11-16-6625_Rev_B_Specification.doc

11-16-6625

Rev. B

Specification for New Magnetic Particle Inspection Machine Spec. # 11-16-6625 Rev. B Manufacturing Engineering Work Group

Watervliet Arsenal

Watervliet, New York 12189

1/13/2017 Department of the Army

TACOM

1 Scope:

The equipment purchased by this specification shall be a new Magnetic Particle Inspection Machine. The machine shall be of the wet, horizontal type. The machine shall have the capacity to inspect the Watervliet Arsenal’s 120mm mortar tubes and full range of cannon tubes (105mm, 120mm 155mm, and prototype tubes).

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. The quality of all work performed and material provided shall meet or exceed the latest applicable industry standards and engineering practices for this type of equipment and its intended function. In all instances, material, quality, and workmanship shall meet or exceed OEM specifications. Where applicable the machine shall meet requirements of ASTM E1444.

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.

3.1 General Requirements

1.1.1 Design and Engineering. The machine shall be designed and engineered in accordance with the latest standards recognized or adopted by the Association for Manufacturing Technology (formerly the National Machine Tool Builders Association). The design and engineering shall incorporate only concepts, systems, materials and new components which have been proven in prior use. Modifications to manufacturers’ standard designs to achieve requirements specified herein are not permissible if they result in deviations from good design practice.

1.1.2 Materials. Materials incorporated in the construction 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 or adopted by the Association for Manufacturing Technology / National Machine Tool Builders Association for this type and class of equipment.

1.1.3 Construction. All parts of the machine shall be new and unused and shall be constructed so as to be capable of withstanding all forces encountered during operation to its maximum rated capacity. The structure and assembly of the machine and its components shall be sufficiently rigid to support Watervliet Arsenal workpieces.

1.1.4 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 a positive means for retaining alignments and regaining them in the event of accidental dislocation. The machine shall include all hardware devices required to maintain all specified alignments and accuracies.

1.1.5 Workmanship. Workmanship throughout the machine and its equipment shall be of good quality and in conformance to the manufacturer's engineering drawings and to standards recognized or adopted by the Association for Manufacturing Technology / National Machine Tool Builders Association.

1.1.6 Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. Weldments, if used, shall be braced, ribbed and gusseted to obtain strength equal to or better than the strength of castings, and shall be properly stressed relieved.

1.1.7 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. Instructions for maintenance and adjustments shall be clear, concise and definite in application.

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

1.1.9 Applicable Power Source. The power source to which the machine will be 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.

1.1.9.1 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. All transformers must meet NEMA TP 1-2002 energy efficiency requirements.

1.1.9.2 Cabinet Enclosure for Electronic Equipment. All separate electrical hardware / circuitry are to be housed in a NEMA rated enclosure/cabinet. Should forced ventilation be necessary to maintain the interior of the enclosure at a temperature to ensure good product reliability, filtered air shall be forced into the cabinet to maintain an over pressure condition in the cabinet. Cabinet shall not inhibit operator access to the controls and/or adjustments.

1.1.9.3 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.

1.1.9.4 Motors. All motors provided shall be of the optimum type and horsepower rating to meet intended application and usage based on accepted engineering practice. 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. Each motor shall bear an identification plate containing, as a minimum, 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. All polyphase AC motors rated at 1 Hp or greater shall be tested per IEEE Standard 112-Method B and must meet Premium Efficiency requirements per NEMA MG 1-2006 Table 12-12 or IE3 (IEC 60034-30:2008). 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.

1.1.9.5 Operator Control Voltage. All electrical controls meant for use by the operator of the machine shall carry a maximum of 120 volts AC @ 60 Hz.

3.1.1.1 Utility Outlet:

The machine shall be provided with an operational 120‑volt single‑phase, 20-ampere dual‑receptacle 3‑wire utility outlet. This outlet shall be protected by a ground‑fault interrupter and shall be externally mounted in the operator inspection enclosure and easily accessible. A “noise" suppression device shall be provided.

1.1.10 Safety and Environmental Features. The contractor shall review the environmental requirements documented in Attachment D and comply as applicable.

