Attachment 0001 - RIPD E4000-19-1-03 Coating Modernization.pdf

ROCK ISLAND ARSENAL RIPD: E4000-19-1-03

PURCHASE DESCRIPTION DATE: 29-April-2022

COATING MODERNIZATION

1. GENERAL SYSTEM DESCRIPTION

2. STANDARDS AND PUBLICATIONS

2.1 Clarification

2.2 National Standards and Specifications

3. DESIGN

3.1 Ownership

3.2 General Design Standards

3.3 Safety, Security and Environmental

3.4 Responsibilities

4. COMPONENT SPECIFICATION

4.1 Design (Current Prime/ Paint Line):

4.2 Design (New Batch Line)

4.3 Dimensions:

5. CLIN 001 Prime/Paint Line Oven

5.1 Convection Cure Oven

5.2 Conveyor Turns

6. CLIN 002 New Batch Line

6.1 Design for Cure Oven

6.2 Cure Oven

6.3 Paint Booth

6.4 Manual Pull Trolley Line

6.5 PLC Control

6.6 CLIN 003 Second Cure Oven

6.7 CLIN 004 Proportioning Equipment .............................. Error! Bookmark not defined.

7. APPROVAL/SHIPPING

7.1 Shipping

7.2 Installation

7.3 Completion

8. TRAINING

8.1 Schedule

8.2 Location

8.3 Type

9. SERVICE

9.1 Service/Support Requirements

1. GENERAL SYSTEM DESCRIPTION

This project is for a turn-key modernization effort of the paint department in Bldg. 208. This project entails the provision of a cure oven extension on to our current chain line as well as the removal of our old chain line and the design/ install of a turn-key batch line. This batch line is to include a paint booth, two cure ovens, and a manual trolley line to include an operator load / unload station as well as a staging area where parts can wait in standby.

2. STANDARDS AND PUBLICATIONS

2.1 Clarification

Any ambiguities, questions, requests for clarification or discrepancies between sections of this purchase description, drawings, national or industry standards discovered by the contractor in reviewing this purchase description shall be reported by the bidder in writing to the contracting officer BEFORE THE DATE SCHEDULED FOR CLOSE OF BIDDING/receipt of proposal.

Submission of a proposal or bid shall be construed as evidence that such examination has been made. Therefore, later claims for labor, material, or equipment required, or for difficulties encountered, which could have been foreseen had such reasonable examination been made, may be denied.

2.2 National Standards and Specifications

The following specifications in effect on the Date of Invitation for Bid/Request for Proposal form a part of this purchase description. In the case of conflicting requirements, the more stringent shall apply.

2.2.1 Occupational Safety and Health Act of 1970 (OSHA).

2.2.2 American Society of Testing and Materials (ASTM).

2.2.3 American Society of Mechanical Engineers (ASME).

2.2.4 American National Standards Institute (ANSI).

2.2.5 National Electrical Manufacturers Association Standards (NEMA).

2.2.6 Electronic Industries Association (EIA).

2.2.7 Institute of Electrical and Electronics Engineers (IEEE).

2.2.8 American Code for Information Exchange (ASCII).

2.2.9 American Welding Society (AWS).

2.2.10 American Gear Manufacturers Association (AGMA).

2.2.11 National Fire Protection Association (NFPA).

2.2.11.1 NFPA-70 National Electrical Code

2.2.11.2 NFPA-79 Electrical Standard for Industrial Machinery.

2.2.12 International Standards Organization (ISO).

3. DESIGN

3.1 Ownership

3.1.1 This equipment a custom designed system and is to be designed for use by the Rock

Island Arsenal by the supplier.

3.2 General Design Standards

3.2.1 DEVIATION FROM PRODUCT: Modifications to the manufacturer’s standard design to achieve require

3.2.2 Cements as specified in this document are only permissible as dictated by good design practice. For example, mounting a 20-hp motor in a power train designed and normally using a

10-hp motor would not be acceptable.

