Benet_Labs_Equipment_Engineering_Specification_BPE-2018-1,_Revision_1.pdf

U.S. Army ARDEC – Benét Labs Watervliet, NY Equip. Engr. Spec. #BPE-2018-1 Date: 08/01/2018 Rev. 1

One New Dual-Spindle Turning Center

Table of Contents

1. Scope

1.1 Abbreviated Description

2. Applicable Standards and Publications

3. Requirements

3.1 General Requirements

3.2 Specific Requirements

3.3 Controls / Control Systems

3.4 Requirements for Demonstration of Conformance

4. Quality Assurance Provisions

4.1 Responsibility for Inspection

4.2 Preliminary Acceptance Inspection

4.3 Government Participation

4.4 Reinspection Provisions

4.5 Post Inspection Procedures

4.6 Final Acceptance Inspection

5. Preservation, Packaging and Delivery Instructions

6. Instructions for Preparing Technical Offers

Equip. Engr. Spec. # BPE-2018-1 Dated 08/01/2018

1. Scope:

1.1 Abbreviated Description: This specification describes the minimum requirements for the design, manufacture, delivery, and installation for one new high precision, high rigidity, dual-spindle turning center equipped with a 12-station 10,000 rpm built-in motor turret. This high-performance turning center shall be capable of manufacturing applications such as a flywheel, port block, or drive shaft in a single setup. The new CNC turning center shall be a DMG MORI NLX 2500|700 or equal.

2. STANDARDS AND PUBLICATIONS:

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

Submission of a proposal or bid shall be construed as evidence that such examination has been made.

Therefore, later claims for labor, material, or equipment required, or for difficulties encountered, which could been foreseen had such reasonable examinations been made, may be denied.

2.2 National Standards and Specifications: All work performed and procedures followed in association with this project shall meet or exceed all applicable and current Benét Labs, 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. The following specifications in effect on the Date of Invitation for Bid/Request for Proposal form a part of this purchase description. In the case of conflicting requirements, the more stringent apply.

3. Requirements:

3.1 General Design Standards/Requirements: This equipment shall be a standard product of the manufacturer and shall require either no change or minor design changes to meet requirements of these specifications. Therefore, ownerships of the design will remain with the manufacturer. Equipment incorporating new or unproven technology is subject to rejection at the discretion of the contracting officer.

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, Benét Labs 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.

3.1.1 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 machine manufacturer’s 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 Environmental Protection. Under the operating, service, transportation, and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

3.1.3.1 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).

3.1.3.2 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 during their manufacture, use, and reuse.

3.1.3.3 Compliance with License and Certification Requirements: Contractor shall obtain all license and certification required by Federal, State, and Local environmental laws and regulations necessary to adhere to the specifications of this contract. The Contractor shall submit all plans, notifications, reports, submittal documents, and fees required by Federal, State, and Local environmental laws and regulations to the appropriate Federal, State, and Local authority and/or agency as necessary to adhere to the specification of this contract. All required licenses and certifications required by Federal, State, and Local environmental laws and/or regulations shall be considered a contract deliverable upon award.

3.1.3.4 Notification of Federal and State Regulators: Contractor shall immediately notify the

Designated Government Representative (DGR) and COR of the arrival on site of any Federal, State, and/or DoD environmental regulator or enforcement agent and/or the receipt of any correspondence from a Federal or State environmental agency.

3.1.3.5 Inspections of Work Sites: Contractor shall submit to potential Federal, State, Army and installation work site environmental regulatory inspections and/or investigations into noncompliance, and fully cooperate with such inspections/investigations by providing the appropriate records and documentation.

Environmental regulatory agencies are authorized by law to inspect any work site for environmental compliance with regulatory requirements. If an inspection is conducted, it will not stop or disrupt ongoing contract activities. The inspection will only require the work site environmental officer, or supervisor/manager to answer questions and/or escort the inspector to specific work site areas with the potential to affect environmental quality.

