FY15_Rebuid_ _Retrofit_Bares_Hone_WV12311.doc

SPECIFICATION #11-15-3411

Watervliet Arsenal

Watervliet, New York 12189-4050 Rebuild & Retrofit Barnes Hone

WV12311

Manufacturing Engineering Work Group

Scope of Work No. 11-15-3411 October 19, 2015 Department of the Army

TACOM

Table of Contents

1. Scope

1.1 Abbreviated Description

2. Applicable Standards and Publications

3. Requirements

3.1 General Requirements

3.2 Specific Requirements

3.3 Controls/Control Systems

3.4 Requirements for Demonstration of Conformance

4. Quality Assurance Provisions

4.1 Responsibility for Inspection

4.2 Preliminary Acceptance Inspection

4.3 Government Participation

4.4 Reinspection Provisions

4.5 Post Inspection Procedures

4.6 Final Acceptance Inspection

4.7 Warranty

5. Preservation, Packaging and Delivery Instructions

6. Instructions for Preparing Technical Offers

1. Scope:

1.1 Abbreviated Description. This specification defines the requirements for the complete machine rebuild and retrofit of one 1985 Barnes Horizontal Honing machine, model HH-15, S/N ZP-10972, Watervliet number WV12311 (machine) to like new condition. Misc. machine info for the machine is as follows. It is the responsibility of vendor to confirm the accuracy of this information.

· 30 HP spindle motor

· 107 feet overall length

· 26,000 LBS. machine weight

· 44 foot stroke

· Bar length 40’ 8”

· 6 bed sections

2. Applicable Standards and Publications All work performed and procedures followed in association with this project shall meet or exceed all applicable and current Watervliet Arsenal, OSHA, local, state, and federal government codes and laws relative to fire, safety, environmental, and electrical issues. Various standards and other publications are referenced in section 3 of this specification. Where they are referenced or required, they are meant to indicate an acceptable level of quality, safety, or performance. Offerors may choose to adhere to standards other than those specified, provided that the substitute represents a level of quality, safety or performance equal to or better than the one specified. Any substitutions must be clearly disclosed and explained in the offerors statement of compliance (see 6.2). Any standards adhered to in complying with this specification shall be the latest issues in effect on the date of the submission of bids or technical proposals and offerors are responsible for obtaining copies of the most current revisions.

2.1 The Following Standards and Other Publications of the Following Organizations Are Referenced Within this Specification:

A. ASSOCIATION FOR MANUFACTURING TECHNOLOGY

B. NATIONAL FIRE PROTECTION ASSOCIATION (NFPA 70) (NFPA 79)

C. FEDERAL SPECIFICATION W‑C‑375

D. UNDERWRITERS LABORATORY

E. NEMA

F. INSTITUTE OF ELECTRICAL AND ELECTRONIC ENGINEERS STANDARD 112, SECTION B.

G. TITLE 29, CODE OF FEDERAL REGULATIONS, PART 1910,

SUBPART 0.

H. SECTION 326 OF PUBLIC LAW # 102‑484

I. ENVIRONMENTAL PROTECTION AGENCY

J. OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION

K. NATIONAL FLUID POWER ASSOCIATION

L. ANSI A13.1

M. ASSOCIATION OF AMERICAN GEAR MANUFACTURERS

N. ELECTRONICS INDUSTRIES ASSOCIATION (EIA)

O. NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST)

3. Requirements. All requirements are mandatory from the standpoint of intended function. Wherever a specific requirement would force an offeror to depart from his standard practice or configuration, the Arsenal will accept, for evaluation, alternative offers for achieving the intended function. Any such alternative offers must be accompanied by sufficient technical information to allow the evaluator to reach a definite conclusion that the alternative is equal to or better than that specified.

3. General Requirements:

3. Design and Engineering. Work performed as part of the rebuild shall be in accordance with current standards recognized for this type and class of equipment. Modifications to manufacturer's original designs to achieve requirements specified herein are not permissible if they result in deviations from good design practice.

3. Materials. Materials incorporated in the rebuild of the machine shall be of sound and uniform quality, free from defects and shall conform in specification, heat treatment and suitability to the standards recognized for this type and class of equipment.

3. Construction. All replacement parts used as part of this rebuild shall be new and unused and shall be constructed so as to be capable of withstanding all forces encountered during operation to the machine’s maximum rated capacity. Distortion and deflection at maximum load shall be limited to a degree consistent with retention of alignments and tolerances, and the machine shall recover from distortions and deflections at no load. The structure and assembly of the machine and its components shall be sufficiently rigid that workpiece finish and accuracy are not impaired by machine vibrations.

3. Construction of Major Components. All major machine components such as beds, saddles, columns, etc. are castings either of iron or semi‑steel, or shall be constructed as mild steel weldments. Weldments, if used, shall be braced, ribbed and gusseted to obtain strength equal to or better than the strength of castings, and shall be thermally stress relieved to preclude spontaneous distortion.

3. Alignment Retention. Non‑integral machine components, including but not limited to columns, heads and ways which are separately assembled and whose alignments determine the squareness and/or parallelism of machine geometry, shall utilize pins, keys, square shoulders or other such positive means of retaining alignment and regaining it in the event of accidental dislocation. The rebuild shall meet or exceed existing methods of retention on the existing machine. Retention of alignment that depends solely upon bolt tension and/or adhesives will be unacceptable.

