1. Statement of Work.pdf

Statement of Work Media Blast System

1.0 Scope.

This specification establishes the requirement for the procurement and installation of multiple media blast systems for use on Anniston Army Depot in Anniston Alabama. The contractor shall not proceed with any verbal or written change(s) to the statement of work from sources other than the Contracting Officer, who will provide changes in writing.

• Three count (3ct.) rubber belt steel shot tumble blast systems for building 31 and 409 (Section 3.0)

• Five count (5ct.) glove box type glass bead blast systems for use in building 31, and 114 (Section 4.0)

• One count (1ct.) glove box type glass bead media blast system for use in building 133 (Section 5.0)

• One count (1ct.) glove box type aluminum oxide media blast system for use in building 133 (Section 6.0)

• One count (1ct.) continuous type turntable glass bead media blast system for use in building 114 (Section 7)

• One count (1ct.) glove box type glass bead media blast system for use in building 474 (Section 8)

• Two count (2ct.) glove box type plastic media blast system for use in building 113 (Section 9)

The contractor shall provide all resources necessary to design, manufacture, deliver, install, calibrate, demonstrate functional operation, and provide operator and maintenance training for the blast systems.

2.0 Responsibilities.

2.1 Contractor. The Contractor shall be responsible for:

• Delivery of all equipment and installation for turnkey blast systems.

• Meeting ventilation, safety, and environmental requirements set forth in this document.

• Delivery of three count copies of commercial of the shelf (COTS) Manuals, two count paper and one count digital/compact disc (CD) for each piece of equipment purchased. Commercial off the shelf manuals containing operation, maintenance, parts lists, and other instructions applicable to equipment designed and manufactured for commercial use.

2.2 Government. The Government will be responsible for:

• Electrician and plumber to be available to field engineer at site prior to starting up equipment

• All applicable electrical and air connections are to be within 10 feet of equipment

3.0 Requirement.

Three count (3ct.) 7 cubic feet rubber belt tumble blast systems for building 31 and 409.

3.1 Performance Requirements.

The equipment will be designed to effectively and efficiently blast clean/peen various metal parts using steel blasting media. The machine will deliver the media using a centrifugal center fed wheel. The parts will gently tumble under a preset blast pattern.

3.1.1 Blast Enclosure.

Shall be fabricated of 1/4"-3/8" plate and strengthened by structural steel members.

Multiple access doors shall be located on the cabinet for ease of maintenance. Interior lined w/AR500 abrasive resistant steel.

3.1.2 Centrifugal Wheel Blast System.

One (1) Wheel per unit. The wheel housing shall be constructed of 1/2" steel plate with 1/2" manganese liners front and rear. Unit shall be attached to a 1" steel base plate. The wheel housing shall be protected from wear by a liner set consisting of manganese side liners, and high chrome -molly alloy cast steel end liners and top liner. Direct Drive 20 HP 3600 RMP TEFC C Face Motor

3.1.3 Media Collection Hopper and Bucket Elevator.

The media collection hopper, located in the bottom of the enclosure shall be fabricated from a minimum 3/8" steel construction. The hopper shall be sloped to a cross auger which allows abrasive to be transferred to the bucket elevator. A removable wire mesh screen shall be located in the bottom of the hopper to prevent large trash and debris from entering the auger/ bucket elevator system.

Elevator belt assembly shall consist of a multi ply rubber belt with the correctly sized cast iron buckets. The elevator shall be motor/gearbox driven and track around an upper drive and lower boot pulley. Belt tension and tracking are set by two bolt adjustments.

No chains or sprockets shall be used on the Bucket Elevator.

3.1.4 Interior Working Dimensions.

Barrel head to Barrel head shall be (40) inches wide by (28) inches diameter.

3.1.5 Abrasive Media Charge.

Shall have a minimum of 1,400 lbs. capacity.

3.1.6 Maintenance Doors.

Doors shall be fabricated from minimum 1/4" metal construction. Felt seals shall be provided to prevent leakage when doors are in the closed position. The doors shall be held in the closed position by two (2) heavy duty cam type latches.

