Section 15970 Machine Tool and Process Equipment Installations

DaimlerChrysler Construction Standards AME-PT Plants 11/15/06

SECTION 15970 – MACHINE TOOL AND PROCESS EQUIPMENT INSTALLATIONS

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes installation requirements for all machine tool and process equipment for Power Train.

B. Related Sections include the following: 1. Division 09 Section “Painting” 2. Division 09 Section “Piping Identification” 3. Division 15 Section “Testing of Piping Systems” 4. Division 15 Section “Basic Mechanical Materials and Methods” 5. Division 15 Section “Breeching, Chimneys & Stacks” 6. Division 15 Section “Cutting Machine Coolant Piping.” 7. Division 15 Section “Meters and Gages.” 8. Division 15 Section “Valves.” 9. Division 15 Section “Hangers and Supports” 10. Division 15 Section “Metal Ducts.” 11. Division 15 Section “Testing Adjusting and Balancing” 12. Division 15 Section “Vibration Isolation.” 13. Division 15 Section “Dust Collector Units” 14. Division 15 Section “Mist Collector Units” 15. Division 15 Section “Coolant Filters” 16. Division 15 Section “Pipe Insulation” 17. Division 15 Section “General Service Compressed Air Piping” 18. Division 15 Section “Automation Systems” 19. Division 15 Section “Special Hazard Fire Protection Systems” 20. Web site address for Master Specifications https://gsp.extra.daimlerchrysler.com/mfg/amedd/powertrain.htm 21. Machine Tool & Process Equipment Specifications esp. Appendix 6 https://gsp.extra.daimlerchrysler.com/mfg/amedd/powertrain/specs/appx/Appendix %206.xls 22. Web site address for Safety Specifications https://gsp.extra.daimlerchrysler.com/mfg/amedd/powertrain/specs/Ptsafety.pdf

DEFINITIONS

A Utilities: All piping, conduit, duct, or flume connection to the machine which introduces compressed air, natural gas, water, coolant, electrical power, or specialty gases.

A. Gage: Device or machine designed and intended to check part features or a device to measure temperature or pressure of fluids or gases.

B. Fitting: A connection installed on any piping, duct, or flume which joins, adjusts, adapts, or dampens utilities to the equipment. This connection will allow for equipment removal or modification from central distribution systems.

C. Roughing-In: Installation of piping and supports for the equipment prior to the final alignment of the equipment.

D. Support: Device to anchor or rest on foundations or building construction, for supporting and securing equipment to foundations or floors or other structural members.

Machine Tool and Process Equipment Installations 15970 - 1 of 13 DaimlerChrysler Construction Standards AME-PT Plants 11/15/06

E. Contractor: Installing contractor holding contract with DaimlerChrysler

F. Owner: DaimlerChrysler Project Engineer

1.3 SUBMITTALS

A. Drawings & Manuals: Within four (4) weeks of receiving a purchase order, the OEM shall submit one (1) hard copy and one (1) electronic set of prints to AME-PT engineer for DaimlerChrysler‘s approval. With shipment, the OEM shall supply and ship one (1) set of paper copy drawings with machine and one CD of drawings and operation and maintenance manuals to the responsible AMEPT engineer. Once installed and qualified, the OEM shall update and ship three (3) paper sets of operation and maintenance manuals showing component parts such as pumps, fans, motors, automatic valves, bearings, etc. to the plant representative as directed by the responsible AME-PT engineer. A signed copy of the Letter of Transmittal and a CD containing all “as installed” drawings of the equipment, operational maintenance manuals, and scanned electronic copy of all individual component specification (“cut”) sheets and all spare parts lists to the responsible AMEPT Engineer.

B. DaimlerChrysler will supply the brass tag and drawing numbering system when the purchase order is issued.

C. All floor plan drawings must show the complete plan view of the entire machine as it sets on the floor. Its base, including projections for leveling or anchoring, shall be shown in heavy dashed lines. Heavy solid lines shall be used for any and all projections above the base including tanks, housing, platforms, conveyors, load and unload locations, panels or any other part of the machine. Clearance for service, including panel and access doors (open position) shall be shown in the proper location. Show all locations of piping, drains, exhaust stacks, and air intakes. Ancillary equipment such as electrical panels and filters shall be shown in correct relation to machine and dimensioned. In no case shall the equipment be located so as to prevent ease of access for service or repairs of any component of the machine or ancillary equipment.

