Attachment 0001 - Purchase Description - 19 July 2021.pdf

DEPARTMENT OF THE ARMY

PINE BLUFF ARSENAL

PINE BLUFF, ARKANSAS 71602-9500

PURCHASE DESCRIPTION 1556

FOR

INERTIA WELDER FOR WP Line 5 (Building 34-110)

19 July 2021

1.0 SCOPE.

The purpose of this contract is for a vendor to provide an inertia welder. This includes Testing, present for Installation, Acceptance, and Training for the inertia welder with unique tooling necessary to weld a closure plug on the rear plate of a white phosphorous (WP) filled canister.

The weldment areas are designed for inertia welding and the two components to be welded have proven inertia weld ability. The welder will be integrated on an existing production line, WP Line 5, at Pine Bluff Arsenal, Pine Bluff, Arkansas.

The welder is required to be a vertical design that is mounted on the existing welder cabinet and it should interface with the existing conveyor system. A pallet on the conveyor system will pass through the welding machine with the welding operation being performed directly over the conveyor that is located on the welder cabinet.

2.0 APPLICABLE DOCUMENTS.

2.1 GOVERNMENT DOCUMENTS.

MIL-STD-1252 (Military Standard Inertia Friction Welding Process, Procedure and Performance Qualification), dated 30 JUN 1975 MIL-C-51508 (EA) Military Specification Canister, 155 MM, WP (For the M825 Projectile), REV A, dated 6 DEC 1985

Drawing Number Title

15-12-270revJ Canister, 155MM WP 15-12-267revR Canister, Components for 15-12-262revM Rear Plate 15-12-271revE Closure Plug 15-12-260revH Canister Tube 34-110ME-3010 Line 5 Layout 34-110ME-3090 Welder Cabinet 34-110ME-3005 Universal base Adapter (Sheet 1-4) 34-110ME-3079 Conveyor Carriage to Base Adapter w/ Munition Holder Assembly

2.2 SAFETY REGULATIONS

All Contractor personnel performing work within the Pine Bluff Arsenal (PBA) will adhere to the regulations and supplements listed below:

• Army Regulation 40-5, Army Public Health Program, dated 12 May 2020

• Army Regulation 380-5, Army Information Security Program, dated 22 October 2019

• Army Regulation 385-10, The Army Safety Program, dated 24 February 2017

• Pine Bluff Arsenal Regulation 190-3, Installation Employee and Visitor Access, REV 5, dated 30

April 2021

• Pine Bluff Arsenal Regulation 385-2, Occupational Safety and Health Program, REV 11, dated 31

July 2020

2.3 NON-GOVERNMENT DOCUMENTS.

Instrumentation, Systems and Automation Society (ISA) ISA-5.1-84 Instrumentation Symbols and Identification

National Electrical Manufacturers Association (NEMA) NEMA ICS-1 General Standards for Industrial Control and Systems

National Fire Protection Association (NFPA) NFPA 70 National Electrical Codes (NEC) 2017 Revision NFPA 79 Electrical Standard for Industrial Machinery 2018 Revision Standards of Manufacturing ASME American Society of Mechanical Engineers ASME A13.1 Scheme for the Identification of Piping Systems ASTM American Society for Testing and Materials OSHA Occupational Safety and Health Administration

3.0 TECHNICAL REQUIREMENTS

This section covers the technical requirements of an inertial welder to weld the Closure Plug (Drawing No.: 15-12-271revE) onto the Canister (Drawing No.: 15-12-267revR). The welder will be fully integrated in to the current production line at the existing welder cabinet. The Contractor is responsible for providing a fully functional and calibrated system as described in this document.

The welder shall be equipped with a control system and shall include:

• An Allen Bradley Programmable Logic Controller (PLC)

• Capability to interface with the current production line’s PLC and Human-Machine

Interface. The current production line’s PLC is an Allen Bradley ControlLogix 5562, Part Number 1756-L62, running RS Logix 5000 software.

• Real-time Process Feedback and Machine Status

• Diagnostic Fault, Status, and Informational Messages

• Modifiable Machine Parameters

• A reporting function to report all acquired weld data, weld program parameters, machine parameters, configuration parameters, trend data etc.

Provide an inertia welding station utilizing the existing welder cabinet on line 5 at the WP plant. The inertia welding station shall consist of a commercial welder (off-the-shelf) with custom tooling specific for this application. Canisters shall be automatically loaded and welded assemblies automatically unloaded from the welder cabinet by cycling the conveyor. The Closure Plugs shall be automatically loaded into the rotating spindle by a feeding mechanism.