3.1.7 Ventilation.

1400 CFM minimum

3.1.8 Electrical Control Panel.

Primary voltage 460/3/60. Control voltage provided by a fused 115 volt stepdown transformer. The control panel shall be a NEMA 12 enclosure with machine functions PLC controlled and ancillary component.

3.1.9 Rotating Mill.

Barrel heads shall be constructed of 3/8” AR500 brinell steel plate minimum. Mill is motor/gear reducer driven. No chains, sprockets, and chain guards are acceptable.

Working capacity of the mill shall be 1400 lbs minimum. Max temperature of the mill belt is 225*.

3.1.10 Rotary Screen Air Wash Separation System.

Abrasive shall be delivered to the rotary screen via the bucket elevator. The media shall fall through the perforated screen drum, then through a single lip air wash separator before re-entering the media storage hopper. The perforated steel drum shall utilize internal flights that auger oversize trash and debris to a trash hose and drum.

3.1.11 Dust Collector.

Dust collector shall be a caged bag reverse pulse type, 1400 CFM @ 8” SP, magnahelic pulse controlled, abrasive inlet, slide gate, drum lid, and flex hose.

4.0 Requirement.

Five count (5ct.) glove box type glass bead blast systems for use in building 31, and 114.

4.1 Performance Requirements.

The equipment shall be designed to effectively and efficiently clean various metal parts using glass bead blasting media, 90 pounds per square inch (psi) compressed shop air and power supplied as called out per building. Overall dimensions of blast systems shall not exceed 44 inches wide x 72 inches deep x 82 inches high as to fit in the work envelop in the shops.

4.1.1 Blast Enclosure.

Shall be no less than 36 inches deep x 42 inches wide x 48 inches high fabricated of steel plate minimum #14 gauge and strengthened by structural steel members as required to support a maximum capacity of 500 pounds. Two count access doors of 29 inches deep x 32 inches high minimum shall be located on the cabinet for ease of part loading and unloading as well as any and all interior enclosure maintenance.

4.1.2 Media Loading.

Media loading shall be inside the blast cabinet configured to eliminate clogs (overloading machine reclaim) when charging the system with fresh media.

4.1.3 Media Collection (Reclaimer Assembly).

The reclaimer assembly shall be 600 Cubic Feet per Minute (CFM) minimum, and be externally tunable. Reclaim shall be ultra-wear lined for maximum life and durability.

4.1.4 Dust Collector.

The dust collector shall be a cartridge style 600 CFM minimum, with a minimum of 206

sq. ft. of NANO Fiber filter media and an electric motor of a minimum of 1-1/2 HP.

Minimum five gallon waste collection drum shall be located under the dust collector hopper. Dust collector purge shall be controlled by an adjustable photohelic pulse control system.

4.1.5 Pressure Blast System.

Shall have a minimum of one cubic foot pressure vessel with minimum of 1 inch moisture separator, air pressure regulator.

4.1.6 Maintenance Doors.

Shall have a minimum of two count swing doors (one per side) for access of no less than 36 inches x 82 inches.

4.1.7 Power Supply Per Building.

Building 31 460/3/60 Building 114 460/3/60

4.1.8 Preventative Maintenance Package.

o To prevent pre-mature wear of blast enclosure, reclaimer, media return hose, exhaust valve, blast nozzle, the following are required.

o Rubber curtains for the blast enclosure walls, doors, front, and cabinet cone.

o Pressure blast nozzle shall be made of tungsten carbide.

o Exhaust valve shall have a boron carbide exhaust restrictor.

o Media return hose shall be of polyurethane.

o Reclaimer shall be internally lined with ultra-wear rubber.

5.0 Requirement.

One count (1ct.) glove box type glass bead media blast system for use in Building 133.

5.1 Performance Requirements.

using glass bead blasting media, 90 psi compressed shop air and power supplied as called out per building. Overall dimensions (footprint) of blast systems shall not exceed 136 inches wide x 124 inches deep x 120 inches high as to fit in the work envelop in the shop.