D. The scale floor plan drawings shall be updated each time a revision is made and submitted for approval to DaimlerChrysler prior to altering the machine, ancillary equipment or orientation.

E. All engineering drawings shall be developed using the CAD software and version agreed upon in CAA. All engineering drawings, upon successful completion of this project become the property of DaimlerChrysler Corporation.

F. Maintenance Manuals in English shall also be developed in an electronic format utilizing Microsoft Word or Adobe Acrobat. All graphics must be embedded into the document, not linked.

G. The OEM shall provide a recommended spare parts list for all of the supplied machines. Included in this list shall be a “where-used” list, current cost of parts, and lead-time in weeks. The spare parts list shall be per DaimlerChrysler TMS electronic format (contact DCX plant engineer).

H. Field Utility routing to equipment and gages including planned placement of all cranes, pull boxes, disconnects, control panels, isolation valves, (including lockout valves), supports, flow balancing valves, flow meters, gages and anchors and sway bracing. Do not route utilities in the path of the automation such as gantries or in the path of any cranes.

I. Wiring diagrams in controls submittals for all field-installed wiring showing panel terminated insulation labels and color of wire

J. All installation submittals must show code clearances such as 42 inches from front of a panel to any obstruction and 48 inches from the fronts of two opposed facing panels.

K. All means of egress between equipment must have a minimum of 28 inches.

1.4 QUALITY ASSURANCE

A. Installations shall comply with all National and local codes applicable to the area where equipment is being installed including but not limited to OSHA and EPA.

B. Installations shall comply with DaimlerChrysler standards including SMI163 Safety Requirements for Contractors.

C. Provide survey results from datum’s and benchmarks

D. The CONTRACT DOCUMENTS define process concepts, materials and equipment, setting forth minimum requirements and details which will assist the BIDDER in the preparation of his Proposal and the successful CONTRACTOR in assuming responsibility for the WORK. However, these minimum requirements and details shall not be construed as relieving the CONTRACTOR from providing all WORK in accordance with the necessary expertise and capacity, even though some items may not be complete or specifically mentioned or indicated, to suit the needs of the required WORK.

These specifications are intended to be a guide. The Successful CONTRACTOR must verify the facility conditions and revise to suit.

1.5 DELIVERY, STORAGE, AND HANDLING

A. All equipment must be inspected by the CONTRACTOR on the delivery truck prior to unloading and all damage must be reported on the shipper and to the appropriate DaimlerChrysler project engineer.

B. All equipment delivered to the project site must be unloaded by the CONTRACTOR the same day it is received and placed in its intended location. The minimum storage requirement is inside of an enclosed building or tent, which provides protection from the elements, and elevates equipment above a hard surface by a minimum of three inches.

C. All equipment must be inspected by the CONTRACTOR to assure that all the equipment components and drawings, software, and set up tools are included with the shipment which identifies all of the required information to allow a quick and accurate installation. Failure to find components or drawings must result in notification of the appropriate DaimlerChrysler project engineer both verbally and in writing.

D. All equipment must be inspected by the CONTRACTOR to assure the vibration isolators and or anchoring systems are provided with the machine. Documented and approved exceptions made from the supplier to the DaimlerChrysler Engineer shall be clearly identified on their machine layout drawing. The installation crew shall subsequently supply vibration isolators and or anchors to meet the manufacturers anchoring requirements. The CONTRACTOR shall supply all shims and or blocks to attain proper elevations of equipment.

E. Moving, erecting, or installing of any OWNER furnished equipment shall be construed to indicate that it has been accepted in good condition. At this time the CONTRACTOR assumes the responsibility and liability for its protection, unless it can be proven that any later-discovered damage is due to faulty workmanship or inferior component parts thereof, necessary to the satisfactory and safe operation of the item. The CONTRACTOR shall protect all materials and equipment from damage from the time it is removed from the point of receipt or storage until acceptance by the OWNER.

