Statement of Work (Water Jet) revision 6 24 2020 cons.docx

STATEMENT OF WORK (SOW)

FOR

PURCHASE AND INSTALLATION OF AN ABRASIVE WATERJET CUTTING SYSTEM

AFCEC, Tyndall AFB, FL 32403 24 June 2020

STATEMENT OF WORK

TABLE OF CONTENTS

1. DESCRIPTION OF SERVICES

The contractor shall provide all equipment including the abrasive water jet, materials, transportation, shipping and labor required to deliver and install a turn-key Abrasive Water Jet Cutting System.

2. WORK REQUIREMENTS

2.1 Abrasive Water Jet. The contractor shall provide a system that is fully assembled and tested at the factory, and includes all the equipment for a turn-key system including the following:

2.1.1 Water Jet Table (Table X-axis)

· Table shall be 180 inches long by 90 inches wide.

· The X-axis shall be controlled by closed loop, digital drives with brushless servo motors that require no periodic tuning. The resolution shall be 1 micron with linear scale.

· The X-axis shall have full X-axis travel.

· Ball screw or rack and Pinion drive systems shall NOT be allowed. Traction Drive system is preferred for superior performance under water and garnet conditions.

· The linear motion system shall use digital linear encoders to provide instant micron-level cutting head position feedback to the controller to assure accurate part production.

· Waterjet table shall support a no less than 400 pounds per square inch.

2.1.2 5-Axis Cutting Head

· The system shall include a 5 axis cutting head that is a complete software-controlled, multi-axis accessory that features the flexibility to automatically compensate for taper, as well as cut severe angles up to 60° off vertical.

· The 5 axis head shall be capable of cutting countersunk holes and precision shapes with beveled edges at angles specified by the user. The accessory supplies additional axes of motion, allowing the operator to fabricate and shape metal edges for weld preparation.

· The 5 axis cutting head shall have a positional accuracy of +- 0.09 degrees.

· Cutting head shall be equipped with a one piece nozzle body with integrated diamond orifice warranted to last 500 hours. The one-piece integrated nozzle eliminates the need for rebuilding the nozzle assembly and instead is replaced when needed.

· Cutting head water supply shall be plumed in a way to follow the X and Y axis. Overhead supply lines (whips) that can cause interference with loading the table will not be accepted.

2.1.3 Rotary Axis

· Machine and machine control shall be capable of supporting a rotary axis.

· The rotary shall be programmable through the machine’s control that will support the hardware to rotate round or square pipe. The control will contain the parametric library for typical round and square pipe transitions.

· The rotary axis shall be a waterproof rotary head that allows waterjet to cut 6 axis paths. Head must be fully submersible and powered by the common table control.

· The system shall include incremental or coordinated continuous rotation with 10,000 steps per revolution.

· The system shall provide a minimum of 28 ftlb of maximum torque and a minimum radial load at the end of the shaft of 390 lbf.

· Rotary axis shall be controlled from the primary machine control, a rotary axis that runs from its own control will not be accepted.

2.1.4 Second Bridge Capable

· The System design shall allow for adding a second bridge that will operate independently from the first bridge.

· The two bridges shall be capable of operating at the same time on different parts or together on the same part.

· Each bridge control shall operate independently and be able to start/stop on a separate schedule.

· The contractor shall demonstrate that the addition of a second independently operating bridge is a current design and could be added at any time in the future without having to engineer it.

· The Y-travel shall be the shorter axis that runs along the bridge that is support on both sides of the catcher tank for the best possible designed accuracy.

2.1.5 Terrain Follower

· The system shall have a terrain following capability. The Terrain Follower allows the waterjet to automatically and accurately cut parts from materials with irregular or warped surfaces without the need for special programming.

2.1.6 Pump System and High Pressure Tubing

· The pump shall be a direct drive crankshaft type pump with variable frequency drive controller, capable of obtaining and maintaining the designed operating pressure, 60,000 psi, without the use of hydraulic assistance. Pressure attenuators are not allowed to maintain operating pressure.

· System shall NOT use pressure control or overflow valves for pressure or flow adjustment.

· System shall have a minimum 1,000 hour interval between maintenance cycles.

· Pump shall be a 30 horse power and drive 0.012” orifice at 60,000 psi.

· The high pressure tubing that supplies pressurized water to the cutting head via the X and Y axis shall be made of 3/8” stainless steel tubing, ¼” tubing supply lines will not be allowed.

· System shall have a minimum of a 36,000BTU chiller.

2.1.7 Bulk Abrasive Feed System

· The system shall have an automatic pressurized bulk garnet feed system, eliminating the need for manually filing any smaller garnet feed hopper in order to perform cutting operations.

· Bulk hopper shall provide a minimum of 12 hours of operating time using a standard cutting head.

· The system shall hold a minimum of 600 pounds of garnet when filled to capacity.

2.1.8 Water System (Water Level Control)

· System shall contains in tank pneumatic system allowing for water level adjust of up to 3” that is easily controlled at the operator’s station.

