New_Carbide_Cut_off_Saw_-_Draft_SOW.pdf

Specification for a New Carbide Cut-off Saw

Spec # 35-17-3408

Rev. A

Manufacturing Engineering Work Group

Watervliet Arsenal

Watervliet, New York 12189-4050

11/13/2017

Department of the Army

TACOM

35-17-3405

Table of Contents

1 Scope:

1.1 Abbreviated Description:

1.2 Preparation of Proposals:

2 Applicable Standards and Publications:

3 Requirements:

3.1 General Requirements:

3.2 Machine Specific Requirements:

3.3 Control System:

3.4 Requirements for Demonstration of Conformance:

4 Quality Assurance Provisions:

4.1 Responsibility for Inspection:

4.2 Preliminary Acceptance Inspection:

4.3 Arsenal Participation in Preliminary and Final Acceptance Inspection:

4.4 Re-inspection Provisions:

4.5 Post Preliminary Inspection Procedures:

4.6 Final Acceptance Inspection:

4.7 Warranty:

5 Preservation and Packaging:

6 Instructions to Offerors:

6.1 Contents of Proposals:

6.2 Offeror’s Statement of Compliance:

6.3 Prior Customer List:

6.4 Standard or Optional Equipment:

6.5 Special Foundations:

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

Attachment B – Class I Ozone Depleting Substances

Attachment C – Electrical Survey

1 Scope:

1.1 Abbreviated Description: The new machine covered by this specification shall be a horizontal, carbide tipped circular cut-off saw. The saw shall come complete with material handling devices for workpiece loading and unloading. The saw will be used for cut-off operations on muzzle and breech end of rotary forged cannon tubes. Tubes will be up to 16” in diameter, 40’ long, and weighing up to 15,000 lbs.

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 their 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 to the standards recognized for this type and class of equipment.

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 the machine’s maximum rated capacity. Distortion and deflection at maximum load shall be limited to a degree consistent with retention of alignments and tolerances, and the machine shall recover from distortions and deflections at no load. The structure and assembly of the machine and its components shall be sufficiently rigid that workpiece finish and accuracy are not impaired by machine vibrations.

3.1.3.1 Construction of Major Components: All major machine components such as beds, saddles, columns, etc. shall be castings either of iron or semi-steel, or shall be constructed as mild steel weldments. Weldments, if used, shall be braced, ribbed and gusseted to obtain strength equal to or better than the strength of castings, and shall be properly stress relieved.

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

3.1.4 Slideway Design and Construction: 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 very 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. 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.

3.1.4.1 Replaceable Ways: The procedure of assembling unfinished ways to a non-precision frame and then finish grinding at assembly is unacceptable. 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.

3.1.4.2 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.

3.1.5 Workmanship: Workmanship throughout the machine shall be of good quality and meet industry standards. For purposes of this specification, good quality workmanship is further defined as the completed machine's conformance to the manufacturer's engineering drawings and to standards recognized or adopted by the Association for Manufacturing Technology.

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

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

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

3.1.8 Operator’s Controls: The operator’s control console shall not be remote from the machine, that is, shall not be in a fixed free-standing location requiring the operator to return to it to accomplish machine control functions.

3.1.9 General Electrical Characteristics: The electrical system shall conform, in quality, safety and performance, to all industry electrical standards equal to or better than that of the

National Fire Protection Association (NFPA 70 and NFPA 79).

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

3.1.9.2 Electrical Safety Devices: The machine and its equipment shall be protected with circuit breakers which comply with NEMA standards for thermal magnetic types and shall have a minimum interrupting capacity of 25,000 RMS symmetrical amperes for 480 volts, 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.