3.2.3 UNITS OF MEASURE: Dimensions and capacities in this purchase description are given in the English-US (in-lb) system. All dials, gauges, and drawings shall be in the English-

US system or both the English-US and the metric systems, unless otherwise specified in this document.

3.2.4 ID DATA PLATE: The equipment shall include a main data plate which will include the following data as a minimum requirement (additional information is acceptable):

Manufacturer Name, Manufacturer’s Dunns and Bradstreet Number, Manufacturer’s Model

Number, Manufacturer’s Serial Number, Year of Manufacture, Contract Number, Machine

Weight. This information is necessary for compliance with the governments Unique

Identification Program (UID).

3.2.5 DATA PLATES: All instruction, data, and identification plates and labels attached to this equipment and its controls shall be manufactured of corrosion and oil resistant metal or plastic material. All wording shall be in the English language using plain, bold face lettering.

Lettering shall be permanent and have a contrasting background.

3.2.6 ITEM UNIQUE IDENTIFICATION (IUID) REGISTRATION: The contractor shall register the equipment in the IUID Registry (as one single system). IUID registration requires the contractor to input Cage Code, Model Number, and Serial Number into a Government

Database to allow for asset and inventory tracking. IUID Registry of the equipment shall be performed at http://dodprocurementtoolbox.com/site/uidregistry/. Training for IUID is available in https://wawftraining.eb.mil. IUID registration of this equipment is required prior to final payment in the Wide Area Work Flow (WAWF). The contractor shall also affix a machine readable 2-dimensional (2-D) matrix representing the IUID registry to the machine. The IUID

2-D matrix may be included on the ID Data Plate outlined in paragraph 3.2.4.

3.2.7 UTILITY CONNECTION: Equipment supplied to the Rock Island Arsenal will have single point shut-off for each utility supplied to a system. This means that equipment constituting a single system shall be wired to a single main electrical disconnect point, plumbed to a single pneumatic shut-off valve, etc… This will be referred to as the “point of first connection”. Each type of power source may have only one point of first connection. E.g. (1) pneumatic shut-off valve, (1) water supply shut-off valve, (1) electrical disconnect, etc… Each point of first connection shall be clearly labeled on the system and shown in the safety lockout portion of the documentation package. These points must be located on a stationary component http://dodprocurementtoolbox.com/site/uidregistry/ https://wawftraining.eb.mil/ and positioned such that they will not create a hazard to personnel during normal operation of the system. The first connection points shall be accessible from the shop floor without the use of ladders, steps, or stools. Access cannot be hampered by operation of the system.

3.2.8 UTILITY CONNECTION LABOR: Rock Island Arsenal shall provide only such labor and materials as will be needed to connect facility utilities to each point of first connection of the system. The supplier will be responsible for all connections beyond the point of first connection for each utility.

3.2.9 UTILITIES AVAILABLE: Rock Island Arsenal shall be responsible for providing the following:

3.2.9.1 Connection of 460-V, 60-Hz, 3-Ph AC electrical power to the fused or breaker type disconnect switch required in the ELECTRICAL DISCONNECT paragraph of this purchase description. Connection does not include filters, surge protection, or any peripheral equipment necessary to make the equipment functional.

3.2.9.2 Connection of approximately 80-psi compressed air to a single point for each system, if needed. Connection does not include filters, dryers, or any peripheral equipment necessary to make the equipment functional.

3.2.9.3 Connection of approximately 65-psi water to a single point for each system, if needed. Connection does not include filters or any peripheral equipment necessary to make the equipment functional. If water is required, the contractor shall be responsible for installing a back-flow limiting device sufficient to prevent possible contamination of the water system. This is necessary to maintain IEPA compliance.

3.2.9.4 Connection of 1.5-in diameter natural gas pipe to a single point for each system, if needed. Connection does not include filters or any peripheral equipment necessary to make the equipment functional.

3.2.9.5 If, due to contractor caused problems, the equipment or components of the equipment must be moved or removed and replaced, by RIA after initial placement, the contractor shall be billed for such work at current RIA labor and overhead rates.

