RIPD 26-1-02 Forge Furnace (Double).docx

FORGING BILLET FURNACE-DOUBLE CHAMBER

GENERAL SYSTEM DESCRIPTION

This project is intended to provide a front-loading, double chamber, two-door, stationary, electrically powered billet furnace in Building 222 Annex of the Rock Island Arsenal Joint Manufacturing & Technology Center (RIA-JMTC).

STANDARDS AND PUBLICATIONS

Clarification Any ambiguities, questions, requests for clarification or discrepancies between sections of this purchase description, drawings, national or industry standards discovered by the contractor in reviewing this purchase description shall be reported by the bidder in writing to the contracting officer BEFORE THE DATE SCHEDULED FOR CLOSE OF BIDDING/receipt of proposal. Submission of a proposal or bid shall be construed as evidence that such examination has been made. Therefore, later claims for labor, material, or equipment required, or for difficulties encountered, which could have been foreseen had such reasonable examination been made, may be denied.

National Standards and Specifications The contractor shall conform and provide equipment conforming to all local and federal codes and standards applicable to the equipment they are providing based on location and purpose of equipment in effect on the date of the opening of solicitation. It is not the responsibility of the government to make modifications to ensure compliance.

DESIGN

Ownership This equipment is a standard product of the manufacturer and shall require either no change or minor design changes to meet requirements of these specifications. Therefore, ownership of the design will remain with the manufacturer.

General Design Standards DEVIATION FROM PRODUCT: Modifications to the manufacturer’s standard design to achieve requirements as specified in this document are only permissible as dictated by good design practice. For example, mounting a 20-hp motor in a power train designed and normally using a 10-hp motor would not be acceptable.

UNITS OF MEASURE: Dimensions and capacities in this purchase description are given in the English-US (in-lb.) system. All dials, gauges, and drawings shall be in the English-US system or both the English-US and the metric systems, unless otherwise specified in this document.

ID DATA PLATE: The equipment shall include a main data plate which will include the following data as a minimum requirement (additional information is acceptable): Manufacturer Name, Manufacturer’s Dunns and Bradstreet Number, Manufacturer’s Model Number, Manufacturer’s Serial Number, Year of Manufacture, Contract Number, Machine Weight. This information is necessary for compliance with the governments Unique Identification Program (UID).

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.

ITEM UNIQUE IDENTIFICATION (IUID) REGISTRATION: The contractor shall register the equipment in the IUID Registry (as one single system). IUID registration requires the contractor to input Cage Code, Model Number, and Serial Number into a Government Database to allow for asset and inventory tracking. IUID Registry of the equipment shall be performed at http://dodprocurementtoolbox.com/site/uidregistry/. Training for IUID is available in https://wawftraining.eb.mil. IUID registration of this equipment is required prior to final payment in the Wide Area Work Flow (WAWF). The contractor shall also affix a machine readable 2-dimensional (2-D) matrix representing the IUID registry to the machine. The IUID 2-D matrix may be included on the ID Data Plate outlined in paragraph 3.2.4.

UTILITY CONNECTION: Equipment supplied to the Rock Island Arsenal will have single point shut-off for each utility supplied to a system. This means that equipment constituting a single system shall be wired to a single main electrical disconnect point, plumbed to a single pneumatic shut-off valve, etc.… This will be referred to as the “point of first connection”. Each type of power source may have only one point of first connection. E.g. (1) pneumatic shut-off valve, (1) water supply shut-off valve, (1) electrical disconnect, etc.… Each point of first connection shall be clearly labeled on the system and shown in the safety lockout portion of the documentation package. These points must be located on a stationary component and positioned such that they will not create a hazard to personnel during normal operation of the system. The first connection points shall be accessible from the shop floor without the use of ladders, steps, or stools. Access cannot be hampered by operation of the system.

UTILITY CONNECTION LABOR: Rock Island Arsenal shall provide only such labor and materials as will be needed to connect facility utilities to each point of first connection of the system. The supplier will be responsible for all connections beyond the point of first connection for each utility.

UTILITIES AVAILABLE: Rock Island Arsenal shall be responsible for providing the following:

1.1.1.1 Connection of 480-V, 60-Hz, 3-Ph AC electrical power to the fused or breaker type disconnect switch required in the ELECTRICAL DISCONNECT paragraph of this purchase description. Connection does not include filters, surge protection, or any peripheral equipment necessary to make the equipment functional.

1.1.1.1.1 The electrical power provided will be in a delta configuration.

1.1.1.2 Connection of approximately 80-psi compressed air to a single point for each system, if needed. Connection does not include filters, dryers, or any peripheral equipment necessary to make the equipment functional.

1.1.1.3 If, due to contractor caused problems, the equipment or components of the equipment must be moved or removed and replaced by RIA after initial placement, the contractor shall be billed for such work at current RIA labor and overhead rates.

ELECTRICAL DISCONNECT: The equipment shall be equipped with a manual, fused or breaker type disconnect switch, readily accessible to the operator, which will deactivate the entire equipment. It shall be located no more than 6-ft 7-in from the floor to the highest point the control device. It shall be capable of being locked in the de-energized state (OFF) only.

