26-30-1900 SAM PD Posting.pdf

Statement of Work (SOW) for Blast Booth at Kinston Facility

1.0 Scope.

1.1Scope.كThe content of this specification describes the minimum requirements for the design, manufacture, delivery, and acceptance testing of a Blast Booth 70’ L x 28’ W x 29’ H equipped with fire suppression system, dust collection system, ventilation system, media removal system, return air system, blast system, ventilation system, oil free compressor system, breathing air system, oil free breathing air compressor system, and connected air shower booth. Blasting operations will produce aluminum, titanium, magnesium, and stainless-steel dust requiring class 2 division 1 classification. Blast Booth system, and all controls inside the booth shall be class 2 division 1 rated, and explosion proof ventilation/media removal system.

It is the intent of the Government to have a single contractor with experience in the design and manufacture of this type of equipment and shall supply and integrate the requirements as specified herein to provide complete systems with testing and training included.

2.0 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 they are listed. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

2.1 Government Documents

2.1.1 Specifications, Standards, and Handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract.

STANDARDS – FEDERAL

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

FED-STD-313F: Material Safety Data, Transportation Data, and Disposal Data for Hazardous Materials Furnished to Government Activities

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

29 CFR 1910 Vol. 5: General Industry, OSHA Safety and Health Standards

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

Environmental Protection Agency (EPA)

40 CFR 761: Polychlorinated Biphenyls (PCBs) Manufacturing, Processing, Distribution in Commerce, and Use Prohibitions

(Application for copies should be addressed to the EPA Ariel Rios Building 1200 Pennsylvania Avenue, N.W. Washington, DC 20460)

DEPARTMENT OF DEFENSE

U.S. NAVY

OPNAV M-5100.23 w/change 1: Navy Safety and Occupational Health Program Manual

(Application for copies of the OPNAVINST should be addressed to Office of the Chief of Naval Operations, The Pentagon, Washington, DC 20350-2000 or to Commander, Naval Safety Center 375 A Street Norfolk, VA 23511 or on the internet at 5100.23 CH- 1.pdf (navy.mil))

MILITARY STANDARDS

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)

2.2 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 issues of these documents are those listed in the solicitation or contract.

RESERVED

2.3 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 issues of these documents are those listed in the solicitation or contract.

https://www.secnav.navy.mil/doni/SECNAV%20Manuals1/5100.23%20CH-1.pdf https://www.secnav.navy.mil/doni/SECNAV%20Manuals1/5100.23%20CH-1.pdf https://quicksearch.dla.mil/qsSearch.aspx

American Gear Manufacturers Association (AGMA)

(Address application for copies to: 500 Montgomery Street, Suite 350, Alexandria, VA

22314-1581 USA)

American National Standards Institute, Inc. (ANSI)

B11/STD B11: General Safety Requirements Common to ANSI B11 Machines

(Address application for copies to the American National Standards Institute, 11 West 42nd Street, New York, NY 10036)

American Society of Mechanical Engineers (ASME)

ASME Y14.100: Engineering Drawing Practices

ASME Pressure Vessel Code BPVC Section VIII

(Applications for copies should be addressed to ASME International Three Park Avenue New York, NY 10016-5990 or www.asme.org)

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 http://www.asme.org/

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 17 Dry Chemical Extinguishing Systems

NFPA 69 Standard on Explosion Prevention Systems

NFPA 70: National Electrical Code

NFPA 79: Electrical Standard for Industrial Machinery

United Facilities Criteria (UFC)

UFC (4-211-02) Corrosion Control

UFC (3-410-04) Industrial Ventilation

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

2.4 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 regulations unless a specific exemption has been obtained.

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3.1.1 Measuring and Indicating Device Graduations. All measuring and indicating devices on the machine shall be graduated in the US Customary Units.

3.1.2 Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's work station(s).

3.1.3 Safety and Health Requirements. All machine parts, components, mechanisms, and assemblies furnished on the machine, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910. Safety signs and labels on all equipment shall comply with NEMA Z535.4.

3.1.3.1 Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11. The safety devices shall not interfere with the operation of the machine. 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.

3.1.4 Audible Noise Level. In accordance with OPNAV M-5100.23, Chapter 18, 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.

3.1.5 Environmental Protection. Under the operating, service, transportation, and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

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

3.1.5.2 Asbestos Restriction. Asbestos and materials containing asbestos shall not be used on or in the machine.

3.1.5.3 Lead. Lead and materials containing lead shall not be used on or in the machine with the exception to radiation cladding and lead solder in circuits.