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

1.1.10.2 Protection of the Machine. The machine shall be fully equipped with the devices necessary to prevent self‑damage in the event of malfunction and/or ordinary operator negligence insofar as practical. The system shall be equipped with the necessary protective devices required to prevent electrical/electronic damage to the system because of over-travel, power failure, and the resultant start and stop due to power failure.

1.1.10.3 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.

1.1.10.4 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 I 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.

1.1.10.5 Asbestos and Mercury Free Certification. All materials utilized in the system shall be certified as asbestos and mercury free unless substitute materials do not exist. This certification shall be provided prior to machine delivery.

1.1.10.6 Lead‑Free and Chromium‑Free Paint Certification. All paints and primers applied to the system 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 prior to machine delivery.

1.1.10.7 PCB‑Free Certification. To the extent that the machine may have been charged with lubrication and/or hydraulic fluids at the contractor's plant for preliminary acceptance inspection, these fluids shall not contain Polychlorinated Biphenyl’s (PCB’s). The machine and its equipment shall be certified as PCB‑free prior to being shipped.

1.1.11 Identification Plate. A 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, as a minimum, the information called for as follows, with space at the bottom for one additional line of information to be applied by the government.

Nomenclature

Manufacturer's name

Model

Manufacturer's Serial Number

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

Government Contract Number

Date of Manufacture

1.1.12 Lubrication. The machine shall be equipped to provide sufficient lubrication to every moving part where lubrication is essential to prevent damage. If the machine requires periodic, additional lubrication over the life of the machine, 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. The contractor is requested to choose required lubricants, fluids, and oils from Attachment A.

1.1.13 Painting. All exterior machine surfaces shall be painted except where bright metal, aluminum, granite, or other critical surfaces are 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. Danger areas shall be painted red and caution areas shall be painted yellow in accordance with OSHA Standard 1910.144. Appropriate warning signs, tags or emblems will be affixed to respective areas of the machine in accordance with OSHA Standard 1910.145.

1.1.14 Technical Data. All data shall be in the English language and shall be furnished in accordance with the quantities, formats and delivery dates below. All data shall be packaged and delivered separately from the machine itself marked to the attention of the Technical POC. Please note any AutoCAD drawings provided shall be saved as AutoCAD 2012 files.

a. Foundation Drawings, Standard or Special (see note): Shall be complete in all construction detail to permit pricing and construction by a general contractor and shall be furnished as soon as possible after contract award, prior to scheduled delivery of the machine. All drawings shall be dimensioned in English units. One electronic copy on CD in AutoCAD .dwg or .dxf format shall be provided. When drawings are finalized the contractor shall certify the accuracy of the drawings by providing a stamped and signed hard copy of the drawings to the Watervliet Contracting Officer.

NOTE: Typical floor thickness at Watervliet is 8”-10”. A special foundation is one which exceeds thickness, load bearing capability and vibration insulation of Watervliet Arsenal's standard monolithic concrete flooring of 1,000 pounds per square foot load rating and/or one which requires a specific thickness, specifically‑shaped excavations for coolant housings, chip conveyors, electrical circuits and conductors, etc.

b. Machine and Equipment Floor Plan: A digitized machine and equipment floor plan in AutoCAD .dwg or .dxf format shall be provided on a CD. This plan shall depict the complete machine space envelope including all ancillary equipment and the dimensioned bolt-hole pattern of the hold-down bolts for the machines. This AutoCAD drawing(s) shall also contain information that indicates the type, magnitude, and connection points of all plant utilities (electrical power including the full load amperage requirements, air, water, etc.) required to operate the machine. This data shall be furnished as soon as possible after contract award, prior to scheduled delivery of the machine. One electronic copy on CD in AutoCAD .dwg or .dxf format shall be provided. Also, if a foundation is required for the offered machine then this drawing shall also clearly depict the outline of the foundation and provide locating dimensions from a fixed point on the machine to at least one corner of the foundation. When drawings are finalized the contractor shall certify the accuracy of the drawings by providing a stamped and signed hard copy of the drawings to the Watervliet Contracting Officer.