CONDUIT: Flexible conduit is not permitted in exposed areas. All wires, cables, and hoses will be enclosed by rigid, oil-proof protection, except where flexibility is necessary for operation of the equipment. Flexible wires, cables and hoses shall be arranged to prevent draping or tripping hazards.

SERVICE ACCESS: Components subject to periodic adjustment, replacement, or servicing shall be readily accessible. Meaning that experienced personnel can access the part after no more than 30-min of labor. If any special tools or equipment are necessary to access these components, said equipment will be supplied as part of the system and provided with a proper storage location within the system.

DEFLECTION: The system shall recover from distortion and deflection at no load. The machine and its components shall be sufficiently rigid that work piece finish and tolerances are not impaired by machine vibration.

NEW EQUIPMENT: The equipment furnished under this purchase description shall be new and unused.

COMPONENT ENVIRONMENT: Under no circumstances shall a component be used in an application not recommended by the component manufacturer. Components shall not be subjected to conditions of operation beyond the recommendations of the manufacturer, such as excessive heat, lack of lubrication, over-loading.

REPLACEMENT COMPONENTS: All replaceable components shall be manufactured to definite standards for tolerance, clearance, and finish, enabling components to be field installed without further machining.

CASTINGS AND FORGINGS: All castings and forgings shall be free of defects, scale, and mismatching. No process such as welding, peening, plugging, or filling shall be used for reclaiming any defective part for use in this equipment without the prior written consent of the contracting officer.

SURFACE BUILDING AND COATINGS: Welding, brazing, soldering, coating or plating shall be employed only where specified in the original design. These operations may not be employed as a means of reclaiming a defective part.

FASTENING DEVICES: All screws, pins, bolts, and similar parts shall be installed in such a manner as to prevent change in tightness. Those devices subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently deformed. They shall not be installed using permanent bonding adhesives.

CLEANING AND DEBURRING: All surfaces of castings, forgings, molded parts, stampings, and welded components shall be cleaned and free from sand, dirt, fins, flash, scale, flux, and other harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. Except as specified herein, the condition and finish of all surfaces shall be commensurate with the manufacturer’s commercial practice.

PAINTING: All unfinished surfaces of the equipment shall be painted with a lead free and chromium free commercial grade of metal primer and a minimum of one finish coat. The color shall be in accordance with the manufacturer’s standard commercial practice, or as necessary to maintain compliance with OSHA regulations, as applicable.

LUBRICATION: Components specified as requiring lubrication by the original manufacturer shall have an appropriate means of providing said lubrication included in the design of the machine.

1.1.1.4 The lubrication points will be labeled on the lubrication drawing provided as part of the maintenance documentation and will also be labeled on the machine at the lubrication point and on any access panel covering the lubrication point. These labels will include as a minimum standard, the specific type of lubricant, the quantity to be used, the frequency for change, and the maintenance manual reference for detailed instructions. The lettering shall be English, and the units shall be English standard (i.e. pints, quarts, and gallons)

1.1.1.5 If an automatic circulation system is used, it shall be complete, including, but not limited to the following: reservoir, valves, nozzles, filters, pumps, sight gages, and other components as necessary to make the system completely functional.

1.1.1.5.1 A system allowing blockages or inadequacies to go undetected is unacceptable. The system shall be interlocked to the machine control, providing an alarm that lubrication failure has occurred. The system shall not initiate immediate shutdown of the affected function during a cutting cycle. It shall allow completion of the cycle and shutdown in an orderly sequence.

1.1.1.5.2 The reservoir shall be sized to allow no less than 80-hrs of machine run time before requiring refill. It shall also have a means provided for draining and cleaning. A means shall be provided to enable the operator to determine the fluid level.

1.1.1.5.3 All filters shall be either cleanable or replaceable.

1.1.1.5.4 All pumps shall be self-priming.

FILTRATION/REGULATION: Equipment requiring filtered or regulated energy sources shall be supplied with the components necessary to perform this function. E.g. the equipment shall be supplied with a Filter, Regulator, Lubricator (FRL) device, if filtered, lubricated, regulated pressurized air is required for the efficient, proper operation of the equipment. These devices shall be located on the equipment side of the lockout devices at the points of first connections.

1.1.1.6 Equipment which requires compressed air 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, and capable of supplying air to the rated standard cubic feet per minute (SCFM) of the equipment. The unit shall purge condensate automatically. In the case of the latter, the refrigerant used shall not be a Class I or Class II, ozone depleting substance. The air dryer shall be connected and/or piped to the equipment by the contractor.

1.1.1.7 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 inductive AC load.

HYDRAULICS: The machine will be equipped with a hydraulic system, and the system shall be complete with, but not limited to, pump, valves, piping, cylinders, pressure controls, filter, and reservoir. All components necessary to make the system completely functional shall be provided.

1.1.1.8 If the duty cycle of the system under maximum usage will cause the hydraulic fluid to exceed 120°F in temperature, a suitable air-cooled heat exchanger shall be provided to maintain fluid temperature at or below that temperature. The exchanger shall be equipped with changeable fiberglass filter(s), unless permanent type filters are supplied.

