22-17-3419_Rev_A.doc

22-17-3419 Rev. A

Specification for New Abrasive Flow Machine Spec. # 22-17-3419 Rev. A Manufacturing Engineering Work Group

Watervliet Arsenal

Watervliet, New York 12189

4/10/2017 Department of the Army

TACOM

Table of Contents

31 Scope:

31.1 Abbreviated Description:

31.2 Preparation of Proposals:

32 Applicable Standards and Publications:

33 Requirements:

33.1 General Requirements:

143.2 Machine Specific Requirements:

153.3 Machine Controls:

163.4 Requirements for Demonstration of Conformance:

164 Quality Assurance Provisions:

174.1 Responsibility for Inspection:

174.2 Preliminary Acceptance Inspection:

174.3 Arsenal Participation in Preliminary and Final Acceptance Inspection:

174.4 Re-inspection Provisions:

174.5 Post Preliminary Inspection Procedures:

184.6 Final Acceptance Inspection:

184.7 Warranty:

185 Preservation and Packaging:

186 Instructions to Offerors:

186.1 Contents of Proposals:

186.2 Offeror’s Statement of Compliance:

196.3 Prior Customer List:

196.4 Special Foundations:

206.5 Standard or Optional Equipment:

206.6 Procurement of More Than One Machine:

21Attachment A – Acceptable Lubricants, Hydraulic Fluids, Oils, and Coolants

22Attachment B – Class I Ozone Depleting Substances

23Attachment C – Electrical Survey

24Attachment D – Environmental Protection Requirements

1 Scope:

To deburr and establish a radius in the bore end evacuator holes of the 120mm M256 and 155mm M284 cannon tubes. To deburr and establish a radius on the rifling transition zone between the powder chamber and rifling feature of the 105mm M68, 155mm M284, 155mm M776, and 155mm ERCA cannon tubes.

1.1 Abbreviated Description:

The new machine covered by this specification shall be an abrasive flow machine with two workpiece stand track assemblie complete with workpiece holding fixtures and tooling for deburring and establishing radius on 105mm, 120mm, and 155mm cannon tubes per drawing requirements. The machine shall be supplied with all features and characteristics as specified herein.

1.2 Preparation of Proposals:

Section 6 of this specification entitled "Instructions to Offerors" includes detailed instructions meant to assist offerors in making their technical proposals. Prospective offerors are advised to read section 6 carefully and completely since failure to do so and to follow the instructions and guidance therein introduces a real risk that their proposals will be classified as unacceptable.

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.

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:

3.1.1 Design and Engineering:

The machine shall be designed and engineered in accordance with 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.

3.1.2 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.

3.1.3 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 that workpiece finish and accuracy are not impaired by machine vibrations.

3.1.3.1 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.

3.1.4 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.

3.1.4.1 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 machine.

3.1.4.2 Spacing:

Spacers that do appear on the engineering drawings are permissible.

3.1.5 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.

3.1.6 Interchangeability:

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

3.1.7 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.

3.1.7.1 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.

3.1.7.2 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.

3.1.7.3 Motors:

1.1.1.1 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, and frequency on 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 of the high efficiency type.

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.

3.1.7.4 Operator Control Voltage:

All electrical controls meant for use by the operator of the machine shall carry 120 volts AC maximum.

3.1.7.5 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 on the operator control panel and easily accessible. A “noise" suppression device shall be provided.

3.1.8 Safety and Environmental Features:

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

3.1.8.1 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.

3.1.8.2 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.

3.1.8.3 Noise Levels:

The government's preference is to achieve noise levels not in excess of 85 dba and this shall be accomplished at no additional expense to the Government. Noise levels shall be measured under load during the test of conformance to specified ranges and capacities and shall be measured at any or various times during this test at the discretion of the Technical POC or other appointed representatives. 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.

3.1.8.4 Ozone Depleting Substances:

1.1.1.2 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. This machine shall utilize 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.

3.1.8.5 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.

3.1.8.6 Material Safety Data Sheets:

The offeror shall provide Watervliet Arsenal with all material safety data sheets at the time of the submission of their proposal.