c. Catalog of Standard Tooling and Accessories shall be furnished 30 days after award of contract. For offers of foreign built machine tools (i.e., machines built outside the United States, its possessions or Canada), the catalog shall set forth U.S. domestic sources of supply. (one electronic copy)

d. Non‑Standard (special) Tooling and Accessories. To the extent that this specification requires the development of unique tooling and/or accessories not generally available commercially, a set of drawings and specifications sufficiently complete to permit manufacture of such tooling and accessories shall be furnished at the time of machine delivery. Dimensional information shall be in English units. One electronic copy on CD in AutoCAD .dwg or .dxf format shall be provided.

e. Installation Instructions and Drawings containing all necessary information to install the equipment. This shall include a drawing containing the certified dimensioned locations of all equipment mounting/holddown holes. To be furnished as soon as possible after contract award, prior to scheduled delivery of the machine. One hardcopy and one electronic copy on CD in AutoCAD .dwg or .dxf format shall be provided.

f. Lubrication Diagram or Instruction. To be delivered at time of machine delivery (if required). One hardcopy and one electronic copy on CD in AutoCAD .dwg or .dxf format shall be provided.

g. Operating Instructions. These instructions shall be in the English language and be provided in separate manuals from other technical data provided. Instructions must include all updates for hardware and software. To be delivered upon machine delivery. Three hardcopies and one electronic copy on CD shall be provided.

h. Maintenance and Troubleshooting Instructions for all machine systems. This material shall also include the machines mechanical assembly drawings. To be delivered at time of machine delivery. Two hardcopies and one electronic copy on CD in AutoCAD .dwg or .dxf format of the machines mechanical assembly drawings.

i. Electrical and hydraulic schematics to be furnished. To be considered acceptable, these schematics must clearly portray all as-built electrical and hydraulic ties to their respective main systems. Two hardcopies and one electronic copy on CD in AutoCAD .dwg or .dxf format. Final as-built drawings to be furnished not later than 30 days after final acceptance of the machine.

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.

j. 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 furnished not later than 30 days prior to delivery of the machine. (Two hardcopies and one electronic copy)

k. Programming Manuals. Programming manuals for all languages and functionality on the machine shall be supplied in the English language and be of the latest revision. These manuals shall include, or be supplemented by, a clear summary of the control functions actually implemented and usable on the system offered or specified. These manuals shall be delivered at machine delivery and include one hardcopy and one electronic copy on CD.

l. Software Documentation. The offeror shall provide copies of all system software and/or ladder logic developed to control and interface with the machine, controller, and computer hardware and include one electronic copy on CD. To be delivered to the technical POC 30 days after final acceptance of the machine.

m. Calibration Documentation. Calibration manual and certified results from the factory runoff shall be supplied prior to preliminary inspection. (One hardcopy and one electronic copy)

1.1.15 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:

Note: For all training, the associated technical data (see 3.1.14) 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.

1.1.1 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 85 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 85 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 85 psig.

1.1.2 Special Tools. If any element of machine operation or maintenance requires the use of specially designed tools, these tools shall be provided with the machine and shall become the property of the Government.

1.1.3 Site Conditions. The machine covered by this specification will be installed in a general machine shop space where there is currently no environmental conditioning. Temperatures will range from 60 °F (15 °C) to 95 °F (35 °C) 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 °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. The only permissible exception is positioning accuracy for numerically controlled machines.

1.1.4 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.

1.1.5 Machine Installation, Startup and Testing.

1.1.5.1 Work to be Performed by the Arsenal. Upon receipt of the required installation and foundation drawings (see 3.1.14), Watervliet Arsenal will prepare the intended installation site prior to delivery of the machine. After placement of the machine by the contractor/riggers, Watervliet Arsenal will run utilities to first points of connection. However, if the installation instructions supplied by the contractor are incomplete or insufficiently detailed, installation work will stop and the contractor will be required to dispatch a service engineer. Installation will resume upon their arrival and continue under their guidance.

NOTE: If installation instructions, foundation drawings and electrical and hydraulic schematics are not delivered at or before the times specified (see 3.1.14), the Government reserves the right to forestall delivery and/or final acceptance testing of the machine by an amount of time equal to the delay in receipt of instructions, drawings or schematics.