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

3.1.9.4 Motors: All motors shall be of the optimum type and horsepower rating to meet intended application and usage based on accepted engineering practice. Under normal operation of the machine throughout its specified range and capacity, no motor shall be operating at overload, and all motors shall be equipped with thermal overload protection. All motors shall be housed in enclosures of the appropriate NEMA type for the class and severity of service and shall be properly balanced. Each motor shall bear an identification plate containing the identity of the manufacturer, the model, serial number, input voltage, amperage, horsepower, phase, frequency, duty cycle, and frame size or mounting identification. All AC unidirectional motor housings shall bear a directional arrow to indicate proper rotation direction when correctly wired.

All AC motors rated at 25 HP or greater shall be equipped with a "soft start" mechanism which provides for reduced voltage starting. If this is a rebuild/retrofit project then replacement motors shall as a minimum meet original OEM specs in continuous HP and torque ratings without the use of additional gearboxes.

All polyphase AC motors rated at 1 HP or greater shall be of the high efficiency type as determined by the testing procedures described in IEEE Standard 112, Section b.

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.

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

3.1.9.6 Utility Outlet: The machine shall be provided with a dual receptacle 3-wire utility outlet fully wired and equipped to deliver 120-volt single-phase AC power at up to 20 amperes, based upon 480-volt 3-phase input. The outlet shall be protected by a ground fault interrupter.

The outlet shall be externally mounted on the on the operator’s control panel. An electrical

"noise" suppression device shall be provided.

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

3.1.10.1 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.

3.1.10.2 Protection of the Machine: The machine 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. Such devices include, but are not limited to, limit switches, positive end stops, overload protection devices, lubrication failsafe, etc.

3.1.10.3 Noise Levels: The government's preference is to achieve noise levels not in excess of 80 dba. Noise levels shall be measured under load during the test of conformance to specified ranges and capacities. Noise levels in the vicinity of the machine, even if not meeting the desired 80 dba, 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. "Vicinity of the

Machine" is further defined as an imaginary line completely surrounding the machine at a distance not exceeding one meter from the nearest point on the machine. The maximum noise level limit shall apply at the operator's console, even if the console lies inside the one meter envelope. Techniques such as sound level averaging or exposure time weighting shall not be used in meeting this requirement. 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

3.1.10.4 Ozone Depleting Substances: Section 326 of Public Law 102-484 precludes the

Dept. of Defense from awarding any contract that directly or indirectly requires the use of a class

I ozone-depleting substance within the Government specification or standards set forth in the contract. Attachment B is a list of the restricted Class I CFC's and Halons. 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. Safety Data sheets (SDS) 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.

3.1.10.5 Asbestos and Mercury Free Certification: All materials utilized in the system shall be certified as asbestos and mercury free. This certification shall be provided at the time of proposal submission.

3.1.10.6 Safety Data Sheets: The offeror shall provide Watervliet Arsenal with all safety data sheets at the time of the submission of their proposal.

3.1.10.7 Lead-Free and Chromium-Free Paint Certification: All paints and primers applied to this system shall be certified as lead free and chromium free. Lead based paint is paint that contains more than nine-thousandths of one percent (0.009%) lead by weight. This certification shall be provided at the time of proposal submission.

3.1.10.8 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, 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.

3.1.10.9 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.

3.1.11 Identification Plate: A corrosion resistant metal plate shall be securely attached to the machine in a visible location in the vicinity of the operator's workstation. This plate shall bear the information listed below, with space at the bottom for one additional line of information to be added 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

3.1.12 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.

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

3.1.14 Utility Connection Labor: Watervliet Arsenal 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 contractor will be responsible for all connections beyond the point of first connection for each utility.

3.1.15 Utility Requirements:

3.1.15.1 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. 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, ETC.). See Attachment C and complete.

3.1.15.2 Pneumatics/Air: If air is needed for any machine operation or function, the machine shall be fully equipped with all necessary accessories, fully installed to the point of connection to which the Arsenal will connect shop air. Available shop air at the Arsenal is 85 psi and if higher or lower pressure is needed at the machine or a different air flow rate is needed, the machine shall be fully equipped with the devices needed to modify the supply pressure and volume. The machine shall also be equipped with devices to remove the normal moisture and other contaminants usually present in shop air supplies. Normal moisture is defined as that moisture produced when air at a relative humidity of 75% has been compressed to 85 psig.