1.1.1.9 The system shall have adequate capacity to provide sufficient pressure and flow to perform all hydraulic operations under all normal machine operating conditions.

1.1.1.10 Protection shall be provided to prevent damage to components.

1.1.1.11 Safeguards shall be provided to alert the operator of temperatures and pressures above/below design limits. If safe limits (within design limits) are exceeded, the system shall automatically shut down.

1.1.1.12 Anti-surge devices or circuits shall be incorporated to ensure uniformity of motion under varying loads.

1.1.1.13 The hydraulic reservoir shall be provided with means for draining and cleaning.

1.1.1.14 Means shall be provided to enable the operator to determine fluid level.

1.1.1.15 Each hydraulic system shall include a filter, which shall be either cleanable or replaceable.

1.1.1.16 All pumps shall be self-priming.

COOLANT: The machine will be equipped with a coolant system, and it shall be equipped with external flood coolant capabilities, as a minimum. Machines using cutting tools shall be equipped with both through the tool and external flood coolant capabilities. Coolant on/off shall be a machine control function.

1.1.1.17 The coolant systems shall include all necessary components necessary to provide completely functional systems, with sufficient capacity to provide satisfactory service and provide adequate pressure and flow under normal operating conditions.

1.1.1.18 Coolant troughs and chip screens shall be provided around the machine table base to trap, direct, and return the coolant to the reservoir. An easily removable strainer shall be provided in the return line to the reservoir. "Easily removable" is defined as being removable after no more than 5-min of work by experienced personnel.

1.1.1.19 All machine coolant systems and their components shall provide drip-proof coolant delivery to the coolant point of discharge. In addition, the machine shall be designed and constructed to prevent coolant from escaping the confines of the machine or leaking to the floor when producing work-pieces of a size within the dimensions of the machine table.

MOTORS:

1.1.1.20 All motors shall be rated for continuous duty.

1.1.1.21 Motors shall not operate in an overload condition during normal operation of the equipment and shall be equipped with overload protection.

1.1.1.22 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.

1.1.1.23 Motor starters and controls shall operate at no greater than 120-VAC. It is preferred that they operate at 24-VDC.

1.1.1.24 Motor starters shall provide drop-out protection. This means that, in the event of a loss of power, the equipment shall be re-energized only by the deliberate action of the operator. Manual or mechanical motor starters shall not be deemed acceptable.

DIALS AND GAUGES: All scales, dials, and gauges shall be manufactured of corrosion and oil-resistant material. All wording shall be in the English language using plain, bold face lettering. Lettering shall be permanent and have a contrasting background.

HANDWHEELS: Hand-wheels turned in a clockwise rotation shall produce a linear motion, of the controlled component, to the right, away, or upwards. If rotary motion is produced by the hand-wheel, clockwise rotation of the hand-wheel shall produce clockwise movement of the controlled component.

CONTROL LEVERS: Control levers shall move in the same direction as the motion of the controlled component.

FOUNDATION: The requirement for a separate foundation or floor alteration is not permissible. The system shall be capable of being installed on an existing concrete floor without modification to the system or the floor, except for installation of anchor bolts. Also see paragraph 4.5.1 for hearth height requirements.

Safety, Security and Environmental SECURITY: The RIA-JMTC is an Army installation subject to Department of Defense safeguards, various precautions, and plant protection measures. All of the below requirements will be necessary of contractors visiting RIA to satisfy requirements of this purchase description; Additional requirements will be placed on contractors requiring access to the Army Network, or Common Access Card (CAC), as specifically detailed below. At all times during the execution of this work, contractor personnel will maintain adequate plant protection devices to minimize espionage, sabotage, and other malicious destruction and damage. The contractor shall comply with all security requirements of the Rock Island Arsenal. Rock Island Arsenal island-wide Force Protection levels may be adjusted/changed at any time, which may cause possible delays and will directly affect procedures for accessing the island.

1.1.1.25 Access and General Protection/Security Policy and Procedures: The contractor and any associated subcontractor employees shall provide all information required for background checks to meet installation access requirements to be accomplished by the installation Director of Emergency Services. All contractor employees must comply with all personal identity verification requirements (IAW FAR clause 52.204-9) as directed by Department of Defense (DoD), Headquarters Department of the Army (HQDA), and any local policy. If the Force Protection Condition (FPCON) changes, the Government may require changes in contractor installation access, security matters, or security processes.

1.1.1.25.1 Access to RIA: Contractor and all subcontractor employees performing work at RIA shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (TSDB) and any applicable installation, facility access screening and local security policies and procedures. The JMTC Representative/ COR shall provide guidance to complete the Access Control Records Check request Form though the Rock Island Arsenal Directorate of Emergency Services.

1.1.1.25.2 Random Antiterrorist Measures Program (RAMP) participation: Contractor personnel are subject to RAMP security program (i.e. vehicle searches, wearing of ID badges, etc.). Contractor shall comply with any, and all instructions issued by the Rock Island Arsenal Police Department. The RAMP is discussed in the RIA-JMTC Anti-Terrorism Training.