F. The Successful CONTRACTOR shall be responsible for the handling and/or relocation of the specified equipment to its final installation site. The CONTRACTOR must verify site access and routing through the plant. The CONTRACTOR will be responsible for furnishing trash dumpsters as required. The CONTRACTOR will need to contact Production Control at the plant to determine the source to use for delivery of trash dumpsters. The CONTRACTOR will be responsible for disposing of shipping containers, trash, etc, and transporting it to the dumpster. Overseas equipment will be delivered to the Site in “Sea-containers” that will need to be unloaded and handled by the CONTRACTOR. The CONTRACTOR shall coordinate with the supplier to have the “Sea-container” removed from the site after it has been emptied. Any fixtures or crates requiring return must be coordinated with the Equipment OEM.

1.6 PROCESS LAYOUTS AND DATA SHEETS

C. Process layouts shall be provided from Daimler Chrysler Plant Engineers showing the location of the equipment within the facility.

D. Certified Machine & Tool Specifications Appendix 6 (utility data) shall be provided from the original equipment manufacturers through the DaimlerChrysler responsible engineer for this scope of work.

E. Certified machine layouts shall be supplied from the Original Equipment Manufacturers.

1.7 TIME OF COMPLETION

A. The Successful CONTRACTOR shall agree to commence work and complete the project scope of work according to a specified time frame developed by DaimlerChrysler. (Timeline is included in this package) The Successful CONTRACTOR shall agree that the specified time of duration take into account the schedule constraints as opportunities identified in the installation drawings and specifications, resulting in the earliest possible completion date.

B. The installation of this equipment should be quoted based on the project schedule. No weekend work should be quoted unless project timing requires it. All utilities (i.e. ventilation, air, electric, coolant, hydraulic, etc.), guarding, interlocks, equipment leveling, and equipment anchoring must be included as part of the base installation price. System installation timeframe and CONTRACTOR bid price will be based on the Successful CONTRACTOR’s estimated amount of man-hours required to successfully complete the project consistent with DaimlerChrysler published machine installation dates.

C. The Successful CONTRACTOR must provide Microsoft Project schedules within two weeks of receiving the authorization to proceed from DaimlerChrysler. This schedule must be tracked weekly indicating progress toward milestone dates. Additionally, the Successful CONTRACTOR will provide schedules to DaimlerChrysler engineers on a weekly basis. The OWNER, the CONTRACTOR, required SUBCONTRACTORs, and other CONTRACTORs will attend Progress meetings that will be held at regular intervals as directed by the OWNER for the purpose of coordination and expedition of Work. An example schedule format can be provided in the event the CONTRACTOR is not familiar with our project schedules.

1.8 FIELD ORGANIZATION AND SUBCONTRACTORS

A. The Successful CONTRACTOR shall furnish to DaimlerChrysler with the proposal, the names, qualifications, experience and positions of the key personnel who will be assigned the work, complete with an organization chart of responsibility, as well as the company names of the SUB CONTRACTORS and suppliers which will be engaged to perform work indicated herein. The Successful CONTRACTOR shall not change the proposed SUB CONTRACTORS after the date of bid without the prior consent of DaimlerChrysler. DaimlerChrysler reserves the right to reject SUBCONTRACTORS. Contractors shall provide one main contact person (contract coordinator) with after hours contact numbers and communicate back up contact if such person is not available.

B. The Successful CONTRACTOR will be responsible to cover costs for the connection and disconnection of any and all required utilities for their own CONTRACTOR trailer(s) as well as their SUB-CONTRACTORs located on-site. This includes but is not limited to telephone and fax lines, computer lines, and electrical service. The Successful CONTRACTOR will also be responsible for contacting any and all commercial utility companies, such as local telephone companies, for service start up. AME Plant Engineering along with Plant ME manager will approve the actual location of the Successful CONTRACTOR's trailers.

1.9 QUOTING

A. All quoting parties shall visit the job site to observe field conditions and to familiarize themselves with all the parameters of this system prior to submitting their quote. Failure to do so does not relieve the successful CONTRACTOR of his total responsibility for supplying a complete, operable, and approved system per these specifications.

B. The CONTRACTORs shall quote the system complete as outlined in these specifications with no deviations. Any deviations from this specification shall be specifically defined as an alternate and shall only be included in the quote following the total original quote. Failure to quote according to these requirements shall constitute a disqualification and result in the quote not being evaluated in the final analysis.