3.1.15.3 Electrical Conversion Equipment/Transformers: 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.

3.1.15.4 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. Installation of the booster and tank shall be provided by the contractor. If the use of an air booster is not possible and an air compressor is required, the contractor must state this in their proposal and provide justification detailing CFM, psi, application, and duration of air usage.

3.1.15.5 Air Dryers/Filtration: The Arsenal’s preference is for the machine to not utilize a refrigerated air dryer. Only if deemed necessary by the contractor, shall the machine be provided with an appropriately sized refrigerated air dryer system complete with input and output filter cartridges. The contractor shall state in their comply sheet the reason why a refrigerated air dryer is necessary. Industrial air dryers are to be of the latest technology that will result in the most energy efficient design such as advanced heat exchangers, use of heat sink reservoir to allow on/off cycling, reduce pressure drop by use of multi-pass flow patterns, and alternative configurations such as desiccant media. Equipment which requires compressed air shall have a regenerative type desiccant or refrigerated compressed air dryer capable of drying air down to

35° F pressure dew point, minimum, from air entering the equipment at 110° F, and capable of supplying air to the rated standard cubic feet per minute (SCFM) of the equipment. The unit shall purge condensate automatically. In the case of the latter, the refrigerant used shall not be a

Class I, ozone depleting substance. The air dryer shall be connected and/or piped to the equipment by the contractor. All designs are to be supplied by manufacturers participating in the

CAGI Refrigerated Dryer Performance Verification Program and have been tested and rated in accordance with CAGI ADF 100. Power for the refrigerated air dryer unit shall be 110 V AC and shall be wired and powered through the machine electrics. Common industrial air dryers that are used at the Watervliet Arsenal include the ZEKS HSE and Ingersoll-Rand D31NC models.

3.1.16 Lubrication: The machine shall be equipped with an automatic system to provide positive lubrication at the proper rate to each internal moving part where lubrication is essential to prevent damage. A system wherein lubrication blockages or inadequacies will go undetected is unacceptable. The lubrication system shall be interlocked to the machine controller and shall be fail safe. The fail safe system shall be designed so that movement of critical machine components cannot take place until proper lubrication flow is achieved at each critical point.

Sideways shall be lubricated by a series-progressive distribution system such as 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. Parts, requiring periodic manual lubrication shall be readily accessible and identified. 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.

3.1.16.1 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.

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

3.1.17 Hydraulic System: Hydraulic system provided shall be appropriately sized and powered for the intended application and shall conform to industry standards. The system shall incorporate cleanable or replaceable filtration devices to ensure 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 under pressure. System pressure in any hydraulic device shall be as low as is practical for the intended application but shall not exceed

3000 PSI in any case. In any system which utilizes hydraulics to produce thrust or direct linear motion, anti surge devices or circuits shall be incorporated to insure uniformity of motion under varying loads. These devices or circuits shall be adjustable. All reservoirs shall be easily accessible for cleaning and flushing. System shall be free of leaks when operating and when idle.

3.1.18 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. 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.

3.1.19 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. In addition, for each hole in the machine base, the contractor shall provide a set of his recommended hold-down and leveling hardware.

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

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

3.1.21 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.

3.1.22 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, as indicated below, in hardcopy and in AutoCAD version 2015 on CD, 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 or Special (see note): Shall be in sufficient detail to permit pricing and construction by a general contractor and shall be furnished 225 days prior to scheduled delivery of the machine. The foundation design shall include railing around pits, ladders to access pits, and pit covers. 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.

6.5.

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 Drawing: 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 by manufacturer’s part number 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 with 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.