5.1.1 Blast Enclosure.

Shall be no less than 48 inches deep x 48 inches wide x 36 inches high fabricated of steel plate minimum #14 gauge and strengthened by structural steel members as required to support a maximum capacity of 500 pounds. Two count access doors of 41

5.1.2 Media Loading.

5.1.3 Media Collection (Reclaimer Assembly).

The reclaimer assembly shall be 900 Cubic Feet per Minute (CFM) minimum and be externally tunable. Reclaim shall be internally ultra-wear lined for maximum life and durability.

5.1.4 Dust Collector.

The dust collector shall be cartridge style with a minimum of 452 square feet of filtration area and utilize an electric motor of a minimum of 2 horse power. Minimum 55 gallon waste collection drum shall be located under the dust collector hopper. The dust collector purge shall be controlled by an adjustable photohelic pulse control system.

5.1.5 Pressure Blast System.

Shall have a minimum of 3.5 cubic foot pressure vessel with a minimum of one inch moisture separator and air pressure regulator.

5.1.6 Maintenance Doors.

5.1.7 Power Supply Per Building.

Building 133 208/3/60

5.1.8 Preventative Maintenance Package.

o Rubber curtains for the blast enclosure walls, doors, front, and cabinet cone.

o Pressure blast nozzle shall be made of tungsten carbide.

o Exhaust valve shall have a boron carbide exhaust restrictor.

6.0 Requirement.

One count (1ct.) glove box type aluminum oxide media blast system for use in building 133.

6.1 Performance Requirements.

using aluminum oxide blasting media, 90 psi compressed shop air and power supplied as called out per building. Overall dimensions (footprint) of blast systems shall not exceed 115 inches wide x 108 inches deep x 119 inches high as to fit in the work envelop in the shop.

6.1.1 Blast Enclosure.

Shall be no less than 36 inches deep x 48 inches wide x 36 inches high fabricated of required to support a maximum capacity of 500 pounds. Two count access doors of 29

6.1.2 Media Loading.

6.1.3 Media Collection (Reclaimer Assembly).

The reclaimer assembly shall be 600 cubic feet per minute (CFM) minimum and be externally tunable. Reclaim shall be internally lined with ultra-wear for maximum wear and durability.

6.1.4 Dust Collector.

The dust collector shall be cartridge style with a minimum of 452 square feet of filtration area and utilize an electric motor of a minimum of 1 1/2 horse power. The dust collector purge system shall be controlled by an adjustable photohelic pulse control system.

Minimum 16 gallon waste collection drum shall be located under the dust collector hopper.

6.1.5 Pressure Blast System.

Shall have a minimum of 3.5 cubic foot pressure vessel with minimum of one inch moisture separator, and pressure regulator.

6.1.6 Maintenance Doors.

6.1.7 Power Supply Per Building.

Building 133 208/3/60

6.1.8 Preventative Maintenance Package.

o Rubber curtains for the blast enclosure walls, doors, front, and cabinet cone.

o Pressure blast nozzle shall be made of tungsten carbide.

o Exhaust valve shall have a boron carbide exhaust restrictor.

7.0 Requirement.

One count (1ct.) continuous turntable glass bead media blast system for use in building 114.

7.1 Performance Requirements.

called out per building. Overall dimensions (footprint) of blast systems shall not exceed 72 inches wide x 84 inches deep x 198 inches high as to fit in the work envelop in the shop.

7.1.1 Blast Enclosure.

Shall be no less than 72 inches wide x 84 inches deep x 88 inches high fabricated of steel plate minimum ¼ inch thick and strengthened by structural steel members as required to support a maximum capacity of 1000 pounds. The part load and unload access shall be 13 inches high x 32 inches wide minimum with a maximum of 42 inches from grade to table. A cone media recovery tube of schedule 80 urethane minimum (for durability) shall be configured and utilized as to reclaim media and eliminate media clogs. Turntable shall be a minimum of 65 inches in diameter with a replaceable wear resistant cover (mat or buffer). Two count access doors of 36 inches deep x 34 inches high minimum shall be located on the cabinet for ease of all interior enclosure maintenance. One of the two count access doors shall have a viewing window providing visibility to component blasting area. The interior and load station of the blast enclosure shall be lit. The inside of the enclosure shall be protected with abrasive resistant material (neoprene rubber is the preferred material) that is fixed to the body of the cabinet enclosure via studs. A part blow-off manifold of a minimum of five count blow-off nozzles will be positioned prior to part exit of the enclosure for removal of excessive media. A manual blow-off gun with trigger shall be fixed adjacent to the part load and unload access opening that complies with Occupational Safety and Health Administration (OSHA) standards.