3.1.8.7 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.

3.1.8.8 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 (see section 3.4), 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.

3.1.8.9 Lockout/Tagout Procedures:

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

3.1.9 Identification Plate:

1.1.2 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

3.1.10 Lubrication:

The machine shall be equipped to provide sufficient lubrication to every moving part where lubrication is essential to prevent damage. Slideways shall be lubricated by an automatically cycled distribution system such as that manufactured by Trabon Inc. Gearboxes or transmission cases shall be lubricated by the wet‑sump splash method. Spindle bearings shall be lubricated by recirculating pressure spray systems. 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 (such as slideway lubrication), 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. Wet‑sump type systems shall be equipped with means to confirm proper oil level. Sight gages, if used, 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.

3.1.10.1 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.

3.1.10.2 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, at time of machine delivery, justification which shall include the manufacturer, type and specification number as well as the reason for the substitution.

3.1.11 Hydraulic System:

Hydraulic systems provided shall be sized and powered for the intended application and shall conform 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° 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 underpressure. 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 and shall be located at floor level.

3.1.12 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 selected by the Government, from a list of standard colors supplied by the offeror with their proposal. This selection shall be made after contract award. 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.

3.1.13 Machine Hold Down and Leveling:

1.1.3 The machine base shall be provided with sufficient and properly located holes for positive hold‑down when operating at full rated capacity. In addition, for each hole in the machine base, the contractor shall provide a set of his recommended hold‑down and leveling hardware. The hold‑down bolts themselves shall be long enough to permit insertion of a series of government‑furnished two‑inch thick blocks between the machine base and the floor surface. Each block is approximately 6" wide by 8" long and is placed at leveling and/or hold‑down sites in the machine's base.

Note: All hold‑down and leveling hardware shall be delivered 30-days prior to scheduled delivery of the machine.

3.1.14 Gears:

All gears used in the machine and its components shall meet or exceed the standards recommended by the American Gear Manufacturers Association for the type and severity of service required.

3.1.15 Handwheels:

Where power feed and/or rapid traverse of a machine component is provided or specified, associated handwheels or cranks, if any, shall not rotate when power feed or rapid traverse is engaged.

3.1.16 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.

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 in the quantities indicated below. A “hardcopy” refers to a reproducible printed, paper copy. An “electronic copy” refers to a document saved on CD. All AutoCAD drawings shall be provided in AutoCAD version 2015, shall be dimensioned in English units, and shall not utilize the color yellow. “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 disks/CDs provided.

a. Foundation Drawings, Standard of Special (see note):

a. Shall be in sufficient detail to permit pricing and construction by a general contractor and shall be furnished 120 days prior to scheduled delivery of the machine. 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. (One hardcopy and one AutoCAD electronic copy) Note: A special foundation is one which exceeds, in required load bearing capability and vibration insulation, Watervliet Arsenal's standard monolithic concrete flooring of 1,000 pounds per square foot load rating and/or one which requires specifically‑shaped excavations for coolant housings, chip conveyors, electrical circuits and conductors, etc. Important: See instruction par. 6.4.

b. Machine and Equipment Floor Plan:

Machine and equipment floor plan AutoCAD drawing shall contain the dimensioned bolt-hole pattern of the holddown bolts for the machine. This AutoCAD drawing(s) shall also contain information that indicates the type, magnitude, and connection points of all plant utilities (electrical power, air, water, etc.) required to operate the machine. This data shall be furnished 60 days prior to scheduled delivery of the machine. (One hardcopy and one AutoCAD electronic copy)

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 hardcopy and 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. (One hardcopy and one AutoCAD electronic copy)

e. Installation Instructions and Drawings:

Instructions 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 60 days prior to scheduled delivery of the machine. (One hardcopy and one AutoCAD electronic copy)

f. Lubrication Diagram and Instruction:

To be delivered to the technical POC at time of machine delivery. (One hardcopy and one AutoCAD electronic copy)

g. Operating Instructions:

These instructions shall be in provided in separate manuals from other technical data provided. To be delivered upon machine delivery. (Four hardcopies and one electronic copy)

h. Maintenance and Troubleshooting Instructions:

To be supplied for all machine and control systems. These instructions shall include the machine’s mechanical assembly drawings. To be delivered at time of machine delivery. (Two hard copies and two electronic copies)

i. Electronic and Hydraulic Schematics:

To be considered acceptable, these schematics must clearly portray all as-built electrical and hydraulic ties to their respective main systems. To be delivered at time of machine delivery. (One hardcopy and one electronic copy)

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 delivered at time of machine delivery. (One hardcopy and one electronic copy)

k. Program Manuals:

Where a CNC machine is offered or specified, programming manuals shall be supplied. 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. To be delivered at time of machine delivery. (One hardcopy and one electronic copy)

l. Software Documentation:

The offeror shall provide documentation of all system software and/or ladder logic developed to control and interface with the control/drives with the machine tool. To be delivered 30 days after delivery of the machine. (One hardcopy and one electronic copy) Two copies of the system memory backup (S-Ram) shall be provided on compact flash drive at startup of machine.

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, operating or programming the machine to its productive capacity. Training shall be in accordance with the applicable areas of the following schedule:

Note: For all types of training, the associated technical data (see 3.1.16) 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 Repair/Replacement Parts and Service:

The offeror shall also agree to provide parts and/or service for the contracted equipment within 72 hrs of notification of a problem. The offeror further agrees, as part of the contract, to store complete ordering data to include specifications, engineering drawings and other information for the contracted machine tools/parts. This data shall be stored within the U.S. or Canada and be sufficient in detail to permit successful acquisition of the parts and associated repair service. In the event of a national emergency the U.S. Government reserves the right to obtain the data and use it to support operation of the machine tool(s) purchased under this contract.

3.1.19 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 (i.e. air dryer). Normal moisture is defined as that moisture produced when air at a relative humidity of 75% has been compressed to 80 psig. Common industrial air dryers that are used at the Watervliet Arsenal include the ZEKS 18HSF and Ingersoll-Rand D31NC models.

3.1.19.1 Air Booster Unit:

If the machine offered requires more than 80 psi at a particular volume then an air booster unit shall be provided with the machine. If necessary, an accumulator tank shall be provided with the booster. Please state in your proposal what the machine requirements will be and if a booster and tank will be required. All installation shall be provided and included. If the use of an air booster is not possible and air compressor is required, the contractor must state this in their proposal and provide justification detailing CFM, psi, application, and duration of air usage.

3.1.20 Special Tooling:

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.

3.1.21 Control of Cutting Fluids:

If the machine is equipped with a coolant system, the contractor shall insure that the machine is designed and 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. If the coolant reservoir is part of the foundation, the coolant shall be contained in a leak‑proof metallic or non‑metallic liner.

3.1.22 Site Conditions:

The machine covered by this specification will be installed in general machine shop space and there will be no environmental conditioning. Temperatures will range from 65° F to 95° 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° 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. For this performance factor, allowances may be made for the effects of temperature fluctuation.

3.1.23 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.

3.1.24 Chip Removal:

An automatic chip removal unit shall be provided to convey chips of any material from the machine to an external container without manual aid. The unit shall be reversible to facilitate clearing of blockages. The unit's drive mechanism shall be equipped with an external square or hexagonal extension piece to permit use of wrenches to manually free blockages which stall the drive mechanism. The unit shall operate successfully in a variety of machining environments including dry‑cutting, machining with cutting oils and machining with water‑extendable oils. Automatic means shall be provided to return cutting fluids to the machine's coolant tank which shall be separate from the unit. The chip removal unit shall be engineered for the machine so that when fully installed in accord with instructions all points subject to periodic maintenance and lubrication shall be externally accessible and the unit shall be capable of being disassembled and removed without disabling the machine itself.

3.1.25 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 one hour. One 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.

3.1.26 Machine Installation, Startup, and Testing:

3.1.26.1 Work to be Performed at the Arsenal:

This project is classified as a turn-key with the contractor being responsible all work associated with the installation unless otherwise stated.

