22-40-1001 P4 Plating Line SOW - Copy.docx

22-40-1001 8 December 2023

PURCHASE DESCRIPTION FOR THE ACQUISITION OF P4 PLATING LINE

SCOPE.

Scope. The content of this specification describes the minimum requirements for the acquisition of a plating line that includes the removal, design, fabrication and installation of tanks, and equipment to support the plating processes of the P4 plating line. This line includes tin plating, silver plating, non-production hard nickel plating, and silver strip wet processes. The contractor, Engineering and Software System Solutions, Inc. (ES3), Commercial and Government Entity (CAGE) Code 1PHL4, shall be responsible for the complete removal of existing equipment, installation of all new equipment, all the qualified personnel and auxiliary and ancillary equipment detailed herein to provide a fully functional system.

APPLICABLE DOCUMENTS. The documents listed in this section are cited in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

Government Documents.

Specifications, Standards, and Handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein.

STANDARDS – FEDERAL

FED-STD-H28B: Screw Thread Standards for Federal Service

U.S Department of Labor, Occupational Safety and Health Administration (OSHA)

29 CFR 1910: OSHA Safety and Health Standards

29 CFR 1926: Safety and Health Regulations for Construction

(Application for copies should be addressed to the OSHA Publications Superintendent of Documents P.O. Box 37535 Washington, D.C. 20013-7535)

MILITARY STANDARDS

OPNAVINST 5100.23 Navy Safety and Occupational Health Manual

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property Item Unique Identification Marking (IUID)

(Application for copies should be addressed to Air Force Product Data Systems Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg. 262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257-0870 or 0853 or https://quicksearch.dla.mil/qsSearch.aspx)

Other Government Documents, Drawings, and Publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

LOCAL ATTACHMENTS

Non-Government Publications, Specifications, Standards, and Handbooks. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

American Conference of Governmental Industrial Hygienists (ACGIH)

Industrial Ventilation: A Manual of Recommended Practice for Design, specifically §6.6.9, Figure 6-26, §13.70 Open Surface Tanks and §13.72 Push-pull Ventilation

American Society of Mechanical Engineers (ASME)

ASME Y14.100 Engineering Drawing Practices

American Society of Safety Professionals (ASSP)

ANSI / ASSP Z9.1 Ventilation and Control of Airborne Contaminants during Open-Surface Tank Operations

Centers for Disease Control and Prevention (CDC) and NIOSH Guide

Pocket Guide and Occupational Safety and Health Administration standards (OSHA)

International Organization for Standardization (ISO)

ISO 4414: Pneumatic power-General rules and safety requirements for systems and their components (Application for copies should be addressed to the International Organization for Standardization (ISO) 1 rue de Varembé, Casepostale56, CH211Geneva 20, Switzerland)

National Electrical Manufacturers Association (NEMA) NEMA 250: Enclosures for Electrical Equipment (1000 V Maximum) NEMA ICS 1: Industrial Control and Systems General Requirements

NEMA ICS 6: Industrial Control and Systems: Enclosures

NEMA MG 1: Motors and Generators NEMA Z535.4: Product Safety Signs and Labels (Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Rosslyn, VA 22209) National Fire Protection Association (NFPA) NFPA 70: National Electrical Code

NFPA 79: Electrical Standard for Industrial Machinery

(Applications for copies should be addressed to the National Fire Protection Association, ATTN: Support Services, 11 Tracy Drive, Avon, MA 02322)

National Institute for Occupational Safety and Health (NIOSH)

NIOSH 75-145 Health and Safety Guide for Electroplating Shops

San Diego Air Pollution Control District (SDAPCD)

SDAPCD Rule 67.61 Cold Solvent Cleaning and Stripping Operations

Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulation unless a specific exemption has been obtained.

REQUIREMENTS.

Design. The items offered shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model, which on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The P4 plating process line shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

Measuring and Indicating Device Graduations. All measuring and indicating devices on the P4 plating process line shall be graduated in either the standard (aka inch/pound) system or both standard and metric.

Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located on or near the tank they control. All controllers shall be BACnet compatible and connect to a Siemens Data Capture Unit for monitoring purposes. This connection shall be provided through either Ethernet or 4-20 milliamp (mA) signal from the equipment.