1.1.5.2 Work to be Performed by the Contractor. This project is classified as a turn-key with the contractor being responsible for all costs and work associated with the installation unless otherwise stated. The Contractor shall be solely responsible for all costs associated with skidding and shipment, rigging, and installation at WVA. Once an installation site is identified by Watervliet personnel and if required, a foundation is constructed, the contractor or their designated third party shall install the machine. 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 to supervise the placement of the machine on the installation site by the rigging service. Outside rigging services should be advised that only certified grade 8 chains are permitted to be used at the Arsenal and that all rigging slings must be tagged and certified for the weights being lifted. In most cases no Arsenal forklift services and/or Arsenal personnel will be available for the installation. Only propane powered forklifts are permitted and they must be equipped with a roll cage. 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. Contractor personnel shall also adhere to the WVA requirements to wear OSHA approved non-tinted safety glasses with side shields and safety shoes while in the manufacturing shop areas. The contractor shall ensure they bring all equipment/material necessary for the installation of the machine(s). Watervliet does not have the resources to provide such material. Crane capacity within each building is limited (2, 5, 10 or 15 tons) and therefore if not adequate then the contractor will need to provide alternate means necessary for the installation. Specific building crane capacities where the equipment is to be installed should be verified with the WVA technical POC.

Once the machine is positioned and rough leveled by the contractor WVA personnel will run utilities to the machine. Watervliet must be provided with sufficient time to accomplish these connections. The contractor, through his own service personnel shall be fully responsible for the startup and testing of the machine, conduct any acceptance tests specified in sections 3 & 4 and perform the required on-site training. The contractor and the service personnel shall remain until the machine activation and testing have 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. If the contractor chooses to request Arsenal assistance in lieu of providing his own resources, the request will be reviewed by the Technical POC who shall reserve the right to impose a charge for the assistance. Approvals, even on a charge basis, should not be taken for granted since there is no guarantee that appropriate Arsenal personnel will be readily available. In such cases, the Arsenal will not be held responsible for delays in acceptance of the equipment resulting from non‑availability of Arsenal personnel or Arsenal‑furnished equipment.

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:

The new Magnetic Particle Inspection Machine shall be capable of inspecting the outer surface and the internal bore of the mortar and cannon tubes manufactured at the Watervliet Arsenal.

3.2.1 Physical Characteristics:

· Workpiece weight up to 7000 lbs.

· Workpiece length

5’ to 40’

· Workpiece outside diameter 5” to 12”

· Workpiece inside diameter

4.7” to 8”

· Height from floor to workpiece centerline between 42” and 48”

3.2.2 Performance Characteristics:

· Inspection booth travel speed up to 1’/sec (variable)

· Tailstock travel speed up to 1’/sec (variable)

· Adjustable shot time

0.5 sec – 2 sec (infinitely variable)

3.2.3 Headstock:

The machine’s headstock shall be come equipped with a vee-block for workpiece loading/unloading and retractable, powered rollers for workpiece rotation. The powered rollers shall accommodate workpieces of the different lengths, diameters, and weights as described in paragraph 3.2.1. The operator shall be able to turn roller rotation on and off from their control station and from a remote pendant located at the tailstock end of the machine. Workpiece rotation shall be bi-directional. The rotation speed shall be variable and agreed upon by the contractor and Watervliet Arsenal contracting officer’s representative (COR).

3.2.4 Tailstock:

The tailstock shall be equipped with an idler roller rest capable of accommodating workpieces of the different lengths, diameters, and weights as described in paragraph 3.2.1. The tailstock shall be power driven and capable of traveling the length of the machine. The operator shall be able to lock the tailstock into place at any desired position along the length of the machine.

3.2.5 Workpiece Magnetization:

Magnetizing current shall be 3-phase rectified to full wave direct current (FWDC).

3.2.5.1 Magnetization Coil:

The magnetization coil shall be of sufficient strength, size, and diameter to magnetize and demagnetize the Watervliet Arsenal cannon tubes as described in paragraph 3.2.1. The magnetization coil shall be capable of traversing the length of the workpieces during inspections. The operation and movement of the coil shall be controlled by the operator from the machine’s inspection enclosure.

