Attachment0001.pdf

ROCK ISLAND ARSENAL RIPD: N2000-14-1-17

PURCHASE DESCRIPTION DATE: 19 July 2012

Die Forging Hammer

1. GENERAL SYSTEM DESCRIPTION

1.1. This Purchase Description represents the purchase of a Forging Hammer. The contractor shall provide and install the Forging Hammer as a “turkey” operation, where all actions are the contractor’s responsibility, unless specifically stated otherwise in this Purchase Description.

The hydraulic Forging Hammer shall be designed and manufactured to enable die forging with a blow energy of at least 160 kilo-Joules (118,010 foot-pounds force). The required machine is comprised of a frame, a ram, an anvil insert and piston rod, a drive mechanism, a filter/chiller circuit, a foot switch, and a programmable controller. The Forging Hammer shall be installed in

Building 222 of the Joint Manufacturing and Technology Center (JMTC) of Rock Island

Arsenal.

2. STANDARDS AND PUBLICATIONS

2.1. Clarification: If there are any ambiguities or discrepancies between sections of this purchase description, drawings, national or industry standards discovered by the contractor in reviewing this purchase description prior to submitting an offer, such ambiguities or discrepancies shall be reported to the contracting officer by the contractor 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.

2.2. Fire Prevention and Protection: The contractor shall comply with all fire prevention measures prescribed in the installation Fire Regulations, a copy of which is on file in the office of the

Contracting Officer. A written fire permit shall be obtained from the installation Fire Marshall for use of open flame devices, such as torches, portable furnaces, tar kettles, or gas and electric welding and cutting equipment, in, on, or within 15-ft of the building. The contractor shall be liable for any fire loss to the Government properly attributable to negligence on the part of the contractor, including failure to comp1y with fire prevention measure described by the terms of this purchase description.

2.3. National Standards and Specifications: The following specifications in effect on the Date of

Invitation for Bid/Request for Proposal, form a part of this purchase description. In the case of conflicting requirements, the more stringent shall apply.

2.3.1. Occupational Safety and Health Act of 1970 (OSHA).

2.3.2. American Society of Testing and Materials (ASTM).

2.3.3. American Society of Mechanical Engineers (ASME).

2.3.4. American National Standards Institute (ANSI).

2.3.5. National Electrical Manufacturers Association Standards (NEMA).

2.3.6. Electronic Industries Association (EIA).

2.3.7. Joint Industrial Council Electronic Standards (JIC-EL-1-1971).

2.3.8. Institute of Electrical and Electronics Engineers (IEEE).

2.3.9. American Code for Information Exchange (ASCII).

2.3.10. American Welding Society (AWS).

2.3.11. American Gear Manufacturers Association (AGMA).

2.3.12. Underwriters Laboratories Inc (UL).

2.3.13. National Fire Protection Association (NFPA).

2.3.13.1. NFPA 70 National Electrical Code

2.3.13.2. NFPA 79 Electrical Standard for Industrial Machinery.

2.3.14. International Standards Organization (ISO).

3. DESIGN

3.1. 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.

3.2. General Design Standards

3.2.1. PREVIOUS EXPERIENCE: In the regular course of its business for a period of at least

3-yrs preceding this solicitation, the manufacturer of this equipment shall have previously supplied or offered for sale this type of equipment to industry for other than its own use.

Such evidence shall be supplied to the Contracting Officer upon request.

3.2.2. 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.

3.2.3. UNITS OF MEASURE: Dimensions and capacities in this purchase description are given in the English-US (in-lb) system. All dials, gauges, machine control systems

(including programming), and drawings shall be in the English-US system or both the

English-US and the metric systems, unless otherwise specified in this document.

3.2.4. 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. The minimum height of lettering shall be 3/16-in or as indicated by industry standards. Lettering shall be permanent and have a contrasting background.

3.2.5. 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).

3.2.6. 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.