C. Each bidding CONTRACTOR will provide a lump sum price breakdown that shall be included with their quote and will equal the lump sum price. A unit cost for the installation of each separate machine line must be supplied by each bidding CONTRACTOR for DaimlerChrysler Accounting purposes. Each unit cost will furthermore be broken down into separate cost categories; rigging, mechanical work (including piping), & electrical work. Awarded CONTRACTORs will be responsible to provide up-to-date schedules of work force and timing for the duration of the project.

1.10 ADDITIONAL INSTALLATION ISSUES

A. DaimlerChrysler will provide each bidding CONTRACTOR with a set of drawings and or Machine & Tool Specifications Appendix 6 (utility data) with the request for quote that will reflect the requirements to ensure an accurate bid price. Failure to quote certain items (i.e. Power drops, air drops) will not relieve the CONTRACTOR of their responsibility to deliver a fully functional installation. The CONTRACTOR shall compare Machine & Tool Specifications Appendix 6 (utility data) with drawings and request clarification during the bid process if discrepancies are discovered.

1.11 ON SITE FIELD SURVEYING

A. The General CONTRACTOR and their SUB-CONTRACTORs are not allowed to visit the plant for on-site surveys without a prior request to the Project Installation Coordinator. Any request that will interfere with plant personnel and/or plant machining operations, such as the shutdown of

operations, access to unauthorized areas, and the opening of electrical equipment, will not be allowed without the permission of the Project Installation Coordinator. Visiting hours will be from 7:00am to 3:00pm Monday through Friday only. After hours and weekend visitations will not be allowed unless special arrangements are approved through plant management for extenuating circumstances. While on-site at the plant, plant personnel and/or plant machining operations are not to be disrupted. No cameras or camcorders are allowed in the plant. It will be assumed that the general CONTRACTOR and their SUB-CONTRACTORs will maintain a safe and responsible behavior while in the plant. Pedestrians, whose job requires the use of mobile communication devices, must remain aware of their surroundings and STOP in a safe place (away from PIV traffic, moving machinery, etc.) before and while using the mobile communication device. Use of mobile communication devices while walking or while driving a cart is prohibited. Note; all personal computers must be checked out by the Plant ITM department prior to use on site. B. It is imperative that all CONTRACTOR personnel shall wear DaimlerChrysler approved industrial hearing protection and safety glasses with properly mounted side shields at all times when in areas designated by DaimlerChrysler Corporation as mandatory hearing & eye protection areas. This does not include any administration area, cafeteria, restroom facilities, or other non- manufacturing area of the plant. If you are not certain what constitutes as a mandatory ear & eye protection area, you must ask a DaimlerChrysler Safety Specialist.

1.12 GENERAL SCOPE OF WORK A. The Bidding CONTRACTOR will provide a lump sum cost and breakdown pricing to install the individual machining lines as outlined in the detailed scope of work request for quote. This scope of work has listed specific items you are responsible for providing. Failure to quote does not relieve the CONTRACTOR of their commitment to deliver a fully functional process at no extra cost to the OWNER.

B. The Successful CONTRACTOR shall be responsible for furnishing all labor, material, and equipment necessary to unload, receive, store, relocate, handle, uncrate, inspect, check, clean, assemble, rig, set, level, anchor, install, test and adjust all materials machines, support equipment and automation each in its proper location as indicated or specified herein, complete with ancillary items, in satisfactory operation conditions as noted in this specification and as specified by DaimlerChrysler Advance Manufacturing Engineering Power Train Operations. The CONTRACTOR shall provide construction aids and equipment required by personnel and to facilitate the execution of the Work (including but not limited to man-lifts, fork-lifts, scaffolds, ladders, stairs, ramps, platforms, railings, hoists, cranes, and other such aids and equipment), and equipment. All machine locations to be verified by the Successful CONTRACTOR before final set. The successful CONTRACTOR shall generate an OEM contact list and shall confirm all shipment dates and coordinate all unloading of equipment.

C. Timing for all installations and scheduling of manpower shall be based on the Master Time Line Schedule distributed at the pre-bid meeting.