3.2.5.2 Central Conductor:

The machine shall come equipped with three aluminum central conductors that shall be for use with the Watervliet Arsenal’s 105mm, 120mm, and 155mm cannon tubes. Each central conductor shall be furnished with centering spacers. The central conductors shall be electrically connected to the power source for magnetizing and demagnetizing the cannon tubes. The electrical connections to the central conductors shall be easily installed and removed during the inspection process. Insertion and removal of the central conductors shall be accomplished without removal of the cannon tube from the machine.

3.2.5.2.1 Holding Rack:

The machine shall come equipped a portable rack which shall be used to hold up to four central conductors or borescopes. The rack shall be capable of assisting the operator in inserting a central conductor or borescope into the cannon tube by providing support at an appropriate height.

3.2.5.3 Auxiliary Connection:

a) The power pack shall come equipped with appropriately sized lugs to allow for an independent, auxiliary connection.

3.2.6 Inspection Enclosure:

The machine’s controls shall be located in an inspection enclosure. The inspection enclosure shall block out ambient light and have a theater-style, curtain entrance with flame resistant curtains. The inspection enclosure shall be a traveling design allowing the powered movement of the enclosure along the full length of the machine. The inspection enclosure shall come outfitted with white light, handheld LED ultraviolet light, and a ventilation fan. The inspection enclosure shall travel out of the way so not to interfere with loading/unloading workpieces from an overhead crane.

3.2.7 Magnetic Particle Solution System:

The machine shall come equipped with a minimum 50 gallon stainless steel tank for the magnetic particle solution. A pump system shall recirculate and agitate the solution such that the magnetic particles will not accumulate or settle during operation. The agitation system shall allow the magnetic particle solution to remain within ±3% of theoretical level. The machine shall come equipped with a fluid catch tray to collect the magnetic particle solution that is applied to the workpiece. The machine shall come equipped with a spray nozzle/hose located in the inspection enclosure. The spray nozzle shall be hung above the catch tray when not in use. The machine shall come equipped with a second spray nozzle/hose located at the headstock end of the machine. The magnetic particle solution shall not spill or splash onto the floor during normal operation.

3.2.8 Borescope:

One borescope shall be supplied with the machine suitable for internal inspection of Watervliet Arsenal mortar and cannon tubes. The borescope shall utilize a video display. The borescope shall include a digital camera with picture capture capability. The digital camera shall be capable of storing pictures on a removable memory card. The borescope shall have an ultraviolet light and a white light in the same head. The borescope shall be capable of easily switching between a 90° and a 360° view.

3.3 Machine Control System:

The machine’s control system shall be located within the inspection enclosure. The control system shall utilize a touch screen panel for storing up to 50 programs and for magnetization/demagnetization functions. Programs shall be password protected.

3.3.1 Control Features:

· Machine On/Off

· Emergency Stop

· Powered Roller Up/Down, Rotation, Speed

· Tailstock Up/Down, Left/Right, Speed

· Inspection Enclosure Left/Right, Speed

· Workpiece Magnetization/Demagnetization

· Pump System On/Off

· Fan On/Off

· White Light On/Off

· Digital Current Meter Display

· Infinitely Variable Current Control

· Adjustable Shot Time

3.3.2 Workpiece Demagnetization:

The control shall perform demagnetization using a one-touch, automatic system. The control software shall be programmed such that the central conductor and magnetizing coil are utilized during the demagnetization function. The magnetization coil shall traverse the workpiece as programmed.

3.3.3 Digital Current Meter Display:

The digital current meter display shall be accurate to ±1%. The meter shall have a “hold and display” feature that displays the magnetizing current level until the next magnetizing shot. The meter shall be fitted with an indicator light that illuminates to show when magnetizing current has flowed through the workpiece.

3.3.4 Diagnostic Capabilities:

The machine unit shall be equipped with diagnostic capabilities covering the controller, interface, and overall machine. 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, has been properly calibrated, and visually examined for appearance, workmanship, maintainability and completeness, including all specified systems, accessories, markings, safety devices, geometric and accuracy requirements. This certification shall be provided to the Technical POC 14 days prior to the scheduled preliminary testing.