3.1.3.6 Reporting Noncompliance: Contractor shall immediately report any nonconformance and/or noncompliance with applicable Federal, State or Local environmental laws, Army and installation environmental regulations or policies to the COR and DGR.

https://acc.aep.army.mil/accapps/ACCMAP/Documents/Quick-Guide-for-Sustainable-Procurement.docx

3.1.3.7 Conformance with Environmental Management System: Contractor shall take the necessary actions to identify, monitor, and control those contract operations and activities that pose risk of contamination, or can negatively impact the natural and/or human environment.

3.1.3.8 Use of Hazardous Materials: Contractor shall assign all hazardous materials management responsibilities to the appointed ECD. Contractor shall contact the DGR or COR to obtain technical assistance from Environmental Office for assisting the ECD with achieving and maintaining compliance with hazardous material storage, issue, use, and disposal requirements. Contractor shall submit to the COR and/or DGR a hazardous material inventory. The hazardous material inventory will be submitted 30 days prior to commencement of work for contracts that exceed 180 consecutive days. The inventory list will contain the hazardous material type and maximum quantities of materials anticipated to be stored on-site. The hazardous material shall be properly identified and include any applicable identification number, such as National Stock Number or Special Item Number. The Contractor shall maintain copies of Safety Data Sheets for all hazardous materials used and stored on-site during performance of the contract. Contractor shall not supply or deliver any hazardous materials or chemicals to an installation that are listed on EPA toxic chemical list without prior written approval from DGR and/or COR.

3.1.3.9 Prevention of Spills: Contractor shall adopt the installation's Spill Prevention Control and

Countermeasures Plan (SPCC) if transporting, processing, storing, or in any way managing hazardous waste, hazardous material, petroleum-oils-lubricants, or other restricted items. In case of a spill, the person in control of the spill site or their designated representative shall take appropriate action to protect workers and bystanders; contain the spill (if it can be done safely); secure the spill site; restrict ignition sources; and immediately contact the installation Fire and Emergency Services (Fire Department).

3.1.3.10 Protection of Sensitive Areas: Contractor shall comply with all installation designated sensitive and/or off-limit area restrictions. Sensitive areas are generally demarked indicating what activities (e.g., driving, digging, foot traffic) are prohibited. The Contractor shall also adhere to the following installation sensitive areas requirements:

Cultural Resources Sites: Do not excavate, remove, damage, or otherwise deface any archeological resource located on public lands.

3.1.3.11 Corrective Action for Noncompliance: the contractor shall, when given a verbal and/or written notice of environmental noncompliance or nonconformance by the COR, take immediate corrective action. Failure or refusal to comply promptly may be grounds for the Contracting Officer to invoke the appropriate contractual remedies. This may cause all or part of the work to be stopped immediately until satisfactory corrective action has been taken.

3.1.3.12 Universal Waste / e-Waste Management: Universal waste including but not limited to some mercury containing building products such florescent lamps, mercury vapor lamps, high pressure sodium lamps, CRTs, batteries, aerosol paint containers, electrical equipment containing PCBs, and consumed electronic devices, shall be managed in accordance with applicable environmental law and installation instructions.

3.1.3.13 Pollution Prevention / Hazardous Waste Minimization: While onsite at Watervliet

Arsenal, the contractor shall minimize the use of hazardous materials and the generation of hazardous waste.

Consult with the Environmental Office for suggestions and to obtain a copy of the installation's pollution prevention/hazardous waste minimization plan for supporting waste minimization goals.

3.1.4 Construction/Deflection: 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.

3.1.4.1 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.

3.1.4.2 Units of Measure: Dimension and capacities in this purchase description are given in

English-US (in-pound) system. All dials, gauges, and drawings shall be in the English-US system or both the English-US and the metric systems, unless otherwise specified in this document.

3.1.5 Slideway Design and Construction: All axes shall use slideways for higher vibration damping performance and dynamic rigidity. All precision ways which guide and bear the rated design loads shall adhere to the following requirements :

3.1.5.1 Design/Hardness: All precision ways which guide and bear the rated design loads shall adhere to the hardness criteria shown in the following examples of acceptable way systems. Please state in your proposal details of the way system being offered.