3.1.5.4 Use of Polychlorinated Biphenyl (PCB). The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited. The machine shall be considered PCB free providing certification to be verified containing less than 5 parts per million (<5ppm) in accordance with 40 CFR part 761.

3.1.6 Lubrication. The machine shall be equipped with a system that provides lubrication (oil, grease, coolant, etc.) for all moving parts in accordance with manufacturer requirements. Recirculating lubrication systems shall include a filter that is cleanable or replaceable. Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low lubrication condition. When a low lubrication condition occurs, the machine shall complete the current operation and come to a complete stop. The machine shall indicate that lubrication is required. All oil holes, grease fittings, and filler caps shall be easily accessible.

3.1.7 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 gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts.

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3.2.1 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.

3.2.2 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.

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

3.2.4 Gears. All gears of axis drive trains shall conform to or exceed all provisions of ANSI/AGMA ISO 1328-1-B14. All gears shall be of proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine. Gears in drive trains shall be hardened and ground steel.

3.2.5 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.

3.2.6 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.

3.2.7 Painting. The machine shall be painted in accordance with the manufacturer’s commercial practice. All paint shall be of the lead-free type.

3.2.8 Pressure Vessel. Pressure Vessels shall meet all ASME Pressure Vessel Code BPVC Section VIII for construction and use.

3.2.9 Workmanship. Workmanship of the machine 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.

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3.3.1 Blast System. The Blast Booth System comprises of the following Major components:

1. Blasting Booth with Air Shower.

2. Dust Collection System

3. Ventilation System with Breathing and Return Make Up Air

4. Pit Mounted Media Floor Removal/Recovery System.

5. Fire Suppression

6. Compressor OIL Free, oil/water trap, receiver, and catalytic dryer for blast system

7. Compressor Oil Free, oil/water trap, receiver, and catalytic dryer for breathing air system

8. Industrial Dust Control Vacuum System

3.3.1.1 Blast Booth Enclosure.

1.One 28’Lx70’Wx29’H enclosed on all sides Blast Booth. Booth shall include Blasting Booth System that shall be rated for Class II Division 1 (Explosion Proof) space and conform to NFPA 652 and NFPA 484. Blast Booth Dust particles will contain Titanium, Aluminum, Magnesium, and Stainless Steel.

Booth Enclosure shall include the following:

1. Construction of minimum 14-gauge galvanized with structural members painted or powder coated steel.

2. Booth shall include a 20’x20’ roll up gasketed door on one side of the booth with safety interlock switches to prevent operation of the pressure blast until the doors are sealed and securely shut. Roll up door shall incorporate a safety light curtain.

4. Booth shall include minimum of six Qty (6) personnel doors with safety interlocks.

5. Booth shall include LED lighting with booth light control that shall provide power for the LED booth lights and includes a switch to independently control the lights. Lights are to be either sealed from the booth or have explosion proof rating if inside exposed to the booth. The room must have an average lighting calculation of 150 foot candles measured three feet above finished floor level.

6. Booth shall include integral air shower to be mounted on the left back of the booth enclosure so the operator may enter from the booth contaminated side and exit on the clean side of the booth after decontamination. Air shower shall include the following:

a. Maximum O.D. Dimensions: 52” wide x 44” long x 116” high

b. Minimum I.D. Dimensions: 39 ½” wide x 40” long x 81 ¾” high

c. Unit constructed of epoxy painted steel; trim to be anodized aluminum.

d. Access Doors shall be fabricated with ¼” clear acrylic glazing, self-closers, electromagnetic door lock and door status switch.

e. High pressure blower capable of producing minimum of 1,200 Cubic Feet Per Minute

(CFM) @ 4” w.g., 460 volt, 3 phase, 60 hertz.

f. Filter section shall include HEPA filter 99.99% effective on particles of 0.3 microns in size.

g. Low wall return air grills with 35% efficient disposable pre-filters.

h. Adjustable air nozzles on walls and ceiling to provide an average nozzle velocity of

7500 FPM.

i. Unit shall contain three (3) each emergency stop buttons, one (1) E-Stop located outside each of the two doors and one (1) E-Stop inside the air shower chamber which will shut down the air shower and unlock the doors.