3.1.26.1.1 Site Designation:

Upon receipt of the required installation and foundation drawings (see 3.1.16), Watervliet Arsenal will designate an installation site and outline a general machine location on the shop floor.

3.1.26.1.2 Utilities:

Once the machine is installed, positioned and rough leveled by the contractor or their designated rigging crew Watervliet personnel will run utilities (power and air) to first points of connection on the machine. Watervliet must be provided with sufficient time to accomplish these connections. Sufficient time may be up to 10 working days depending on Watervliet personnel availability. 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 3.1.16), 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.

3.1.26.2 Work to be Performed by the Contractor:

1.1.4 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. Contractor personnel shall adhere to the WVA requirements to wear OSHA approved non-tinted safety glasses with side shields, to wear safety shoes, and to refrain from wearing loose clothing (i.e. “hoodies”) and jewelry while in the manufacturing shop areas. The contractor shall ensure they bring all equipment/material necessary for the installation of the machine(s).

3.1.26.2.1 Site Preparation:

Once an installation site is identified by Watervliet personnel and if required, a foundation is constructed, the contractor or their designated third party shall layout and core drill the holes for the machine anchor bolts. Please note that the majority of the Watervliet Arsenal’s shop floor is covered with 2” thick wood block. It shall be the contractor’s responsibility to cut out and remove wood block and to install any leveling pads necessary for installation.

3.1.26.2.2 Rigging

: 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 must also 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) may be available for use by the Arsenal personnel during installation. The contractor shall ensure they bring all equipment/material necessary for the rigging of the machine(s). If necessary, the Watervliet Arsenal can provide the contractor with information for local rigging companies.

3.1.26.2.3 Installation:

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 their 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 their 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:

3.2.1 Machine Tool Description:

3.2.1 The machine tool covered by this purchase description shall be a floor mounted, hydraulically actuated, one-way abrasive flow system. The machine shall be supplied complete with workholding fixtures and tooling to deburr and form radii on evacuator holes and the rifling transition zone of 105mm, 120mm, 155mm, and prototype cannon tubes per drawing specifications.

3.2.1.1 Workpiece Processing:

Cannon tubes shall be loaded onto one of two workpiece stand track assemblies with moveable workholding fixtures allowing the tube to advance over the tooling. The tooling shall be stationary. Workpieces may weigh up to 8000 lbs. and be up to 40’ long. One workholding stand shall be used for evacuator holes, the other workholding stand shall be used for the rifling transition zone. A media piston ram shall force the media supply through the tooling into the workpiece. When the media ram advances fully, the process will automatically stop and fully retract the ram. Media shall be returned to the hopper and the ram shall be activated again to force the media through the tooling into the workpiece. This process shall be repeated until the desired finish and radii are achieved. After the workpiece is complete, the workpiece shall be retracted from the tooling leaving a minimum of 18” of space between the workpiece and the tooling.

3.2.1.1.1 Evacuator Holes:

After the cannon tube is moved in position over the tooling and cycle start is initiated, media will be forced through the tooling into the cannon tube and exit through the evacuator holes. The media shall exit the evacuator holes and fall into a media catch hopper.

3.2.1.1.2 Rifling Transition Zone:

After the cannon tube is moved in position over the tooling and cycle start is initiated, media will be forced through the tooling into the cannon tube and then returned to the media hopper via a return line. The tooling shall be capable of reversing the media flow direction across the transition zone.

3.2.2 Required Characteristics:

3.2.2.1 Hydraulics:

All movement of the machine shall be actuated hydraulically from an externally mounted hydraulic unit. The hydraulic drive unit shall consist of an electrically operated, variable volume pressure pump of the flooded inlet type to prevent cavitation. The hydraulic system shall be provided with a relief valve to prevent overcharging the system. The hydraulic system shall have the following characteristics:

Operating Hydraulic Pressure 300 - 2000 psi Hydraulic Pump Capacity 15 gpm at 2000 psi Reservoir Capacity 40 gal