Safety and Health Requirements. All parts, components, mechanisms, and assemblies furnished on the P4 plating process line, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910, OSHA 29 CFR 1926, OPNAVINST 5100.23, NEMA Z535.4 and Centers for Disease Control and Prevention (CDC) and NIOSH Guide, “Pocket Guide and Occupational Safety and Health Administration standards (OSHA). During installation of the P4 plating process line, the contractor shall conform to all safety regulations of NIOSH 75-145. The contractor shall provide a Safety and Health plan.

Safety Guarding. Covers, guards, thermal or electric insulators, or other safety devices shall be provided on the plating line. The safety devices shall not interfere with the operation of the line. The safety devices shall prevent unintentional contact with the guarded part, and shall be easily removed to facilitate inspection, maintenance, and repair of the parts.

Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

Mercury Restriction. The P4 plating process line shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture with the exception of fluorescent lighting where required.

Asbestos Restriction. Asbestos and materials containing asbestos shall not be used on or in the P4 plating process line.

Lead. Lead and materials containing lead shall not be used on or in the P4 plating process line with the exception to radiation cladding, lead solder in circuits, and plating anodes.

Use of Polychlorinated Biphenyl (PCB). The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited.

Tank Height above Work Floor. Tanks shall be installed to maintain OSHA standards referenced in Section 2.1.1 for worker safety when operating around the wet process tanks. The tank height above the work floor (i.e. grating) shall be achieved by modification to the tank support structure to raise/lower the tank lip to a safe working height from the grating per OSHA standard.

Grating, Support Structure and Toeboards. As defined in CFR 1910 Subpart D, §1910.21 walking-working surfaces (i.e. the grating walkway) shall not have a hole, gap or void > 2 inches in its least dimension or an unprotected edge > 4 feet above the lower basement level. The grating, supporting I-beams, and toeboards need to be added or modified to meet this requirement. Modifications to the supporting I-beams require stamped drawings from a California licensed Professional Engineer showing the design can support the new line. Any new I-beam grating supports shall be coated with an epoxy primer and topcoat to match the color of the existing grating support beams. Installation of walkway shall comply with OSHA minimum walking/working surface width requirements (see OSHA standard referenced in Section 2.1.1). Grating type shall be 1½-inch thick, 19-W-4 Stainless Steel Light-Duty 3/16-inch Bar Smooth. All added or expanded grating must be supported to carry a minimum load of 75 lbs/ft2.

Lockout/Tagout Energy Control Procedures. The contractor shall create an Energy Control Procedure (ECP) for all assets installed per standards 29 CFR 1910: OSHA Safety and Health Standards and OPNAVINST 5100.23 Navy Safety and Occupational Health Manual (The Control of Hazardous Energy Lockout/Tagout). The ECP shall follow the format per FRCSW 5100/19 (12/2020) FRCSW Plant Maintenance Energy Control Procedures. The contractor shall submit the ECP(s) to the Technical Point of Contact (TPOC) for review (see Section 4.5 for TPOC contact information).

Environmental Protection. The completed installation shall meet all applicable Environmental Protection Agency (EPA) and Occupational Safety Health Association (OSHA) restriction for materials classified as hazardous to the environment in effect on the date of contract. During the operation of the equipment at their final location, all equipment shall comply with all applicable EPA and OSHA regulations in effect on the date of contract regulating the emission of material hazardous to the environment. The contractor shall coordinate with FRCSW and Naval Air Station, North Island (NAS) regarding installation site approvals and environmental permits required by Federal, State, Country, and Local Laws. For additional information, the contractor is instructed to contact the TPOC. Within thirty (30) days from contract award, contractor shall provide in writing the make, model, capacity, footprint, mechanical, and electrical requirements of the equipment to the TPOC and Designated Government Representative (DGR) (see Section 4.5 for TPOC and DGR contact information).

Permitting: FRCSW is responsible for obtaining the required Authority to Construct and Permit to Operate from the San Diego County Air Pollution Control District (SDCAPCD), but the contactor is responsible for supplying the data and calculations required within 30 days after contract award for FRCSW to complete the application for SDAPCD evaluation of the equipment/processes and ensure the design meets all applicable rules and regulations with respect to emissions. Installation shall not commence until the Authority to Construct is received by FRCSW. Upon completion of the installation, the SDAPCD must be contacted to approve and close out the ATC. Typically, an inspection is also required for final approval. Final acceptance will be contingent upon the installed equipment meeting all conditions listed on the SDCAPCD Authority to Construct and Permit to Operate issued to FRCSW.