3.2.10 ELECTRICAL DISCONNECT: The equipment shall be equipped with a manual, fused or breaker type disconnect switch, readily accessible to the operator, which will deactivate the entire equipment. It shall be located no more than 6-ft 7-in from the floor to the highest point the control device. It shall be capable of being locked in the de-energized state (OFF) only.

3.2.11 CONDUIT: Flexible conduit is not permitted in exposed areas. All wires, cables, and hoses will be enclosed by rigid, oil-proof protection, except where flexibility is necessary for operation of the equipment. Flexible wires, cables and hoses shall be arranged to prevent draping or tripping hazards.

3.2.12 SERVICE ACCESS: Components subject to periodic adjustment, replacement, or servicing shall be readily accessible. Meaning that experienced personnel can access the part after no more than 30-min of labor. If any special tools or equipment are necessary to access these components, said equipment will be supplied as part of the system and provided with a proper storage location within the system.

3.2.13 DEFLECTION: The system shall recover from distortion and deflection at no load. The machine and its components shall be sufficiently rigid that work piece finish and tolerances are not impaired by machine vibration.

3.2.14 NEW EQUIPMENT: The equipment furnished under this purchase description shall be new and unused.

3.2.15 COMPONENT ENVIRONMENT: Under no circumstances shall a component be used in an application not recommended by the component manufacturer. Components shall not be subjected to conditions of operation beyond the recommendations of the manufacturer, such as excessive heat, lack of lubrication, over-loading.

3.2.16 REPLACEMENT COMPONENTS: All replaceable components shall be manufactured to definite standards for tolerance, clearance, and finish, enabling components to be field installed without further machining.

3.2.17 CASTINGS AND FORGINGS: All castings and forgings shall be free of defects, scale, and mismatching. No process such as welding, peening, plugging, or filling shall be used for reclaiming any defective part for use in this equipment without the prior written consent of the contracting officer.

3.2.18 SURFACE BUILDING AND COATINGS: Welding, brazing, soldering, coating or plating shall be employed only where specified in the original design. These operations may not be employed as a means of reclaiming a defective part.

3.2.19 FASTENING DEVICES: All screws, pins, bolts, and similar parts shall be installed in such a manner as to prevent change in tightness. Those devices subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently deformed. They shall not be installed using permanent bonding adhesives.

3.2.20 CLEANING AND DEBURRING: All surfaces of castings, forgings, molded parts, stampings, and welded components shall be cleaned and free from sand, dirt, fins, flash, scale, flux, and other harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. Except as specified herein, the condition and finish of all surfaces shall be commensurate with the manufacturer’s commercial practice.

3.2.21 PAINTING: All unfinished surfaces of the equipment shall be painted with a lead free and chromium free commercial grade of metal primer and a minimum of one finish coat. The color shall be in accordance with the manufacturer’s standard commercial practice, or as necessary to maintain compliance with OSHA regulations, as applicable.

3.2.22 LUBRICATION: Components specified as requiring lubrication by the original manufacturer shall have an appropriate means of providing said lubrication included in the design of the machine.

3.2.22.1 The lubrication points will be labeled on the lubrication drawing provided as part of the maintenance documentation and will also be labeled on the machine at the lubrication point and on any access panel covering the lubrication point. These labels will include as a minimum standard, the specific type of lubricant, the quantity to be used, the frequency for change, and the maintenance manual reference for detailed instructions. The lettering shall be

English and the units shall be English standard (i.e. pints, quarts, and gallons)

3.2.22.2 If an automatic circulation system is used, it shall be complete, including, but not limited to the following: reservoir, valves, nozzles, filters, pumps, sight gages, and other components as necessary to make the system completely functional.

3.2.22.2.1 A system allowing blockages or inadequacies to go undetected is unacceptable. The system shall be interlocked to the machine control, providing an alarm that lubrication failure has occurred. The system shall not initiate immediate shutdown of the affected function during a cutting cycle. It shall allow completion of the cycle and shutdown in an orderly sequence.