1.1.1.25.3 During FPCONs levels of Charlie or Delta, services may be discontinued/postponed due to a higher National or local security threat. Services will resume when FPCON Level is reduced to Bravo, or lower. FPCON levels are described in Anti-Terrorism Level I Training.

1.1.1.25.4 Contractor personnel shall return all Installation Badges and access passes as soon as possible prior to contract completion. RIA-JMTC electronic keys and access passes are accountable items, shad shall be returned within 24-hours of no longer being needed. Items will be returned to the COR, or placed in a drop box at an RIA-JMTC access point.

1.1.1.26 Security Training: The contractor shall complete the following training:

1.1.1.26.1 Anti-Terrorism, Level I: All contractor employees, including subcontractor employees, requiring access to Army installations, facilities, or controlled access areas shall complete Anti-Terrorism (AT) Level I Awareness training. The COR will be provided a copy of the Rock Island Arsenal –Joint Manufacturing and Technology Center (RIA-JMTC) AT Level I Awareness Training and assure that the training is complete. The contractor shall sign a memorandum of record for each contractor employees and subcontractor employee to the RIA-JMTC Operations Center prior issuing any electronic keys, or access pass being authorized.

1.1.1.26.2 iWatch (See Something, Say Something) Training: The Contractor and all associated subcontractors shall complete iWatch Training. iWatch Training shall be provided during the Anti-Terrorism Training.

1.1.1.27 For Contractors requiring Common Access Card (CAC): Before CAC issuance, the contractor employee requires a favorably adjudicated National Agency Check with Inquiries (NACI) or an equivalent or higher investigation in accordance with Army Directive 2014-05. The contractor employee will be issued a CAC only if duties involve one of the following: (1) Both physical access to a DoD facility and access, via logon, to DoD networks onsite, or remotely or (2) Remote access via logon, to a DoD network using DoD-approved remote access procedures, or (3) Physical access to multiple DoD facilities or multiple Non-DoD Federally controlled facilities on behalf of the DoD on a recurring basis for a period of 6-months, or more. At the discretion of the sponsoring activity, an initial CAC may be issued based on a favorable review of the FBI fingerprint check and a successfully scheduled NACI at the Office of Personnel Management. Contractors needing a NACI or equivalent investigation or higher investigation will coordinate this investigation through their COR. Contractor personnel shall turn in CAC cards upon completion of their contractual obligations, or at the request by the COR, or at the request of the Contracting Officer.

1.1.1.27.1 No CAC cards will be issued for this action.

FEDERAL MARIJUANA LAWS REMAIN UNCHANGED: Note: Rock Island Arsenal is under the exclusive federal jurisdiction of the United States. Under federal law, marijuana is still defined as a Schedule I drug, and possession and use of marijuana is still illegal. Any person using or in possession of marijuana on Rock Island Arsenal may be criminally prosecuted in federal district court. In addition, such individuals may be permanently barred from entering Rock Island Arsenal.

REAL ID: Starting 07-May-2025 all personnel entering Rock Island Arsenal will be required to show a Real ID form of identification.

INDUSTRY AND REGULATIONS: The equipment shall comply with the most current of all local, state, and federal laws and regulations listed in Standards and Publications.

MATERIAL EXCLUSIONS: The equipment shall not contain polychlorinated biphenyl (PCB), ozone depleting substances (Class I or Class II), or asbestos materials.

SAFETY REGULATION COMPLIANCE: The contractor shall comply with standard OSHA and RIA safety standards, including but not limited to conforming to confined space work requirements when applicable and wearing of Personal Protective Equipment (PPE) where designated.

SAFETY LOCKOUTS: Each point of first connection shall be designed and constructed to allow the utility to be completely isolated from the equipment. This isolation shall be insured by application of a standard key locking padlock. The device(s) shall only be lockable in the de-energized (OFF) condition.

LOSS OF PRESSURE: Hydraulic and pneumatic circuits shall be designed such that loss of pressure, or pressure surges, shall not cause a hazard. Means shall be provided to prevent operation of the equipment with insufficient pressure, if such operation could cause a hazard.

TRAPPED ENERGY: Means shall be provided for the controlled release of stored energy. This energy may be in the form of, but not limited to, air and hydraulic pressure accumulators, capacitors, springs, counterbalances and flywheels. When appropriate, a label shall be affixed to the stored energy source to identify the hazard.

WORKING RANGE: Hydraulic and pneumatic components shall be selected, which cannot be adjusted outside the safe working range of the circuit and/or equipment.

ACCUMULATORS: Gas charged accumulators operating above 200-psi charging pressure shall be charged with inert gas.

BRAKES: Braking systems shall be designed to “fail-on”. This means, energy supplied to the brake shall be used to disengage the brake. Loss of energy shall therefore cause the brake to activate.

EMERGENCY STOP: The system will incorporate a clearly identified, red, mushroomed, control button with a yellow backing plate at every operator workstation. Upon momentary operation, any emergency stop button shall de-energize all machine motions and override all other controls without creating additional hazards. All motion stopped shall be restarted by the deliberate action of the operator (requiring manual reset). No other red mushroomed buttons shall be allowed on the equipment. It is preferred that there are no other red buttons of any type.