A. Integral cast iron ways shall be hardened to RC 50 to RC 54 to a depth of .100 inch or more.

B. Hardened and ground steel ways for mating with Turcite, Rulon or other such low friction forgiving materials shall be hardened within the range of RC 55 to RC 62. Actual hardness within this range shall not vary more than 5 RC points.

C. Hardened and ground steel ways for use with anti-friction roller bearings shall be to a hardness of RC 62 to RC 65 to a depth of 1/8 inch or more. Slideway systems other than the three (3) referred to above may be offered provided that their design is consistent with all specified performance characteristics of the machine.

3.1.5.2 Way Covers: All slideway systems having less than a 60-degree incline to the horizontal shall be protected by way covers unless it can be substantiated that covers will interfere with the functions of the machine.

3.1.5.3 Replaceable Ways: If the machine being offered is portrayed as having replaceable ways, the assembly of the way bars to the machine frame shall be such that finish ground ways are fastened to a precision ground or scraped surface to permit field replacement without additional grinding.

3.1.5.4 Way Wipers: All way systems, regardless of type shall be equipped with wipers designed to prevent intrusion of foreign material. Wipers shall be adjustable to compensate for wear. Wipers shall also be easily removable and replaceable.

3.1.6 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. Shims that do not appear on the engineering drawings shall not be incorporated in the machine. Spacers that do appear on the engineering drawings are permissible.

3.1.7 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.

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

3.1.9 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: Manufacturer's name, Model, Manufacturer's Serial Number, Power Input (voltage, phase, frequency, and total amps), Government Contract Number, Date of Manufacture, Weight.

3.1.10 Data Plates: All instruction, data, and identification plates and labels attached to this equipment and its controls shall be manufactured of corrosion and oil resistant metal or plastic material. All wording shall be in the English language using plan, bold face lettering. Lettering shall be permanent and have a contrasting background.

3.1.11 Utility Connections: Equipment supplied to Benét Laboratories will have single point shut-off for each utility supplied to a system. This means that equipment constituting a single system shall be wired to a single main electrical disconnect point and plumbed to a single pneumatic shut-off valve. This will be referred to as the “point of first connection”. Each type of power source may have only one point of first connection, for example: (1) pneumatic shut-off valve, (1) water supply shut-off valve, (1) electrical disconnect. Each point of first connection shall be clearly labeled on the system and shown in the safety lockout portion of the documentation package. These points must be located on a stationary component and positioned such that they will not create a hazard to personnel during normal operation of the system. The first connection points shall be accessible from the shop floor without the use of ladders, steps, or stools.

Access cannot be hampered by operation of the system.

3.1.12 Utility Connection Labor: Benét Labs shall provide only such labor and materials as will be needed to connect facility utilities to each point of first connection of the system. The supplier will be responsible for all connections beyond the point of first connection for each utility.

3.1.13 Utilities Available: Benét Labs shall be responsible for providing the following:

3.1.13.1 Electrical: The power source to which the machine will be connected furnishes a nominal 480 volts, 3 phase, 60 Hz AC to the fused or breaker type disconnect switch required in the electrical disconnect paragraph (3.1.14.3). However, the machine shall be tolerant enough of line fluctuations to operate normally at source voltages ranging from 432 to 504 volts. Connection does not include filters, surge protection, or any peripheral equipment necessary to make the equipment functional. OFFEROR IS

TO STATE REQUIRED POWER/ELECTRICAL REQUIREMENTS FOR OFFERED MACHINE

(VOLTAGE, FULL LOAD AMPS, KVA). See Attachment C and complete as much as possible.

3.1.13.2 Pneumatics/Air: If air is needed for any machine operation or function, the machine shall be fully equipped with all necessary piping or valving, fully installed to the point of connection to which the Arsenal will connect shop air. Available shop air within the Benét Labs Manufacturing Prototype Center is

85 psi. The machine shall also be equipped with devices (ie., air dryer) 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. Connection does not include filters, dryers, or any peripheral equipment necessary to make the equipment functional.