7. System shall have eight (8) Grade “D” breathing air connections with a minimum of 35 scfm supply air to each connection (140 CFM Total) to allow four personnel to be inside the booth at the same time. Air connections shall be compatible with the four Qty (4) Nova and four Qty (4) 3M helmets. Breathing air panel shall be explosion proof. Breathing air panel shall be powder coated.

8. System shall have a Breathing Air Carbon Monoxide Alarms System that monitors all eight Qty (8) breathing air outlet connections. Audible and Visual alarms shall be located inside the booth. The alarms mounted within the blast enclosure shall have the following listings: Class I, Groups C and D and Class II, Groups E, F, and G. Contractor to provide a calibration kit for the CO Monitor provided. Breathing air system shall include a visual flowmeter to verify air flow to the Carbon Monoxide monitor and a safety relief valve. Alarm set point shall be 10 ppm (OSHA standard), 5 ppm (Canadian standard).

9. System shall include four Qty (4) XL heavy duty blast suits.

10. System shall include four Qty (4) heavy duty glove sets.

11.Booth shall include four (4) GVS/RPD Respirator NV3-703-50 with cool air tubes.

12.Booth shall include a Control Panel with Allen Bradley controls and PanelView 1000 with 10 inch screen mounted on the control panel door. The control panel must be mounted a minimum of 3’ away from any Blast booth openings. Program shall be supplied on a CD ROM disk.

Supply Voltage: 460/3/60 VAC. Interface located next minimum 3’ away to the entry door.

13.Booth shall include four (4) compressed air fitting assemblies; each with four (4) ½” quick fit connections spaced equally down the length of the booth to accommodate air powered tools complete with compressed air manifold kits.

14. Booth shall include Booth Acoustic Sound Quilts – For the Side & Back Booth Walls; with up to 21dB noise reduction, Class I ASTM E-84 for flammability.

3.3.1.2 Explosion Proof Blasting Module Ventilation Dust Collection System.

System shall be a cross draft design with100 FPM minimum face velocity for a total of 81,200 cfm minimum. Contractor shall provide all required ducting for dust collection/media removal and return air. Ducting shall conform to SMACNA HVAC Ducting Standards. Wall penetrations and flashing to be provided by the contractor. The dust collection system shall incorporate a dust collector explosion mitigation system that may use active (suppression, isolation valves, spark detection) or passive (venting) methods to control deflagrations, protecting equipment and workers by either suppressing the explosion with chemicals/powders within milliseconds or safely directing pressure and flames out of the collector to a safe area. Dust collection system shall be coated for corrosion protection for outside mounting (reference UFC (4-211-02).

Dust Collection System shall include the following:

a. Dust Collector System shall be down-flow cartridge-type.

b. Dust Collector Capacity shall be 81,200 CFM minimum in this application

(required by ANSI/AIHA Z-9.4-2011) with a 2.09 to 1 air to cloth ratio at a minimum.

c. Room Ventilation Velocity shall be One Hundred (100) fpm through blast room cross section of (28) ft. wide x (29) ft. high.

d. Reverse-Pulse Control: 24VDC, PLC reverse-pulse control panel. Control panel shall have an Allen Bradley HMI controller on the face of the control panel door

e. Dust Collector Exhauster

f. HEPA Filtration System for Dust Collector

g. Ducting: Ducting from the blast room to the room ventilation collector, blower motor, and HEPA filter. Duct elbows shall be reinforced long sweep elbows to resist abrasion from media (reference UFC 3-410-04 sections 6-3.5 and 6-3.8).

h. Explosion Vents for Dust Collector shall be a minimum of one (1) set of explosion vents that shall be supplied along with backdraft damper per dust collector. The Dust collector system must incorporate explosion mitigation systems that use active (suppression, isolation valves, spark detection) or passive (venting) methods to control deflagrations, protecting equipment and workers by either suppressing the explosion with chemicals/powders within milliseconds or safely directing pressure and flames out of the collector to a safe area.

i. Dust collector system shall include 55-gallon drum lid connection kits for each collection outlet with level monitor.

j. Particulate monitor shall be provided down stream of the last filter to monitor particulate size in discharge air stream and to shut down the PMB system and signal an alarm when particulate levels rise above alarm set point. Provide particulate monitor consisting of a insertion probe utilizing triboelectric measurement principle to sense the dust concentration and a control unit to convert the concentration level signal to a 4-20 mA signal.