3.1 DELIVERABLES

3.1.2 Government (PBA) Responsibilities

3.1.2.1 Government Furnished Utilities. Utility services consisting of water, compressed air, steam and electricity, to the extent available, will be available for use with the machine. The contractor shall ensure the welder uses only the type of services available. Such utility services available are as follows:

Steam 90 PSIG Saturated Air 100 PSIG Plant Air Electric 480 Volts, 3-Phase, AC 120/240 Volts, 1-Phase, AC Industrial Waste Drain System

3.1.2.2 PBA will be responsible for locating existing utilities and installing new tie ins/hook ups that will be necessary for operation of the welder.

3.1.2.3 PBA will be responsible for shipping Government Furnished Material (GFM) to the contractor to aid in the design and checkout of the welder, fixturing and tooling. The following items will be shipped to the contractor facility:

10ea Closure Plug 10ea Canister, 155 WP 1ea Conveyor Carriage 1ea Universal Base Adapter 1ea M825 Munition Holder

The contractor shall submit, in writing, to the Contracting Officer if any more quantities of the Closure Plugs or Canisters are required for any reason.

3.1.2.4 PBA will be responsible for coordinating a time frame for set up, installation, final adjustments, qualification and training. PBA will be responsible for receiving and unloading of all material, supplies and equipment associated with this contract.

3.1.3 Contractor Responsibilities

3.1.3.1 Contractor shall coordinate with PBA and identify exact locations and sizes of utility services required for operation of the welder.

3.1.3.2 Contractor shall return all GFM with the delivery of the equipment, fixturing and tooling.

3.1.3.3 Contractor is to furnish all materials, labor, equipment, and supplies necessary to construct, and deliver the inertia welder. The contractor will be present for installation and will provide machine installation supervision and training.

3.1.3.4 Contractor shall design a M825 Munition Holder to be assembled on to the Universal Base Adapter that is attached to the Conveyor Carriage. The M825 Munition Holder is to be part of the nest tooling and will hold the Canister before, during and after the weld operation. The M825 Munition Holder shall be capable of integrating with any other tooling requirements that are necessary to complete the welding operation.

3.1.3.5 Contractor shall design a clam shell mechanism that will secure the Conveyor Carriage, Universal Base Adapter and M825 Munition Holder, ensuring proper location and absorbing the axial weld forces.

3.1.3.6 Contractor shall design a clamp fixture that will clamp the Canister to center and resist radial weld forces.

3.1.3.7 Contractor shall design an automatic spindle loader that will transfer the Closure Plug from its nest on the pallet into the spindle collet.

3.1.3.8 Contractor shall provide unlimited rights to the data and design of the items in sections

3.1.3.4 – 3.1.3.7.

3.1.3.9 Contractor is responsible for verifying all dimensions of the following drawings:

34-110ME-3010 Line 5 Layout 34-110ME-3090 Welder Cabinet 34-110ME-3005 Universal base Adapter (Sheet 1-4) 34-110ME-3079 Conveyor Carriage to Base Adapter w/ Munition Holder Assembly

These drawings are for reference only. Any modifications that are required on the welder cabinet in order to operate the inertia welder shall be the responsibility of the contractor.

3.2.1 PERFORMANCE CHARACTERISTICS

3.2.1 The welder and tooling shall be designed such that the cycle time is ≤ 30 seconds. The sequence of operation is as follows:

1. The conveyor carriage will enter the friction welding cabinet on government furnished conveyor.

2. A Clam Shell mechanism will secure the pallet, ensuring proper location and absorbing the axial weld forces

3. A clamp fixture will clamp the canister to center and resist radial weld forces

4. An automatic loader will transfer the Closure Plug into the rotating spindle collet

5. The collet will automatically clamp the Closure Plug

6. The automatic welding sequence will begin

7. After weld is complete, the fixture and clam shell unclamp

8. Cycle is complete

3.2.2 The inertia friction welding machine shall be capable of joining similar materials of known weld ability with a resultant forged bond equal in cross-sectional strength to the weakest parent material. The machine doesn’t require it, but the canister and plug may be designed with faying surfaces concentric and perpendicular to the centerline between the headstock and tailstock, with the axis of the rotating work piece (closure plug) being coincident with the centerline between the headstock and the tailstock. The hydraulic ram needs to be mounted at the headstock. When the controlled hydraulic ram pressure forces the parts together, the axial weld forces should be absorbed by a clam shell mechanism in order to prevent fatigue failure on the conveyor carriage and conveyor. The clam shell mechanism will be secured to each conveyor carriage utilizing the universal base adapter. In a previous production line, weld parameters were optimized at 4200 rpm and a pressure of 800 psi. The inertia welder shall have variable rpm and pressure ranges that meet these weld parameters. The limit to these ranges will be determined based off the contractors experience forging the material that makes up the closure plug and rear plate.