D. The quote for the installation of each specified process machine, automation, and support equipment will include the following items, if applicable (Please refer to the INSTALLATION BID PACKAGE SCOPE OF WORK CHECKLIST for further detail):

E. The standard process machine unit(s).

1. Specific equipment may arrive from the supplier disassembled for shipment and require assembly. Perform installation, assembly of items shipped “loose” by manufacturer including intercomponent piping and wiring, field terminal hook up, start-up, testing, debugging and related work based on approved drawings, and under the direction of an

authorized representative of manufacturer. Provide as required all miscellaneous conduit, wiring, piping, and fittings necessary for the complete installation of the system.

2. Any spacer plates, mounting blocks, epoxy grouting, anchor bolts, shims, or pipe adaptors required to install the equipment will be the CONTRACTOR’s responsibility unless otherwise stated in the Machine & Tool Specifications Appendix 6 (utility data) and scope of work.

3. Specific equipment may require removal from existing machining operations and will either be reinstalled to designated locations as shown on the layouts, relocated within the facility, or shall be identified as scrap by the DaimlerChrysler Project Installation Coordinator who will determine the means of disposal.

F. Mechanical equipment including but not limited to all drip pans and drain pipes. Drip pans are to be provided by the Machine supplier, but there will be times when the CONTRACTOR will be required to modify drip pans to fit the on site installation and be functional at no additional expense to the OWNER. Electrical equipment including but not limited to: Electrical panels, transformers, control panels, junction boxes, interlock requirements including cabling, terminations & marking, Human Machine Interface panels, photo-eyes, limit switches, part- present switches, proximity switches, and fiber optics. (Note: Some equipment interlocks may consist of over head conduit and wiring in the truss spaces i.e. for pump back systems and coolant filters, etc). The Successful CONTRACTOR shall install electrical utility connections from and including the fused buss plug and fuses from the buss duct to the machine electrical panel, and shall verify electrical requirements as noted on the supplier's floor plan or utility sheets and provided within the electrical panel. CONTRACTOR to receive approval from the local plant operations and via the shop drawing process prior to scheduling / connecting to electrical buss ducts. All connection work will be done in accordance with DaimlerChrysler safety procedures including NEC 70E requirements for Arc Flash.

Communications Wiring: DCX ITM will install the “Local Network Drop”. The CONTRACTOR will be required to terminate vendor supplied Ethernet, fiber optic, Cat 5, Profibus cabling.

Locations for all the lift assists may not be shown on the individual line layouts. For quoting purposes provide for (4) 120 V. power drops (two at each end of the line). These shall be supplied by the CONTRACTOR from the building electrical 120V panels located at building columns from a distance no further than 100’ away. If the process layout identifies more detail, follow the line layout direction for 120 V power specifics.

G. Automation equipment including but not limited to: Machine internal and external material handling systems, conveyors, meters, gantries, drives, supports, guarding, e-stops, shot pins, disconnects, interlocks, part-grippers, part escapements, drip pans, and blue-steel chutes. The Successful CONTRACTOR shall supply all material, labor, and equipment necessary to provide electrical utility connections from the main panel, in each zone, for the automation systems to remote control panels for the conveyors and gantries. The Successful CONTRACTOR shall verify electrical requirements as noted on the automation drawings and / or provided within the electrical panels. Electrical interlocks will be plug in connections from machine to machine or machine to automation, without overhead pipe and wire runs unless noted otherwise on installation or OEM drawings. A typical example of an application of field wiring from panels to junction boxes includes filter systems located in pits. The machine and automation suppliers will provide pre-wired junction boxes with interconnecting wiring. The requirements for pneumatic lines for the machines also apply to the automation.

I. Utility requirements including but not limited to: Piping/conduits and connections from plant utility supply to equipment for compressed air, coolant, hydraulic, Automatic Transmission Fluid, chilled water, potable water, non-potable water, Reverse Osmosis water, fire protection, industrial waste, natural gas, and industrial gases, engine oil and electrical power supply. The

CONTRACTOR is responsible for the provision and installation of Mist collection ductwork from the plant supply to the machines utilizing coolant or dust collection ductwork as noted in the Machine & Tool Specifications Appendix 6 (utility data) or drawings provided. Required support components including but not limited to sway and vibration bracing, mounting brackets raceways, and cable trays including supplementary structural steel and ancillary devices necessary to support the WORK. The Successful CONTRACTOR shall install all utility lines from the main supply to the machines where required. All isolation valves provided in the installation shall be accessible from the plant floor, or as otherwise noted, and must be capable of accepting a pad lock in order to comply with Safety Energy Lockout Procedures. Utilities to be installed per the size and material type specified on the Machine & Tool Specifications Appendix 6 (utility data). At a minimum, isolation valves are required at the overhead main pipe header (above building truss elevation) and lockable valves at the “Point of Use”. Some equipment may have factory installed lockable isolation valves at the machine in which case the “Point of Use” valve will not be required.