3.1.4. Bed Table with T-Slots. As part of this rebuild shall be re-ground as required to re-establish original geometrical characteristics. The existing OEM bed table on this machine is an integral cast iron table.

3.1.4.1 Wipers. All wiper systems, regardless of type shall be replaced with wipers designed to prevent intrusion of foreign material. Wipers shall be adjustable to compensate for wear. All way wipers shall be replaced as part of this rebuild.

3.1.5 Workmanship. Rebuild workmanship throughout the machine shall be of good quality and meet industry standards.

3.1.5.1 Shimming. A shim is herein defined as an unplanned insert whose presence, dimension and shape do not appear on the engineering drawings and which cannot, therefore, be reproduced from those drawings. Shims, as defined above, shall not be incorporated as part of this rebuild.

3.1.5.2 Unacceptable Repair Measures. Welding, brazing, soldering, and other such techniques shall be used only where called for in the original machine's design. They shall not be used as part of this rebuild to repair machine components defective in material or in machining accuracy.

3.1.6 Maintainability. All parts subject to wear, distortion, or failure and all parts which require periodic adjustment shall be readily and safely accessible for repair, replacement, or adjustment as applicable.

3.1.7 Interchangeability. All parts bearing the same part number shall be functionally interchangeable.

3.1.8 General Electrical Characteristics. The electrical system shall conform, in quality, safety, and performance, to all industry electrical standards.

3.1.8.1 Applicable Power Source. The power source to which the machine will is connected furnishes a nominal 480 volts, 3 phase, 60 Hz AC. However, the machine shall be tolerant enough of line fluctuations to operate normally at source voltages ranging from 432 to 504 volts.

3.1.8.2 Electrical Safety Devices. The machine and its equipment shall be protected with circuit breakers which comply with NEMA standards for thermal magnetic types and shall have a minimum interrupting capacity of 25,000 RMS symmetrical amperes for 480 volt, 3-phase system. Breaker terminals shall be UL listed as suitable for the type of conductors provided. Plug‑in circuit breakers or current‑limiting fuses are not acceptable.

3.1.8.3 Conversion Equipment. If DC or reduced voltage AC is required to meet any specified requirement, the necessary conversion or transformation equipment shall be furnished with the machine by the contractor.

3.1.8.4 Motors. All motors shall be of the optimum type and horsepower rating to meet intended application and usage based on accepted engineering practice. Under normal operation of the machine throughout its specified range and capacity, no motor shall be operating at overload, and all motors shall be equipped with thermal overload protection. All motors shall be housed in enclosures of the appropriate NEMA type for the class and severity of service and shall be properly balanced. Each motor shall bear an identification plate containing the identity of the manufacturer, the model, serial number, input voltage, amperage, horsepower, phase, frequency, and frame or mounting. All AC unidirectional motor housings shall bear a directional arrow to indicate proper rotation direction when correctly wired. All AC motors rated at 25 HP or greater shall be equipped with a "soft start" mechanism which provides for reduced voltage starting. If this is a rebuild/retrofit project then replacement motors shall as a minimum meet original OEM specs in continuous HP and torque ratings without the use of additional gearboxes.

Note: All motors are to be permanently lubricated and sealed unless the contractor can substantiate that this feature cannot be offered by two (2) or more major motor manufacturers.

3.1.8.5 Operator Control Voltage. All electrical controls meant for use by the operator of the machine shall carry 120 volts AC maximum. Class "A" ground fault interrupt protection shall be provided.

3.1.8.6 Utility Outlet. The machine shall be provided with a dual‑receptacle 3‑wire utility outlet fully wired and equipped to deliver 120‑volt single‑phase AC power at up to 20 amperes, based upon 480-volt 3‑phase input. This outlet shall be protected by a ground‑fault interrupter and shall be externally mounted and easily accessible. An electrical "noise" suppression device shall be provided.

3.1.9 Safety and Environmental Features.

3.1.9.1 Protection of Machine Operator. Protection of the machine operator and other personnel shall be accomplished in accordance with all pertinent arsenal, state, federal, and local regulations.

3.1.9.2 Protection of the Machine. The proposed control system shall be fully equipped with the devices, software, etc. necessary to prevent self‑damage in the event of malfunction and/or ordinary operator negligence in so far as practical.

3.1.9.3 Noise Levels. Noise levels at a distance not exceeding one meter from the nearest point on the machine shall, under no circumstances, exceed a maximum of 85 dba when measured by a properly calibrated sound level meter set for “A” weighting and slow response. Any shields, baffles, enclosures or other devices required to bring the machine into conformance with this noise level requirement shall be furnished by the contractor. Any such devices shall not interfere with the proper operation of the machine and shall be designed to preserve the visibility needed for safe operation and ease of maintenance.

3.1.9.4 Ozone Depleting Substances Section 326 of Public Law 102‑484 precludes the Dept. of Defense from awarding any contract that directly or indirectly requires the use of a class 1 ozone‑depleting substance within the government specification or standards set forth in the contract. Attachment #B is a list of the restricted Class I CFC's and Halons. All shall be replaced by new functionally equivalent substances or systems that are approved for use by the Environmental Protection Agency (EPA) and have an "Ozone‑Depletion‑Potential" (ODP) rating of zero. Material Safety Data sheets (MSDS) shall be submitted for approval to Watervliet Arsenal at the time of the submission of proposal.