Replacement Parts. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as pumps, filters, solenoids, and level, resistivity, and electrode probes. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts.

Construction. The P4 plating process line shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the process line to its maximum rating and capacity without distortion.

Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, filling with solder or paste shall be used for reclaiming any defective part.

Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed. All fasteners/hardware shall be made of 316SS.

Threads. All threaded parts used on the P4 plating process line, and its related attachments and accessories shall conform to FED-STD-H28B and the applicable “Detailed Standard” section referenced therein.

Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

Painting. The P4 plating process line tanks shall be painted in accordance with the manufacturer’s commercial practice. All paint shall be of the lead-free type. Color shall be safety blue. No paint shall be applied to the inner surfaces of the tanks.

Workmanship. Workmanship of the process line shall meet all requirements specified herein, and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

Components. The P4 plating process line shall be used to process parts up to 83 inches long × 13 inches in diameter, and shall consist of not less than the following components:

Tanks. The P4 plating process line consists of 12 outer tanks and 13 inner tanks, which shall be fabricated from 3/16-inch-thick 316L stainless steel. The tanks shall have a 3 inch × 3 inch × ¼ inch channel rim and two (2) 3 inch × 3 inch × ¼ inch channel girths. In addition, all tanks shall have two (2) 4” x 65” or 90” or 100” long, depending on tank size, 316L I-beams welded to the bottom of tank with the length in the direction of travel (DOT). All heated tanks shall be insulated. All unpainted tank welds shall be passivated for corrosion prevention. Tanks shall be inspected and hydrostatic tested to ensure tanks are leak free prior to delivery. See Attachment A for model numbers, tank sizes, materials, chemistry, temperatures, and required liners.

Tank Lining. One (1) outer tank, ½ of a divided tank, and six (6) inner tanks shall be lined with 3/16-inch thick thermoplastic fused Koroseal (PVC) in accordance with Attachment A. The linings shall be constructed in accordance with industry standard to prevent leakage.

Box Liners/Inserts. Three (3) full sized, eight (8) half size and three (3) 1/3 size Kynar (PVDF) box liners constructed of ¼-inch thick PVDF walls and 3/8-inch thick PVDF bottoms shall be provided in accordance with Attachment A. Dimensions for liners listed in Attachment A are approximate; thermal expansion rate of liner material used in heated tanks shall be taken into consideration.

Inner Tank Stands. To support non-full depth inner tanks, nine (9) inner tank stands in accordance with Attachment A shall be constructed of 316L stainless steel and welds passivated for corrosion prevention.

Air Agitation System. Low pressure air agitation piping shall be installed on all rinse tanks in accordance with Attachment A. Low pressure air shall be provided by existing facility blower equipment. Air agitation materials shall be constructed to withstand the tank chemistry and operating temperatures in accordance with Attachment A. The agitation system shall be equipped with ball and diaphragm valve controls. The system shall be sized to provide the proper agitation turnovers in accordance with Attachment A. Air spargers shall be located at the bottom of the tanks and anchored one (1) to three (3) inches from bottom of tank inner surface to prevent debris and sludge from clogging the lines. All air agitation piping shall be anchored and remain static during operation. The piping shall direct the airflow upwards for proper solution circulation throughout the tank. The air volume provided is approximately one (1) cubic foot per minute (CFM) per linear foot of length.

Mechanical Agitation System. Mechanical agitation shall be provided for tanks in accordance with Attachment A. Pumps shall be hardwired at the tank. The pump, eductors, and any piping materials shall be constructed to withstand the tank chemistry and operating temperatures in accordance with Attachment A. The agitation system shall be equipped with on and off switches to control the pumps. The contractor shall assess and determine an optimal agitation design taking into consideration the turnover rates in accordance with Attachment A and the ideal agitation rates in accordance with industry standards for the tank sizes and contents. The mechanical agitation shall provide for proper solution circulation throughout the tank.

Eductors. The eductor nozzles shall be distributed in a manner that provides uniform agitation throughout the full volume of the tank. The eductors shall be anchored at intervals along the bottom of the tank to provide turnovers of the solution in accordance with Attachment A, agitation rates in accordance with industry standards for the tank sizes and contents, and not allow debris or sludge to build up. See Attachment A for materials and tanks requiring eductors.