3.1.23 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:

Type of training Number of persons When required Training location

Machine operation 4 During or after machine performance testing

On site

Mechanical maintenance

2 During startup On site

Hydraulic maintenance

(if applicable)

2 During startup On site

Electrical maintenance 2 During startup On site

Electronics (CNC) maintenance

2 During Installation On site

Spindle/Axes Drives

(if applicable)

2 During Installation On site

Programming training 2 During Installation On site

Note: For all types of training, the associated technical data (see 3.1.22) 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.

3.1.24 Repair/Replacement Parts and Service: The offeror shall 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.

3.1.25 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.

3.1.26 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.

3.1.27 Site Conditions: The machine covered by this specification is installed in general machine shop space and there will be no environmental conditioning. Temperatures will range from 60° 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.

3.1.28 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.

3.1.29 Machine Installation, Startup, and Testing:

3.1.29.1 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.

3.1.29.1.1 Site Designation: Upon receipt of the required installation and foundation drawings (see 3.1.22), Watervliet Arsenal will designate an installation site and outline a general machine location on the shop floor and install a foundation if necessary.

3.1.29.1.2 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 3.1.22), 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.

3.1.29.2 Work to be Performed by the Contractor: This project is classified as a turn-key with the contractor being responsible for all costs and work associated with the installation unless otherwise stated. The Contractor shall be solely responsible for all costs associated with skidding and shipment, rigging, and installation at WVA. 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.

3.1.29.2.1 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 2.5” thick wood block. It shall be the contractor’s responsibility to cut out and remove wood block and to supply and install any leveling pads necessary for installation.

3.1.29.2.2 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. Only propane powered forklifts are permitted and forklifts must also be equipped with a roll cage. Operators of forklifts shall have and be able to produce valid forklift licenses. The contractor shall ensure they bring all equipment/material necessary for the rigging of the machine. If necessary, the Watervliet Arsenal can provide the contractor with information for local rigging companies.

3.1.29.2.3 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 his own service personnel shall be fully responsible for the startup and testing of the machine, conduct any acceptance tests specified in sections 3 & 4 and perform the required on-site training. The contractor and the service personnel shall remain until the machine activation and testing have been successfully completed. Under no circumstances should the contractor plan on gratuitous

Arsenal assistance for diagnosis, troubleshooting or repair of the equipment during activation and testing. Should such activity prove necessary, it shall be the contractor's responsibility to provide the appropriate labor and materials. If the contractor chooses to request Arsenal assistance in lieu of providing 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: The new machine covered by this specification shall be a horizontal, carbide tipped circular cut-off saw. The saw shall come complete with material handling devices for workpiece loading and unloading. The saw will be used for cut-off operations on muzzle and breech end of rotary forged cannon tubes. Tubes will be up to 16” in diameter, 40’ long, and weighing up to 15,000 lbs. The machine shall include all components, accessories, and features necessary to meet the performance requirements specified. The machine shall be the manufacturers current standard model and shall not be a new or unproven model or design.

3.2.1.1 Intended Use: The machine will be used by the Watervliet Arsenal to perform cut-off operations on the muzzle and breech ends of various rotary forged cannon tubes. The tubes to be cut off are forged from SAE 4340 modified alloy steel which has been through hardened to

HRC 38 – 42. The tubes to be cut will range in overall nominal length from 230” to 480”, overall nominal breech end diameter of 9.5” to 16”, overall nominal muzzle end diameters of

6.5” to 8.5”, overall nominal through bore diameter of 3.5” to 5.5”, and maximum nominal weight of 15,000 lbs.