J. Gauging equipment including but not limited to CMM units, gauging units and enclosures.

1. Locations for all the gauging tables may not be shown on the individual line layouts. If not shown, for quoting purposes, at a minimum provide for (3) gauge tables on each line with the following provided and mounted to the back of the gauge table: 480 V. power drop with a 30 Amp bus plug to a 480V / 120V transformer, and a 1” air supply line with filter regulator both from a distance no further than 50’ away. Provide all wiring terminations and wiring identification. Provide as built documents for actual installations. Refer to Installation Bid Package Check List for specifics.

K. Safety equipment including but not limited to: Safety fencing, expanded metal guarding, Lexan guarding, tunnel guarding, light curtains, safety mats, emergency stops (e-stops) and e-stop cording, pinch point guarding, guard posts, guarding interlocks, and additional safety and guarding requirements, if any, following the Plant Safety final safety review. Procurement of any additional safety component requirements will be the responsibility of the equipment supplier and not that of DaimlerChrysler or the successful installation CONTRACTOR.

L. Support equipment including but not limited to: Operator platforms, part stands and tables, granite benches, gage tables and structural crossovers, sump pumps, eyewash & safety showers, drinking fountains, wash sinks, lift assists, lockers, etc as noted in the INSTALLATION BID PACKAGE SCOPE OF WORK CHECKLIST.

M. Any required painting due to the installation of the equipment. Bring all finished materials / equipment surfaces damaged prior to final acceptance to “as new” condition by touch-up, including paint / coating finishes. Paint must be compliant with DaimlerChrysler Paint Specifications Section 09915 and AME-PT modifications.

N. Identification and labeling of mechanical and electrical components, wiring and piping per the specifications. Mechanical Identification of all piping shall be painted and labeled. Labels to be wrap-around type, with color background and lettering to match existing plant labeling standards. Labels to be manufactured by Brady Inc., or approved equal. Pipe that requires insulation does not need to be painted, but must be labeled. All electrical buss plugs and conduits shall be labeled to indicate the voltage and circuit designation per the Corporate Safety Specifications.

O. Shop drawing submittals from the CONTRACTOR shall include required copies of all utility plan drawings including power connections, piping connections, mist collection connections, wiring diagrams and installation details for construction field conditions. Maximum size 11” x 17”. At the completion of the project, the CONTRACTOR shall provide Record Drawings – Paper copy and CD with AutoCAD Format files to the responsible AME-PT engineer.

P. The Successful CONTRACTOR shall agree to pay for the repair or replacement of any equipment and/or components damaged or lost while under the handling and installation of the Successful CONTRACTOR and/or their sub-CONTRACTOR’s.

Q. Materials and equipment furnished, and WORK done, shall be subject to inspection by the OWNER and authorities having jurisdiction. Such inspection shall not relieve the CONTRACTOR’S responsibility for furnishing qualified labor and material in strict accordance with these SPECIFICATIONS. Materials and equipment not meeting specified requirements shall be rejected and replaced at once with materials or equipment of the specified type and quality, at no additional cost to the OWNER.

R. Provide, maintain and enforce safety and environmental protection provisions necessary to the work. All process fluids (chemicals), including cleaning solvents, shall be received, handled, stored, dispensed, utilized, and together with resultant waste, shall be disposed of in accordance with requirements of the Local Environmental Protection Authority and OWNER’S On-Site Chemical Coordinator. The CONTRACTOR shall advise the OWNER in advance of the WORK and furnish Materials and Safety Data Sheets for each product involved. Special care shall be exercised in handling/disposing of spills/wastes, to prevent injury to personnel, damage to facility/equipment, fire and pollution of environment. Waste fluids shall be removed off-site to approved disposal facilities. For materials that are disposed of off-site, provide the OWNER with paper audit trail and certification of disposal in accordance with the requirements of authorities having jurisdiction.