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

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

3.2.8.1. Connection of 460-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.

3.2.8.2. Connection of approximately 100-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.

3.2.8.3. Connection of approximately 65-psi water to a single point for each system, if needed. Connection does not include filters or any peripheral equipment necessary to make the equipment functional. If water is required, the contractor shall be responsible for installing a back-flow limiting device sufficient to prevent possible contamination of the water system. If water is used for cooling, the system shall be a closed loop system, where the water is cooled and recirculated. This is necessary to maintain IEPA compliance.

3.2.8.4. 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.

3.2.9. 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. This disconnect shall be provided and installed by the contractor. 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.

3.2.10. 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.

3.2.11. 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.

3.2.12. 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.

3.2.13. NEW EQUIPMENT: The equipment furnished under this purchase description shall be new and unused. Such evidence shall be supplied to the Contracting Officer, when requested.

3.2.14. 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.

3.2.15. 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.

3.2.16. 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.

3.2.17. 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.

3.2.18. 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.

3.2.19. 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.

3.2.20. 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.

3.2.21. 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.

3.2.21.1. 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.

3.2.21.2. 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.

3.2.21.2.1. 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.

3.2.21.2.2. 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.

3.2.21.2.3. All filters shall be either cleanable or replaceable.

3.2.21.2.4. All pumps shall be self-priming.

3.2.22. 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.

3.2.22.1. Equipment which requires compressed air shall have a regenerative type desiccant or refrigerated compressed air dryer capable of drying air down to 35-deg-F pressure dew point, minimum, from air entering the equipment at 110-deg-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, ozone depleting substance. The air dryer shall be connected and/or piped to the equipment by the contractor.

3.2.22.2. 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.

3.2.23. HYDRAULICS: 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.

3.2.23.1. If the duty cycle of the system under maximum usage will cause the hydraulic fluid to exceed 120-deg-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.

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

3.2.23.3. Protection shall be provided to prevent damage to components.

3.2.23.4. 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.

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

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

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

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

3.2.23.9. All pumps shall be self-priming.

3.2.24. WORK LIGHT: If work light(s) are required herein, the work light(s) shall be equipped with an individual switch mounted at the control station; or the work light shall come on automatically when master start is depressed. In the latter case, means shall be provided to change the bulb without deactivating the machine. The light shall be pre-wired and fused.

The light(s) shall be capable of illuminating the entire machine work area, and shall be constructed to meet environmental conditions inherent to machining operations. Operation voltage shall be nominal 115 Volts Alternating Current (VAC).

3.2.25. MOTORS:

3.2.25.1. All motors shall be rated for continuous duty.

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

3.2.25.3. 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.

3.2.25.4. Motor starters and controls shall operate at no greater than 120-VAC. It is preferred that they operate at 24-Volts Direct Current (VDC).

3.2.25.5. 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.

3.2.26. 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.

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

3.2.28. CONTROL NOISE: Electronic controls shall be designed and constructed such that they shall not be affected by radio frequency signals generated by communication equipment used at Rock Island Arsenal. Such equipment includes:

3.2.28.1. Portable, two-way radio – 139.05 MHz

3.2.28.2. Portable, two-way radio – 164.9875 MHz

3.2.28.3. Portable, two-way radio – 165.0875 MHz

3.2.28.4. Fork truck radios – 165.1875 MHz

3.2.28.5. Pager system – 412.875 MHz

3.2.28.6. Crane remote controls – 406 MHz through 420 MHz

3.2.28.7. Controls shall not be affected by radio frequency interference generated by machinery. Controls shall not be affected by radio signals transmitted by any and all legal radio stations.

3.2.28.8. The equipment supplied under this description shall not generate radio frequencies which will interfere with the electronic controls of existing equipment located at the Rock Island Arsenal. Emission of such electromagnetic noise shall be grounds for rejection of the equipment supplied. Relocation of the equipment to avoid interference shall not be considered an acceptable means of correction.

3.2.28.9. Testing for conformance to FCC regulations relating to maximum permissible radio frequency radiation shall be accomplished after installation. It shall be the responsibility of the contractor to supervise installation and testing before acceptance and certification as required by FCC rules and regulations.