OFFEROR IS TO STATE REQUIRED AIR REQUIREMENTS FOR OFFERED MACHINE (AIR

PRESSURE, FLOW RATE) AND IF EXTERNAL EQUIPMENT IS REQUIRED (COMPRESSOR,

AIR DRY, OR FILTERS)

3.1.13.3 Electrical Conversion Equipment/Transformers: (Also see par. 3.1.12.1) 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. Equipment which requires a high quality constant power source shall have proper isolation and/or power conditioning equipment for the power service designated in this description. All electrical equipment shall have a power factor (ratio of real power to apparent power) of no less than 80%, as read at the equipment main disconnect. Equipment with a power factor of less than 80% shall be fitted with suitable power factor correction capacitance, sized on the basis of the equipment inductive AC load. See Attachment D for additional transformer requirements.

3.1.13.4 Air Booster Unit: If the machine offered requires more than 85 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.

3.1.14 Motors: All motors provided shall be of the optimum type and horsepower rating to meet intended application and usage based on accepted engineering practice.

3.1.14.1 All motors shall be rated for continuous duty.

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

3.1.14.3 Each motor shall bear an identification plate containing the identity of the manufacturer, model number, serial number, input voltage, amperage, horsepower, phase, frequency, duty cycle, and frame size or mounting identification.

3.1.14.4 Motor starters and controls shall operate at no greater than 120-VAC. It is preferred that they operate at 24-VDC.

3.1.14.5 Motor starters shall provide drop-out protection. This means that, in the event of a loss of power, the equipment shall be re-energized only by the deliberate action of the operator. Manual or mechanical motor starters shall not be deemed acceptable.

3.1.14.6 All motors shall be housed in enclosures of the appropriate NEMA type for the class and severity of service.

3.1.14.7 All AC unidirectional motor housings shall bear a directional arrow to indicate proper rotation direction when correctly wired.

3.1.14.8 All AC motors at 25 hp or greater shall be equipped with a “soft-start” mechanism which provides for reduced voltage starting.

3.1.14.9 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

9IEC 60034-30:2008).

3.1.14.10 All motors are to be permanently lubricated and sealed.

3.1.15 Electrical Enclosures: All separate electrical hardware / circuitry are to be housed in a NEMA-

12 rate enclosure that are air conditioned and air filtered to maintain a constant temperature, reduce humidity and prevent contamination of control boards and other critical system components. Air conditioning units shall not utilize Ozone Depleting substances. Enclosures shall be painted with a color as close to the machine tool as possible.

3.1.15.1 Utility Outlet: The machine shall be provided with an operational 120-volt AC 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 and easily accessible. A “noise" suppression device shall be provided.

3.1.15.2 Interconnect Wiring: All wiring shall comply with accepted Joint Industry Code (JIC), National Machine Tool Builders Association (NMTBA), and the National Fire Protection Association (NFPA) standards.

3.1.15.3 Electrical Disconnect: The equipment shall be equipped with a manual, fused or breaker type disconnect switch, readily accessible to the operator, which will deactivate the entire equipment. It shall be located no more than 6-ft 7-in from the floor to the highest point the control device. It shall be capable of being locked in the de-energized state (OFF) only.

3.1.15.4 Electrical Safety Devices: The machine and its equipment shall be protected with circuit breakers which comply with Underwriters Laboratories’ 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.

3.1.15.5 Electrical Conduit: Flexible conduit is not permitted in exposed areas. All wires, cables, and hoses will be enclosed by rigid, oil-proof protection, except where flexibility is necessary for operation of the equipment. Flexible wires, cables and hoses shall be arranged to prevent draping or tripping hazards.

3.1.16 Service Access: Components subject to periodic adjustment, replacement, or servicing shall be readily accessible. Meaning that experienced personnel can access the part after no more than 30-min of labor. If any special tools or equipment are necessary to access these components, said equipment will be supplied as part of the system and provided with a proper storage location within the system.