3.2.22.2.2 The reservoir shall be sized to allow no less than 80-hrs of machine run time before requiring refill. It shall also have a means provided for draining and cleaning. A means shall be provided to enable the operator to determine the fluid level.

3.2.22.2.3 All filters shall be either cleanable or replaceable.

3.2.22.2.4 All pumps shall be self-priming.

3.2.23 FILTRATION/REGULATION: Equipment requiring filtered or regulated energy sources shall be supplied with the components necessary to perform this function. E.g. the equipment shall be supplied with a Filter, Regulator, Lubricator (FRL) device, if filtered, lubricated, regulated pressurized air is required for the efficient, proper operation of the equipment. These devices shall be located on the equipment side of the lockout devices at the points of first connections.

3.2.23.1 Equipment which requires compressed air shall have a regenerative type desiccant or refrigerated compressed air dryer capable of drying air down to 35°F pressure dew point, minimum, from air entering the equipment at 110°F, and capable of supplying air to the rated standard cubic feet per minute (SCFM) of the equipment. The unit shall purge condensate automatically. In the case of the latter, the refrigerant used shall not be a Class I or Class II, ozone depleting substance. The air dryer shall be connected and/or piped to the equipment by the contractor.

3.2.23.2 Equipment which requires a high quality constant power source shall have proper isolation and/or power conditioning equipment for the power service designated in this description. All electrical equipment shall have a power factor (ratio of real power to apparent power) of no less than 80%, as read at the equipment main disconnect. Equipment with a power factor of less than 80% shall be fitted with suitable power factor correction capacitance, sized on the basis of the equipment inductive AC load.

3.2.23.3 All pumps shall be self-priming.

3.2.24 MOTORS:

3.2.24.1 All motors shall be rated for continuous duty.

3.2.24.2 Motors shall not operate in an overload condition during normal operation of the equipment and shall be equipped with overload protection.

3.2.24.3 Each motor shall bear an identification plate containing the identity of the manufacturer, model number, serial number, input voltage, amperage, horsepower, phase, frequency, duty cycle, and frame size or mounting identification.

3.2.24.4 Motor starters and controls shall operate at no greater than 120-VAC. It is preferred that they operate at 24-VDC.

3.2.24.5 Motor starters shall provide drop-out protection. This means that, in the event of a loss of power, the equipment shall be re-energized only by the deliberate action of the operator. Manual or mechanical motor starters shall not be deemed acceptable.

3.2.25 DIALS AND GAUGES: All scales, dials, and gauges shall be manufactured of corrosion and oil resistant material. All wording shall be in the English language using plain, bold face lettering. Lettering shall be permanent and have a contrasting background.

3.2.26 HANDWHEELS: Hand-wheels turned in a clockwise rotation shall produce a linear motion, of the controlled component, to the right, away, or upwards. If rotary motion is produced by the hand-wheel, clockwise rotation of the hand-wheel shall produce clockwise movement of the controlled component.

3.2.27 CONTROL LEVERS: Control levers shall move in the same direction as the motion of the controlled component.

3.2.28 FOUNDATION: The requirement for a separate foundation is permissible, if necessary to meet the specified alignment tolerances, to provide isolation, or to conform to a standard system configuration. The contractor shall describe the foundation requirements at the time of bid. RIA-JMTC shall be responsible for installation of the foundation based upon the drawings provided by the vendor.

3.3 Safety, Security and Environmental

3.3.1 SECURITY: The RIA-JMTC is an Army installation subject to Department of Defense safeguards, various precautions, and plant protection measures. All of the below requirements will be necessary of contractors visiting RIA to satisfy requirements of this purchase description; Additional requirements will be placed on contractors requiring access to the Army

Network, or Common Access Card (CAC), as specifically detailed below. At all times during the execution of this work, contractor personnel will maintain adequate plant protection devises to minimize espionage, sabotage, and other malicious destruction and damage. The contractor shall comply with all security requirements of the Rock Island Arsenal. Rock Island Arsenal island-wide Force Protection levels may be adjusted/changed at any time, which may cause possible delays and will directly affect procedures for accessing the island.