3.2.29. FOUNDATION: The requirement for a separate foundation is permissible, if necessary to meet the specified alignment tolerances, to provide isolation, or to conform to a standard system configuration. The contractor shall describe the foundation requirements at the time of bid. Also see Documentation – Installation and Preparation. Any required foundation will be provided by RIA in accordance with vendor-supplied drawings.

3.3. Safety and Environmental

3.3.1. 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.

3.3.2. MATERIAL EXCLUSIONS: The equipment shall not contain polychlorinated biphenyl

(PCB), ozone depleting substances (Class I), or asbestos materials.

3.4. SAFETY REGULATION COMPLIANCE: The contractor shall comply with standard OSHA and RIA safety standards, including conforming to confined space work requirements when applicable. Contractor shall comply with all applicable local, state, federal, and RIA safety regulations during all phases of installation, start-up, warranty services, or routine maintenance.

3.4.1. PERMITS: The contractor shall provide a list of permits and certifications required by the agencies in Standards and Publications and those recommended by the general industry.

The contractor shall also provide the information necessary to obtain required permits for the system.

3.4.2. 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. Also see Documentation-Safety Lockout

Procedure.

3.4.3. 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. Also see Documentation-Safety Lockout Procedure.

3.4.4. TRAPPED ENERGY: Devices in which energy is contained, e.g. air reservoir tanks, shall be equipped with a means to manually drain the energy to a safe condition. E.g. drain hydraulic fluid back to the reservoir, or vent trapped air to atmosphere. Also see

Documentation-Safety Lockout Procedure.

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

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

3.4.7. 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.

3.4.8. EMERGENCY STOP: The system will incorporate a clearly identified, red, mushroomed, control button with a yellow backing plate at every operator work station.

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. No other red mushroomed buttons shall be allowed on the equipment. It is preferred that there be no other red buttons of any type.

3.4.9. CONTROL GUARDS: Controls shall be guarded against accidental operation.

3.4.10. 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.

3.5. Responsibilities

3.5.1. 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.

3.5.2. SITE CONDITIONS: Rock Island Arsenal will be responsible for additional costs incurred by unforeseen, but controllable manmade issues with the location of the system.

Examples would include, but are not limited to, buried sewer lines, standing water, and so forth. The contractor will be responsible for all costs associated with correcting foreseeable conditions, including but not limited to low hanging electrical lines which are clearly visible, encountering rock during excavation, inclement weather, interference with established machines or structures by components not shown on the footprint drawing, etc.

4. MACHINE SPECIFICATION:

4.1. General Machine Description: The contractor shall provide and install a hydraulic Die Forging

Hammer as described in this Purchase Description. The machine shall be a Lasco Model HO-U

1600 (or equivalent). The below descriptive paragraphs outline salient, and performance characteristics of the machine required. The machine provided shall provide a per blow energy capacity of at least 160 kilo-Joules (118,000 foot-pounds).

4.1.1. Basic Machine Components: The system shall consist of, but not be limited to, a frame, guides, sow block/anvil insert, a ram, a piston rod, a drive mechanism (pumps, motors and valving), a filter/chiller unit, a foot switch, a programmable controller, and vibration dampening units.

4.1.1.1. Frame: Frame shall be manufactured of cast steel and heat treated, The frame will configured/shaped to optimize machine rigidity. The frame will integrate a sub-base to for stability, aiding in absorbing forging blows.

4.1.1.2. Guides: The guides shall be fastened to the frame. They will be manufactured of steel and heat-treated, for long wear. The guides shall be configured to minimize wear during off-center ram loading.

4.1.1.3. Sow Block/Anvil Insert: The sow block/anvil insert shall be machined from a steel alloy and heat treated for ductility and wear resistance. SOW Blocks shall have dovetails configured as detailed at enclosure 1.

4.1.1.4. Ram: The ram shall made of alloy steel, and ultrasonically tested before machining. The ram shall be heat treated and stress relieved several times to extend part durability. The ram will be geometrically sized with high length to width ratio for uniform guidance in offset forging scenarios. Top die dovetail notch, keys and dowels shall be in accordance with details at enclosure 1.

4.1.1.5. Piston Rod: Rod and Piston are the highest stressed component of a die forging hammer. The rod shall be flexible to absorb the excessive shock created by the forging forces. The rod and piston shall be heat treated, and surface hardened.

