SOLICITATION NOTICE
K -- Testing Machine Controls Upgrade
- Notice Date
- 4/27/2012
- Notice Type
- Presolicitation
- Contracting Office
- Bureau of Reclamation-DO-Acquisition Operations Group PO Box 25007, 84-27810 Denver CO 80225
- ZIP Code
- 80225
- Solicitation Number
- R12PS80286
- Response Due
- 5/7/2012
- Archive Date
- 4/27/2013
- Point of Contact
- Ann Manning 3034452433 amanning@usbr.gov;
- E-Mail Address
-
Point of Contact above, or if none listed, contact the IDEAS EC HELP DESK for assistance
(EC_helpdesk@NBC.GOV)
- Small Business Set-Aside
- N/A
- Description
- The Bureau of Reclamation is conducting a market survey in accordance with the Federal Acquisition Regulation (FAR) Part 10.001 to obtain feedback from industry regarding the general requirements for an upcoming procurement. THIS SYNOPSIS IS NOT A REQUEST FOR PROPOSAL. It is a market research tool to determine potential sources and interested parties for the pending requirement. The pending requirement will consist of new controls and hydraulic power supply for the existing load frame for the in-house Southwark Emery 120,000 pound capacity universal testing machine (estimated date of manufacturer is 1944 - serial number is 42375). The requirement includes a new cabinet, a new hydraulic power supply and all associated equipment, new electronic controls, a PC based control interface, a PC, software, and all labor and materials required to integrate the new controls and power unit to the existing test frame to make a complete and fully functional test system. Due to in-house, operation compatibility issues with the other Instron 5598WHVL unit, the Government requires the following: Software The Instron 5598WHVL is operated using Instron Partner software. It is required that the upgraded equipment use the same Partner software to give operators identical functionality, identical operating procedures and user interface, and test profile interchangeability. Hardware MERL has four existing extensometers that are connectorized and calibrated for use with the Instron 5598WHVL testing machine. The upgraded equipment shall have identical connectors and pin assignments to allow use of these extensometers interchangeably with either machine without modification. Specific Requirements General Component Layout a.The new control cabinet shall be located in approximately the same position as the existing control cabinet. b.The power input connection for the testing machine shall enter the control cabinet at its right rear side, as viewed from the front. c.Hydraulic and electrical connections between the test frame and the control cabinet shall exit the control cabinet from the rear or the left rear of the cabinet. Test Frame Modifications a.Hydraulic Connections i. Hydraulic hoses connecting the test frame and control cabinet shall be replaced with new hoses of the appropriate size and type. The new hoses shall be configured to connect to the ports on the existing test frame. b.Electrical Connections i. All electrical cables and flexible conduit connecting the test frame and control cabinet shall be replaced with new materials. The cabling shall be oil-resistant industrial-duty cord of the appropriate size and type. 1. Crosshead control and power connections. 2. Load transducer cabling. 3. Limit switch cabling. ii. The existing crosshead operating switches and junction box mounted on the moveable crosshead shall be replaced with new equipment. iii. The existing junction box mounted on the crosshead motor shall be replaced with new equipment. iv. All existing junction boxes shall be replaced with new equipment or removed if not used. c.Piston Extension Limit Switch i. The existing main piston extension limit switch shall be incorporated into the control scheme to prevent excess extension of the main piston. d.Motorized Crosshead i. The control switches and junction box mounted on the moveable crosshead shall be replaced with new equipment. ii. Wiring and conduit between the crosshead controls, motor, and control cabinet shall be replaced with new materials. e.Load Indicating Pressure Transducer i. The existing pressure transducer used to measure applied load shall be replaced with a suitable device capable of providing load measurement to the full capacity of the testing machine. The existing pressure transducer is rated 1500 psi. Reclamation will retain ownership of this transducer. ii. The electrical cable connecting the pressure transducer to the controls shall be replaced with new cabling using oil-resistant industrial-duty cord of the appropriate size and type and it shall be enclosed in flexible conduit. f.Actuator Rod Displacement Measurement i. A digital encoder displacement transducer shall be furnished and installed to measure actuator position. ii. This transducer shall be capable of measuring the full stroke of the actuator which is approximately 6.5 inches. iii. The transducer shall be incorporated into the control system to provide displacement measurement and control during testing. iv. Accuracy shall be ? 0.5% or better over the full stroke range. 3.Control Cabinet - The new control cabinet shall be furnished with all hydraulic, electrical, and electronic components that are not directly attached to the existing test frame that are required to make the testing machine fully functional. a. Cabinet i. The cabinet shall be constructed of heavy gauge steel and shall be finished with a durable industrial coating. ii. The cabinet top shall be finished with a plastic laminate top to provide a working surface for the controls. iii. The top of the cabinet shall be at a convenient level for use of the controls and PC while standing (nominal 36 to 40 inches). b. Hydraulic Components i. All hydraulic components shall be located inside the control cabinet. ii. Electric motor driven air cooled variable pressure hydraulic pump. iii. Servo valve. iv. Oil pressure regulating system. 