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

3.1.18 Component Environment: Under no circumstances shall a component be used in an application not recommended by the component manufacturer. Components shall not be subjected to conditions of operation beyond the recommendations of the manufacturer, such as excessive heat, lack of lubrication, over-loading.

3.1.19 Replacement Components: All replaceable components shall be manufactured to definite standards for tolerance, clearance, and finish, enabling components to be field installed without further machining.

3.1.20 Castings and Forgings: All castings and forgings shall be free of defects, scale, and mismatching. No process such as welding, peening, plugging, or filling shall be used for reclaiming any defective part for use in this equipment without the prior written consent of the contracting officer.

3.1.21 Surface Building and Coatings: Welding, brazing, soldering, coating or plating shall be employed only where specified in the original design. These operations may not be employed as a means of reclaiming a defective part.

3.1.22 Fastening Devices: All screws, pins, bolts, and similar parts shall be installed in such a manner as to prevent change in tightness. Those devices subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently deformed. They shall not be installed using permanent bonding adhesives.

3.1.23 Cleaning and Deburring: All surfaces of castings, forgings, molded parts, stampings, and welded components shall be cleaned and free from sand, dirt, fins, flash, scale, flux, and other harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. Except as specified herein, the condition and finish of all surfaces shall be commensurate with the manufacturer’s commercial practice.

3.1.24 Painting: All unfinished surfaces of the equipment shall be painted with a lead free and chromium free commercial grade of metal primer and a minimum of one finish coat. The color shall be in accordance with the manufacturer’s standard commercial practice, or as necessary to maintain compliance with OSHA regulations, as applicable.

3.1.25 Machine Hold Down and Leveling: The machine base shall be provided with sufficient and properly located holes for positive hold-down when operating at full rated capacity. However, per section 3.1.39, the machine will not be held to the floor in this manner.

3.1.26 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.

3.1.27 Dials and Gauges: All scales, dials, and gauges shall be manufactured of corrosion and oil resistant material. All wording shall be in the English language using plain, bold face lettering. Lettering shall be permanent and have a contrasting background.

3.1.28 Hand-wheels: Hand-wheels turned in a clockwise rotation shall produce a linear motion, of the controlled component, to the right, away, or upwards. If rotary motion is produced by the hand-wheel, clockwise rotation of the hand-wheel shall produce clockwise movement of the controlled component.

3.1.29 Control Levers: Control levers shall move in the same direction as the motion of the controlled component.

3.1.30 Work Area Enclosure: The machine shall also be provided with a work envelope enclosure to confine coolant to the working area (leak proof). The guarding shall include transparent panels to permit viewing of the machining operation. The enclosure shall designed with double doors at least in the front to allow the operator full access to the work area. Additional access doors for maintenance or other purposes are acceptable. It shall be possible to load parts from overhead.

3.1.30.1 Work Area Lighting: The enclosure shall include a sufficient number of light fixtures conveniently mounted in the work compartment to provide illumination to the work piece and entire work area when all safety shields are closed and machine is operating. The lights shall be LED type with water proof construction to resist penetration of coolant. On/Off control should be at the operator’s station. The light shall be prewired and fused. The light(s) shall be capable of illuminating the entire machine work area, and shall be constructed to meet environmental conditions inherent to machining operations. Operation voltage shall be nominal 115 VAC.

3.1.30.2 Mist Collection System: The enclosure shall include a mist collection system. The system shall continually collect coolant and machining/cutting mist from inside the enclosure, separate it at the mist collector, discharge clean air above and drain the liquid back into the coolant reservoir.

3.1.31 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.

3.1.32 Control of Cutting Fluids: The contractor shall ensure 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.

3.1.33 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.

3.1.34 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 capable of full recirculation and shall not require the continuing input and discharge of Watervliet Arsenal’s water supply. Waste water systems of any type are not acceptable.