Pumps and Filters. Pumps and filters shall be located at the tank and provide sufficient circulation and filtration for the processing tanks. The pumps shall be compatible with the tank solution, chemistry and operating temperatures. In addition, the pumps shall include filters mounted internal to the tank that are compatible with the tank solution chemistry and operating temperatures and are equipped with slide-in filter cartridge adaptors to ease filter replacement. Filters shall provide filtration down to 5-30 microns in accordance with Attachment A. The filtration system shall show flow pressures before and after the filter media in order to show filter usage. See Attachment A for pump material, turnover values, and filtration values.

Heating Coils & Heaters. In-tank heat exchangers and associated controls shall be installed in accordance with Attachment A and are to be sized to reach the tanks operating temperature from ambient temperature in a maximum of six (6) hours. Heating source shall be hot water (205°F ± 5°F) or 480V, 60Hz, 3-Phase power in accordance with Attachment A. The electric heater design shall be equipped with a safety disconnect shut off. All heating coils/heaters shall be manufactured from chemically compatible materials as required in Attachment A. All heated tanks shall be equipped with temperature control and level control systems. Refer to Attachment A for tank, temperature and model requirements.

Hot Water Piping Insulation. The contractor shall provide new insulation on all hot water and return lines up to working envelope of each tank.

Tank Thermal Insulation. The contractor shall provide thermal insulation on all tanks. Insulation shall be applied to the internal baffles/dividers in all heated tank sections.

Electrical Control and Level Monitoring System. All controllers shall be BACnet compatible and connect to a Siemens Data Capture Unit for monitoring purposes. This connection shall be provided through either Ethernet or 4-20 milliamp (mA) signal from the equipment. Modify, add or replace existing tank control and monitoring systems as required to provide digital controls that will integrate with FRCSW’s existing Direct Digital Control (DDC) system. Connect new equipment control and monitoring systems to nearby DDC control panel. Create requisite control points within DDC control system and update graphics within front-end operating system, Desigo, for remote monitoring and control of new equipment. DDC system remote monitoring to include all monitoring visible at local DDC controllers, and any additional points identified by manufacturer as indicative of equipment operational status. DDC system remote controls to include tank systems enable/disable, tank temperature setpoint, and tank level controls. Coordinate integration to DDC system with DDC system operators. Provide as-built DDC controls drawings. The control systems and level monitoring system shall include the following items.

Temperature Control with Automatic Level Control. The heating coil digital temperature control system shall include a thermostat, temperature sensor, stack light, 5-probe level sensor, and redundant solenoids (1 NO and 1 NC). There shall be an electrical control unit with stack-light that has a twist-lock female receptacle to plug into the electrical control unit. The level control probe shall be compatible with the temperature and tank solution in accordance with Attachment A.

Analog Temperature Gauge. All tanks with a digital temperature controller shall have a separate analog temperature gauge mounted at the tank with a probe compatible with the tanks chemistry.

Conductivity Monitoring System. A conductivity monitor with local display and solenoid valve shall be installed at all rinse tanks in accordance with Attachment A to monitor water quality. The setpoint for makeup shall be adjustable to meet water quality requirements. The conductivity monitoring system shall consist of a conductivity/resistivity module, probe, indicating transmitter, dual relay module, and a NEMA 250 type 4X enclosure. The conductivity probe shall be compatible with the temperature and tank solution in accordance with Attachment A.

pH Monitoring System. A pH monitor with local display shall be installed at tanks in accordance with Attachment A to monitor chemistry pH level. The pH monitoring system shall consist of a pH measuring electrode, reference electrode and a high input impedance meter, indicating transmitter, dual relay module, and a NEMA 250 type 4X enclosure. The pH electrode shall be compatible with the temperature and tank solution in accordance with Attachment A.

Rectifier Control. Remote controls shall be located at the tank for rectifier setup during plating operations. The rectifier controller shall include an amp-hour meter, static polarity reversing, and a safety disconnect.

Fixed and Portable Rectifiers. The tanks shall include fixed switch mode rectifiers that are water cooled with DC amperages in accordance with Attachment A and installed in corrosion resistant enclosures. Fixed rectifiers shall be mounted in the plating shop basement on Uni-struts. All rectifiers shall have less than 5% ripple on the full range. Rectifiers shall have protection for over current, over voltage, over temp, short circuit and open circuit. Portable rectifiers shall also be provided in accordance with Attachment A with an amp-hour meter and static polarity reversing.