3.2.3 Drawing Number 34-110ME-3090 is a drawing of the Welder Cabinet that is already assembled on the production line. Drawing number 34-110ME-3010 is a drawing of the assembled production line with the Welder Cabinet. Installation shall include adequate space for both the operation and the maintenance of all equipment.

3.3 CANISTER AND CLOSURE PLUG PHYSICAL CHARACTERISTICS

The canister is approximately 5.0” diameter, 21.75” long. The empty canister weighs approximately 24 lbs. while a WP filled round weighs approximately 37 lbs. The main component of interest on the canister is the Rear Plate. The Rear Plate is what the Closure Plug will be welded to.

Rear Plate Characteristics:

Material - Steel Bars, Carbon, Hot-wrought, special quality, ASTM-A576, AISI 1018- 1020 or Plates, Carbon Steel, for forging and similar applications ASTM A827, SAE 1020.

The closure plug is 1.0” diameter, 0.5” long.

Closure Plug Characteristics:

Material - Steel Bar, Carbon, Cold Finished, Grade 1018 to 1020, SPEC ASTM A29/A29M. Parts must be fabricated from ½ nom thick flats. Convex surface permitted due to manufacturing process

3.4 CONTROL SYSTEM

3.4.1 The control system will shall allow an operator to run in either a manual or automatic processing mode. The operator control panel shall have selector switches or pushbuttons for manual motions and an E-Stop. If a station is stopped for rejects there shall be a visual indication device. The welder will shall receive a 24V DC signal indicating that the canister is present and ready to weld. Upon completion of the weld cycle, the welder will send a 24V DC signal to the main controller that the cycle is complete. In addition, not all WP canisters that pass through line 5 have to be welded so a bypass mode in which the part will progress through the inertia welding cabinet without a cycle must be programmed.

3.4.2 Program Logic Control (PLC) System:

3.4.2.1 PLC: The PLC shall be an Allen Bradley PLC and shall interface with line 5’s PLC and line 5’s Human Machine Interface (HMI) as needed. The existing PLC is an AB ControlLogix 5562 PN# 1756-L62 running RS Logix 5000 software. The processor shall have a minimum of 32K words. (NOTE: This capacity is only a minimum not maximum). The processor shall contain a battery to retain programming after external power is removed. The processor shall have timing, counting, and internal control relay function, (the number of which shall only be limited by the memory capacity) arithmetic, and other characteristics necessary to meet the performance requirements of these. All of the software and hardware will be required to function on a government laptop that uses Windows XP operating system. This laptop will not be available for contractor’s use.

3.4.2.2 Racks: The input and output modules shall have a maximum of sixteen channels per module if needed. All outputs shall be fused. The racks for each system shall be located in the control cabinet for that system with the processor. The system shall allow for minimum of 25% expansion.

3.4.2.3 Operator Interface: The contractor may use switches and lights or a color touch screen monitor. If the monitor is used the contractor shall also supply the development kit used to develop the screens for the panel view system with all necessary cables.

3.5 INSTALLATION AND TRAINING

3.5.1 Contractor shall be responsible for training, setup, and final adjustments as needed.

Contractor shall provide the Contracting Officer (KO) a milestone chart within 15 days after award of contract. The milestone chart shall be provided electronically and shall contain all phases from award to installation, set-up and qualification.

See Exhibit B – Contract Data Requirements List (CDRL): Data item 007

3.5.2 Contractor and all associated sub‐contractors employees shall provide all information required for background checks to meet installation access requirements to be accomplished by installation Provost Marshal Office, Director of Emergency Services or Security Office.

Contractor workforce must comply with all personal identity verification requirements (FAR clause 52.204‐9, Personal Identity Verification of Contractor Personnel) as directed by DOD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any individual facility or installation change, the Government may require changes in contractor security matters or processes.

3.5.3 Contractor and all associated sub‐contractors employees shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC‐III) and Terrorist Screening Database (TSDB) (Army Directive 2014‐05/AR 190‐ 13), applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative), or, at OCONUS locations, in accordance with status of forces agreements and other theater regulations.