7.1.2 Media Storage Hopper.

Media Storage Hopper shall hold between four and five cubic feet of media. Media Storage Hopper shall utilize a replaceable pull-out screen to ensure debris/contaminates do not clog blasting guns of the rotary head (Section 7.1.4). Media Storage Hopper shall utilize a means of low-level media condition sensor with light indicator visible at the machine control panel.

7.1.3 Rotary Head and Blasting Guns.

Media Blasting shall be accomplished via a rotary head with minimum nine count 3/8” boron carbide wide spray blasting nozzles. Rotary Head shall be driven by its own electric motor with speed variability from zero to at least fifty revolutions per minute (rpm).

7.1.4 Media Separation System.

Media Separation System shall utilize a minimum #12 gauge steel cylindrical cyclonic reclaimer to recover reusable media and return to the for mentioned media storage hopper while conveying expired media and debris to the dust collector (Section 7.1.6).

Media Separation System shall be capable of 1,600 cubic feet per minute of flow. The cutoff point of reusable and expired media shall be fully adjustable. A removable replaceable screen shall be utilized to capture large debris in route to media storage hopper. The conveying duct of the Media Separation System shall be rigid and a minimum of schedule 80 urethane for durability (abrasion resistance). Reclaim shall be lined with ultra-wear for maximum life and durability.

7.1.5 Dust Collector.

Dust collector shall be constructed of minimum #12 gauge steel with an air volume minimum of 1,600 cubic feet per minute flow while maintaining at least 99.9% efficiency at 0.5 microns. Adjustable photohelic auto pulse filter cleaning shall be able to operate on shop supplier 90 psi compressed air.

7.1.6 Control Panel.

All electrical components shall be pre-wired in a NEMA-12 rated enclosure mounted adjacent to the operator load station. The following controls shall be of a minimum.

a. System: On -Push Button

b. Blast: On/Off Selector Switch

c. Nozzle Speed: 6-60 RPM (via process controller)

d. Turntable Speed: 0.2-2.3 RPM (via process controller)

e. Interior Lights: On/Off Selector Switch

f. Emergency Stop:

g. Indicators: Media Low (indicator light), Blast Hour Meter

7.1.7 Power Supply Per Building.

Building 114 460/3/60

8.0 Requirement.

One count (1) glove box type glass bead media blast system for use in building 474.

8.1 Performance Requirements.

The equipment shall be designed to effectively and efficiency clean various metal parts called out per building. Overall dimensions (footprint) of blast system shall not exceed 52” W x 82” D x 82” H as to fit in the work envelope in the shop.

8.1.1 Blast Enclosure.

Shall be no less than 46” deep, x 52’ wide, x 48” high fabricated of steel plate minimum #14 gauge and strengthened by structural steel members as required to support a maximum capacity of 500 pounds. Two count access doors of 39”deep x 32” high minimum shall be located on the cabinet for ease of part loading and unloading as well as any and all interior enclosure maintenance.

8.1.2 Media Loading.

Media loading shall be inside the blast cabinet and configured to eliminate clogs (overloading machine reclaim) when charging the system with fresh media.

8.1.3 Media Collection (Reclaimer Assembly).

The reclaimer assembly shall be 600 cubic feet per minute (CFM) minimum and be externally tunable. Reclaim shall be ultra-wear lined for maximum life and durability.

8.1.4 Dust Collector.

The dust collector shall be a cartridge style with a minimum of 206 square feet of filter media and an electric motor of a minimum of 1-1/2 horse power. The dust collector purge shall be controlled by an adjustable photohelic pulse control system.

8.1.5 Pressure Blast System.

Shall have a minimum of one cubic foot pressure vessel with a minimum of one inch moisture separator, and pressure regulator.