Zero testing shall be performed directly at the control unit. The controller shall be installed in a lockable NEMA 4X enclosure. The probe shall be flange mounted to ductwork system, probe length, and shall be as required by manufacturer. The probe shall be compatible with air flow between -5 degree F and 250 degree F. System shall operate on 120V single phase power with an average integration time of 2 seconds. Monitoring system shall have differential pressure gauges for readings across all filters and establishment of differential pressure levels for the filter banks to support timely changeout of filter media when required.

k. Dust collection system shall include a broken bag monitor.

l. Rotary airlocks shall be provided between the dust collector sump discharge and the 55 gallon drums.

m. Fan inlet box

n. Blower Outlet Damper

o. Exhaust Silencer

p. Inlet isolation flex connector; rectangle type between the blower to Hepa transition.

q. Filter-to-Fan Ducting

r. Service Platform – Integral service platform & ladder assembly, toe kick plates, safety gate, built to OHSA design, safety yellow.

s. Contractor shall provide all required ducting for dust collection/media removal. Ducting shall conform to SMACNA 1108-2008. Wall penetrations and flashing to be provided by the contractor.

t. Dust collection system controls shall include direct digital control interface with Building Control monitoring System to allow remote monitoring of waste containers level, dust collector filter(s) pressure drop and system status. Controls interface shall include scheduling and trending of filter changes and waste container replacement.

u. Contractor shall provide a Concrete pad as required for auxiliary equipment approximately 75’ from booth. Contractor shall provide required design for mounting pad for dust collection system for approval by FRCE.

3.3.1.3 Media Recovery System

Media Recovery System shall consist of the following:

a. The underfloor blasting media recovery system shall be pneumatic, multiple trench type system. The base plates for the recovery floor system shall include a abrasive resistant rubber coating. Mechanical belt, screw and augur systems shall not be allowed.

b. The blasting media recovery system shall be pit mounted to a Government supplied pit that will be 75’-3” Inside Pit Length x 26’-3” Inside Pit Width.

c. Grating Capacity shall be a minimum of (10,000) LBS/SF and a point single wheel load of (10,000) LBS.

d. Grating Material: Type 316 stainless steel conforming to ASTM A 666 or Alloy 6063-T6 aluminum conforming to ASTM B 221.

e. Recovery Area shall be 26’-3” x 70” to match Pit area within booth.

f. Recovery system shall include a 24V DC timer control panel.

g. Media Recovery System shall comply with UFC 3-410-04 section 6-3.7.

3.3.1.4 ABRASIVE CLEANING SYSTEM

Abrasive Cleaning system shall consist of the following:

a. Cyclone reclaimer

b. The reclaimer shall be equipped with replaceable abrasive-resistant rubber liners. The reclaimer shall also include an externally adjustable vortex tube which will allow the operator to fine tune media classification. The media reclaimer shall have a rotary airlock between the reclaim outlet and the inlet to the vibratory classifier.

c. Heavy Particle Separator

d. Deionizer

e. Magnetic Separator

f. Vibratory Separator

g. Transfer Bucket elevators

h. Abrasive Storage Hopper shall have minimum 50 cubic feet for clean media storage with high/low level indicators which will provide a signal to the Allen Bradley HMI on the main control panel door.

i. Access Platform: Maintenance access platform with personal safety tie off cable and ladders.

j. Pressure Vessels (Pots) and Media Storage shall consist of the following:

Four (4) pressure (blast) pots, constructed of hot rolled steel in accordance with ASME, Section VIII of the Pressure Vessel Code. Media shall be Type V Acrylic Polymer Plastic. Media pots shall have a epoxy coated interior. Media Each vessel/pot shall have an operating pressure ranging from ten (10) to one-hundred fifty (150) psig. The vessels/pots shall have a minimum capacity of six (6) cubic feet, be constructed with a minimum sixty- (60) degree outlet cone. The main storage hopper for new/clean media shall have a minimum capacity of 50 cubic feet. The storage hopper shall incorporate four (4) separate pneumatically operated media feed outlets. Each of the outlets shall incorporate its own automatic refill unit and pressure vessel. Each vessel/pot shall be sealed and tested to prevent dust blowouts and all exhaust valves shall be fitted with noise suppression device to minimize noise. Pressure vessels/pots and media storage shall not have any internal valves, seals, and/or valve stems. All valves shall be external from the Blasting Enclosure.

k. Media Metering System shall include the following:

Open blasting equipment shall be designed specifically for PMB use. The equipment will control the media feed rate from 300 to 750 pounds per hour per nozzle. The equipment will maintain a nozzle pressure between 0 and 60 psi to a nozzle with an inside diameter, bore size, of 1/2 inch. Clean, dry, oil-free compressed air shall be used to pressurize the blasting equipment. The equipment shall have a pneumatic, vacuum collection system which effectively allows for plastic media reuse. The equipment will classify the media to remove particles larger than 16 mesh and smaller than 80 mesh from the used media. The recovery equipment will have a magnetic particle separator to remove ferrous contaminants. The recovery system must maintain a media cleanliness of 0.02 percent by weight or less heavy particle contamination. Heavy particle contaminants have a specific gravity greater than 1.9 and are typically aluminum oxide fragments, steel grit, glass beads, etc. Equipment ventilation and dust capture systems shall be coordinated with local Occupational Safety and Health Administration requirements as well as state and federal Environmental Protection Agency regulations.

l. Blast Hose shall consist of the following:

Each system shall include a minimum of four (4) one hundred (100) foot lightweight media delivery hoses (maximum hose weight 0.8 pounds per foot) with a maximum outside diameter of 1-7/8” inches and rated at 150 PSI working pressure and 30 lbs/minute media flow. Blast hose shall be manufactured with static dissipating materials. Each hose connector shall be fiber-reinforced nylon quick couplings with integral spring locks. Hose-to-hose connectors shall include a corrosion resistant, high-strength safety cable with spring-loaded loops at both ends.

m. Blast Nozzle/Nozzle Holder shall consist of the following:

System shall provide minimum of 4 fiber-reinforced nylon nozzle holder and four silicon carbide (0.5 inch bore) blast nozzles per nozzle holder rated for 30 lbs/minute media flow. Nozzle material shall be selected for maximum impact resistance and minimum weight. Nozzle shall thread into nozzle holder with 50-millimeter thread to provide a high strength attachment with minimum galling.

Connection of the nozzle to the blast hose shall be accomplished leak free to provide a secure connection at all blasting pressures. System shall include a Remote Control with abrasive cut-off system.

n. Abrasive cleaning system dust collector rated for minimum 4,800 CFM.

o. Explosion relief Panels

p. Backdraft dampers

q. duct silencer

r. Reverse-Pulse Control: 24VDC, PLC Reverse-Pulse Control Panel. The Pulse control panel shall have an Allen Bradley HMI controller on the face of the control panel door

s. HEPA Filtration System for Reclaimer Dust Collector.

t. The abrasive recovery dust collection system must sit outside the building and incorporate explosion relief panels, backdraft dampers, HEPA filters and duct silencers for return air back to the building. The Dust collector system must incorporate explosion mitigation systems that use active (suppression, isolation valves, spark detection) or passive (venting) methods to control deflagrations, protecting equipment and workers by either suppressing the explosion with chemicals/powders within milliseconds or safely directing pressure and flames out of the collector to a safe area.

3.3.1.5 Return Air System.

Return Air System shall include the following:

a. Return air system shall be an 100% percent recirculation system supplied from the dust control/ventilation system for maximum efficiency.

b. Return air system shall be a pull thru system that ducts the air from the dust collection/media removal system to the fan, and then pushes the make up/return air through duct(s) with explosion venting to Hepa Filters mounted above the booth.

Booth shall have vents on the booth to maintain laminar flow at a max negative .05”WG inside the booth.

d. Return air system shall be complete with wall penetration, and all associated ductwork with 3 way air diffuser inside the room.

e. Return air system shall have electronic controls that interact with Blast Booth Dust Collection system for adjusted return air.

f. Contractor shall provide a Concrete pad for system approximately 75’ from booth.

Contractor shall provide required design for mounting pad.

g. Return air system shall have a filtration system that meets all HVAC OSHA and NFPA federal, state, and local codes.

h. Wall penetrations shall be provided by the contractor.

3.3.1.6 Industrial Dust Control Vacuum System

Industrial Dust Control Vacuum System shall be mounted outside that includes the following items:

a. Minimum 25HP power-module

b. Qty (2) cu yd end dump hopper

c. Support stand and airlift assembly

e. Explosion vent with built in flame arrestor

f. Grounded filter cartridges

g. Dual agent fire suppression system unit with high purity compressed dry nitrogen.

h. Stainless steel inlet assembly

i. Explosion proof (480/3/60) electric motor

j. 50' grounding reel

k. Vacuum system shall be EXPLOSION PROOF ELECTRICAL RATING.

l. The control panel enclosure meets the NEMA 7 & 9 specification, and the electric motors shall be rated for use in Class I & II environments meeting the requirements for Divisions I & II and Groups C, D, E, F, & G

m. 1 - 4" female camlock coupler

n. 1 - 4" male camlock coupler

m. 1 - 4" x 4" hose adapter

o. Minimum 80' section of 3" abrasion resistant work hose p.1 - 3" unthreaded round aluminum nozzle q.1 - 3" unthreaded Duck Bill flared nozzle

r. Contractor shall provide a Concrete pad for system approximately 75’ from booth.