S. Safety in accordance with DaimlerChrysler Safety Program including SMI-163, OSHA and the State or Local OSHA programs for the State or location of the subject project.

T. CONTRACTOR shall protect concrete floor from stains and damage and will be responsible for remediation.

U. In case of discrepancies between the Layout Drawing, Machine Utility Sheet, individual Scopes of work, and Process Flow Diagram, the CONTRACTOR must submit clarification requests to the Project Installation Coordinator prior to the close of questions as stated in the line-up meeting. V. CONTRACTOR to hire a building roofing CONTRACTOR for any roofing work. Note: Utilize existing roofing supplier to continue warranty of existing roof.

X. The Scope-of-Work covers the responsible project work to be completed on-site at the plant by the Successful CONTRACTOR. It is the responsibility of the bidding CONTRACTOR to determine the mechanical, electrical, and other utility requirements of each unit from the drawings and information furnished by the associated supplier, (i.e. if there is an electrical panel you will be providing a power drop) and the components of each unit from the drawings and information furnished by the associated supplier. The components of each unit from the drawings and information furnished by the associated supplier.

PART 2 - PRODUCTS

2.1 Benchmark Monuments

A. Benchmark monuments must be placed at strategic locations in foundations (note; site specific where applicable). 1. The type, size and location must be determined by the combined effort of the Architectural Engineer and the appropriate DaimlerChrysler Engineer. 2. All Benchmarks must be surveyed and documented prior to the equipment installation and also surveyed and documented after the equipment is installed.

3. The installing riggers and millwrights shall use these surveyed results for installations of equipment.

2.2 Equipment Anchors

B. Refer to Division 15, “Vibration Isolation” specifications for the different types of anchors and applications. 1. Install all anchors with anchor manufacturer’s recommended grouts or epoxies. 2. Install all anchors and level the equipment per the manufacturer’s recommendations. Note: A two part resin epoxy mix caulk tube anchoring system shall not be used, due to past failures (incorrectly mixing resin together).

2.3 Piping Anchors

A. Install pipe anchors and or sway bracing for coolant piping to minimize pipe hammering upon start up of the coolant system or during valve activation.

B. Install pipe anchors and or sway bracing for process water piping and or compressed air piping where quick acting valves or rotary powered equipment will cause velocity shocks to the system.

C. Provide pipe stanchions to support piping from the floor where the distance between the supports exceeds the recommended minimums in the Division 15 specifications and where vibration isolation is needed between the piping and the equipment such as grinders and polishers.

2.4 MISCELLANEOUS FITTING STANDARDS

A. Provide unions, flanges or grooved fittings between lockable shut off valves and the flow meters or final connections to equipment to allow maintenance.

2.5 FLUMES

A. Coolant discharge chutes for all “side discharge” machines (ex. Grinders) will be fabricated and installed by the equipment installation CONTRACTOR. All flume skirts for bottom discharge machines must be furnished by the OEM, but installed by Equipment Installation Contractor.

B. The level and alignment accuracy to floor elevation and an approved field datum is the responsibility of the flume’s installation contractor. The equipment installation contractor must review, understand and concur with the “as built” flume conditions. Any equipment installation costs or issues that may affect installation timing related to “as built” flume conditions must be discussed with the responsible DaimlerChrysler Plant Engineer prior to any contract award.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine all shipments prior to unloading and report all damaged or missing items per part 1 of this specification.

B. Examine roughing-in location for equipment for properly cured foundations and for available central utilities.

C. Examine utilities to verify what other equipment will be affected by any utility tie-ins. Coordinate these tie-ins so as not to affect scheduled production or scheduled debug or scheduled qualifications.

D. Verify submittal drawings have been approved.

E. Verify benchmark surveys are documented and available.

F. Proceed when conditions have been verified and coordinated.

3.2 APPLICATION

A. Install equipment, in accordance with designations and locations indicated on Drawings.

G. Rough in equipment prior to installing utilities.

H. Install utilities and supports and leveling devices for equipment and utilities.

I. Final align equipment with both the leading and leaving automation and anchor equipment

B. Mark all anchoring devices with a felt tipped paint pen once final alignment is complete to record the proper set points of all jam nuts.