3.3.1.1 Access and General Protection/Security Policy and Procedures: The contractor and any associated subcontractor employees shall provide all information required for background checks to meet installation access requirements to be accomplished by the installation Director of Emergency Services. All contractor employees must comply with all personal identity verification requirements (IAW FAR clause 52.204-9) as directed by

Department of Defense (DoD), Headquarters Department of the Army (HQDA), and any local policy. If the Force Protection Condition (FPCON) changes, the Government may require changes in contractor installation access, security matters, or security processes.

3.3.1.1.1 Access to RIA: Contractor and all subcontractor employees performing work at

RIA shall comply with adjudication standards and procedures using the National Crime

Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening

Database (TSDB) and any applicable installation, facility access screening and local security policies and procedures. The COR shall provide guidance to complete the

Access Control Records Check request Form though the Rock Island Arsenal Directorate of Emergency Services.

3.3.1.1.2 Random Antiterrorist Measures Program (RAMP) participation: Contractor personnel are subject to RAMP security program (i.e. vehicle searches, wearing of ID badges, etc.). Contractor shall comply with any, and all instructions issued by the Rock

Island Arsenal Police Department. The RAMP is discussed in the RIA-JMTC Anti-

Terrorism Training.

3.3.1.1.3 During FPCONs levels of Charlie or Delta, services may be discontinued/postponed due to a higher National or local security threat. Services will resume when FPCON Level is reduced to Bravo, or lower. FPCON levels are described in Anti-Terrorism Level I Training.

3.3.1.1.4 Contractor personnel shall return all Installation Badges and access passes as soon as possible prior to contract completion. RIA-JMTC electronic keys and access passes are accountable items, shad shall be returned within 24-hours of no longer being needed. Items will be returned to the COR, or paced in a drop box at a RIA-JMTC access point.

3.3.1.2 Security Training: The contractor shall complete the following training:

3.3.1.2.1 Anti-Terrorism, Level I: All contractor employees, including subcontractor employees, requiring access to Army installations, facilities, or controlled access areas shall complete Anti-Terrorism (AT) Level I Awareness training. The COR will be provided a copy of the Rock Island Arsenal –Joint Manufacturing and Technology Center

(RIA-JMTC) AT Level I Awareness Training and assure that the training is complete.

The contractor shall sign a memorandum of record for each contractor employees and subcontractor employee to the RIA-JMTC Operations Center prior issuing any electronic keys, or access pass being authorized.

3.3.1.2.2 iWatch (See Something, Say Something) Training: The Contractor and all associated subcontractors shall complete iWatch Training. iWatch Training shall be provided during the Anti-Terrorism Training.

3.3.1.3 For Contractors requiring Common Access Card (CAC): Before CAC issuance, the contractor employee requires a favorably adjudicated National Agency Check with Inquiries

(NACI) or an equivalent or higher investigation in accordance with Army Directive 2014-05.

The contractor employee will be issued a CAC only if duties involve one of the following:

(1) Both physical access to a DoD facility and access, via logon, to DoD networks onsite, or remotely or (2) Remote access via logon, to a DoD network using DoD-approved remote access procedures, or (3) Physical access to multiple DoD facilities or multiple Non-DoD

Federally controlled facilities on behalf of the DoD on a recurring basis for a period of 6-months, or more. At the discretion of the sponsoring activity, an initial CAC may be issued based on a favorable review of the FBI fingerprint check and a successfully scheduled NACI at the Office of Personnel Management. Contractors needing a NACI or equivalent investigation or higher investigation will coordinate this investigation through their COR.

Contractor personnel shall turn in CAC cards upon completion of their contractual obligations, or at the request by the COR, or at the request of the Contracting Officer.

3.3.2 FEDERAL MARIJUANA LAWS REMAIN UNCHANGED: Note: Rock Island

Arsenal is under the exclusive federal jurisdiction of the United States. Under federal law, marijuana is still defined as a Schedule I drug, and possession and use of marijuana is still illegal. Any person using or in possession of marijuana on Rock Island Arsenal may be criminally prosecuted in federal district court. In addition, such individuals may be permanently barred from entering Rock Island Arsenal.