3.1.35 Lubricants, Hydraulic Fluids, Oils and Coolants: Benét Labs is a tenant on the Watervliet

Arsenal facility, which has established a standardized list of lubricants, hydraulic fluids, oils and coolants.

The contractor shall 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, 90 days prior to delivery, justification which shall include the manufacturer, type and specification number as well as the reason for the substitution.

3.1.36 Lubrication System: Components specified as requiring lubrication by the original manufacturer shall have an appropriate means of providing said lubrication included in the design of the machine.

3.1.36.1 The lubrication points will be labeled on the lubrication drawing provided as part of the maintenance documentation and will also be labeled on the machine at the lubrication point and on any access panel covering the lubrication point. These labels will include as a minimum standard, the specific type of lubricant, the quantity to be used, the frequency for change, and the maintenance manual reference for detailed instructions. The lettering shall be English and the units shall be English standard (i.e. pints, quarts, and gallons).

3.1.36.2 If an automatic circulation system is used, it shall be complete, including, but not limited to the following: reservoir, valves, nozzles, filters, pumps, sight gages, and other components as necessary to make the system completely functional.

3.1.36.3 A system allowing blockages or inadequacies to go undetected is unacceptable. The system shall be interlocked to the machine control, providing an alarm that lubrication failure has occurred. The system shall not initiate immediate shutdown of the affected function during a cutting cycle. It shall allow completion of the cycle and shutdown in an orderly sequence.

3.1.36.4 The reservoir shall be sized to allow no less than 80-hrs of machine run time before requiring refill. It shall also have a means provided for draining and cleaning. A means shall be provided to enable the operator to determine the fluid level.

3.1.36.5 All filters shall be either cleanable or replaceable.

3.1.36.6 All pumps shall be self-priming.

3.1.37 Hydraulic System: If the machine is equipped with a hydraulic system, the system shall be complete with, but not limited to, pump, valves, piping, cylinders, pressure controls, filter, and reservoir.

All components necessary to make the system completely functional shall be provided.

3.1.37.1 If the duty cycle of the system under maximum usage will cause the hydraulic fluid to exceed 120-deg-F in temperature, a suitable air-cooled heat exchanger shall be provided to maintain fluid temperature at or below that temperature. The exchanger shall be equipped with changeable fiberglass filter(s), unless permanent type filters are supplied.

3.1.37.2 The system shall have adequate capacity to provide sufficient pressure and flow to perform all hydraulic operations under all normal machine operating conditions. The system shall be protected against overpressure as well as underpressure. System pressure in any hydraulic device shall be as low as practical for the intended application but shall not exceed 3,000 psi in any case.

3.1.37.3 Protection shall be provided to prevent damage to components.

3.1.37.4 Safeguards shall be provided to alert the operator of temperatures and pressures above/below design limits. If safe limits (within design limits) are exceeded, the system shall automatically shut down.

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

3.1.37.6 The hydraulic reservoir shall be provided with means for draining and cleaning and shall be accessible at floor level.

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

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

3.1.37.9 All pumps shall be self-priming.

3.1.38 Coolant System: If the machine is equipped with a coolant system, it shall be equipped with external flood coolant capabilities, as a minimum. Machines using cutting tools shall be equipped with both through the tool and external flood coolant capabilities. Coolant on/off shall be a machine control function.

In addition to an automatic cycle whereby coolant flow is started with spindle actuation, a provision for manual actuation at the operator’s discretion shall be included.

3.1.38.1 The coolant systems shall include all necessary components (pumps, motors, filters, piping, valves, or reservoir) necessary to provide completely functional systems, with sufficient capacity to give satisfactory service and provide adequate pressure and flow under normal operating conditions.

3.1.38.2 Coolant troughs and chip screens shall be provided around the machine table base to trap, direct, and return the coolant to the reservoir. An easily removable strainer shall be provided in the return line to the reservoir. "Easily removable" is defined as being removable after no more than 5-min of work by experienced personnel. All components shall be floor mounted, easily accessible for cleaning and flushing, and not required special pits or foundations for installation.