Definition: Ozone‑Depletion‑Potential (ODP). The relative capacity of a substance, per unit weight, for destroying the earth's stratospheric ozone layer, in comparison with CFC‑11, CFC‑12 and CFC‑ 114, each having been assigned an ODP of 1.00.

Note: Offerors are responsible to obtain and adhere to the most current list of prohibited substances as of the date of the submission of bids or proposals.

Order of Precedence: In the event of a conflict between the text of this paragraph and the references cited elsewhere in this specification the text of this paragraph shall take precedence. Nothing in this specification, however, shall supersede Section 326 of Public Law 102‑484 unless a specific exemption has been obtained.

3.1.9.5 Asbestos and Mercury Free Certification. All materials utilized as part of this rebuild shall be certified as asbestos and mercury free. This certification shall be provided at the time of proposal submission.

3.1.9.6 Material Safety Data Sheets. The offeror shall provide Watervliet Arsenal with all material safety data sheets at the time of the submission of his proposal.

3.1.9.7 Lead‑Free and Chromium‑Free Paint Certification. All paints and primers applied as part of this rebuild shall be certified as lead free and chromium‑free. Lead based paint is paint that contains more than six one-hundredths of one percent (0.06%) lead by weight. This certification shall be provided at the time of proposal submission.

3.1.9.8 PCB‑Free Certification. The machine and its equipment shall be certified as PCB‑free prior to being shipped back to Watervliet. PCB free is defined as a level of contamination which is undetectable using EPA approved methodologies.

3.1.9.9 Lockout/Tagout Procedures. The manufacturer is required to provide the proper control of hazardous energy (lockout/tagout) per OSHA 29 CFR 1910.147. The rebuilder shall ensure this information be incorporated into the maintenance manual. The control of hazardous energy sources includes electrical, pneumatic, hydraulic, chemical, mechanical, UV, electromagnetic and thermal.

3.1.10 Identification Plate. A second corrosion‑resistant metal plate shall be securely attached to the machine in a visible location in the vicinity of the operator's workstation. This plate shall bear the information called for as follows, with space at the bottom for one additional line of information to be applied by the government. The original ID plate shall not be removed from the machine

Nomenclature

Manufacturer's/Rebuilders name

Model

Manufacturer's/Rebuilders Serial Number

Power Input (voltage, phase, frequency, and total amps)

Government Contract Number

Date of Rebuild

3.1.11 Lubrication. Spindle bearings, gearboxes, and transmission are lubricated by a recirculating lubrication system. Systems of the foregoing types are considered automatic systems and they shall be equipped to be fail safe to the maximum extent possible. Any sensors or other devices used to detect the presence (or absence) of lubrication shall be accessible for test or replacement without major disassembly. Manual lubrication methods (e.g. Grease fittings, oil cups etc.) are permissible for lubrication points not practically served by automatic systems. For non‑recirculating automatic systems, the reservoirs shall be sized to provide lubrication reserve equivalent to 80 operating hours and shall be located at floor level. For recirculating automatic systems (such as pressure spray), easily cleanable or replaceable filtration devices shall be provided. Recirculating type systems shall be equipped with means to confirm proper oil level. Sight gages shall be of the external standing tube type rather than the flush‑mounted porthole type. Standing tube sight gages shall be protected against accidental breakage.

3.1.11.1 Lubrication Plate. A lubrication plate (or plates) shall be permanently fastened to the machine and shall clearly indicate the type and viscosity of lubricant and the service interval for all automatic and manual lubrication reservoirs and fittings. The plate shall include a simple diagram which depicts the physical location of all lubrication points on the machine structure.

3.1.11.2 Lubricants, Hydraulic Fluids, Oils and Coolants. Watervliet Arsenal established a standardized list of lubricants, hydraulic fluids, oils, and coolants. The contractor is requested to choose the required lubricants, hydraulic fluids, oils and coolants from Attachment “A”, enclosed or where designated (*see note) approved industry/commercial equivalents. If a substitute is required, the contractor shall provide justification which shall include the manufacturer, type and specification number as well as the reason for the substitution.

3.1.12 Hydraulic System. The hydraulic system shall be replaced and appropriately sized and powered for the intended application and shall conform to industry standards. The system shall incorporate cleanable or replaceable filtration devices to insure fluid cleanliness. Reservoirs shall be equipped with easily visible gages to indicate fluid level. If duty cycle of the system under maximum usage will cause the hydraulic fluid to exceed 120 degrees f in temperature, a suitable heat exchanger shall be provided to maintain fluid temperature at or below this level. The system shall be protected against overpressure as well as under pressure. System pressure in any hydraulic device shall be as low as is practical for the intended application but shall not exceed 3000 PSI in any case. In any system which utilizes hydraulics to produce thrust or direct linear motion, anti‑surge devices or circuits shall be incorporated to insure uniformity of motion under varying loads. These devices or circuits shall be adjustable. All reservoirs shall be easily accessible for cleaning and flushing.