3.3.3 REAL ID: Starting 01-Oct-2020 all personnel entering Rock Island Arsenal will be required to show a Real ID form of identification.

3.3.4 FIRE PREVENTION AND PROTECTION: The contractor shall comply with all fire prevention measures prescribed in the installation Fire Regulations, a copy of which is on file in the office of the Contracting Officer. A written fire permit shall be obtained from the installation

Fire Marshall for use of open flame devices, such as torches, portable furnaces, tar kettles, or gas and electric welding and cutting equipment, in, on, or within 15-ft of the building. The contractor shall be liable for any fire loss to the Government properly attributable to negligence on the part of the contractor, including failure to comp1y with fire prevention measure described by the terms of this purchase description.

3.3.5 INDUSTRY AND REGULATIONS: The equipment shall comply with the most current of all local, state, and federal laws and regulations listed in Standards and Publications.

3.3.6 MATERIAL EXCLUSIONS: The equipment shall not contain polychlorinated biphenyl

(PCB), ozone depleting substances (Class I or Class II), or asbestos materials.

3.3.7 SAFETY REGULATION COMPLIANCE: The contractor shall comply with standard

OSHA and RIA safety standards, including conforming to confined space work requirements when applicable.

3.3.8 SAFETY LOCKOUTS: Each point of first connection shall be designed and constructed to allow the utility to be completely isolated from the equipment. This isolation shall be insured by application of a standard key locking padlock. The device(s) shall only be lockable in the de-energized (OFF) condition.

3.3.9 LOSS OF PRESSURE: Hydraulic and pneumatic circuits shall be designed such that loss of pressure, or pressure surges, shall not cause a hazard. Means shall be provided to prevent operation of the equipment with insufficient pressure, if such operation could cause a hazard.

3.3.10 TRAPPED ENERGY: Means shall be provided for the controlled release of stored energy. This energy may be in the form of, but not limited to, air and hydraulic pressure accumulators, capacitors, springs, counter balances and flywheels. When appropriate, a label shall be affixed to the stored energy source to identify the hazard.

3.3.11 WORKING RANGE: Hydraulic and pneumatic components shall be selected, which cannot be adjusted outside the safe working range of the circuit and/or equipment.

3.3.12 ACCUMULATORS: Gas charged accumulators operating above 200-psi charging pressure shall be charged with inert gas.

3.3.13 BRAKES: Braking systems shall be designed to “fail-on”. This means, energy supplied to the brake shall be used to disengage the brake. Loss of energy shall therefore cause the brake to activate.

3.3.14 EMERGENCY STOP: The system will incorporate a clearly identified, red, mushroomed, control button with a yellow backing plate at every operator work station. Upon momentary operation, any emergency stop button shall de-energize all machine motions and override all other controls without creating additional hazards. All motion stopped shall be restarted by the deliberate action of the operator (requiring manual reset). No other red mushroomed buttons shall be allowed on the equipment. It is preferred that there is no other red buttons of any type.

3.3.15 CONTROL GUARDS: Controls shall be guarded against accidental operation.

3.3.16 OPERATOR REACH: Controls shall be within reach and located such that the operator, when in the normal operating position, is not required to reach past moving parts, which may cause injury.

3.4 Responsibilities

3.4.1 SITE INSPECTION: Any site inspections and/or measurements, which must be taken in order to determine the suitability of the proposed location or to perform the design of the system, are the sole responsibility of the contractor. This may begin prior to completing the bidding process. Rock Island Arsenal will support this function through the POC (point of contact) by guiding personnel, facilitating security registration, and providing general assistance. The contractor will be responsible for providing any and all equipment necessary for this process.

3.4.2 SITE CONDITIONS: Rock Island Arsenal will be responsible for additional costs incurred by unforeseen, but controllable manmade issues with the location of the system.

Examples would include, but are not limited to, buried sewer lines, standing water, and so forth.