3.4.2 Test of Conformance to Specified Workpiece:

The contractor shall perform a magnetic particle inspection of a Watervliet Arsenal cannon tube. Internal and external inspections shall be performed. The machine shall be observed for proper function and compliance with the requirements of this specification. The Watervliet Arsenal may elect to perform this test on more than one workpiece.

3.4.3 Additional Testing:

Watervliet Arsenal personnel may elect to have the contractor demonstrate or verify the machine’s compliance with any requirement in this specification.

3.4.4 Provision of Materials and Equipment for Preliminary and Final Acceptance Testing:

3.4.4.1 Workpieces:

All workpieces to be tested as required in paragraph 3.4.2 shall be provided by the Watervliet Arsenal.

3.4.4.2 Magnetic Particle Solution:

The magnetic particle solution shall be provided by the contractor for the preliminary acceptance and by the Watervliet Arsenal for final acceptance.

3.4.4.3 Hydraulic Fluids and Lubricants:

All hydraulic fluids and lubricants necessary to perform any of the required tests shall be furnished by the contractor during preliminary acceptance testing and by Watervliet for the final acceptance.

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 and shall provide such materials, supplies and equipment as specified.

4.2 Preliminary Acceptance Inspection:

Preliminary acceptance inspection shall occur at the contractor's facility prior to machine shipment to WVA and shall consist of the certifications and tests specified in paragraph 3.4. When the certification of conformance is completed, 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.

4.2.1 Re-inspection Provisions:

If, during the course of preliminary acceptance inspection, deficiencies are disclosed which cannot be satisfactorily corrected during this visit, preliminary acceptance will be withheld and the contractor will be required to take corrective actions. In such cases, the Arsenal's Technical POC reserves the right to dispatch Arsenal representatives to observe a re-inspection and to charge the contractor's account for the travel and per diem costs of such re-inspections.

4.3 Post Preliminary Inspection Procedures:

The Arsenal's representatives will not grant authority to ship the machine following preliminary acceptance inspection, even in cases where there have been no apparent instances of non‑conformance. Authority to ship will be granted only by the Arsenal's Contracting Officer. In cases where it is determined that the machine and its equipment conform to specification, the Arsenal's Contracting Officer will grant shipping authority within (10) working days of completion of the preliminary acceptance inspection. In cases where deficiencies requiring correction are disclosed, the Arsenal's Contracting Officer will furnish a formal listing of required corrective actions within 15 working days of completion of the preliminary acceptance inspection. Also, in such cases, the provisions of paragraph 4.2.1 shall apply.

4.4 Final Acceptance Inspection:

Final inspection and acceptance of the machine shall be after installation at the Arsenal. At this time the machine shall again be subjected to, and required to pass, the test procedures specified in paragraph 3.4.

4.5 Warranty:

Upon final acceptance of the machine a Standard Commercial Warranty shall commence for duration of One Year, to include as a minimum, parts and labor for the duration of the warranty, at no cost to the Government. The one year period shall commence from the date of notification by the Contracting Officer of the final acceptance. Final acceptance is defined as the act of an authorized representative of the Government, by which the Government assumes ownership of existing supplies/equipment and/or approves specific services rendered, as partial or complete performance of the contract (i.e. testing, training, and delivery of all required technical documentation). This requirement does not waive any warranty requirement of FAR 52.212-4.

5 Preservation, Packaging and Delivery Instructions:

3 The contractor shall utilize standard commercial methods of preservation and packaging appropriate for machine tools and acceptable to commercial carriers. As a minimum, all areas susceptible to damage from exposure to the elements shall be preserved and/or packed to prevent damage. The machine and equipment shall be blocked, braced and skidded to prevent damage during transport and to facilitate handling, loading and unloading. The contractor shall be responsible for insuring that the machine and equipment are delivered to Watervliet Arsenal in good condition and shall retain this responsibility until the machine and equipment are off loaded at Watervliet Arsenal by the responsible parties.

Note: If any special lifting devices are recommended by the contractor to facilitate handling, such devices shall be shipped with the machine. They will be returned to the contractor upon completion of use at the Arsenal, at no expense to the contractor.