3.1.13 Painting. All exterior machine surfaces shall be painted except where bright metal is required for machine function or to otherwise adhere to the requirements of this specification. Paint shall be chromium‑free and lead‑free. Quality and manner of application shall be such as to afford protection throughout the normal life of the machine. Paint shall be "semi‑gloss" and shall closely match the existing colors. Danger areas shall be painted red and caution areas shall be painted yellow, warning signs, tags or emblems will be affixed to respective areas of the machine in accordance appropriate safety standards.

3.1.14 Machine Hold Down and Leveling. Existing machine hold down hardware shall be retained for re-installation by offeror.

3.1.15 Gears. All gears shall be inspected and Magna Fluxed for cracks and defects. If found to be worn or cracked or defected, the gear shall be replaced as part of this rebuild. The new gear and or gears shall meet or exceed OEM provided gears and shall also adhere to the industry standards recommended for the type and severity of service required.

3.1.16 Technical Data. All data shall be in the English language and shall be furnished in accordance with the quantities and delivery dates below. The contractor shall provide full documentation in the form of (as-built) drawings and manuals. Drawings shall not be generic. Drawings/schematics shall be provided, as indicated below, in hardcopy and in AutoCAD 2007 or newer version on CD. “On-line” technical data will not be acceptable as the sole means of providing technical data for any of the systems provided. The Government contract number and the Watervliet WV# shall be printed in a conspicuous place on the covers of every manual, on each drawing/schematic, and on all CDs provided. All data shall be packaged and delivered separately from the machine itself marked to the attention of the Technical POC.

a. Lubrication Diagram or Instruction. To be delivered to the technical POC at time of machine re-delivery. (two hard copies and two electronic copies)

b. Operating Instructions. Machine and control system operating instructions shall be provided in separate manuals from other technical data provided. These instructions/manuals shall include a clear description of the functions on the control system operator’s panel. To be delivered to the technical POC at time of machine re-delivery. (four hard copies and two electronic copies)

c. Maintenance and Troubleshooting Instructions. For all machine and control systems. These instructions shall include assembly drawings. To be delivered to the technical POC at time of machine re-delivery. (two hard copies and two electronic copies)

d. Electrical and hydraulic schematics. To be considered acceptable, these schematics must clearly portray all electrical and hydraulic ties to their respective main systems. To be delivered to the technical POC at time of machine re-delivery. (two hard copies and two electronic copies)

Note: If, during installation and testing, the actual electrical and/or hydraulic systems are configured differently than depicted on the schematics, receipt of the revised "As‑Built" schematics shall be a condition of final acceptance.

e. Repair Parts Catalog. This catalog shall encompass every replaceable part in the machine and shall include appropriate identification and ordering data. Items which can normally be purchased locally may be so indicated provided they are sufficiently described. The repair parts catalog shall include illustrations which clearly locate parts within larger sub‑assemblies. To be delivered to the technical POC at time of machine re-delivery. (two hard copies and two electronic copies)

f. The offeror shall provide two paper hardcopies and two electronic copies (CDs, and preferably a flash card if control is equipped) of all final system software and ladder logic developed to control and interface the new control/drives with the existing machine tool (system backup). Final revision software to be furnished to the technical POC not later than 30 days after final acceptance of the rebuild/retrofit or at such time when all software revisions have been completed.

3.1.17 Training Required. The contractor shall be responsible for providing acceptable training of Arsenal personnel. The type and extent of training shall depend upon whether the machine specified or offered is equipped with numerical control. All instructions and materials, oral or written, shall be in English. "On-Site" means "At Watervliet Arsenal", and "Off-Site" means "a location within the U.S. away from Watervliet Arsenal as determined and arranged for by the contractor". The quality of the training shall be such that at the conclusion of the specified training time, each individual within their assigned category shall be capable of repairing or operating the machine to its productive capacity. Training shall be in accordance with the applicable areas of the following schedule:

Hydraulic maintenance

(if applicable)

SCR drives

(if applicable)

Programming training

(if applicable)

Note: For all types of training, the associated technical data (see 3.1.17) shall be on hand at the time of instruction and its use and interpretation shall be covered during the training. A training schedule showing the hours of training for each person under their assigned category, shall be sent in with proposals for review.

3.1.18 Pneumatic Requirements. If air is needed for any machine operation or function, the machine shall be fully equipped with all necessary piping, valving, etc., fully installed to the point of connection to which the Arsenal will connect shop air. Available shop air at the Arsenal is 80 psi and if higher or lower pressure is needed at the machine, the machine shall be fully equipped with the devices needed to modify the 80 psi supply pressure. The machine shall also be equipped with devices to remove the normal moisture and other contaminants usually present in shop air supplies. Normal moisture is defined as that moisture produced when air at a relative humidity of 75% has been compressed to 80 psig.

3.1.19 Control of Cutting Fluids. The machine is equipped with a coolant system, the contractor shall ensure that upon completion of the rebuild the machine is still equipped to prevent coolant from escaping the confines of the machine or leaking to the floor when producing workpieces of a size within the machine's normal working range. The rebuilder will not be required to provide any additional enclosures that were not originally part of the machine provided by the OEM. If a portion of the enclosure or coolant guarding is missing when the rebuilder takes possession of the machine then the rebuilder shall fabricate a replacement as part of the rebuild project.