3.1.38.3 All machine coolant systems and their components shall provide drip-proof coolant delivery to the coolant point of discharge. In addition, the machine shall be designed and constructed to prevent coolant from escaping the confines of the machine or leaking to the floor when producing work-pieces of a size within the dimensions of the machine table.

3.1.38.4 Heat exchange/chiller equipment shall be furnished with the coolant system wherever it is needed to keep the 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 facilities water supply. Waste water systems of any type are not acceptable.

3.1.39 Chip Removal: An automatic, belt or auger type reversible chip removal unit shall be provided, by the contractor, capable of conveying various types of ferrous and nonferrous chips from the entire work area of the machine to a suitable container outside of the machine without manual aid.

3.1.39.1 The unit shall be of watertight construction.

3.1.39.2 The unit shall be a hinge-type conveyor in a right-discharge configuration.

3.1.39.3 The conveyor belt shall be equipped with a master link, easily disconnected, allowing the belt to be removed for maintenance purposes. All pillow block bearings shall be mounted for ease of replacement. Pillow block bearings shall be fitted with external lubrication fittings. Drive and idler shafts shall extend through the pillow blocks and shall be provided with a hexagonal end, allowing manual movement of the conveyor belt.

3.1.39.4 The conveyor shall facilitate draining of excess coolant back to the sump and main coolant tank before chips are discharged. The height of the discharge chute from the floor shall be not less than 49.5-in.

3.1.39.5 The chip removal unit shall be installed in a manner facilitating collection of chips from the entire work area without interfering with normal operation of the machine.

3.1.39.6 As a minimum, the chip removal unit shall be provided with an on/off switch or buttons, stop button, and reversing switch. Operation of the chip conveyor shall be possible both at the operator’s control station and the discharge end of the conveyor.

3.1.39.7 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.

3.1.40 Foundation: This equipment is intended to be installed in the Benét Labs Manufacturing

Prototype Center, which is located on the 2nd floor of B25 at Watervliet Arsenal. A foundation cannot be installed in this instance and all equipment shall be compatible with the 2nd floor installation requirements.

These requirements include avoiding the need to core-drill anchor holes.

3.1.41 Safety and Environmental: The machine shall be fully designed and equipped with features to protect the machine operator, other personnel, and prevent self-damage to the machine itself in the event of malfunction and/or ordinary negligence insofar as practical.

3.1.41.1 Industry And Regulations: The equipment shall comply with the most current of all local, state, and federal laws and regulations listed in Standards and Publications (Section 2.2).

3.1.41.2 Material Exclusions: The equipment shall not contain polychlorinated biphenyl (PCB), ozone depleting substances (Class I), lead/chromium based paints, or asbestos/mercury containing materials.

3.1.41.3 Safety Regulation Compliance: The contractor shall comply with standard OSHA and RIA safety standards, including conforming to confined space work requirements when applicable.

3.1.41.4 Permits: The contractor shall provide a list of permits and certifications required by the agencies in Standards and Publications (Section 2.2) and those recommended by the general industry. The contractor shall also provide the information necessary to obtain required permits for the system.

3.1.41.5 Safety Lockouts/Tagout: Each point of first connection shall be designed and constructed to allow the utility to be completely isolated from the equipment. This isolation shall be insured by application of a standard key locking padlock. The device(s) shall only be lockable in the de-energized (OFF) condition.

3.1.41.6 Loss Of Pressure: Hydraulic and pneumatic circuits shall be designed such that loss of pressure, or pressure surges, shall not cause a hazard. Means shall be provided to prevent operation of the equipment with insufficient pressure, if such operation could cause a hazard.

3.1.41.7 Early Power Failure Detection: The system shall automatically detect a power failure before the system is affected. It shall then react to prevent damage to the system, controls, tools, and fixtures. This may include, but is not limit to, storing table position data to prevent the next to zero when power is restored, controlled stop and locking of the spindle to prevent dropping or otherwise moving in an uncontrolled fashion such that it may cause damage to the workpiece, or machine tool including the spindle itself.