8.1.6 Maintenance Doors.

8.1.7 Power Supply Per Building.

Building 474 460/3/60

8.1.8 Preventative Maintenance Package.

o Rubber curtains for the blast enclosure walls, doors, front, and cabinet cone.

o Pressure blast nozzle shall be made of tungsten carbide.

o Exhaust valve shall have a boron carbide exhaust restrictor.

9.0 Requirement.

Two count (2) glove box type plastic media blast system for use in building 113.

9.1 Performance Requirements.

The equipment will be designed to effectively and efficiently clean various delicate parts using plastic blasting media, 90 pounds per square inch (psi) compressed air and power supplied as called out per building. Overall dimensions of blast system shall not exceed 44 inches wide x 72” deep x 82” high as to fit in the work envelope in the shop.

9.1.1 Blast Enclosure.

Shall be no less than 36 inches deep x 42 inches wide x 48 inches high, fabricated of required to support a maximum of 500 pounds. Two count access of 29 inches deep x 32 inches high minimum shall be located on the cabinet for ease of part loading and unloading as well as any and all interior enclosure maintenance.

9.1.2 Media Loading.

Media loading shall be inside the blast cabinet and configured to eliminate clogs (overloading machine reclaim) when charging the system with fresh media.

9.1.3 Media Collection (Reclaimer Assembly).

The reclaimer assembly shall be 600 cubic feet per minute (CFM) minimum, and be externally tunable. Reclaim shall be internally ultra-wear lined for durability.

9.1.4 Dust Collector.

The dust collector shall be cartridge style with a minimum of 206 square feet of media and an electric motor of a minimum of 1-1/2 horse power. Dust collector purge shall be controlled by an adjustable photohelic pulse control system. Minimum 5 gallon waste collection drum shall be located under the dust collector hopper.

9.1.5 Pressure Blast System.

Shall have a minimum of one cubic foot pressure vessel with a minimum, of 1 inch moisture separator, air regulator. Unit shall be designed for light weight blast media

(plastic), to include an vibrating reclaimer screen, metal separation magnet, ¾ inch ground light weight urethane blast hose with a 3/8” venturi tungsten carbide nozzle.

9.1.6 Maintenance Doors.

9.1.7 Power Supply Per Building.

Building 113 460/3/60

9.1.8 Preventative Maintenance Package.

o Rubber curtains for the blast enclosure walls, doors, front, and cabinet cone.

o Pressure blast nozzle shall be made of tungsten carbide.

o Exhaust valve shall have a boron carbide exhaust restrictor.

10.0 Warranty Service

Contractor shall provide no less than one year warranty on all parts/components.

Contractor shall respond to a request for warranty repairs of solicited parts/components within 48 hours and provide the required repairs within 96 hours unless the Contracting Officer agrees to another period of performance.

11.0 Delivery.

The Contractor shall be responsible for delivering the replacement media blast equipment to each final destination point where installation will take place at Anniston Army Depot. Delivery Hours are: 8:00 AM – 3:30 PM, Monday – Thursday. Reference section 1.0. The Contractor shall complete all machine installations within 120 days of contract award.

12.0 Acceptance.

12.1 Conformance. The replacement media blast equipment shall meet the requirements of this specification. The Government reserves the right to, at any time during the contract period, require proof of such conformance or to inspect the unit(s) to determine compliance with the requirements of these specifications.

12.2 Performance Test. In the event that an equally performing replacement package is provided the Contractor shall demonstrate each unit(s) ability to meet or exceed the performance requirements in accordance with OEM upon completion of assembly and set up by Government employees. During these tests, the contractor shall demonstrate proper conformance, functions and features of the parts/components procured. A malfunction or failure that occurs during any test shall be corrected by the contractor and the entire test shall be executed again from the start and proceed without further malfunction to finish.

12.3 Acceptance. The Government shall accept the parts/components only after the contractor successfully completes the acceptance requirements of paragraphs 12.1 and

12.2 above. Final acceptance will be at Anniston Army Depot. Upon acceptance of all items described above, the Contractor shall submit a completed DD Form 250 for signature by the ANAD Contracting Officer.