Copper Bussing. The buss bars and work bars on the tank shall run parallel to the direction of travel of the plating line. Anode and cathode bus bars shall be round copper bussing and sized appropriately per Attachment A for the full capacity of the rectifiers to which they are attached. The rectifiers shall be connected to the tanks by copper plate sized appropriately for the full capacity of the rectifiers to which they are attached.

Copper Bussing Insulation. The contractor shall insulate the copper bussing in the plating shop basement in areas that are deemed dangerous to personnel working in the basement. In addition, the contractor shall design a cage around bussing near walkways to prevent injury to personnel walking along the tank perimeter.

Tank Electrical Isolation. The contractor shall provide electrical isolation on all tanks. Isolation shall be applied between the tank and the basement support beams, between copper bussing plates, and between the tank and the cathode and anode buss bar mounts.

Push-Pull Ventilation. The P4 plating process line tanks with a ventilation exhaust system in accordance with Attachment A shall utilize a push/pull design equipped with ventilation hoods on the pull side and a pipe with holes or slot is mounted on the opposite side of the tank as the ventilation hood for the push side. Push-pull system calculations and design shall be performed by the contractor and results must comply with the San Diego Air Pollution Control District (SDAPCD) Rule, SDAPCD Rule 67.61, “Cold Solvent Cleaning and Stripping Operations”; American Conference of Governmental Industrial Hygienists (ACGIH) Standard, “Industrial Ventilation: A Manual of Recommended Practice for Design”, (specifically §13.70 Open Surface Tanks and §13.72 Push-pull Ventilation); and the American Society of Safety Professionals (ASSP) Z9.1 Standard, “Ventilation and Control of Airborne Contaminants during Open-surface Tank Operations”. Authority to Construct (ATC)/Permit to Operate (PTO) application must be filed with the SDAPCD per paragraph 3.1.4.1.

Ventilation Hoods (Pull Side). The ventilation hoods shall be connected to the existing plenum located in the B472 basement of the plating shop, and shall be Type II, Grade I made of 3/8-inch-thick impact resistant PVC. The hoods shall have a baffle to allow for adjustability in the flow rate including the ability to close the opening completely and a Magnehelic differential pressure indicating transmitter with a scale range of 0 inches to 2.0 inches WC (± 0.5% electrical accuracy and ± 2% mechanical accuracy), and shall be BACnet compatible and connect to a Siemens Data Capture Unit to indicate the pressure differential across the ventilation hood. This connection shall be provided through either Ethernet or 4-20 milliamp (mA) signal from the equipment.

Push-Side Piping. The push side pipe shall be mounted with a union fitting to allow for rotation adjustability, an inline diaphragm valve for adjustability of the flow rate and a ball valve providing an on/off switch for the push-side at the tank location. This pipe system shall be connected to the existing low-pressure blower in the basement of the B472 plating shop. Hole size and spacing is calculated per section 3.3.7 Push-Pull Ventilation.

Process Line Accessories. The following items shall be provided in the quantities listed as per Attachment A and Table 1 below. Attachment A takes precedence over Table 1 if quantity inconsistencies exist.

Table 1: Process Line Accessories

(one at each tank)

(one at each tank)

(one at each tank)

((5) 1x4 horizontal, (15) 2x2 stacked) (each sign includes four (4) 8.5 inch × 11 inch slots)

Pneumatic System. The pneumatic system and all components shall conform to ISO 4414. The system shall be complete, including all valves, piping, cylinders, and pressure controls.

Electrical System. The P4 plating process line shall conform to NFPA 79. The existing source power available at the facility includes 110/120 volt, single-phase, 60 Hertz (Hz) and 460/480 volt, 3-phase, 60 Hz. The system’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete, including any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated, and fused, single disconnect device shall be utilized on the P4 plating process line with means of lockout in the off position only. Electrical connections made to the facility electrical system shall conform to NFPA 70. All electrical equipment in the P4 plating process line shall be connected to a single emergency shutoff that is located at the end of the line (East side).

Electrical Enclosures. Construction of the electrical enclosures shall conform to NEMA ICS 6 standards. The enclosure shall be a NEMA 250 type 12 and shall provide for ventilation of components and shall be designed for an indoor non-hazardous location. All electrical components shall conform to applicable NEMA ICS 1 standards. The P4 plating process line shall be provided with interlocks on its electronic cabinet that shall instantly remove power from the equipment when the door is opened in accordance with NFPA 79.

Arc Flash Protection. The P4 plating process line enclosures shall be marked for arc flash in accordance with NFPA 79 Paragraph 16.2.3 “Safety Signs for Electrical Enclosures” for arc flash safety.