CONTROL GUARDS: Controls shall be guarded against accidental operation.

OPERATOR REACH: Controls shall be within reach and located such that the operator, when in the normal operating position, is not required to reach past moving parts, which may cause injury.

Responsibilities SITE INSPECTION: Any site inspections and/or measurements, which must be taken in order to determine the suitability of the proposed location or to perform the design of the system, are the sole responsibility of the contractor. This may begin prior to completing the bidding process. Rock Island Arsenal will support this function through the POC (point of contact) by guiding personnel, facilitating security registration, and providing general assistance. The contractor will be responsible for providing any and all equipment necessary for this process.

MACHINE SPECIFICATION

The equipment provided shall be a complete, front-loading, two-door, stationary, electric furnace. The system will be a double chamber front-loading billet furnace. The system shall comply with the standards and performance requirements listed in this purchase description. The billet furnace shall consist of the following components: front guillotine-style doors, hearths, chamber, shell, insulating board and firebrick insulation, power supply, thermocouples, controls and gauges.

Equipment: The supplier shall furnish all equipment normally considered by him or her to be standard for their machine, whether specifically called for in this purchase description, or not. The following equipment shall be provided in addition to the equipment specified in other sections of this purchase description, which may not be standard. The inclusion of standard equipment in this paragraph is inadvertent and should not be construed to allow duplication.

System Dimensions:

DOOR ACCESS: The equipment shall be shipped either assembled or disassembled to pass through a door 12-ft wide by 12-ft high, and shall not exceed 25-ft in length.

INSTALLED FLOORSPACE: When installed complete, the equipment shall become an integral component to JMTC’s forge cell. The furnace design, door access, the furnace’s positioning, coupled with the forging cell’s material handling system will allow for access to, and manipulation of a total (quantity) 12 typical billets (6 per chamber), 4-inches in diameter, and 12-inches long. The installed footprint of this machine shall not exceed 17.5-feet wide by 13.5-feet deep.

Standards:

The furnace shall be designed and built to meet the most recent version of the following specifications as published at the time of contract award. If there are any inconsistencies between this specification and the standards below, the standards shall govern unless specifically noted otherwise within individual paragraphs of this specification.

Society of Automotive Engineers (SAE) Aerospace Material Specification (AMS) 2750H titled “PYROMETRY”:

1.1.1.28 Class of Furnace: The furnace shall be Class 5 or better.

1.1.1.29 Temperature Range: The work zone shall be capable of maintaining process operating temperatures in the range of at least 1800 degrees-Fahrenheit (F) through 2300F with a maximum variance of plus or minus 25F. The maximum temperature shall be at least 2500°F.

1.1.1.30 Instrumentation Type: The Instrumentation provided with the billet oven shall conform to at least Type D, or better (Types A, B, or C). As a minimum, each control zone will have at least one control sensor connected, and displayed on the control, the sensor in each control zone shall be recorded by a recording instrument, and each control zone will have over-temperature protection.

1.1.1.31 Thermocouples: All thermocouples shall be Type-S, Platinum-Rhodium composition, with a temperature sensing range of at least -58F though 2700F, and accuracy of .25% error or less.

1.1.1.32 Performance Testing: System Accuracy Test (SAT) and Initial Temperature Uniformity Survey (TUS) shall be performed by JMTC/RIA Maintenance Division (see Performance Test Section, paragraph 5.3). The TUS shall be performed with a Rack. The rack shall be molybdenum and supplied by RIA-JMTC.

NFPA 86: The furnace shall comply with the requirements of NFPA 86 as it applies to Class A “ovens”.

Production Design Requirements:

The furnace shall be electric powered.

1.1.1.33 The supplied electrical power will be 480-V, 60-Hz, 3-Ph AC in a delta configuration.

1.1.1.34 The vendor shall supply a power conditioner for the power supply feed.

1.1.1.35 The vendor shall supply the proper transformer, if needed, and most current Allen Bradley PLC model.

The furnace shall have an operating temperature range of at least 1800ºF - 2300ºF.

The billet furnace shall be capable of heating (quantity) 12 bars of steel, with a weight of 50 pounds per billet, and heat the billets from room temperature to 2300ºF in a maximum of 40-minutes. Ramp up from ambient to maximum temperature in 3-hrs or less (empty).

Components, Dimensions and Capacities EXTERIOR SHELL: The exterior of the billet furnace shall be constructed of at least .1875-inch thick steel for the walls, roof, and door, with at least a .25-inch thick steel hearth plate. While the furnace interior temperatures may approach or exceed 2500 ºF, the exterior shell temperature shall not exceed 180 ºF (“cold face temperature”) when the furnace is operating through its required temperature range.

HEARTH

1.1.1.36 HEARTH DIMENSIONS AND ELEVATION: The billet furnace’s hearths shall be no less than 3-feet wide and 36-inches deep x 36-inches each. The furnace hearths shall be elevated so the center of a 4-inch diameter billet rests 36-inches above floor grade when the billet is placed on the hearth.