3.6 SERVICE MANUALS AND DRAWINGS.

The following drawings, manuals, and documentation shall be supplied with the Inertia welder as electronic files and hard copies:

• Machine assembly drawings

• Electrical, Hydraulic, Pneumatic, and Lubrication circuit drawings

• Tooling and Attachment assembly drawings

• Detail drawings of all tooling

• Operating and Maintenance manuals

• PM Schedule

• Recommended Spare Parts List

See Exhibit A – Contract Data Requirements List (CDRL): Data item 001

3.7 PREVENTIVE MAINTENANCE SCHEDULES.

The contractor shall furnish separate from the maintenance and operating manuals, copies of preventive maintenance schedules for the process equipment. Schedule shall be submitted in hard copy (3 ea) and electronically (3 ea) in PDF Format. These manuals shall be indexed and tabbed, with a hard cover binder and label. The schedule for the equipment will be broken down into daily, weekly, monthly, semi-annual and annual checks or services that should be performed on the equipment, along with any other frequency that is required. Also to be included is a schedule for replacing wear type items on the process equipment. Also to be included shall be a recommended spare parts list with recommended stocking levels, sufficient to properly maintain the equipment.

See Exhibit B – Contract Data Requirements List (CDRL): Data item 006

3.8 SOFTWARE.

The contractor shall provide all software necessary for operation of the system. This includes:

any on line/off line program packages that the government does not currently own, required for the operation of equipment. The contractor shall supply copies of each commercial manual supplied with the commercial software and any software written by the contractor with each copy of operation and maintenance manuals. All programs shall be supplied in a fully commented format along with the programming language that the program was written with.

Software supplied to the government shall satisfy all licensing agreements. Software functions should include machine parameters, weld program parameters, weld data files, trend data files, high speed weld data files and video files.

See Exhibit A – Contract Data Requirements List (CDRL): Data item 003

3.9 ENVIRONMENTAL CONDITIONS.

When not in operation, no climate control is provided and humidity can vary from 30 to 100 percent and temperature from 0 to 110 F. The interior of the building is exposed to environmental conditions such as pollen, mold, dirt, and dust. When in operation, the welder will be operating in a nitrogen filled cabinet operating at 140 – 160 F. The controls shall be designed and built to withstand these conditions and shall still operate as intended. This environment also requires that tooling be made of 316L Stainless Steel.

The welding operation shall produce negligible amounts of smoke, fumes or slag.

3.10 SAFETY

The system shall be designed to conform to the established safety rules and regulations as outlined in Occupational Safety and Health Administration, National Fire Protection Association, National Electrical Code, and Army Regulation 385-64. The inertia welder shall also include all of the protection devices, safety shields, indicating and audible signals required for complete personnel safety.

3.10.1 PROCESS SAFETY INFORMATION

The contractor shall provide pertinent Process Safety Information required by 29CFR 1910.119 (d)(3)(i), including, but not limited to: Materials of Construction, electrical classification, ventilation requirements, Design codes and standards employed, energy balances, and safety systems (e.g., interlocks, detection or suppression systems etc.)

See Exhibit A – Contract Data Requirements List (CDRL): Data item 004

3.10.2 HAZARD ANALYSIS

The contractor shall provide a copy of the hazard analysis for all commercial equipment.

See Exhibit A – Contract Data Requirements List (CDRL): Data item 004

3.11 FACILITIES

The proposed equipment shall fit into the space provided. The contractor shall submit a drawing with sufficient detail to demonstrate that the welder will fit in the envelope as shown in drawings 34-110ME- 3090 and 34-110ME-3010. Copies of these drawings in AutoCAD will be provided. The drawings shall be annotated to show the approximate size and location of proposed penetrations.

See Exhibit A – Contract Data Requirements List (CDRL): Data item 005

4.0 QUALITY ASSURANCE PROVISIONS.

4.1 General

Weld in accordance with MIL-STD-1252. Type I, Class B.

Weld Flash is permitted to 1.25” diameter max. Specifications MIL-A-2550 and MIL-C-51508 (EA) apply. The inertia weld shall not fail when subjected to a push-off force of 17,000 lbs.

See Exhibit A – Contract Data Requirements List (CDRL): Data item 002

5.0 PERIOD OF PERFORMANCE

Project delivery shall be completed within 12 months from date of award.

6.0 PREPARATION FOR DELIVERY

The Contractor shall be responsible for delivery of equipment to PBA. PBA shall be responsible for receiving and unloading of all material, supplies and equipment associated with this contract.