1.The maximum system pressure shall not exceed 3000 psi. v. Self-contained oil cooling system - no external oil coolers allowed. vi. Oil filters as required. 1. The filters shall be easily accessible and replaceable. 2. The filters shall have at least 3 micron particle filtration or better. vii. Pressure gauge. viii. Oil reservoir. 1. Furnished with appropriate type and quantity of hydraulic oil. 2. Sized for stroke of hydraulic ram and cooling requirements (assuming continuous operation). 3. Oil level sight gauge. ix. Oil cooling equipment. 1. Sized to allow continuous operation at full capacity. 2. Self-contained air cooling is required - no external cooling utilities are allowed, i.e. water cooling or external oil chillers. x. All other hydraulic piping, valves, and components as required to make a fully functional system. c.Electrical Power i. The system shall use the available power source which is 480-volt, 3-phase, 60-Hz. ii. Power entry shall be into an isolated section of the control cabinet. iii. Power entry shall incorporate a power disconnect switch and appropriate fusing and/or circuit breakers for all components of the system. iv. The door of the power entry panel shall be interlocked with the power disconnect switch to prevent inadvertent exposure to the electrical power source. v. Reclamation will assume responsibility for connecting power to the new control cabinet. 1. The contractor shall notify Reclamation of the required current for operation at the above specified voltage within 30 days of award of the contract. 2. A Reclamation electrician will disconnect power from the existing control cabinet and connect power to the new control cabinet. a. The contractor shall provide Reclamation with a 7 day notice prior to installation so the power disconnection/reconnection can be scheduled. b. A flexible liquid tight conduit will be installed from the ceiling over the testing machine to the power entrance location at the right rear of the control cabinet. Reclamation's electrician will install wire of the appropriate size and will provide fusing at the power source. c. The contractor shall provide a recommendation for fuse type and rating at least 30 days before delivery. 3. Reclamation will connect a 120 VAC 20 amp circuit to a double gang electrical box with two duplex receptacles to be mounted on the control cabinet at the right rear. d.Electronic Components i. The electronic servo control equipment, interface equipment, and PC shall be located either inside the cabinet or on the top of the cabinet. ii. The monitor, keyboard, and mouse for the control PC shall be located on working surface on top of the cabinet. 4.Testing Machine Controls a. Controls at the hydraulic power supply cabinet i. System power. ii. Control computer. iii. Other controls as required. b. Control Panel at test frame i. Power and status lights. ii. Hydraulic power supply start/stop. iii. Jog up/down. iv. Fine jog adjustment. v. Start Test/Stop Test/Reset Test controls with status lights. vi. Motorized crosshead up/down controls. vii. Other controls as required. c.Controls on test frame i. Motorized crosshead up/down controls. 5.Testing Machine Controller a. The controller shall be a standard product that has been used for many similar testing machines. Custom-built "one-off" equipment is unacceptable. b. Electronic Test Control i. Digital closed loop electronic control of hydraulic servovalve. 1. 500 Hz minimum control loop update rate. ii. Minimum of four control feedback channels. 1. Load control using weighing capsule pressure transducer as the feedback source. 2. Position and displacement rate control using actuator displacement encoder. 3. Minimum of two additional control channels for use with extensometers, LVDTs, strain gages, voltage output transducers, and other types of transducers. 4. Minimum 19-bit digitization of transducer inputs. 5. Minimum 40-kHz data sampling rate. 6. Signal conditioning electronics a.Signal conditioners for the load and displacement transducers. b.Signal conditioners for the additional control channels suitable for extensometers, LVDTs, strain gages, and analog voltage inputs. c.Signal conditioning for strain gages shall use AC excitation to minimize noise and drift. 7. Simultaneous sampling of all control channels. 8. Automatic transducer identification and calibration association. iii.Bumpless control-mode transfer between control channels.iv.Interfaced with PC for automated test profile execution and data acquisition. c.Test profile control by PC - see Software section 10. 6.Safety a. Over-travel limit switch on actuator piston to prevent unsafe operating conditions and equipment damage. b. Emergency stop button. c. Test lockout on loss of control transducer signal. d. Transducer over-range protection. e. Password required for operation of testing software. 7.Computer Controller a. A PC having the specifications and configuration determined by the contractor to be adequate for the application and meeting the minimum requirements specified below. b. Minimum PC requirements i. Software to be furnished with the system 1. Test machine control and data acquisition software as specified in section 10 below. 2. Microsoft Windows 7 Professional 64-bit operating system. 3. Microsoft Office Professional 2010. 4. CD/DVD writing software. ii.Hardware 1. Processor - Intel Core i5-2400, 3.1-GHz 2. Memory - 8-Gbyte 3. Hard Disk - 250-Gbyte minimum 4. Video - 512-Mbyte memory, minimum resolution 1024x768, 16-bit color 5. CD/DVD combination disk drive - 16x DVD+/-RW, 24x CD-RW 6. Keyboard 7. Wireless six-button optical scrolling mouse. 8. 100BaseT network interface connection minimum. 