2.1.9 Settling System

· The settling tank shall efficiently clean overflow water from the Catcher Tank for environmental disposal to a public drain.

· The tank shall be rust resistant and the baffles shall be easily removable.

· The tank shall have an inlet of no less than 1-1/2” NPT and an outlet of no less than 1” NPT with a clean-out of no less than 1” NPT.

· The system shall include a “hopper” or “catch tank”.

· The system shall contain a submersible sediment pump with ground fault circuit interrupter (GFCI) that moves sediment laden water to a Hopper or Catcher Tank.

2.1.10 Computer Control System:

· The system shall be provided with a fully automatic, solid-state, integrated circuit, 64-bit, multiple microprocessor based-type personal computer integrated with CAD/CAM software and LCD flat panel display.

· The system shall include USB port and CD ROM drive to allow for CAD drawings to be input into the system to fabricate parts.

· Machine control shall contain a parametric library for typical round and square pipe transitions.

· The machine control shall NOT have an umbilical chord that lies on the floor where it can be easily damaged or cut.

2.1.11 Solids Removal System

· The garnet removal system shall utilize a programmable variable frequency drive providing precise control over garnet evacuation rate, direction, and duration to efficiently remove garnet from the waterjet Catcher Tank.

· The system shall be capable of a Garnet removal rate as high as 5.6 pounds per minute.

· The system shall be CE and UL approved.

· The system shall include a Reverse Osmosis (RO) water system with water softener

2.1.12 Software and Software Seats

· Software shall run on Windows® 10 and be specifically designed for all abrasive jet and waterjet machining functions.

· Functions of the software shall include: automatic and manual lead in/out tools, parametric shape generator, automatic collision prediction and correction, support tool path fonts and Windows® true type fonts, specialize in automatic raster to vector format conversions, advanced corner and piercing optimizations are automatically applied, advanced taper reduction methods, calculate cutting in software before sending to machine, comprehensive and highly accurate part time estimates and job quoting, generate custom reports, optimal stack height calculator, special cutting quality for minimum taper, easily resize, rotate, or flip part for prototyping or to align with existing features, open over 70 file formats (CATIA, SolidWorks, 3d dxfs, etc), easily create 3D tool paths from solid models, comprehensive alert system of machine status including email/SMS notifications, customizable pause and alert triggers, comprehensive interactive waterjet reference including articles, videos, and tutorials. Software to allow for 3D file importing. Create 3D tool paths along with 3D to 2D conversion tools. Automatically recognize viable cutting surfaces from 3D shapes, including variable bevels and tilted cones.

· Software shall include 25 seats.

· Upgrades to software shall be provided when available for all 25 seats.

2.1.13 Proof of Accuracy

· The complete water jet system shall be assembled and tested prior to shipping and an origin run off can be requested by the government prior to shipping.

· At the government’s request the contractor shall provide a ball bar accuracy report from the exact serial numbered machine to be shipped. The ball bar test report must be approved by the government prior to shipping.

2.1.14 Garnet Abrasive

· The system shall come with a starting supply of 2200 pounds of garnet abrasive - supplied in 50 lb. bags

2.1.15 Spares

· The system shall include a Pump spares kit to include: minor rebuild kit, replacement pump filters.

· The system shall include a Lubricants and Nozzles spares kit

2.1.16 Certification

· The system shall meets or exceed the federally mandated green energy requirement.

· The system shall be National Recognized Testing Lab (NRTL) compliant.

2.1.17 Labeling

· The system shall be labeled with an IUID tag plate per MIL-STD-130x

2.1.18 Accuracy

· The manufacture shall provide a with minimum accuracy as described in the following table:

AXIS REPEATABILITY

ALIGNMENT

2.2 On-Site Installation, Startup and Training.

The contractor will perform the complete installation of the abrasive water jet table, utilizing qualified installers. INSTALLER(S) MUST BE CERTIFIED by the manufacture of the equipment so that the manufacture warranties are not voided and the equipment is installed correctly.

The contractor shall provide the necessary drawings and specifications (Electrical, Compressed Air, etc.) to the government 60 days prior to installers’ arrival to ensure the government provided items referenced below are installed correctly and that the appropriate lifting equipment is available.

2.3 The government shall provide the following:

- Off-loading of Waterjet at delivery location

- Prepared foundation, anchoring, and rigging

- Electrical supply

- Compressed Air

- Water

- Other fluids as specified

- Final Acceptance

3. WARRANTY

At a minimum, the contractor shall provide a 1-year warranty in accordance with standard commercial practice.

4. GENERAL INFORMATION

4.1 Security Requirements (if required)

The contractor shall ensure the following pass and identification items required for contract performance are obtained for employees and non-government owned vehicles:

4.1.1. Pass and Identification Items: The contractor shall ensure the following pass and identification items required for contract performance are obtained for employees and non-government owned vehicles: AF Form 75, Visitor/Vehicle Pass (AFI 31-204): The Service Provider shall adhere to local security policy when applying for short/long term visitors’ passes. Any contractor requesting a pass for more than 3 days will complete a Local Files Check with 325 SFS/Pass & ID.