3.1.20 Site Conditions. The machine covered by this specification is installed in general machine shop space and there will be no environmental conditioning. Temperatures will range from 60 degrees f. To 95 degrees f. and relative humidity will range from 20% or less to 95%. On any given day, the temperature in the machine shop may change as much as 4 degrees f. per hour. These are the conditions under which the machine is expected to perform as specified, and the contractor shall be responsible for supplying whatever is required to meet the specified performance.

3.1.21 Heat Exchange Equipment. Heat exchange equipment shall be furnished with the machine wherever it is needed to keep operating temperatures within design or specified limits. Any heat exchange equipment using water as the heat exchange medium shall be fully recirculating and shall not require the continuing input and discharge of Arsenal water supply. Waste water systems of any type are not acceptable. Furthermore, it is the Arsenal's preference to avoid heat exchange equipment making use of the refrigeration cycle, and refrigeration systems of any kind are not acceptable unless design or specified temperature limits cannot be achieved without them. If a refrigeration system is absolutely necessary, the contractor shall insure that it operates properly using a refrigerant having an ozone depletion potential of zero. The contractor shall be responsible for identifying and providing such a refrigerant and its material safety data sheet.

3.1.22 Filtration System. The machine utilizes a new Barnes model RMP-100, S/N: TRSP-10620 magnetic and fabric filter with chiller. This unit will be left on site.

3.1.23 Elapsed Time Meter. The machine shall be fitted with a meter to measure operating time of the spindle drive. The time totalizing meter shall be of the non‑resetting type and shall have a range of 0 to 99,999 hours in increments of 1 hour. 1-hour being the least significant digit. Upon reaching the maximum accumulative hours the meter readout shall automatically revert to zero and continue to totalize time. The meter shall be designed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by the equipment. The meter shall be located as to be readily visible but not subject to abuse relative to the operating environment of the equipment. Time meters resident in the numerical control unit are unacceptable.

3.1.24 Machine Removal and Installation, Startup and Testing.

3.1.24.1Work to be performed by the Arsenal. In preparation for machine shipment Watervliet personnel will disconnect main machine power and compressed air supplies. Watervliet will also drain all fluids as much as possible.

After re-delivery of the machine Watervliet personnel will re-connect main machine power, compressed air and re-charge the machine with the required fluids.

3.1.24.2Work to be performed by the Contractor. This project shall be a turn-key operation with the contractor being fully responsible for all work, and providing all personnel and equipment necessary to perform the required scope of work. Unless otherwise specified, all components and/or systems replaced/rebuilt as part of this project shall meet or exceed the original equipment manufacturers (OEMs) specifications. Where possible it shall be required that components and/or systems rebuilt/replaced as part of this project be commercially available standard parts/systems obtained from sources within the United States.

Contractor personnel shall be solely responsible for costs associated with disconnection/reconnection, removal/reinstallation, rigging, skidding and shipment and return. After all required work has been completed, and upon completion of paragraphs 4.2 and 4.5 the contractor shall ship the machine to Watervliet Arsenal.

Contractor personnel shall coordinate the return of the machine to Watervliet. Contractor personnel shall arrange for rigging services to off load the machine and contractor personnel shall be on-site at Watervliet when the machine arrives and is off loaded. Outside rigging services should be advised that chain hoists are not permitted to be used at the Arsenal and that all rigging slings must be tagged and certified for the weights being lifted. Contractor personnel shall supervise the placement of the machine on the installation site by the rigging service. In most cases no Arsenal forklift services and/or Arsenal personnel will be available for the re-installation. Operators of forklifts shall have and be able to produce valid forklift licenses. Arsenal overhead pendant cranes (within load capacities) can be used by the contractor/rigging service for the installation. The contractor shall provide written certification to the WVA representative that all contractor/rigger personnel are qualified, through either formal training or experience per OSHA, to operate pendant controlled overhead cranes. The contractor shall ensure they bring all equipment/material necessary for the reinstallation of the machine. Watervliet does not have the resources to provide such material.

The contractor shall install all systems and place the machine in operation and conduct the acceptance tests specified in section 4. The contractor, through their service personnel, shall be fully responsible for the complete interfacing, startup, debugging and testing of the machine.

The service personnel shall remain until the machine activation and all testing and training has been successfully completed. Under no circumstances should the contractor plan on gratuitous Arsenal assistance for diagnosis, troubleshooting, or repair of the equipment during activation and testing. Should such activity prove necessary, it shall be the contractor's responsibility to provide the appropriate labor and materials.

IMPORTANT: Under normal circumstances the contractor will be allowed to work as long as is desired during normal work days. Contractor work outside Watervliet’s normal work days cannot be guaranteed. Watervliet is on a condensed work schedule. Normal work hours/days for this schedule are four 9-hour workdays (Friday off) one week and four 9-hour days, one 8-hour day (Friday) the following week. Contractor work on the Friday off and weekends cannot be guaranteed. Contractor’s classified as foreign nationals may further restrict work hours and days available.

If the contractor requests Watervliet Arsenal to ship misc. material via UPS, FedEx or by other similar carrier then the contractor shall provide their carrier account number for this purpose.

3.2 Machine‑Specific Requirements.

Machine Tool Description: This specification defines the requirements for the complete machine rebuild and retrofit of one 1985 Barnes Horizontal Honing machine, model HH-15, S/N ZP-10972, Watervliet number WV12311 (machine). The entire machine except for the filtration system shall be removed from WVA and returned in like new condition.