1.1.1.37 WEIGHT CAPACITY: The furnace shall be capable of supporting work payloads of at least 1500-lbs where the billets are uniformly distributed.

1.1.1.38 CONSTRUCTION: The furnace shall provide a strong uniform structure combined with refractory and insulation which withstands the extreme heat generated in billet heating operations. Construction materials shall include firebrick whose composition provides density, strength, insulation and temperature stability required during billet/part heating, and handling operations. Hearth and curbing (extending up the walls from the hearth at least 6-inches) construction shall also be designed for ease of handling and maintenance; the insulation components shall be completely removable, and replaceable.

CHAMBER: The chamber shall be an unobstructed interior volume in the furnace bordered by the hearth, side-walls, door, and roof of the furnace. It shall be at least 8-feet wide, 3-feet tall and 42-inches deep. The entire chamber volume shall be accessible from a horizontal part movement perpendicular to the door. The billet furnace will be capable of withstanding at least 1500-pounds of steel inside the chamber. The exterior of the furnace will be marked with the rated weight limit of the furnace.

1.1.1.39 WORK ZONE: The work zone is a volume contained within the chamber, where temperature accuracy and uniformity is required. The work zone volume shall be at least 7-feet wide, 30-inches deep, and begin at hearth extending to 36-inches tall.

DOOR: Furnace door shall be vertical, pneumatic, guillotine type supported by the shell frame. The door shall automatic lockout pins. The door will operate through the machine control, and at a foot activated switch be capable of stopping mid-stroke.

MACHINE CONTROL: The Master Controller for the furnace shall be an SSI 9205. The control shall include an Allen Bradley MicroLogix Program Logic Controller (PLC), most current model. Operators shall interface with the furnace via a 10-inch (or larger) color touch-screen Human Machine Interface (HMI). The machine control shall be NEMA 12 rated as it applies to personnel access to hazardous parts, and protection of control from the ingress of solid foreign objects, water, and oil. RIA-JMTC’s in-house recorder is an SSI system. RIA-JMTC shall make all connections to the SSI system.

1.1.1.40 Includes automatic shutdown in an over-temperature event.

1.1.1.41 Includes emergency stop button that cuts power to heating elements and controller.

Machine Models The contractor shall provide models of the machine to be used for cad drawing and programming purposes.

INFORMATION TECHNOLOGY SYSTEMS AND SUPPORT

Installation IT Support:

PERSONNEL: RIA-JMTC will not provide the technician credentials to access the workstation. Access to the workstation will be provided by the RIA-JMTC IT Support Staff escort. Removable Media e.g., CD/DVD/USB/SD/External hard drive will be scanned prior to use. Programs and software must be run from RIA-JMTC approved/provided media or CD/DVD(s). Contractor Devices will not be allowed to connect to the RIA-JMTC network, nor will they be allowed to connect to RIA-JMTC equipment other than to scan and transfer media.

INSPECTION/FINAL ACCEPTANCE:

LICENSING: The software/ hardware license shall not have an internet connection. A license dongle or license file must be provided for offline use.

1.1.1.42 There shall be no connection to the RIA-JMTC network. Future connection shall remain at RIA-JMTC’s discretion.

1.1.1.43 There will be no vendor remote access.

Media/ Devices REMOVABLE MEDIA: Removable media consists of the following: CD, DVD, USB, SD, and External Hard Drives. Removable media shall be scanned prior to use. Programs and software must be run from RIA-JMTC approved/ provided media or CD/ DVD(s).

CONTRACTOR DEVICES: Contractor Devices will not be allowed to connect to the RIA-JMTC network, and they will not be allowed to connect to RIA-JMTC equipment other than to scan and transfer media.

NON-GOVERNMENT OWNED SYSTEMS OR DEVICES: The contractor shall comply with AR 25-1 and AR 25-2. The contractor shall not install or connect non-Government-owned computing systems or devices to Government networks without the COR’s coordination and obtaining the proper authorization from the appropriate Information System Security Manager (ISSM), ensuring that all software has a Government Assess Only Authorization. The non-Government-owned computing systems or devices include, but are not limited to, personal or Contractor-owned thumb drives e.g., memory sticks, flash drives, Universal Serial Bus (USB) drives, jump drives, pen drives, removable or external hard drives, Personal Digital Assistants (PDA), PC Cards/Express Cards, MP3 players, cell phones, digital media, floppy disks, compact disc (CD)/digital video disk (DVD) burners, optical recordings, photo flash cards, laptops, or any devices that can store data.

1. INFORMATION ASSURANCE AND ACCREDITATION:

Non-Government-Owned computing systems or devices: The Contractor shall comply with AR 25-1 and AR 25-2. The Contractor shall not install or connect non-Government-owned computing systems or devices to Government networks without a government representative coordinating and obtaining proper authorization from the appropriate Information System Security Manager (ISSM), ensuring that all software has a Government Assess Only Authorization. The non-Government-owned computing systems or devices include, but are not limited to, personal or Contractor-owned thumb drives e.g., memory sticks, flash drives, Universal Serial Bus (USB) drives, jump drives, pen drives, removable or external hard drives, Personal Digital Assistants (PDA), PC Cards/Express Cards, MP3 players, cell phones, digital media, floppy disks, compact disc (CD)/digital video disk (DVD) burners, optical recordings, photo flash cards, laptops, or any devices that can store data.