Contractor shall provide required design for mounting pad for dust control vacuum collection system.

3.3.1.6 Compressor System.

Blast Booth System shall include the following for the pneumatic Blast System Air requirements:

a. Oil Free Compressor sufficient of supplying air for the Blast Systems including blast pots, air connections with four Qty (4) nozzles running simultaneously.

b. Oil Free compressor for supplying Grade D breathing air to four Qty (4) Artisans simultaneously.

c. Compressed air piping from compressors to all blast process equipment connections and breathing air connections.

d. Oil/Water trap prior to air dryer for Blast system compressor and breathing air compressor.

e. Desiccant air dryer for each compressor system

3.3.1.8 Fire Suppression System.

Blast Booth System shall include a fire suppression system. System shall conform to NFPA 17. The contractor shall design and install a dry pipe fire sprinkler system to protect one (1) blasting booth that is a combined size of approximately 70’L x 28’W x 29’ H, by installing piping and heads and connecting the piping to a fire sprinkler system that is protecting the building being constructed now. System shall connect to the new system piping in the building being constructed now to connect the blast booth piping to the existing sprinkler system that serves the building. System shall include Explosion Isolation Valve (Required for Explosive Dusts) explosion isolation back draft damper with flanged pipe connections. Complete with micro switch for dust collector system shut-down, dust level sensor, and control panel for sensor power and integration; to be installed on the dirty airside of the duct system (inside or outside of the building) to prevent the transmission of energy from a fire and/or explosion to inside the building; *NFPA 69-2014 Compliant*

Contractor shall design and install a dry pipe fire sprinkler system that will provide protection for approximately 120 L.F. of Blast booth exhaust duct as defined in NFPA-13 as connections to the new dust collector, that will be on the outside of the building and include a dedicated riser mounted air compressor to support the dry pipe riser operation.

3.3.2Pneumatic System. The pneumatic system and all components shall conform to ISO 4414.

The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

3.3.3 Electrical System. The machine shall conform to NFPA 79. The existing source power available at the facility is 460 volt, 3-phase, 60 Hertz (Hz). The machine’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 machine with means of lockout in the off position only.

3.3.3.1 Electrical Enclosures. Construction of the electrical enclosures shall conform to NEMA ICS 6 standards and NEMA 250. The enclosure shall be a NEMA 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 machine 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.

3.3.3.2 Solid-State Components. Electrical devices used to power electrical motors of control voltage delivered electrical components shall be solid-state devices. Such devices shall handle the electrical load imposed by operation of the machine to its maximum capability. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

3.3.4 Controller Features. The machine controllers shall consist of an Allen Bradley PC with

HMI.

3.3.4.1 Universal Serial Bus (USB) Connection Port. A minimum of one (1) Standard USB connection port for the transfer of process information to the system control shall be provided.

All protocol documentation shall be supplied.

3.3.4.2 Ethernet Connection Port. An RJ-45 connection port for Ethernet shall be readily available on the exterior of the machine. The CNC controls shall have the capability to upload and download part program results using standard Ethernet protocol.

3.3.4.3 CNC and Control Restoration Data. The contractor shall be responsible for the generation of all program logic and documentation necessary for machine operation. The Programmable Memory Controller (PMC) program, CNC parameters and all data required for configuring a new control and any other configured or programmed electronic device shall be provided in electronic format on read-only optical disc and delivered with the equipment. For safety and security reasons, the vendor shall not provide encrypted files containing proprietary cycles PMC, PLC programs/data.

3.3.4.4 Software. Programming by contractor to meet the requirements for the blast booth controls to meet system requirements (Section 3.3.1 and all sub-sections).

3.3.4.5 Hardware. Allen Bradley HMI.

3.3.5 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 3.5 to identify manufacturer, model number, serial number, voltage, amperage, horsepower, phase, frequency, and frame number.