4.1.1.6. Drive Mechanism: The drive mechanism for this Forging Hammer shall be hydraulic. The head of the machine shall include a hydraulic reservoir mounted on isolation pads. The hydraulic unit shall include motors, axial piston pumps, filters and fluid chillers sized to endure (without failure) the repeated blows of steel forge operations.

4.1.1.7. Filter/Chiller: The hydraulic system shall include a filter and chilling unit integrated into the drive system. It shall include a low micron filter to keep the drive medium clean and free of contaminants. If the filters restrict flow because of a build-up of a contaminant buildup, a pressure valve will signal to the operator of the hydraulic circulation failure, and machine shall be shutdown down. The chiller shall be provided with the equipment, and used to control and regulate optimum hydraulic temperature to ensure consistent operation, and long life. The chiller shall be a oil/water/heat exchanger, or an oil/air/cooler to regulate the drive medium.

4.1.1.8. Programmable Controller: The control provided shall be a programmable controller, a Siemems Simatic S7 or equivalent. It shall include various individual control settings, and have a LCD display. The controller shall have various modes of operation including “setting”, “continuous blow”, and “program” modes. The “Setting

Mode” shall allow the ram to be up and down, and allow the accumulator to be charged and discharged. During “Continuous Blow Mode”, the machine will be operated via the dual foot switch in increments of .1-second intervals between blows from .1-seconds to 9.9-seconds. In the “Program Mode”, 20 individual steps can be programmed into each program, where blow energy can be separately programmed, as well as the interval between each blow, delays for material to be received, and a air blast impulse can be programmed for die cleaning purposes. The controller will also have the capability to control hydraulic fluid temperature.

4.1.2. Dimensions:

4.1.2.1. The equipment shall be shipped either assembled or disassembled to pass through a door 12-feet wide by 12-feet high, and shall not exceed 35-feet in length.

4.1.2.2. When installed complete, the equipment shall be contained in an area 170-inches wide (at the frame base) and 130 inches deep, and 265 inches tall (above the floor line). Depth is defined as front to back of the machine from the operator’s normal operating position.

4.2. PERFORMANCE SPECIFICATIONS:

4.2.1. Blow Energy: The machine shall be capable of generating at least 118,010 foot pounds of energy per blow (160 kilo-Joules).

4.2.2. Blow Frequency: The Forging Hammer shall be able to perform continuous blows (with a blow energy of 118,000 foot-pounds per blow) at a rate of 55 blows per minute.

4.2.3. Ram Impact Speed shall be at least 17 feet-per-second.

4.2.4. Maximum Ram Stroke shall be at least 39-inches (with minimum die height).

4.2.5. Minimum Ram Stroke shall be at least 31-inches. (with maximum die height).

4.2.6. Ram weight shall be at least 20,000-pounds (excluding rod and top die weight).

4.2.7. The Forging Hammer shall be capable to operate with a Die Height range of 28-inches through 35-inches (without dovetails).

4.2.8. The Daylight Between Guides will be at least 42-inches.

4.2.9. Total Weight of the Forging Hammer shall be at least 390,000-pounds.

5. APPROVAL/SHIPPING

5.1. Pre-shipping

5.1.1. PRESHIPMENT TESTING: Prior to shipment, the contractor shall perform tests to demonstrate that the system performs as specified by the manufacturer and this description.

The results of this testing shall be provided by the contractor to the contracting officer.

5.1.2. DATE OF TESTING: The date of testing shall be furnished at least 10-working-days prior to test so that, if the contracting officer deems it necessary, a government representative may be present.

5.1.3. PRESHIPMENT DEFICIENCIES: If, during the course of pre-shipment testing, deficiencies are disclosed which cannot be immediately satisfactorily corrected, the Rock

Island Arsenal observers shall return to the Rock Island Arsenal, and the contractor shall be required to take corrective actions. In such cases, the contracting officer shall declare a new testing date. The government reserves the right to terminate the contract for default at any time after the first failure of the contractor’s equipment to meet contractual requirements.