3.2.1 Physical Characteristics. Misc. machine info is as follows:

· 30 HP spindle motor

· 107 feet overall length

· 26,000 LBS. machine weight

· 44 foot stroke

· Bar length 40’ 8”

· 6 bed sections

· Work pieces weight 20,000 LBS.

3.2.1.1 Performance Characteristics. The performance characteristics of the machine shall be as they were when the machine was new. Below is a sample of some of the performance characteristics.

· Honing spindle speed range 30 rpm to 300 rpm.

· Rate of honing head reciprocation 20 linear ft per minute to 90 linear ft per minute.

· Honing head reversal points .080˝ from set position.

· Stock Removal Rate 65 in3/ Hour or more

3.2.1.2 Alignment and Accuracy Characteristics.

Characteristics

Value

Honing Headstock & Drive Shaft ± .0025˝ non-accumulative

Supports parallel & square to each other measured over horizontal & for their full travel along the bed ways vertical plane using a common centerline

Guideways supporting the honing .002˝ over 36˝ distance headstock & drive shaft supports measured longitudinal & parallel & flat to each other across ways not to exceed

.005” variation over full length of ways

Honing spindle, axial or face runout .001˝ maximum T.I.R.

Honing spindle, radial runout .001˝ Maximum T.I.R.

(Measured at the honing tool

Body interface) Note: The contractor shall submit, in their proposal, the method of testing for each parameter required by this paragraph and what equipment they will use at their factory to perform those tests.

3.2.2 Other Required Characteristics. It is understood that, at this time, bidders are not fully aware of the extent of the work required for this rebuild. However, each bidder should be cautioned that statements such as "Watervliet will be notified of additional costs" or "a separate quote will be issued" or any other similar statements that could result in additional expenses to Watervliet after contract award will not be acceptable. The only exception to this is pertaining to major castings of this machine. Therefore, bidders should formulate their quotes/proposals assuming a worst case rebuild scenario, if in doubt quote NEW.

The following shall be basic minimum requirements of the rebuild and shall not be interpreted as being all-inclusive of the work required. All quotes shall reflect at least these requirements. Again, if in the work listed below it is designated to be "rebuilt or reconditioned" and a bidder does not think rebuilding or reconditioning will be sufficient then it should be quoted as Replace or New. The intent to have the machines returned in “As New” condition.

a.) The existing control system shall be replaced with a New Allen-Bradley PLC control system as to capture all the OEM existing machine control features, and functions.

· Allen-Bradley PLC processor complete with rack, I/O and components as required.

· PanelView 10” color touch screen, operator interface complete with menu screens and diagnostics mounted in pendant mounted operator console.

· Multi-part file system to store, recall and reset all machine parameters.

· Electrical enclosure for above control plus all starters, disconnects, fuses, terminal strips, and interconnecting wiring.

· All wire ways, junction boxes, and hardware.

· Power track for electrical cables.

b.) All axes drive motors and drive packages shall be replaced. The new axes drive motors and drive packages must be sized and rated to meet or exceed the OEM systems originally provided with the machine in continuous HP and torque ratings without the use of additional gearboxes. The contractor will be responsible for any mounting adaptation that may be required.

c.) The spindle motor and drive package shall be replaced. New 40 HP spindle drive motor and 40 HP variable speed drive arrangement in place of existing 30 HP motor. Complete with new motor coupling and motor spacer. Such the type continuous HP and torque ratings without the use of additional gearboxes. Spindle RPM will be programmable thru the Operator Console color touch screen. The contractor will be responsible for any mounting adaptation that may be required.

d.) New Reciprocation Chain Drive Unit. A new chain drive arrangement complete with gear box, hydraulic fluid motor, shafts, bearings, sprockets, chain and hydraulic chain tension assembly. Tension assembly includes new hydraulic cylinder and yoke. New 20HP servo motor. Reciprocation rate will be programmable thru the Operator Console color touch screen.

e.) Recondition of traveling support assemblies including new bumpers, rollers, wipers, and bushings. Traveling Supports, inspect wear items if any discrepancies are found items are to be replaced, assembly including new polyurethane wipers and new oil cups.

f.) Rebuild Hone Cradle Assembly. Rebuild hone cradle assembly complete with new gear box, pinon, rack, raising jacks, pillow blocks, bushings, and seals. The existing troughs will be cleaned and inspected if found to have excessive wear shall be replaced or reconditioned.

g.) Recondition Work Supports. Recondition work support assemblies – front, rear, center - including new brass clamp pads, bushings, bearings, springs, washers, and nuts.

h.) New Guide Way Bars and Roller Assemblies. New guide way bars, Thomson Class “L” 2 ½” diameter and guide bar roller assemblies complete with bearing shafts, bushings and bearings.

i.) Coolant Valve and Splash Guarding. New coolant valve with plumbing and nozzles to distribute coolant at each end of work support table. New splash guards to contain coolant within work support table assembly.

j.) All bearings, collars, retaining clips, and hydraulic cylinders, bumpers and shock absorber cylinders throughout the machine, shall be replaced with new of equal or better quality to OEM.

