the manufacturer’s standard commercial warranty shall not minimize the rights of the Government under clauses in the contract, and in any conflict that arises between the terms and conditions of the contract and manufacturer’s warranty, the terms and conditions of the contract shall take precedence. The warranty period of one (1) year (12 months) shall commence when final acceptance has been achieved as determined when all contract line item numbers have been processed through Wide Area Workflow (WAWF).

1.24 Technical Manuals. A set of three (3) Commercial Off-The-Shelf technical manuals is required for each specific make, model year, and serial numbered piece of equipment scheduled for delivery under the terms of the contract. The manuals shall provide instructions, illustrations, and other associated data for operations, maintenance, repair, overhaul, including a complete catalog of parts used in the assembly of the end item enabling an average journeyman mechanic to operate, program, maintain, repair, and overhaul the equipment. The manuals provided shall contain complete instructions and information for all equipment, components, assemblies, subassemblies, attachments, and accessories assemble in the end item. The contents of a complete set of technical manuals shall include, as a minimum, the following:

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

b. Maintenance, service, and overhaul instructions, including all preventive maintenance schedules and lubrication chart

c. Trouble-shooting guides

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

e. Energy control procedure, in accordance with 29 CFR 1910.47, OSHA Energy Control Standard to bring equipment to a zero energy state for service and maintenance

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

g. Programming requirements

2. OSHA Approved Certification.

2.1 The equipment, installation and its component parts shall be in compliance with the applicable Occupational Safety and Health Administration (OSHA) regulations in accordance with CFR Title 29, Chapter XVII, Part 1910 and NFPA 70 and NFPA 79.

Approval shall be as specified under the “Approval” and “Acceptance” criteria in the OSHA regulations Subpart “O”, Machinery and Machine Guarding paragraph 1910.212 and Subpart “S” Electrical, paragraph 1910.303 and paragraph 1910.399. After equipment delivery and installation, and prior to testing, the contractor shall provide an compliance label, paragraph 2.2. Failure to provide this certification will delay acceptance of the equipment, and could result in rejection for failure to comply with the terms of the contract. The machine shall be listed or approved, and labeled by one of the following methods:

• The equipment specified herein shall be listed and labeled by an OSHA recognized and approved Nationally Recognized Testing Laboratory (NRTL).

• The equipment and its installation specified herein shall be field inspected, approved, and labeled by an OSHA recognized and approved NRTL.

2.2 OSHA Compliance Label. The contractor shall apply a NRTL label identifying the OSHA compliance on the equipment. Failure to provide this label will delay acceptance of the equipment, and could result in rejection for failure to comply with the terms of the contract.

3. Transportation

3.1 Contractor shall be responsible to ship equipment, components and manuals to PSNS&IMF from their facility.

3.2 Building site

3.2.1 Conditions: The building does not have a loading dock; therefore, recommend the material delivery vehicle have an operational lift-gate. There is a freight elevator adjacent to the work site.

3.3 Delivery address:

3.4 The "Ship/Deliver to" address on the Bill of Lading (B/L) should include the JML number as shown below.

3.5 Puget Sound Naval Shipyard & IMF

Receiving Officer PSNS, N4523A Bldg. 514, JML- 02132005 1400 Farragut Ave.

Bremerton, WA 98314-5001

2.2 OSHA Compliance Label. The contractor shall apply a NRTL label identifying the OSHA compliance on the equipment. Failure to provide this label will delay acceptance of the equipment, and could result in rejection for failure to comply with the t...