5.1.4. OBSERVERS: The government reserves the right to dispatch representatives to observe a retesting and to charge the contractor for the travel and per diem costs of such retesting.

5.1.5. SHIPPING AUTHORITY: Government observers will not grant authority to ship the equipment following the pre-shipment testing, even in cases where there have been no apparent instances of non-conformance. Authority to ship will be granted only by the contracting officer. In cases where it is determined that the equipment conforms to specifications, the contracting officer will grant shipping authority within 10-working-days of completion of pre-shipment tests. The contractor shall inform the contracting officer of the anticipated delivery date no less than 2-working-days prior to equipment arrival at Rock

Island Arsenal.

5.1.6. TEST STANDARDS AND SPECS :

5.1.6.1. OPERATIONAL TEST: Functions of the machine and the control unit shall be checked.

5.1.6.1.1. The runoff checks shall include operating the machine in each of its modes of operation to determine proper response of the machine to control commands.

The cycle checks shall include feed rate changes, independent and simultaneous operation of machine axis motions, and diskette controlled auxiliary functions.

Should a failure occur, the cycle shall be restarted after the correction and runoff for a full 8-hour period.

5.1.6.1.2. No machine adjustments or tooling adjustments shall be allowed after the start of any test. Adjustments during the test shall require restarting the test from the beginning.

5.1.6.1.3. PERFORMANCE TEST: A performance test shall be conducted at Rock

Island Arsenal (RIA) with RIA personnel in attendance. The purpose of this test is to verify the ability of this machine to produce quality at both the normal and extreme areas of the work envelope. The contractor must produce the program to create the test parts, and run the machine to produce the parts. Failure of the test shall consist of any work piece being out of the tolerances stated herein. The part will be required to be produced by running the part program. Pre-testing for programming parameters is allowed. The generation of the first part (single) will not be included in the verification. Failure of the performance test may result in

Termination for Default if remedies cannot be accomplished prior to delivery.

The test shall consist of one part reproduced three consecutive times without reprogramming. The part shall be the Line of Communication Bridge

Connector, RIA Tooling Drawing 350709 (the drawing is available from RIA

Contracting Officer upon request). RIA shall supply the dies, and material.

5.2. Shipping

5.2.1. 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.

5.2.2. SHIPPING SCHEDULE: Be aware, the Rock Island Arsenal will only off-load equipment arriving between 7:00 am and 12:00 am (noon), local time on Mondays through

Fridays 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. Delivery of the equipment to Rock Island Arsenal shall be no later than 10 working days after granting of shipping authority.

5.2.3. 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. Kent Stone, TARA-MOE”.

5.2.4. 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.

5.3. Installation

5.3.1. 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 must be performed prior to system installation to Rock Island Arsenal. Refer to the Installation and Preparation

Documentation section of this document.

5.3.2. SITE PREPARATION EXECUTION: The contractor will be solely responsible for site preparation except as specifically excluded in this document. Any required foundation will be provided by RIA in accordance with vendor supplied drawings.

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

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

5.3.5. 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.

5.3.6. 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.

5.3.6.1. OFF-LOADING/PLACEMENT OPTION: At the request of the contractor, Rock

Island Arsenal will perform the off-loading and placement of the equipment.

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

5.3.6.3. 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 scheduled to allow arrival of the contractor or his representative, but shall be completed within 90-calendar-days of receipt of the equipment at Rock Island Arsenal.

5.3.6.4. 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.

5.3.7. 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.

5.3.8. 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. The contractor shall be allowed 30-calendar-days to complete set-up of the equipment and notify the contracting officer that the equipment is fully functional and available for final inspection.

5.4. COMPLETION: Final acceptance of the equipment shall occur after the following:

5.4.1. Set-up completion by the contractor.

5.4.2. Successful completion of performance testing at Rock Island Arsenal.

5.4.3. 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 insure 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.