3.2.2.2 Media Delivery:

Media shall be delivered one-way, accomplished by stroking a hydraulically actuated media tube cylinder. Media shall be moved under pressure through the tubing to the workpiece, then returned to the media bin. The media delivery system shall have the following characteristics:

Displacement 980 in3 Extrusion Pressure 300 – 1300 psi Media Flow Rate 23 gpm Media Cylinder Diameter 10” Total Media Capacity (Cylinder & J-tube) 10 gal

3.2.2.2.1 Media:

The contractor shall provide engineering support to select a media optimized for the Watervliet Arsenal’s parts and process. The selected media must be agreed to by the Watervliet Arsenal Technical POC. With the delivery of the machine, a sufficient amount of this media shall be provided to initially load the machine as well as enough additional media to provide one entire media replacement at a later time.

3.2.2.3 Tooling and Adapters:

The contractor shall provide all necessary tooling, adapters, and accessories required to process 105mm M68, 120mm M256, 155mm M284, 155mm M776, and 155mm ERCA cannon tubes per their respective drawings.

3.2.2.4 Media Chiller:

The machine shall come equipped with a method to chill the media to the recommended operating temperatures as the media is being delivered to the workpiece. Reference paragraph 3.1.22 for the site condition in which the machine will be required to operate.

3.3 Machine Controls:

The machine controls shall utilize an Allen-Bradley PLC capable of running in automatic mode and in manual mode. A color, touch-screen HMI shall be provided. The HMI shall be mounted in a pendant enclosure attached to a swing arm. The HMI shall display cycle volume, media pressure, and process time to the operator. The machine process parameters shall be entered via the HMI and shall be monitored by operator via the HMI. Machine status information and malfunctions shall displayed on the HMI. The workpiece shall advance and retract over the tooling via the control. A stationary control consisting of cycle start, cycle stop, and emergency stop shall be mounted on the workpiece stand track assembly furthest from the HMI,

3.3.1 Enclosures:

Enclosures where controller hardware is installed shall be NEMA‑12 rated. In addition:

a.) If required, given shop environmental conditions as detailed in par. 3.1.22, 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.) If no AC units are deemed necessary by the contractor Watervliet is recommending that as a minimum small ventilation fans be installed in electrical enclosures and/or operators panel.

3.3.2 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.

3.3.3 Diagnostic Capabilities:

The machine control shall be equipped with diagnostic capabilities covering the control itself, the interface, and the 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, 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 the scheduled preliminary testing.

3.4.2 Test of Conformance to Specified 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.

3.4.3 Test of Conformance to Specified Performance on Workpiece:

The contractor shall demonstrate the machine function by processing Watervliet Arsenal cannon tubes. The machine shall be capable of achieving required workpiece accuracy and finish per their respective drawings. 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.

3.4.4 Additional Testing:

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

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

3.4.5.1 Workpieces:

All workpieces to be tested as required in paragraph 3.4.3 shall be provided by the Watervliet Arsenal.

3.4.5.2 Tooling:

All tooling, adapters, and fixtures shall be provided by the contractor.

3.4.5.3 Abrasive Media:

All abrasive media necessary for to perform any of the required tests shall be furnished by the contractor during preliminary and final acceptance testing. The abrasive media shall be determined per paragraph 3.2.2.2.1.

3.4.5.4 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.

3.4.5.5 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 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. The contractor shall notify the Arsenal’s Technical POC 14 calendar days prior to the beginning of the inspection so that arrangements can be made to dispatch Arsenal representatives to observe the inspections. 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 Testing:

During the test of conformance to specified performance on workpieces (see par. 3.4.3), the Arsenal's representatives will observe the operation of the machine and its equipment and reserve the right to inspect the workpiece for conformance to drawing requirements after completion of the test.

4.3.3 Supplementary Tests and Examinations:

The Arsenal's representatives reserve the right to ask for demonstration of any specified feature or machine characteristic not demonstrated during the tests conducted in accord with paragraphs 3.4.

4.4 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.

4.5 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 4.4 shall apply.

4.6 Final Acceptance Inspection:

Final inspection and acceptance of the machine shall be after installation at the Arsenal.