Solid-State Components. Electrical devices used to power electrical servo and spindle motors of control voltage delivered to solid-state electrical components shall be solid-state devices. Such devices shall be equipped to handle the electrical load imposed by operation of the P4 plating process line to its maximum potential. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

Motors. Motors shall be rated for continuous duty. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG-1. Each motor shall have an identification plate in accordance with paragraph 3.6.2 to identify manufacturer, model number, serial number, voltage, amperage, horsepower, phase, frequency, and frame number. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

Tolerance Characteristics. The tolerances of the system shall be as specified in Table 2 below.

Table 2: Tolerance Characteristics

Pump, eductors and associated plumbing equipment shall be sized appropriately to allow adequate flow of solution to meet turnover requirement as listed in Attachment A

Standard Tooling and Equipment. All standard tooling and equipment required for proper operation of the P4 plating process line and maintenance shall be furnished. A list of these items shall be furnished at time of proposal.

Marking on Instruments, Control Panels, and Plates. All words on plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

Lubrication Plate. A lubrication plate shall be permanently and securely attached to each plating process line. The plate shall contain the following information.

Points of Lubricant Application Servicing Interval Type of Lubricant Viscosity Military or Federal Specification for Each Lubricant (If available) Size and Type of Each Lubricant Filter

Nameplate. A nameplate shall be permanently and securely attached to each rectifier, pump, conductivity and pH controller, and autofiller in the P4 plating process line. The nameplate shall contain the information listed below. If the P4 plating process line is a special model, the model designation shall include the model number of the basic standard plating process line and a suffix identified in the manufacturer's permanent records.

Nomenclature Manufacturer’s Name Manufacturer’s Model Designation Manufacturer’s Serial Number Power Input (Volts, Total Amps, Phase, Frequency) Contact Number Date of Manufacture

Identification Marking of Military Property. An Item Unique Identification Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text. At a minimum this tag shall contain the information listed in paragraph 3.6.2 Nameplate.

Technical Data. Two (2) hard copies and one (1) searchable .pdf electronic copy of technical data shall be provided with the P4 plating process line. Technical data shall contain specifications, instructions for the operation, maintenance of all the components of the P4 plating process line and recommended spare parts list. All copies of technical data shall be legible and written in the English language. All technical data shall identify manufacturer’s name, model number, serial number and contract number. Technical Data shall include the following items.

a. Manuals/Drawings: The contractor shall furnish two (2) hard copies of all technical, OEM manuals and drawings containing all information in compliance with modifications of the system. The manuals shall provide the data necessary for the programming, operation, and maintenance of the P4 plating process line and ancillary equipment. The contractor shall also furnish one digital copy of the above technical manuals and drawings in Adobe’s Portable Document Format (*.pdf) file format or Excel on CD-ROM(S)/DVD optical drive media. The digital manuals and drawings shall be organized, indexed and referenced similar to the equivalent hardcopy format (i.e. volume, manual, section, etc.). 2D drawings shall comply with ASME Y14.100 in Solidworks (*.slddrw) file format and 3D models in Solidworks (*.sldprt, *.sldasm) file formats.

b. OEM Manuals: Shall cover in detail all phases and cycles of operation such as start-up, maintenance, idle, shut down, troubleshooting, programming, running programs, printing, re-starting systems, etc. Manuals shall include the contractor’s contact information, parts list, preventive maintenance cycles, any/all information and documentation necessary to properly service, operate, maintain, adjust, and perform all functions within the equipment.

c. Calibration Manuals: Shall properly identify in detail the extent of calibration, part numbers, model numbers, specific calibration tools or adapters required, and manufacturer used. A complete list of all materials, chemicals, substances, and parts used for the calibration, or that need to be calibrated within the equipment shall be provided to the Government.

d. Materials: A complete list of all materials, chemicals, substances, and parts used for the calibration, or that need to be calibrated within the equipment shall be provided to the Government 120 days prior to installation of equipment. Manuals shall be provided at the time of delivery and/or before acceptance of equipment.

e. Changes and Adjustments: Any and all adjustments made to the equipment during testing, acceptance, and warranty period shall be properly noted by the contractor. Updated manuals with any and all adjustments, updates, or changes made to the system shall be provided to the Government at no additional cost.