k.) New Stroke Control Unit. A new stroke control unit shall be mounted to the base including an encoder, encoder cable and mounting bracket. The stroke parameters will be programmable thru the Operator Console color touch screen.

l.) New Hone Expansion Motor. New Exlar linear actuator (motor) complete with push rod and mounting bracket to connect to carriage head assembly. Expansion rates will be programmable thru the Operator Console color touch screen.

m.) All motors (other than those designated as being replaced) shall be inspected and rebuilt. This shall include replacing bearings, painting, and mega testing of windings and if necessary rewinding and balancing. If this isn’t cost effective then replace with new.

n.) Lubrication. New Bijur Delimon automatic metering block type lubrication system. The system will be arranged to provide grease to the guide way bars.

o.) New Hydraulic Power Unit complete with 40 gallon tank, pump, 30 HP motor and hoses. Hydraulic Pump(s) and motor(s) shall be replaced with new. The entire hydraulic system chiller unit and its components shall be completely replaced.

p.) All flexible hoses (fluid carrying, pneumatic, etc.) shall be replaced with new of equal or better type and quality. All lubrication tubing shall be free of blockages, cleaned and replaced as required. Oil-tight (non-fluid carrying) protective hoses shall be inspected for kinks and/or cracking and replaced as required.

q.) All Cylinders (Hydraulic & Pneumatic) shall be replaced. All Hydraulic & Pneumatic valves throughout machine.

r.) All Limit Switches throughout machine and ancillary equipment shall be replaced with new of equal or better type and quality.

s.) Transmission Gears shall be inspected and mag tested if not being replaced and shall be replaced if deficiencies are found. Inspection report shall be provided for review by WVA representative.

t.) The electrical panels shall be rewired and all relays replaced, contactors shall be replaced where possible with PLCs or new components. All other wiring shall be replaced.

u.) The entire machine and all associated equipment shall be thoroughly cleaned and painted. The color shall be the same.

v.) A Bill of Materials will be submitted of those parts replaced in the rebuild of this machine. The Government also shall reserve the right to inspect those parts replaced as part of the rebuild.

3.2.3 Coolant injection unit. A coolant injection unit shall be supplied with the machine. Coolant injection unit disperse coolant at a pressurized rate throughout the length of the bore diameter being honed. Mounted to the work support table of the machine. Complete with mounting plate, cradle assembly for moving longitudinally along the work support table and sliding bar assembly for moving laterally. Also, shall include pneumatic cylinder and coolant delivery can(s) and coolant drainage hose.

The coolant injection Unit shall have the following functions/capabilities:

· Manual control of the pneumatic cylinder that seats the gasket. Control shall include starting/stopping the cylinder and ram speed.

· Manual control of the X-axis positioning of coolant injection system

· Clamping means for the coolant injection assembly at any position the Z-axis ways.

· Pressure Relief set so the forward stroke of the hone remains smooth

· Coolant flow control (Manual valve and flow meter)

Note: The contractor shall use a stainless steel cylinder, fittings, and tubing in the pneumatic system. The contractor will be allowed to connect to the Watervliet Arsenal compressed air system

3.3 Machine Control System. The offered system shall be capable, as a minimum, of maintaining or emulating full functionality of the existing control as well as other features specified.

a.) The control system shall include a flash memory card reader. One spare blank 128mb flash card shall also be provided.

3.3.1 Operator Control Panel. The contractor shall provide an operator control panel to house the display screen, and all machine controls, including control knobs, buttons, and handwheels. The operator’s panel/mounting shall be designed to permit visible access to the work envelope. The operators control panel shall also include the following:

a.) The panel provided shall have at least a USB port and a flash card reader port. Twelve spare screen protectors shall be provided for machine control.

b.) An emergency stop button shall also be located on the panel.

3.3.2 Enclosures. All new controller hardware may be installed in existing electrical enclosures is desired. If new enclosures are provided, they shall be NEMA‑12 rated. In addition:

a.) If required, given shop environmental conditions as detailed in par. 3.1.8, new control system enclosures for electronic circuitry shall be air conditioned and air filtered to maintain constant temperature, to reduce humidity and to prevent contamination of control boards and other critical system components. Air conditioning units shall not utilize Ozone Depleting substances.

b.) New enclosures shall be painted with a color as close to the painted color of the original machine tools as possible.

3.3.3 Interconnecting Wiring. All wiring shall comply with accepted Joint Industry Code (JIC), National Machine Tool Builders Association (NMTBA), and National Fire Protection Association (NFPA) Standards.

3.3.4 Control/Operating System Software and Documentation. One copy of the control software, ladder logic, interface software, etc. and all pertinent documentation are to be provided prior to final acceptance. A flash card loaded with the final version of the system software (Static RAM or S RAM) back up shall be provided with the final documentation. Also to be provided is a bill of materials for the control and drive systems detailing all control system standard features/options. Ladder logic documentation provided shall include a listing of logic error/alarm messages and a cross reference list of the full descriptive relay contact and coil names to the abbreviated names in the logic.

3.3.5 Control Functions and Capacities.

Also, prior to the development of system software for this machine it shall be required that the contractor actively communicate with Watervliet machine operators and maintenance personnel to ensure control/machine functionality is maintained with the new control system(s). This communication will be best achieved on-site at Watervliet.