System Accreditation and Re-Accreditation: The Contractor shall assist in providing system accreditation documentation such as required artifacts and shall answer technical questions required for registration for accreditation. All documents shall be IAW Chapter 5, and Appendices D and E, AR 25-2, Information Systems Security (dated 3 August 2007) and DOD Instruction 8510.01, Risk Management Framework (RMF) Program or future DOD regulation that supersedes these regulations. The Contractor shall assist in performing yearly reviews of the accreditation, or whenever changes/additions are made to the system. The Contractor will assist in preparing risk assessments, as required.

APPROVAL/SHIPPING

Shipping RESPONSIBILITY: The contractor is responsible for delivery of the equipment to the Rock Island Arsenal. Adequate preserving of equipment surfaces, packing, marking, and skidding of materials for shipment shall be the responsibility of the contractor. If special lifting devices, such as hooks or eyes, are required for ease of handling, they shall be supplied with the equipment. Any special devices shall be returned to the contractor upon request only if they will not be required for future movement of the equipment, and at the contractor’s expense.

SHIPPING SCHEDULE: Be aware, the Rock Island Arsenal will only off-load equipment arriving between 6:00 am and 12:00 pm (noon), local time on Mondays through Thursdays except holidays. For information concerning holidays, the contractor should consult the contracting officer. There is no place to stage transporting vehicles awaiting the arrival of contractors. All equipment shall be delivered at the same time, meaning the same day (multiple trucks are acceptable) unless pre-authorized to deliver on multiple days by the RIA-JMTC contracting officer.

RECEIVER: All shipments to Rock Island Arsenal including installation tools and/or replacement parts, as well as the original shipment of the equipment, shall be marked “ATTN: Mr. Robert Mcclure TARA-LGC”. Items not correctly marked are subject to being returned at the vendor’s expense.

ARRIVAL INSPECTION: Upon receipt of equipment at Rock Island Arsenal, a preliminary inspection shall be performed to determine condition and/or count. This inspection shall be performed by Rock Island Arsenal personnel.

Installation SITE PREPARATION REQUIREMENTS: The contractor shall be solely responsible for any necessary site inspections required for determining the specifications of work that must be completed prior to final system installation. The contractor will then provide detailed information of any preparation work that the vendor must perform prior to system installation to Rock Island Arsenal.

SITE PREPARATION EXECUTION: The contractor will be solely responsible for site preparation except as specifically excluded in this document. This includes but is not limited to excavation, foundation work, and surface preparation. This work may be performed through the use of a sub-contractor, but the specification, supervision, and certification of the work remains the responsibility of the primary contractor.

PREPARATION EXECUTION SUPPORT: Rock Island Arsenal will support the preparation portion of the installation by providing utilities to the points of first connection.

LABOR AND MATERIAL: The supplier is solely responsible for providing all labor, materials, hardware, tools, and equipment necessary for complete installation/start-up of this system except as specifically listed in this document as being provided by the Rock Island Arsenal.

1.2.1.1 Any lubricants, coolants, oils etc. required for initial start-up and operation shall be the responsibility of the contractor to provide.

1.2.1.2 Any anchoring mechanisms/materials shall be the responsibility of the contractor to provide. If RIA-JMTC is installation the foundation, JMTC will be responsible for the installation of the contractor provided anchoring mechanisms in preparation for machine placement.

1.2.1.3 Any decking, stairs, rail systems, or other specialized operator/machine interfaces shall be provided by the contractor for use at the install location SUPERVISION: Supervision of the installation process will be the responsibility of the contractor. Rock Island Arsenal shall retain the right to periodic inspection and evaluation of the process, as it deems necessary.

OFF-LOADING/PLACEMENT: Off-loading of the equipment from the delivery vehicle, and placement of the equipment in position for the installation is the responsibility of the contractor. The contractor shall not be allowed to use government equipment to accomplish this work.

OFF-LOADING/PLACEMENT OPTION: At the request of the contractor, Rock Island Arsenal will perform the off-loading and placement of the equipment.

1.2.1.4 Any special requirements or precautions to be observed shall be the responsibility of the contractor to provide.

1.2.1.5 The contractor or his representative may be present during this process; however, such person will be responsible for being present upon arrival of the equipment at Rock Island Arsenal. Off-loading and placement shall not be delayed to allow arrival of the contractor or his representative.

1.2.1.6 If, due to contractor caused difficulties, the equipment or components of the equipment must be moved, removed or replaced by Rock Island Arsenal after initial placement, the contractor shall be billed for such work at current Rock Island Arsenal labor and overhead rates.

LIABILITY: In any case, the equipment remains the property of the contractor, and the contractor shall assume all responsibility and liability for the equipment and the work performed upon it. The government shall be held harmless for any damage done to the equipment at any time up until final acceptance of the equipment by Rock Island Arsenal, except in the case of intentional damage and/or gross negligence on the part of Rock Island Arsenal personnel.