6 Instructions to Offerors:

4 The purpose of these instructions is to provide prospective contractors with additional guidance relative to the structure of their technical proposals.

4.1 Contents of Proposals. All proposals must as a minimum include:

A. A complete statement of compliance (see 6.2) B. Foundation information (if instruction 6.3 is included) C. MSDS sheets

D. Completed Attachment C

Note: Failure of any proposal to meet the above minimum requirements may render that proposal technically unacceptable. In addition, brochures, illustrations, narratives, drawings and sketches pertinent to the equipment being offered are permissible and are encouraged. Offerors are cautioned, however, to screen such materials carefully before submission to insure that they will not introduce any of the deficiencies described in the request for technical proposals. Generalized information not pertinent to the equipment being offered is not encouraged and will not be evaluated.

4.2 Offeror's Statement of Compliance. Enclosed with the specification is a prepared form entitled "Offeror's Statement of Compliance". The left hand margin of this form lists, in order, the number of all the paragraphs in the specification containing requirements which must be addressed by offerors. To the immediate right of each paragraph number are two blocks headed "comply" and "non‑comply". The entry of "x" or a check mark is required in one of these two blocks for each numbered paragraph of the form. However, offerors are advised that the checking of the "non‑comply" blocks for any paragraph will result in non‑acceptance of the offer unless explanation is provided and deemed acceptable by the Arsenal. For this reason, space is also provided on the form for offerors to explain any entry of "non‑comply". This explanation should point out the degree of, and reason for, non‑compliance, and it should explain what is being offered as an equal or better alternative to the specified requirements. Furthermore, checking of “comply” without providing the pertinent supporting information is not acceptable. A thorough explanation of how compliance will be achieved is required. Space provided for comply/non-comply explanations on the form is limited. If additional space is required, a separate sheet may be used to continue the explanation. If such a continuation sheet is used, it should refer to the paragraph number being explained. Offerors are further advised that although specified requirements are mandatory, they normally stem from performance needs at the Arsenal. Thus, when an offeror must take exception to a specified requirement he/she is well advised to provide as much information as possible about what he/she is offering so that the Arsenal can judge the impact, if any, upon the equipment’s performance, as well as the builders adherence to proper design practices. On the lower right hand corner of each page of the form is a signature block. Each page of the form should be signed by the offeror or his/her authorized representative.

6.1 Special Foundations:

1.1 Due to the periodic need for machine tools to be relocated because of changing production requirements, it is the Arsenal's preference to avoid special foundations. The footnote to paragraph 3.1.14(a) of this specification defines the essential properties of the machine shop floors at the Arsenal. It also defines special foundation as any foundation which requires alteration to that floor. That includes not only the installation of deeper concrete footings, and/or isolation pads, but also any excavations within the floor to house chip conveyors, coolant sumps, wire ways, and other items. Consequently, offerors are to provide with their proposals a narrative addressing the foundation requirements for the machine tool being offered. This narrative must address at least the following questions:

A. Will the offered machine tool require a special foundation?

B. If so, why is the foundation required? The response to this question should make clear whether the foundation is required for vibration isolation, retention of leveling and alignment, installation of support hardware of systems or a combination of these.

C. If a foundation is required for vibration isolation or for retention of leveling and alignment, what will be the probable impact upon machine tool performance and longevity if the Arsenal chooses not to provide the foundation?

6.2 Standard or Optional Equipment:

The machine described by this specification shall be provided with all required equipment whether or not stated requirements are standard or optional with the machine tool builder/supplier. Proposals which include offers of any specified equipment or specific requirements as an option, or as options at extra cost, may be considered as non‑responsive.