3.3.6 Diagnostics Capabilities. Shall be equipped with diagnostic capabilities covering the control itself, the interface, and the machine tool. As a minimum, diagnostic capability shall include the display of a message or other meaningful indicator to identify any fault that causes the machine to be inoperable. This includes electrical/electronic faults and also any mechanical faults that result in operation of a safety interlock.

3.4 Requirements for Demonstration of Conformance.

3.4.1 Certification of Completeness. The contractor shall provide written certification that the machine is complete, including all specified systems, accessories, markings, safety devices, geometric and accuracy requirements. The certifications shall be provided to the Technical POC 14 days prior to schedule preliminary testing.

3.4.2 Tests Required. The contractor shall demonstrate the machine's conformance to all specified requirements by the following:

3.4.2.1 Test of Conformance to Specified Performance Characteristics. The machine shall be dry cycled at least 30 minutes, during which time the machine shall be tested for conformance to specified performance characteristics, including but not limited to, feeds, speeds and manual as well as automatic cycling.

3.4.2.2 Test of Conformance to Specified Alignments and Accuracies. The machine shall be tested for conformance to the alignments and accuracies specified in paragraph 3.2.1.2.

3.4.2.3 Required Accuracy on Workpieces. For preliminary and finial acceptance testing the contractor shall be required to demonstrate the following.

Characteristic Allowable Tolerance

Out of roundness of the bore measured

0.0005˝ or less over total hone depth

At 5 random locations

Overall taper of the workpiece bore Not to exceed 0.002˝ from over 528˝

Overall taper of the workpiece bore Not to exceed .0002” in 4 to 8 feet

Overall taper of the workpiece bore Not to exceed .0004” in 8 to 14 feet

Surface finish of workpiece bore 16 Micro-inch or finer

3.4.2.4 Test of Conformance to Specified Performance on Workpieces:

Paragraph 3.4.2.3 outlines the types of accuracies of physical characteristics which the machine shall be capable of producing on actual workpieces. The contractor shall submit in their proposal a print of a workpiece to be used for both preliminary and finial testing, using 4340 alloy steel pre‑heat treated to a Rockwell hardness number of RC 35‑41. For finial testing an actual WVA production work piece 120mm or 155mm shall be honed in conjunction with the contractor’s test part. The contractor’s work piece shall incorporate the machine characteristics listed in paragraph 3.2. The contractor’s test part shall be approved by the Watervliet Arsenal to be judged acceptable.

3.4.3 Provision of Materials and Equipment for Preliminary and Final Acceptance Testing.

3.4.3.1 Material for Workpieces. All materials necessary to produce the workpieces required in paragraphs 3.4.2 shall be furnished by the contractor except where otherwise specified.

3.4.3.2 Tooling. All tooling required for the test part specified in paragraphs 3.4.2 shall be furnished by the contractor. Watervliet shall provide tooling for cutting tests performed at Watervliet Arsenal.

3.4.3.3 Cutting Fluids. Any cutting fluids (coolants) necessary to perform the tests specified in paragraph 3.4.2 shall be furnished by the contractor (at preliminary acceptance). Watervliet will provide for final acceptance.

3.4.3.4 Hydraulic Fluids and Lubricants. All hydraulic fluids and lubricants required to fully charge and activate the machine at the contractor’s facility shall be furnished by the contractor. Watervliet will provide for final acceptance.

3.4.3.5 Testing and Measuring Equipment. All testing and measuring equipment needed to perform any of the required tests and measure the results shall be furnished by the contractor and shall be properly calibrated to standards traceable to the National Institute of Standards and Technology (NIST).

4. Quality Assurance Provisions:

4.1 Responsibility for Inspection. The contractor shall be responsible for performing all certifications and tests required in paragraph 3.4.1 and 3.4.2 and shall provide such materials, supplies, and equipment as are specified.

4.2 Preliminary Acceptance Inspection. Preliminary acceptance inspection shall occur at the contractor's facility prior to machine shipment back to WVA and shall consist of the certifications and tests specified in paragraph 3.4. However, prior to officially scheduling the preliminary acceptance inspection the contractor shall perform preliminary machine geometry alignments, and cut the test part. When these tests are completed successfully, the contractor shall provide no less than 14 calendar days notice to the Arsenal Contracting Officer that the machine is ready for the preliminary acceptance inspection. This notification shall also include for review the test results of all preliminary tests performed. If acceptable, the Arsenal representatives will schedule an inspection and the contractor shall await the arrival of the Arsenal representatives before starting the official inspection.

4.3 Arsenal Participation in Preliminary and Final Acceptance Inspection.

4.3.1 Examination for Completeness. The contractor shall furnish the Arsenal's representatives with a certification of completeness (see par. 3.4.1). The Arsenal's representatives will reserve the right to examine the machine to ascertain the presence of all specified features, equipment, markings, and safety devices.

4.3.2 Examination of Performance Characteristics. During the test of conformance to specified performance characteristics (see par. 3. 2), the Arsenal's representatives will observe the machine and its equipment for proper operation. Also during this test, the Arsenal's representatives may perform independent measurements of sound levels for conformance to par. 3.1.9.3.

4.3.3 Examination of Alignments and Accuracies. During the test of conformance to specified alignments and accuracies (see par.