Motors requiring variable speed drives shall be rated for variable frequency drives. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

3.3.6 Work light. A work light, whether built-in or added on, shall be provided. The light shall comply with NFPA 79 requirements, have a protective shield, and provide maximum light to the work area. Lighting shall be LED and explosion proof.

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

3.4 Standard Tooling and Equipment. All standard tooling and equipment required for proper operation of the machine (such as special tools needed for maintenance) shall be furnished. A list of these items shall be furnished at time of proposal.

3.4.1Tooling and/or Required Accessories. All required tooling and accessories to be provided as required for operation of booths by the contractor and per this document.

3.5 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.

3.5.1 Lubrication Plate. A lubrication plate shall be permanently and securely attached to each machine. 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

3.5.2 Nameplate. A nameplate shall be permanently and securely attached to each machine. The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine 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) Contract Number Date of Manufacture

3.5.3 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 3.7.2 Nameplate.

3.6 Technical Data. Technical data shall contain technical information, specifications, instructions for the operation, maintenance of the machine, and recommended spare parts list. All copies of technical data shall be legible and written in the English language.

3.6.1 Manuals. Two (3) complete printed sets and one (1) electronic copy (CD-ROM) of the Blast Booth systems shall be provided to the TPOC. The manuals shall include the following:

a. Operation, Software, and Maintenance manuals shall be provided with delivery of the equipment. Documentation shall include at a minimum, operations, installation, maintenance, routine service schedule, calibration, preventive maintenance, lockout/tagout procedures, illustrated parts break down, recommended spare parts list including part numbers, vendor’s literature, mechanical design drawings, pneumatic schematics, and electrical/electronic schematics.

b. All original software manuals and registration keys/codes shall be provided, along with original software installation disks.

c. The maintenance procedures section of the technical manuals shall address procedures required for the corrections of faults occurring with each piece of equipment.

d. The manuals shall contain diagnostic procedures for isolating faults, correcting the faults, and replacing parts.

e. The technical manuals shall provide an engineering approach to the determination of preventive maintenance tasks. Preventive maintenance tasks shall be clearly outlined, with specified periods/cycles for performance of tasks.

f. Review by the Government of all technical data and manuals furnished will be accomplished during the Contract Quality Assurance Inspection (Origin) at the contractor's facility (see 4.2). Final manuals are due at completion of installation of the equipment.

3.6.2 Plan of Action and Milestones (POA&M). The contractor shall provide a Plan of Action and Milestones (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 at the time of proposal. The milestones shall be prepared 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 must be approved in advance by the Government. The POA&M shall detail such items as system design concept, system development, software design concept, software development, engineering, procurement of major hardware, assembly, operational debug, factory acceptance, shipment, installation, training, and final acceptance test.

3.6.3 Control of Hazardous Energy (Lockout/Tagout) Procedures. A written procedure for locking out all energy sources shall be provided by the contractor in accordance with 29 CFR

1910.147. The contractor shall submit draft copies to the Government in accordance with the contractor submitted and Government approved Plan of Action and Milestones (Section 3.8.5) and final copies are due at start of equipment installation. The contractor shall provide an electronic copy of the procedure in Microsoft Word to the Government as well as include the procedure in the technical manuals.

3.6.4 Instrument and Calibration Procedures. Calibration procedures and/or tooling requiring operator verification or recalibration as part of a production run or on a daily or periodic basis shall be provided to the Government.. The contractor shall provide and comply to the following items listed below:

a. The contractor shall provide a list of calibration procedures and/or tooling at the time of proposal.

b. All instruments provided shall have a certificate of calibration traceable to the National Institute of Standards and Technology (NIST).

c. The calibration procedure shall be formatted in accordance with NAVAIR 17-35TR-04.

d. An example calibration procedure will be provided by the Government at the request of the contractor. Government calibration personnel will advise the contractor in producing a suitable calibration procedure. A first draft calibration procedure shall be provided to the Government at the time of installation.

e. At the completion of installation, an initial calibration and verification shall be performed by the contractor with the inclusion and hands-on involvement of Government calibration personnel. During this initial calibration and verification, the Government shall provide comments and change recommendations related to the calibration procedure to the contractors.

f. A final calibration procedure shall be provided to the Government within one (1) week after final acceptance of the equipment.