3.2.2 Size Characteristics:

Cutting Capacity ........................................................ ≤ 4” to ≥ 16” (round)

≤ 4” to ≥ 14” (square)

Saw Blade Diameter .................................................. 36” to 40”

Saw Blade Body Width .............................................. ¼ ”

Saw Blade Mounting.................................................. 5.50” by Ø10”, straight flange

Saw Blade Drive Pins ................................................ Ø1” located 180° apart to form a center of rotation dia. of

7.25” nominal blade holder

Workpiece conveyor type .......................................... V-roller

V-Roller Spacing ....................................................... 12” or less

V-Roller Diameter ..................................................... 5” or more

V-Roller Height from Floor ....................................... 36” – 40”

Material Handling Capacity ....................................... 5 tube input – 5 tube output, . Walking Beam Type

3.2.3 Performance Characteristics:

Saw Cutting Speed (infinitely variable) ..................... ≤ 25 to ≥ 55 RPM

Saw Feed Rate (infinitely variable) ........................... ≤ 6” / min. to ≥ 30” / min.

Saddle, Full Travel ..................................................... ≥ 24”

Spindle Drive ............................................................. 100 Hp

Saddle Feed Drive ...................................................... 15 Hp

Clamping Pressure ..................................................... 10,000 lbs. each clamp

Conveyor Feed Rate, Entry & Exit (adjustable) ........ 0 to ≥ 200” / min.

Unclamp, Full Travel ................................................. 1”

Bar Spreader, Full Travel ........................................... 1/8” each side of blade

3.2.4 Alignments and Accuracies: .

Rise & Fall of Saddle Over Guideways ..................... .001” TIR over 24” travel

Left to Right Movement of Saddle Over Guideways .001” TIR over 24” travel

Saw Mounting Runout ............................................... .001” TIR on 5.5” flange dia.

. and 10” flange face

Leveling of Conveyor, Entry & Exit .......................... not to exceed 1/8” total deviation between all roller centerlines for the full length of each conveyor

Squareness of V-Rollers to Plane of Cut ................... not to exceed 1/8” total deviation between all v-roller centers for the full length of each conveyor

3.2.5 Saw Blade Adaptability: The saw drive spindle shall be designed so as to accept the many blades that the Watervliet Arsenal currently stocks in its inventory. The Arsenal owned blades are 40” in diameter with 70 carbide teeth which mount by a single nut to a straight flange bladeholder and are prevented from slipping by two 1” drive pins located on a 7.25” diameter from the center of rotation.

3.2.6 Entry & Exit Conveyor: The machine shall be provided with conveyors to transport cannon tubes through a plane in which a sequence of through cuts will be made at the muzzle and breech ends of various tubes (straight and tapered). All cuts will be made in a perpendicular land to the direction of the conveyor travel and the conveyor shall be arranged so as a workpiece can be transported to a cut position, clamped in place, cut through, and eventually directed to the walking beam output side of the machine. The input/output conveyors shall be identified as input being on the right side of the machine and output being on the left side of the machine.

Each v-roller of this conveyor system shall be driven by the through feed motor.

3.2.7 Material Handling System: The machine shall be provided with a walking beam type material handling system capable of transporting cannon tubes. The material handling system shall be capable of being tied in with the Watervliet Arsenal’s Selas Furnace in line conveyor.

The walking beam system shall lower the tubes from the pick off height of the Selas conveyor to the nominal height of the entry and exit conveyor and shall be located on the right side of the machine. The left side of the machine the machine shall be provided with a walking beam material handling system capable of transporting the cut-off cannon tubes from the exit side of the conveyor to stand by positions where they will be picked off by an overhead crane.

3.2.8 Workpiece Clamping System: The machine shall be provided with v-type clamps located on each side of the cut and shall be so arranged to firmly clamp round or square workpieces for the full capacity of the machine. These clamps shall also be designed with a spreading feature to separate the workpieces after cut-off is completed for eliminating any drag of the saw blade along the cut surfaces when retracting the blade. Unclamping shall also be provided on each side of the cut to prevent workpiece springing while cutting parts with heavy shear nose. The workpiece clamps shall be positioned close enough to the saw blade to allow ¾” thickness discs to be cut from each end of the cannon tubes.

3.2.9 Workpiece Retrieval: The…