5.4.4. All required training is complete.

5.4.5. Complete documentation packages are delivered.

6. DOCUMENTATION

6.1. The contractor shall furnish the following sets of technical data, as a minimum standard. All documentation shall be provided in the English language. In addition, all drawings, manuals and other technical data not listed herein, but necessary for efficient maintenance and operation of the equipment shall be furnished by the contractor. Each separate piece of equipment requires a complete set of documentation. Therefore, if (2) machines are supplied, (2) complete sets of technical data shall also be supplied. Manuals and documentation may be combined, but the combined manual must contain clearly separated sections.

6.2. Data Delivery

6.2.1. Each section of Documentation shows a required delivery for technical data. The information shall be sent to the following address:

COMMANDER

Rock Island Arsenal

ATTN: TARA-MOE, Attn: Mr. Kent Stone

Plant Engineering Division

Rock Island, IL 61299-6400

6.2.2. Delinquent delivery of technical data may result in the following:

6.2.2.1. Contractor caused delay of Payment of Contract Price, if equipment installation and acceptance are delayed;

6.2.2.2. and/or equipment delivery delayed until 90-calendar-days after delivery of technical data;

6.2.2.3. and/or assessment of damages, should late delivery cause damage to the government or it’s mission;

6.2.2.4. and/or termination of the contract for default.

6.3. Drawing Standards

6.3.1. TEXT: All text shall be standard bold face type in the English language.

6.3.2. DIMENSIONS: Dimensions shall be given in the English-US format. They may alternately use both metric and English-US.

6.3.3. SCALE: Where possible, drawings shall be drawn to ¼-in = 1-ft scale. The smallest standard paper size, which will depict the equipment using the required scale, is preferred.

Standard paper sizes allowed include, 8.5” x 11”, 11” x 17”, 17” x 22”, or 22” x 34”.

6.3.4. INFORMATION NOTE: Each drawing shall include either in the title or as a note, the following information: Contract Number, Equipment Name, Manufacturer’s Name, Model

Number, and Serial Number.

6.3.5. VERIFICATION: Each drawing will be certified as correct by both the contractor and the Original Equipment Supplier. This includes, but is not limited to foundation, installation, and all drawings listed in the documentation section of this description.

6.4. INSTALLATION AND PREPARATION: The contractor shall provide (1) approved copy of the information from this section, in paper format, a minimum of 90-calendar-days prior to delivery of equipment. Additional copies shall be provided as part of the Maintenance Manual.

6.4.1. Installation Document List: A plainly visible cover sheet shall be provided with the

Installation and Preparation Documentation package listing drawings and schematics required for installation.

6.4.2. Tool List: An itemized list of all fixtures, tools, and equipment, whether special or not, required to install, align, and maintain the equipment in this purchase description. NOTE:

Rock Island Arsenal may or may not have such fixtures, tools, and equipment in stock. In any case, the contractor is responsible for providing any such items needed for installation, alignment inspection, and start-up of the equipment prior to final acceptance by Rock Island

Arsenal.

6.4.3. Foundation Drawing: Since the proposed equipment requires a separate foundation, a drawing must be provided from the contractor to JMTC for review and approval. This will show all information necessary for a contractor to perform the required preparation work prior to final installation of the system. The JMTC shall provide and install the foundation after approval.

6.4.4. Footprint Drawing: A dimensioned drawing shall be provided to accurately depict the layout of system, showing contours. It shall fully dimensioned and include net operating clearance for moving components which travel beyond the gross contour. The drawing shall distinguish between the base of the equipment at floor level and the gross contour where it may overhang the base. Location of access doors/flooring plates for servicing of the equipment shall also be designated.

6.4.5. Installation Drawing: This drawing may be combined with either the Foundation

Drawing or the Footprint Drawing, providing clarity is maintained. This drawing will provide location dimensions for anchor bolts (if applicable) including both the anchor bolt size and height of anchor bolt concrete surfaces clearly shown. Dimensions will be from a common baseline, not chain dimensions. This is to prevent tolerance stack-up errors.

Locations of the first connection points for all required power sources shall be shown and dimensioned. Approximate gross weight of each separate component shall be indicated.

This drawing shall show capacity requirements at each utility point of first connection.

6.4.6. Electrical Schematic: If the equipment includes this type of utility, a complete system schematic is required. The capacity required at the point of first connection must be clearly stated.