Plan of Action and Milestones (POA&M). The contractor shall provide a POA&M to identify contractor performance dates of all major events from contract award to completion of all contract requirements. The initial POA&M shall be delivered thirty (30) calendar days After Contract Award (ACA). The milestones shall be prepared and submitted using a recognized project management technique (preferably Microsoft Project). The Government and the contractor shall review the report on a monthly basis. The contractor shall notify the Government prior to making any changes to the POA&M. All changes to the POA&M shall be approved in advance by the Government. The POA&M shall detail such items as engineering, procurement of major hardware, assembly, operational debug, factory acceptance, shipment, loading and laydown area, installation, and final acceptance test.

Acceptance Test Plan (ATP). The Contractor shall prepare an Acceptance Test Plan (ATP). The ATP shall be a step-by-step written instruction on how to verify compliance during the Final Inspection/Acceptance Test specified in Section 4.3.2. The Manufacture’s standard testing procedures shall be included in the ATP. In addition, identify and include procedures necessary for compliance with Section 4.0 not covered by the Manufacturer’s standard testing procedures. The initial ATP shall be submitted thirty (30) calendar days ACA for Government review and approval. The Government shall respond with acceptance or recommendations within ten (10) business days. The accepted test procedures shall become part of this contract.

Removal of Existing Plating Line. The contractor shall provide all qualified personnel and equipment to ensure safe removal of the existing equipment. Removal of the P4 plating process line must be done in such a manner to accommodate the installation of a new P4 plating process line. The existing plating line removal and/or modification requirements will be determined upon completion of the site assessment.

Waste Disposal

Non-Hazardous Waste: Disposal of non-hazardous solid waste shall be the contractor’s responsibility.

Hazardous Waste: FRCSW shall assume all responsibility and associated liability for disposal of hazardous waste as defined in California Code of Regulations Title 22. Contractor to contact TPOC and obtain specific instructions with respect to location and latest regulation from the Government for disposal of hazardous equipment/parts. Contractor to remove and prepare (i.e., disassemble or cut, if necessary) all tanks and supporting equipment for excess. FRCSW will provide hazardous waste roll-off bins, as needed. Contractor must provide own riggers and rigging equipment; contractor cannot use FRCSW equipment, and any forklift must be powered by propane tank.

1. Tanks will need to be emptied, rinsed, and dry/free of any liquid before they are removed for disposal.

2. The tanks/hardware will be disposed of as hazardous waste.

3. If necessary, tanks shall be cut apart in order to properly fit in hazardous waste disposal bins.

In the event of an emergency, including hazardous material spills, the contractor or present contractor representative discovering the emergency shall call 911 from any FRCSW phone and relay the location of the spill to include building and specific area within the building. If calling from a cell phone, caller must state that this is a North Island Coronado Naval Base emergency at FRCSW and relay the location so they can transfer the call to our local 911. Also, individual needs to notify the TPOC for this project (see Section 4.5 for contact information).

Installation. The contractor shall provide all qualified personnel and equipment to ensure safe, complete installation and operability of the new P4 plating process line. The contractor shall provide materials and tools necessary for complete installation of the P4 plating process line. The contractor shall take into consideration the artisans’ safety with respect to OSHA Standards per Sections 2.1.1 and 3.1.3 for working surfaces and ergonomic risk factors and control methods per Sections 3.1.2 and 3.3. The contractor shall survey the plating facility, coordinate with stakeholders (i.e. FRCSW facilities, maintenance, and environmental personnel) to identify needs regarding the new process line with respect to utilities (see section 3.9.1) and hazardous waste disposal, and shall comply with safety and environmental standards as described in sections 3.1.3 and 3.3.7. The individual requirements for the P4 plating process line are outlined in Attachment A and are designed to meet the needs of the chemical composition in each tank. The operational parameters of each tank have been addressed for reactivity to material, operational temperature, power requirements, filtration, agitation and required ventilation.

Utilities. The contractor shall install the P4 plating process line utility hookups including low pressure air, DI and RO water, hot water, electrical, and ventilation to the existing site in a way to make the finished line operational. The Government shall provide all utility connections to within twenty (20) feet of the P4 plating process line. Contractor shall be responsible for all utilities and connections from that point to the equipment.

Loading/Laydown Area. The Government and contractor shall discuss the space requirement in the post award conference.

Work Stoppage. For unforeseen issues that are found during installation of the equipment, the contractor shall notify the TPOC and DLA immediately to determine further course of action.