Attachment A – Acceptable Lubricants, Hydraulic Fluids, Oils, and Coolants

Coolant, Water Soluble, “No Dye”

Concentrate Must Be Clear Andersol “C”

Cutting Fluid Sulfur and Chlorine Additive

285°F min. Flash Point

18-22 Centistokes at 100°F Viscosity (Gun Drilling) MIL-C-46149 Grade 4 *

Cutting Fluid Sulfur and Chlorine Additive

30°F Pour Point, 285°F min. Flash Point

40-44 Centistokes at 100°F Viscosity (Honing) MIL-C-46149 Grade 5 *

Cutting Fluid Sulfurized Fatty And Mineral Oils

Federal Test Method Std. No. 791

WVTPD 1051 *

Cutting Oil, Non-Staining, Mineral Oil Base

400°F Flash Point Mobilmet Omicron

Lubricating Oil, General Purpose, Corrosion & Salt Spray Resistant

39.8-55 Centistokes at 130°F

MIL-L-3150

Lubricating Oil, Light Spindle

Velocite #10 (Sunvis #911)

MIL-L-46014 *

Oil, Hydro Treated

Paraffinic Mineral Oil Pillsbury Circlene

FG #21

* Approved industry/commercial equivalents will be acceptable substitutes

Attachment B – Class I Ozone Depleting Substances CFC‑11 (cfcl3) CFC‑213 (c3f3cl5)

Trichlorofluoromethane Pentachlorotrifluoropropane

CFC‑12 (cf2cl2) CFC‑214 (c3f4cl4)

Dichlorodifluoromethane Tetrachlorotetrafluoropropane

CFC‑113 (c2f3cl3) CFC‑215 (c3f5cl3)

Trichlorotrifluoroethane Trichloropentafluoropropane

CFC‑114 (c2f4cl2) CFC‑216 (c3f6cl2)

Dichlorotetrafluoroethane Dichlorohexafluoropropane

CFC‑115 (c2f3cl) CFC‑217 (c3f7cl)

Monochloropentafluoroethane Monochloroheptafluoropropane

CFC‑13 (cf3cl) Halon ‑ 1211 (cf2clbr)

Chlorotrifluoromethane Bromochlorodifluoromethane

CFC‑111 (c2fcl5) Halon ‑ 1301 (cf3br)

Pentachlorofluoroethane Bromotrifluoromethane

CFC‑112 (c2f2cl4) Halon ‑ 2402 (c2f4br2)

Tetrachlorodifluoroethane Dibromotetrafluoroethane

CFC‑211 (c3fcl7) Halon – 1011 (ch2BrCl)

Heptachlorofluoropropane Bromochloromethane

CFC‑212 (c3f2cl6) Halon –1202 (CBr2F2)

Methyl Chloroform (chci3)

CCL4

Carbon Tetrachloride

Methyl Chloroform (c2h3cl3)

Attachment C – Electrical Survey

The Watervliet Arsenal requests that all offerors provide the following machine information along with their proposal (please complete as much as possible):

1. Full Power Load (FLA) @ 480 V

2. Start-up (surge) current

3. Average Power requirement ( 75%)

4. Standby power load at ideal (if applicable)

5. Power Factor Information (efficiency)

6. Wiring schematics

7. Size of largest motor

8. Number of motors

9. Type of motor

a. Synchronous

b. Induction

10. Equipment Manufacturer contact information:

a. Point of contract for equipment electrical power requirements

i. Telephone Number

ii. Email address

11. Manufacture’s Recommendations for Installation

a. Electrical Manual

b. Manufacture’s Point of contact

i. Telephone Number

ii. Email address

1. Compliance with Environmental Laws and Regulations: Contractor shall comply with all applicable federal, state, and local environmental laws, statutes, regulations, executive orders, permits, Army regulations (with supplements), as well as Major Subordinate Command (MSC) and installation regulation, policy, Host Tenant Agreement, Interagency Service Support Agreement, or Status-of-Forces Agreement. Contractor shall immediately report any conflicts between applicable federal, state, local environmental laws, statutes, executive orders, and provisions of Army Regulation 200-1, and any specifications within this contract to the Contracting Officer Representative (COR).

2. Compliance with Green Procurement Requirements: Contractor shall follow Federal EPA Comprehensive Procurement guidelines (www.epa.gov/cpg) and Army Contracting Command Quick Guide (https://acc.aep.army.mil/accapps/ACCMAP/Documents/Quick-Guide-for-Sustainable-Procurement.docx) for acquisition of building materials and products and select materials that have a long life cycle; the least toxic materials; recyclable materials; materials that are resource-efficient; materials with the maximum recycled content; materials harvested on a sustained yield basis; and products causing the least pollution…