4.5. TRAFFIC LAWS. The contractor and its employees shall comply with base and local traffic regulations.

4.6. HOURS OF OPERATION. The contractor shall perform the services required under this contract withinduring the following hours: Monday through Friday, 0730 (7:30 AM) to 16001400 (4:00 PM) Local Time. The contractor may work, with prior approval of the Contracting Officer, extended hours and/or weekends to ensure timely completion of work at no additional cost to the government.

4.7. RECOGNIZED HOLIDAYS. The contractor is not required to provide service on the following days: New Year’s Day, Martin Luther King Day, Presidents Day, Memorial Day, Independence Day, Labor Day, Columbus Day, Veterans Days, Thanksgiving Day and Christmas Day. If the holiday falls on Saturday, it is observed on Friday. If the holiday falls on a Sunday, it is observed on Monday.

4.8. UTILITIES. The Government will furnish electricity, water, and sewage as necessary for accomplishment of work in accordance with this contract. All facilities do not receive the same utility services. The Contractor shall not change or modify any utility system or component; or connect any Contractor property, equipment or system without prior CO review and approval. The contractor shall practice energy conservation in the Government provided facilities. The contractor shall instruct employees in utilities conservation practices. The contractor shall be responsible for operating under conditions which prevent the waste of utilities which include the following:

4.8.1. Lights shall be used only in areas where and when work is actually being performed.

4.8.2. Mechanical equipment controls for heating, ventilation, and air conditioning systems shall not be adjusted by the contractor or by contractor employees unless authorized.

4.8.3. Water faucets or valves shall be turned off after the required use has been accomplished.

4.9. ENVIRONMENTAL LAWS & REGULATIONS. The contractor shall be knowledgeable of and comply with all applicable Interstate, Federal, State, and Local laws, regulations, and requirements regarding environmental protection. In the event environmental laws/regulations change during the term of this contract, the contractor is required to comply as such laws come into effect. If there is an increase or decrease in cost as a result of the change, the contractor shall inform the Contracting Officer pursuant to notice requirements and negotiate a modification to the contract.

4.9.1. The CO shall approve all hazardous materials brought on-site by the contractor prior to use. The contractor shall obtain approval using the application requirements of the AF Form 3952. Once the process is implemented and contractor is trained, the contractor may submit the AF Form 3952 electronically. The CO has the right to prohibit the use of hazardous materials it deems to be especially hazardous to human health and environment. In the event the CO does not approve a hazardous material for use, the CO may provide the contractor a list of suitable substitutes; however, the contractor shall retain responsibility for finding an acceptable substitute. The contractor shall take appropriate actions to comply with waste minimization and pollution prevention practices and policies.

4.9.2. Spill Controls. The contractor shall maintain spill control material on hand at all times sufficient to contain a worse case spill, both volume and hazard level.

4.9.3 Hazardous Materials Inventory (if required): The contractor shall maintain an up-to-date hazardous material inventory with copies of MSDS(s) for all materials used on the job site. The contractor shall maintain a complete copy of all approved MSDS and AF Form 3952s.

4.9.4 Hazardous Materials Management (if required): The contractor shall remove all hazardous materials by the end of each workday. Contractor shall not conduct process treatments (e.g. paint thinner solvent recycling) on base.

4.10. SAFETY REQUIREMENTS. In performing work under this contract, the contractor shall:

4.10.1. Conform to the safety requirements contained in the contract for all activities related to the accomplishment of the work.

4.10.2. Take such additional immediate precautions as the contracting officer may reasonably require for safety and mishap prevention purposes

4.10.3. Record and report promptly (within 24 hours) to the contracting officer or designated government representative (GR), all available facts relating to each instance of damage to government property or injury to either contractor or government personnel.

4.10.4. In the event of an accident/mishap, take reasonable and prudent action to establish control of the accident/mishap scene, prevent further damage to persons or property, and preserve evidence until released by the accident/mishap investigative authority through the contracting officer.

4.10.5. If the government elects to conduct an investigation of the accident/mishap, the contractor shall cooperate fully and assist government personnel in the conduct of investigation until the investigation is completed.

4.11. Publications. Publications can be accessed on-line at http://www.e-publishing.af.mil/. Supplements or amendments to listed publication from any organizational level may be issued during the life of the contract.

4.11.1. Compliance with all publications, regulations and operating instructions provided by the Government is required when:

4.11.2. They pertain to the procedures for materials expediting herein and where the contractor is authorized by the statement of work to accomplish the work specified in the publication, regulation or operating instructions.

4.11.3. The publications prescribe USAF policies, use of materials, procedures and processes applicable to the work requirements. The contractor is required to acquire and work on the latest version of the publication.

5. DELIVERY.

The contractor shall ensure delivery is prior to 1400 CST, Monday through Friday excluding holidays.

Deliver to

AFCEC/CXA

Attn: Michael Mifsud 104 Research Road Tyndall AFB FL 32403 Cell number is 850-819-5877