1.1 Training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is proficient in the English language, shall be provided for specialized training to familiarize Government personnel with the scrubber equipment and to help ensure reliable performance and maximum service life, during normal usage. The training shall be for a minimum of ten (10) Government employees (to include Government contract employees) such as facility and maintenance personnel, engineering, materials engineering, and personnel working or operating the equipment. Training shall be in the operation, maintenance, calibration, support, and programming of the air scrubber for the P4 plating process line. The training shall be performed at the Government’s facility and shall be eight (8) hours a day for five (5) workdays or 40 hours, between 0600 and 1430 hours excluding any weekends, federal holidays, furloughs, and base closures. The course shall utilize as-built drawings and manuals provided under this contract, and shall include both classroom and handson portions. All printed training aids shall be supplied for the course, be in the English language, and become the property of the Government. The following items shall be covered during the training:

a. Familiarization with the equipment including description of the system, description of safety and emergency features, and familiarization with related technical data to be provided

b. Demonstration by contractor personnel of all operation, safety, and emergency aspects of the equipment

c. Hands on operation by Government personnel with assistance from the contractor

d. Upon completion of training, Government personnel shall be capable of fully operating the equipment without assistance, perform the required maintenance, and calibrate the equipment

QUALITY ASSURANCE.

Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein and in accordance with the attached Quality Assurance Provision (QAP). The Government reserves the right to witness any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

Responsibility for Compliance. All items must meet all requirements of sections 3.0 and 4.0.

Classification of Inspections. The inspection requirements specified herein are classified as follows:

Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient temperature conditions in the range of 55° F to 100° F and 10% to 95% relative humidity.

Final Inspection/Acceptance Test (Destination). Final Inspection and acceptance test shall be performed on the P4 plating process line to ensure conformance with this purchase description. The acceptance test shall be performed only after the P4 plating process line is installed at its final location. The acceptance test shall consist of the examination in 4.3.3 and all tests in 4.4. The P4 plating process line shall pass the examination and all tests to be accepted.

Examination. The equipment shall be examined for design, dimensions, construction, materials, components, electrical equipment and workmanship to determine compliance with the requirements of this specification.

Tests. Unless otherwise specified within this document, all programs, instruments, materials, material handling equipment, qualified personnel, and tools required to perform and evaluate the tests shall be furnished by the contractor. All measurement tools and indicating devices shall be calibrated in accordance with the attached QAP. If a malfunction occurs during the test, the test shall be restarted each time until all tests in Section 4.4 are completed without a malfunction. Three (3) consecutive failures without completion of the test may be considered cause for rejection of the system. For the purpose of this test, a “failure” is defined as any equipment malfunction which requires remedial action to restore the system to full operation in accordance with this specification.

Accuracy Tests. Tests shall be conducted to ensure the system meets the tolerances specified in paragraph 3.4, Table 2.

Operational Test. The system shall be run in accordance with the ATP provided by the manufacturer see 3.7.2.

Performance Test. Performance tests shall be run in accordance with the ATP provided by the manufacturer, see 3.7.2., to ensure each piece of equipment meets the requirements of this specification, at a minimum, to test the performance of every individual piece of equipment, including:

a. Tank/Inner Tank/Liner

b. Heater

c. Rectifier

d. Conductivity Controller

e. pH Controller

f. Autofill/Temperature Controller System

g. Push-pull Ventilation System

h. Pump/Agitation System

i. Test to validate tank by performing leak check and equipment check with water. Make sure that all systems function and stay constant over a minimum 24-hour continuous period

Audible Noise Level Test. The equipment shall be tested for compliance with paragraph 3.1.3.2 “Audible Noise Level”.

Designated Government Representative (DGR) and Technical Point of Contact (TPOC) The Designated Government Representative (DGR) is Rudy Gonzales, Fleet Readiness Center Southwest, Bldg. 90-2, Code KN25100, PO Box 357058, NAS North Island, San Diego, CA 92135-7058, PH: (619) 767-1209, E-mail: rudy.gonzales52.civ@us.navy.mil.

The Technical Point of Contact (TPOC) is Raquel Wise, Fleet Readiness Center Southwest, Bldg. 90-2, Code KN25100, PO Box 357058, NAS North Island, San Diego, CA 92135-7058, PH: (619) 545-7719, E-mail: raquel.l.wise.civ@us.navy.mil.

WARRANTY

A warranty shall be provided for a minimum of twelve (12) months (e.g.