3.1.41.8 Trapped Energy: Devices in which energy is contained, e.g. air reservoir tanks, shall be equipped with a means to manually drain the energy to a safe condition. e.g. drain hydraulic fluid back to the reservoir, or vent trapped air to atmosphere.

3.1.41.9 Working Range: Hydraulic and pneumatic components shall be selected which cannot be adjusted outside the safe working range of the circuit and/or equipment.

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

3.1.41.11 Brakes: Braking systems shall be designed to “fail-on”. This means, energy supplied to the brake shall be used to disengage the brake. Loss of energy shall therefore cause the brake to activate.

3.1.41.12 Emergency Stop: The system will incorporate a clearly identified, red, mushroomed, control button with a yellow backing plate at every operator work station. Upon momentary operation, any emergency stop button shall de-energize all machine motions and override all other controls without creating additional hazards. All motion stopped shall be restarted by the deliberate action of the operator.

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

3.1.41.13 Control Guards: Controls shall be guarded against accidental operation.

3.1.41.14 Operator Reach: Controls shall be within reach and located such that the operator, when in the normal operating position, is not required to reach past moving parts, which may cause injury.

3.1.41.15 Audible Noise: The equipment noise level during normal operation shall not exceed 85-dbs, “A” scale. Tests shall be conducted around the entire equipment 60-in to 65-in above the floor within 3-ft of any major sound source. Metal removal equipment shall comply with the standard noise requirement while making a midrange horsepower cut on rigidly clamped mild steel. The contractor shall furnish shields, baffles, enclosures, or other devices necessary to bring the equipment into conformance. Any such device shall not interfere with the proper operation of the equipment and shall be designed to preserve the visibility necessary for safe operation of the system.

3.1.42 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 CAD drawings provided shall not utilize the color yellow or any other colors that cannot be made readily visible when plotted out in color.

3.1.42.1 Machine and Equipment Floor Plan: A digitized machine and equipment floor plan in

AutoCAD .dwg or .dxf format shall be provided electronically. 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, or water) required to operate the machine. This data shall be furnished within two weeks of contract award. One reproducible hardcopy and one digital copy in AutoCAD .dwg or .dxf format shall be provided. AutoCAD drawings shall not utilize the color yellow or any other colors that cannot be made readily visible when plotted out in color. 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.

3.1.42.2 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. (two copies)

3.1.42.3 Non-Standard (special) Tooling and Accessories: To the extent that this specification requires the development of unique tooling and/or accessories, 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 reproducible hardcopy and one digital copy on CD in AutoCAD .dwg or .dxf format.

3.1.42.4 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 within two weeks of contract award. One reproducible hardcopy and one digital copy in AutoCAD .dwg or .dxf format, The specific AutoCAD version will be determined by Benét Labs.

3.1.42.5 Lubrication Diagram or Instruction. To be delivered at time of machine delivery. One reproducible hardcopy and one digital copy in AutoCAD .dwg or .dxf format. AutoCAD drawings shall not utilize the color yellow or any other colors that cannot be made readily visible when plotted out in color.

3.1.42.6 Operating Instructions. These instructions shall be in provided in separate manuals from other technical data provided. These are to be delivered upon machine delivery with at least four (4) copies provided at a minimum.

3.1.42.7 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. Four copies minimum of the Maintenance and Troubleshooting Instructions. One reproducible hardcopy and one digital copy in AutoCAD .dwg or .dxf format of the machines mechanical assembly drawings.

3.1.42.8 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.

One reproducible hardcopy and one digital copy 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.

3.1.42.9 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 copies)

3.1.42.10 Programming 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. These manuals shall be delivered at machine delivery. (two copies)

3.1.42.11 Software Documentation. The offeror shall provide three copies of all system software and/or ladder logic developed to control and interface the new control/drives with the existing machine tool.

Two copies shall be on CD and the third copy shall be a paper (hard) copy.