6.4.7. Pneumatic Schematic: If the equipment includes this type of utility, a complete system schematic is required. The capacity required at the point of first connection must be clearly stated.

6.4.8. Hydraulic Schematic: If the equipment includes this type of utility, a complete system schematic is required. The capacity required at the point of first connection must be clearly stated.

6.5. MAINTENANCE MANUAL: The contractor shall provide (3) copies of this manual/information. Of these, (2) will be paper, and (1) shall be electronic. Acceptable electronic formats include acrobat files (.pdf), drawing exchange files (.dxf), and initial graphic exchange specification (.igs). This manual will include the following as a minimum acceptable standard. The contractor shall deliver this information no later than the delivery of the equipment.

6.5.1. Installation and Preparation: Copies of the information provided in the Installation and

Preparation section shall be included in this manual. This is to facilitate future relocation and maintenance of the equipment.

6.5.2. Safety ad Lockout Procedure: This shall be a written procedure describing safe machine shutdown and the sequence by which lockout devices, and if necessary, line blocks and other restraints are affixed and removed prior to maintenance and service. This may include drawings or photographs for clarity.

6.5.3. Preventative Maintenance: This section of the documentation shall include: Daily

Operator Checklist, Visual Inspections, and a Lubrication Schedule. Procedures and schedules for inspections, adjustments, cleaning, and component replacements.

6.5.4. Lubricant: This will include a drawing and detailed instructions and procedures. The drawing will depict the location of each lubrication point and indicate the type, viscosity, frequency, approximate quantity of the lubricant to be used. All lubrication documentation shall be referenced to this drawing.

6.5.5. Replacement Component List: This list shall contain every replaceable component in the equipment. It shall include appropriate identification and ordering data including, but not limited to, the contractor, vendor and original equipment manufacturer (OEM) part names and numbers. Enough information shall be included to allow ordering of the component from the contractor, vendor, or OEM. Illustrations shall be included which clearly locate the parts within larger assemblies. Also included, shall be procedures for performing replacements. A written procedure is not required if it would consist of obvious steps, e.g.

remove screws, then remove component, insert new component, and install screws. This would not require a written procedure, unless standards must be met, e.g. install screws to specified torque.

6.6. OPERATOR MANUAL: The contractor shall provide (3) copies of this manual/information.

Of these, (2) will be paper, and (1) shall be electronic. If the equipment uses numerical control

(N/C), (1) additional paper copy shall be provided. Acceptable electronic formats include acrobat files (.pdf), drawing exchange files (.dxf), and initial graphic exchange specification

(.igs). This manual will include the following as a minimum acceptable standard. The contractor shall deliver this information no later than the delivery of the equipment.

6.7. PROGRAMMING MANUAL: The contractor shall provide (4) copies of this manual no later than 30-calendar-days prior to delivery of the equipment.

6.7.1. Instructions: The programming manual shall include instructions for programming the machine and any auxiliary equipment, e.g. steady rests, chucks, tailstocks, bar feeds, tool changers;

6.7.2. Equipment Specifications: Complete equipment specifications, e.g. spindle speeds and ranges, axis travel limits, pallet configuration drawings (T-slots, key slots, hold down bolt holes, weight limits);

6.7.3. Tool Changer: Tool changer information (length limits, diameter limits, weight limits);

and spindle interlock zones.

6.7.4. Code Examples: Examples of N/C code shall be provided to enable Rock Island Arsenal to solicit an equipment interface of it’s choice.

6.8. Point of Origin: If the equipment originates in a country other than the United States of

America, the contractor shall provide a point of origin document to the contracting officer. This document shall be provided at the time of equipment delivery. NOTE: This shall not be construed as a waiver of Buy American Act and other such laws and regulations, as may be applicable to this acquisition. The contractor is advised that it must comply with all Buy

American Act and other requirements set forth in the solicitation for this item.

7. TRAINING

7.1. 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 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.

7.2. Schedule: Training shall training shall be coordinated with the Rock Island Arsenal. It shall commence within 5-working-days of notification of set-up completion and final inspection by the contracting officer, government representative or inspector.

7.3.…