3.6.5 Acceptance Test Plan (ATP). The contractor shall prepare an acceptance test plan for inspecting and a test plan for the Blast Booth. The ATP shall be a step-by-step written instruction on how to verify compliance during Contract Quality Assurance Inspection and the Final Inspection/Acceptance Test specified in Sections 4.4 and 4.5. Acceptance test plan shall include a minimum of Qty (2) Design Reviews that shall be scheduled and approved prior to acceptance.

The Manufacture’s standard testing procedures shall be included in the ATP. The ATP shall include any procedures necessary for compliance with Sections 4.4 and 4.5 that are 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 approved ATP shall become part of the contract.

3.6.6 Joint Design Review. The purpose of the Joint Design Review shall be to review and comment on the contractor's proposed solutions. The initial Joint Design Review shall be conducted 45 days after post award conference. Reviews are not approvals and are no way binding to the Government. However, it is in the best interest of the Government and the contractor to review the work periodically. They shall be conducted when deemed necessary by either the Government or the contractor. Acceptance of the equipment shall only be obtained through meeting the requirements of Section 4.0 of this specification.

3.6.7 Equipment Drawings. The Contractors proposal shall be provided with dimensioned equipment drawings in both a .PDF file and CAD file compatible with AutoCAD 2015 edition.

The dimensioned CAD file shall be drawn to actual size and show footprint and any manufacturer’s special foundation requirements of new equipment to include ancillary pieces, utility connection points, access doors and required maintenance clearance dimensions. The CAD file shall show side and elevation views.

3.7 Installation. Contractor shall be responsible for all equipment (forklifts, man lifts, etc.) and qualified personnel required for unloading, rigging, installation, anchoring, connecting machine to utilities, and leveling the machine in place. The Contractor shall provide the necessary leveling device and related hardware to secure machine components to the foundation.

Contractor shall also be responsible for the Installation Responsibilities as follows:

a. Furnish labor and material handling equipment for off-loading and placing items on foundation.

b. Provide and install anchor bolts and nuts.

c. Set and rough mount blast booth to foundation.

d. Connect machine to the provided utilities connection point within 35 ft. of the machines.

e. Provide all necessary tools, gages, and instrumentation necessary to perform the required tests.

f. Provide and charge all systems with fluids in accordance with manufacturer's instructions.

g. Material for performance testing at Government facility and Contractor’s facility.

h. Material handling, Rigging equipment and Qualified Personnel for performance testing.

Contractor shall be responsible for reading, understanding, and complying with Government facility requirements and contract Performance Requirements. The Contractor shall not transport loads across any mezzanine or building roof without prior approval of a contractor supplied rigging plan by contacting the FRC East PM.

No work shall be performed by customer personnel when the contractor's representative is not in the immediate work area during installation, verification, and initial start-up of the machine.

3.7.1 Verification. The meaning of verification for the purpose of this contract is to assure that the items installed and/or connected by Government personnel are correct.

3.7.2 Field Supervisor. The Contractor shall provide a full-time field supervisor to direct installation and testing of the supplies from start of installation to final acceptance. The field supervisor shall be capable of reading, writing, and conversing fluently in the English language.

The field supervisor shall have full authority to implement field decisions expeditiously. No work shall be accomplished when the field supervisor is not in the immediate work area. The field supervisor shall be identified to the receiving activity prior to the start of installation. The field supervisor shall be responsible for coordinating with the receiving activity for any security clearances for all contractor personnel expected to perform on-site work. The receiving activity Government Point of Contact shall be notified of any change in personnel performing this duty.

3.7.3 Site Preparation and Installation Plan. The contractor shall provide clear and concise site preparation and installation plan. The plan shall include a detailed description of all installation work, a detailed site layout, general equipment specifications (i.e. size, weight, etc.), any required structural modification or additions, utility requirements and location, pertinent electrical details, and any other details required for site preparation and layout. The plan shall be based on a working schedule of normal business hours (6:00 AM-3:30 PM Monday-Thursday), excluding Government holidays. As part of the site preparation and installation plan the contractor shall include facilities preparation instructions, including detailed information concerning any equipment that applies a load to a facility structure, wall, or roof. The site preparation plan shall be submitted at least 60 days prior to installation for review and approval.

3.7.4 Compressed Air Connection. CFM is CFM at standard conditions. The standard conditions of air are defined as 60 degrees Fahrenheit, 14.7 PSIA and relative humidity of zero.

The piping installation shall meet or exceed the current Department of Defense construction criteria as defined in UFC 1-200-01. Contractor shall provide color code marking of piping/tubing conforming to ASME A13.1.