9. Minimum of two USB 2.0 ports or higher on front panel and four on rear panel. iii.Peripherals 1. Flat panel LCD TFT active matrix monitor, 19 inch 8.Instrumentation a. Load as measured by a pressure transducer on the Emery Weighing Capsule. i. A new pressure transducer shall be furnished with the upgrade and shall be installed on the existing weighing capsule port. ii. Accuracy of ?0.5% or better from 250 pounds to the 120,000 pound capacity of machine. b. Digital encoder actuator displacement transducer. i. Accuracy of ?0.5% or better. c. Extensometers i. Must be compatible with existing extensometers enumerated as follows: 1. Instron 13543-0800-100T/E84683 2. MTS 634.12E-24/10212345A 3. MTS 632.25-20297 4. Shore Western 1000AE/123 ii. These extensometers are configured for use with MERL's existing Instron 5598WHVL testing machine with 5500 series electronics. The upgraded system shall be plug-compatible with these extensometers so they can be used interchangeably with either machine. d.Low-range load cell i. An additional load cell will be used with the upgraded testing machine for low range load testing. ii. The load cell is a 2000 pound capacity full bridge strain gage type load cell. iii. The load cell shall be connectorized to match the signal conditioning electronics. iv. The load cell shall be calibrated with the signal conditioning electronics. v. Reclamation will provide the load cell to the contractor for adaptation to the new controller.e.All transducers shall be calibrated with the signal conditioning electronics. 9.Data Acquisition, Analog Outputs and Digital I/O a. The PC shall acquire test data during testing. b. Minimum of 12 channels of data acquisition (including the 4 control channels). i.Eight non-control input channels. 1. Differential inputs. 2. 16-bit resolution or better. 3. Input ranges to 10 volts, unipolar or bipolar. 4. Programmable input gains of 1, 2, 4, and 8. 5. Minimum 500 samples/second. ii.Four control channel inputs as specified above in section 5.b.ii. c.User definable data acquisition rate based on any combination of time/sample, or percent change. d.Analog voltage output of all conditioned control channel transducers. i. Analog output voltage level of +/- 10 volts. e.Digital I/O lines i. Minimum of 4 digital output lines. ii. Minimum of 4 digital input lines. iii. TTL level compatible. f.Non-proprietary data storage format in Microsoft Access database. 10.Software a. All software shall have a graphical user interface and shall adhere to Windows standards. b. Operating System - Microsoft Windows 7 Professional 64-bit edition. c. Report Preparation Tools - Microsoft Office Professional 2010. d. Utilities - CD/DVD writing software and DVD playing software. e. Test Control i. Instron Partner Universal Materials Testing Software. 1.This is required to provide compatibility with MERL's existing Instron 5598WHVL testing machine. 2.The Partner software shall be supplied with the same capabilities as those installed on the 5598WHVL system including the following options: a. Tensile Suite b. Compression Suite c. Fastener Test Suite d. Expanded Data Acquisition Suite 11.Installation a. Deliver the control console and all components to the specified site. b. Install the control console and all components and assemblies. i. Installer must be factory trained and be covered by liability insurance. c. Verify and demonstrate operation of all functions and features of the system at completion of installation. d. Perform a full calibration of the machine upon completion of installation in compliance with all requirements of the current version of ASTM E4. e. Reclamation resources available for use by the contractor during installation include: i. Forklift of 8,740 pound capacity. ii. Forklift will be operated by Reclamation personnel. f. Installation of the testing machine shall be started by the contractor upon delivery, or within 7 calendar days of delivery. g. Installation shall be completed within 14 calendar days. h. Reclamation will make electrical connections from the power source to the power input terminals of the HPS cabinet. If a solicitation is released it will be synopsized and posted at http://ideasec.nbc.gov. The Government is not obligated to and will not pay for any information received from potential sources as a result of this synopsis. ALL interested parties are requested to respond. If adequate interest or sufficient supporting documentation is not received from viable business concerns, the solicitation may be issued without further notice. Therefore, replies are requested from ALL interested parties, regardless of business size or category. All interested parties are encouraged to respond to this synopsis not later than May 7, 2012. Please submit all requested documentation listed below to: Ann Manning, Contracting Officer, Bureau of Reclamation, PO Box 25007 (84-27810), Denver, CO 80225-0007. Alternatively, information may be e-mailed to the following: amanning@usbr.gov. Interested parties should submit a capabilities package not longer than 5 pages demonstrating the ability to perform the principal components of the effort. Packages should include the following information: (1) Business name, address, CAGE code, size classification based on NAICS size standard, socioeconomic classification (e.g., HUBZone), and a point of contact. Responsible sources having relevant experience and the capabilities to perform the work will be considered. The applicable North American Industry Classification System (NAICS) code is 334519 and the related small business size standard is 500 employees.
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- Place of Performance
- Address: Denver Federal Center, Lakewood (Denver metro), CO
- Zip Code: 802250007
- Zip Code: 802250007
- Record
- SN02733724-W 20120429/120427235845-50e112cad67a36a3a159f2390b7304f4 (fbodaily.com)
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