C. Accurate floor layout marking for equipment placement and anchoring shall be the responsibility of the successful Contractor

3.3 INSTALLATION OF EQUIPMENT

A. Install equipment and gages level and plumb, in accordance with the manufacturers’ written installation instructions, drawings, and referenced standards.

B. Install dry floor guarding including any flume skirting with no or minimum oil resistant caulking. Note: Machine tool equipment supplier must provide dry floor guarding and flume skirting components.

C. Anchor all tanks in pits to restrain them from floating up, in the event the pit is flooded.

D. Provide pumps per the construction drawings for all pits to minimize the retention of any spilled fluids.

E. Activate all valves slowly to initially fill all systems. Follow with testing for leaks.

F. Extend all tank and overflow drains from but not limited to the following items, headers, mist collection, “pipe clean units”, filter back flush and overflow drains from high pressure skids and coolant filters to the associated flume, pump back, filter, or pit sump to eliminate any fluids on the floor.

G. Install traps with clean outs on drains from mist collection equipment to prime with process fluid to eliminate air bypass from the drainage pipe.

H. Install cranes and hoists to facilitate full range of motion of the hoists for the intended service.

I. Install flow meters or venturi measuring devices with memory stop valves and /or balancing valves on all coolant piping connections, including flume flush and where high pressure skids are provided, install a separate coolant drop to each high pressure skid which allows continuous

flow through the reservoir. Where reservoirs are not provided for high pressure pumps, provide automatic air vents ahead of each machine connection to evacuate air from the piping upon start up. Each vent shall be piped back to the respective flume or pump back system to eliminate any fluids on the floor.

J. Install compressed air connections to all machines, lift assists, cranes, back-flush filters, and gauge tables as required.

K. Install totalizing meters on process water or reverse osmosis water make up to water soluble coolant systems and washer tanks or filters.

L. Initiate and follow through with surveys of foundation benchmarks once final alignment is complete. Provide documented survey results to the appropriate DaimlerChrysler Plant Engineer.

M. Attach Temporary (paper) Safety Placards prior to power up and Final Safety Placards for each machine per SMI105.

N. Install all industrial waste sump pumps and associated level controls. Fill sump to test and validate level controls.

O. Install emergency showers and eyewash stations as indicated on drawings and at a minimum near each chemical or cleaner add for washers and in the area of filters. Where possible, locate near sumps or trench drains to allow direct drainage.

P. Coordinate the installation of oil mist or dust collection systems to provide an active collection system as soon as possible for machine qualifications.

3.4 ADJUSTING, CLEANING AND LABELING

A. Open all tank inspection ports including high pressure coolant skids and clean tanks thoroughly. Document date of such and obtain signature from DCX plant engineer assigned to the machining line.

Q. Adjust flow balancing valves to machine tool manufacturer’s recommended flow rate and set memory stops. Inspect all fittings and valves for leaks. Replace damaged or leaking, fittings, and valves.

R. Inspect all equipment guarding and piping for leaks as needed using the DaimlerChrysler standard PDCA (Plan, Do, Check, Act) forms (Doc. Number AAFM003). The equipment must be “leak free” while in continuous operation for at least 30 days.

S. Verify all check valves hold and do not allow flow in the wrong direction.

T. Label all piping and voltages per DaimlerChrysler standards.

U. The electrical contractor will be responsible for calculating and posting, based on the wiring methods used, fusing and distances, the fault currents and Arc Flash requirements, according to the current NFPA 70E code. Daimler Chrysler will supply to the equipment installing contractor via the building trades contractor, the fault level available at the buss for these calculations.

V. Clean all equipment and touch up paint as required for final acceptance from DaimlerChrysler.

3.5 PROTECTION

A. Provide protective covering for stored equipment inside a building or enclosed tent.

W. Do not allow use of equipment for temporary machining, ventilating, or heating of facilities, except when approved in writing by DaimlerChrysler

END OF SECTION

Note: Before pre bid meeting, AME engineers or Architect and Engineers are to fill out Excel Spread Sheet “Process Layout Scope of Work Check List. The scope of work shall designate lead contacts from DaimlerChrysler and clarify specific details where necessary.

Machine Tool and Process Equipment Installations 15970 - 13 of 13