SET-UP: The contractor shall be responsible for set-up and connection of the equipment beyond connections of the utilities to the points of first connection.

SECURITY: The RIA-JMTC is an Army installation subject to Department of Defense safeguards, various precautions, and plant protection measures. At all times during the execution of this SOW, the contractor will maintain adequate plant protection devices to minimize espionage, sabotage, and other malicious destruction and damage. The contractor shall comply with all security requirements of the Rock Island Arsenal. Rock Island Arsenal Island-wide Force Protection levels may be adjusted/changed at any time, which may cause possible delays and will directly affect procedures for accessing the Island.

Delivery Hours or Service Hours: Service calls, equipment installation, training, and equipment delivery (where the contractor offloads) will only be allowed from 0600 – 1530, Monday through Thursday, except for Government Holidays. Deliveries of items where the contractor has opted for Government “off-loading option”, must be received before 1200 hours. These hours are subject to change; however, the Government will notify the contractor of such changes. The vendor will contact the designated Performance Certifier/ COR to obtain an electronic key for their representative (i.e. delivery driver) in order to have access to the facility. Deliveries and service calls outside the normal hours stated above will be coordinated with the Performance Certifier/ COR to address any emergency situations."

Completion Final acceptance of the equipment shall occur after the following:

1.2.1.7 Set-up completion by the contractor.

1.2.1.8 Successful completion of performance testing at Rock Island Arsenal.

1.2.1.9 Final inspection approval by the government representative or inspector. This is to verify full compliance with this description to include amendments and modifications to the final contract. The government representative shall perform any and all tests he deems necessary to ensure compliance with this description and industry standards to include, but not limited to ease of control, convenience of operation, safe operation, and adequacy of lubrication devices.

1.2.1.10 All required training is complete.

1.2.1.11 Complete documentation packages are delivered.

TRAINING

The contractor shall provide instruction in proper operation and maintenance of the equipment without additional cost to the government. Training shall be of sufficient duration so that the recipients are able to demonstrate a reasonable level of competence as determined by the equipment installer and/or the inspector. Acceptance may be delayed as a result of inadequate training.

Schedule Training shall training shall be coordinated with the Rock Island Arsenal. Daily training shall begin no later than 6:30 a.m. CST and shall continue until at least 2:15 p.m. CST. This is required to get full coverage of the 1st shift of operation at RIA-JMTC. If training does not begin until after the stated time, RIA-JMTC may at its option require additional training at a different time to compensate for the loss of training caused by the late start. This may include more time than what is represented by the delay (e.g. a 1-hr delay may require 2-hrs later to impart the knowledge lost).

Location All training shall be performed at the Rock Island Arsenal. It shall be performed using the equipment purchased in this description.

Type Each type of training shall be given independently. Rock Island Arsenal shall coordinate with the contractor to provide the proper personnel for each type of training. The following types of training shall be provided by the contractor.

OPERATOR: Training shall be provided by the contractor for (5) operators. This shall include instruction on the safe, efficient operation of the equipment delivered. The trainees supplied by RIA-JMTC shall be familiar with machine operation, but not necessarily with the style or type of controls provided with the equipment. (E.g. for a new CNC lathe, the operator will be familiar with CNC lathe operation, but may have no experience with a Fanuc control system.)

PROGRAMMING: If the equipment includes a programmable controller, programmer training shall be provided, separate from the operator training for (2) personnel. If programming is normally performed by the operator only, then this training may be combined with the operator training.

MAINTENANCE: Mechanical and electrical control and diagnostic maintenance training shall be provided by the contractor. This shall include information on troubleshooting and preventive maintenance procedures. This shall be provided for (2) personnel.

METHODS: Methods Training shall be provided by the contractor. The Methods Division of JMTC traditionally workload parts across various machines within the JMTC factory. The contractor shall provide a general overview of the machine capabilities during this training. This training shall define basic information such as material capable of manufacture with the machine, maximum and/or minimum part size, speeds and feeds, and accuracies of the machine provided. It shall also provide overview of the controls, instructions for basic edit commands, and accessing histories. This training shall be no longer than 4 hours, and provide training for 4 students.

SERVICE

Service/Support Requirements The contractor shall have as a minimum, a verifiable service/repair capability which meets or exceeds the following requirements:

STAFF: Staffed by qualified, English-speaking personnel fully knowledgeable in the service/repair of the equipment offered.

TELEPHONE ACCESS: Telephone access to service/repair personnel shall be available for consultation during Rock Island Arsenal normal working hours. Rock Island Arsenal normal working hours are 8:00 am CST to 3:00 pm CST, Monday through Friday, except legal federal holidays.

ON-SITE RESPONSE: Physical, on-site response shall be possible within 48-hrs of notification that service/repair of the equipment is necessary.

MAINTENANCE PARTS: Parts necessary for periodic replacement such as belts, hoses, filters, and other parts normally considered as spare parts, by the manufacturer, shall be stocked and available for shipment.

PRIOR HISTORY: Said service/repair capability shall have been available to the general public prior to the issue date of this purchase description. Adequate proof of prior availability shall be provided upon request.