The contractor will be responsible for all costs associated with correcting foreseeable conditions, including but not limited to low hanging electrical lines which are clearly visible, encountering rock during excavation, inclement weather, interference with established machines or structures by components not shown on the footprint drawing, etc.

4. COMPONENT SPECIFICATION

Equipment: The supplier shall furnish all equipment normally considered by him to be standard for his machine unless identified in this requirement to be of specific manufacture. The following equipment shall be provided in addition to the equipment specified in other sections of this purchase description, which may not be standard. The inclusion of standard equipment in this paragraph is inadvertent and should not be construed to allow duplication.

4.1 Design (Current Prime/ Paint Line):

4.1.1 Largest Part Size: 7’ W x 8’ H x 12’L

4.1.2 Largest Part Weight: 500lbs.

4.1.3 Profile Opening: 4’ W x 8’ H

4.1.4 Top of Conveyor to Top of Opening: 2’-6”

4.1.5 Top of Conveyor to Top of Part: 3’

4.1.6 Design Line Speed: 6 FPM (Variable)

4.1.7 Product Throughput: lbs / hr: 15000

4.1.8 Minutes in Oven: 8.9

4.1.9 Design Temperature: 400 degrees Fahrenheit (Part cure temp is 180-220 degrees

Fahrenheit)

4.1.10 Air Changes in Oven: 4.1 per minute

4.2 Design (New Batch Line)

4.2.1 Largest Part Size: 7’ W x 8’ H x 12’L

4.2.2 Largest Part Weight: 1000lbs

4.2.3 Profile Opening: 12’ W x 12’ H

4.2.4 Top of Conveyor to Top of Opening: 2’6”

4.2.5 Top of Conveyor to Top of Part: 3’

4.2.6 Design Line Speed: Manual

4.2.7 Product Throughput: 6 Carrier rigs/ Long parts / hr

4.2.8 Part Cure Temp: 180-220 degrees Fahrenheit for 30 min

4.3 Dimensions:

4.3.1 DOOR ACCESS: The equipment shall be shipped either assembled or disassembled to pass through a door 12-ft wide by 12-ft high, and shall not exceed 25-ft in length.

4.3.2 COMPONENT WEIGHT: The maximum weight of any one piece shall not exceed

25,000-lbs.

4.3.3 INSTALLED FLOORSPACE: The modifications to the current chain line shall stay within the footprint provided for the chain line. The new batch line must be confined within the remaining space usable once the old chain line has been removed.

5. CLIN 001 PRIME/PAINT LINE OVEN

5.1 Convection Cure Oven

5.1.1 DESIGN MODIFICATIONS: RIA-JMTC currently has a Prime/ Top Coat Paint Line with two overhead IR Ovens located above the respective paint booths. To resolve humidity and part curing issues, the contractor shall install an elevated gas-fired convection oven on the back-end of the process to assist with the curing of parts.

5.1.2 SIZE: The oven shall be no more than 26’ 6” W x 25’6” L x 14’ 6” H (not including burner box).

5.1.3 CIRCULATION: The convection cure oven shall have a high efficiency plug circulation fan. The fan shall have a 6” thick insulated plug. The fan shall have a CFM rate of at least

35,000 with static pressure at 2.5 inches. The plug fan size shall be DPF-440 or equivalent. The circulation fan shall include a soft start. All of the bearings, motor, and V-belt drives shall be mounted outside of the oven.

5.1.4 EXHAUST SYSTEM: The cure oven shall include an exhaust system that has a purge/ exhaust cfm rate of at least 2,613 or equivalent in order to produce a purge time of 15 minutes.

The exhaust shall be in the form of a Centrifugal exhaust fan Static Pressure shall be at 0.5”.

The exhaust system’s motor shall be at least 1.5 hp. The exhaust system shall include all components/ ductwork needed to integrate the system with the oven and rest of the environment. This may include but not be limited to elbows, transitions, exhaust stacks, roof collar with flashing and any required stack termination cap.

5.1.5 POWERED AIR SEAL: The cure oven shall have a powered air seal enclosure with a cfm rate of at least 5,000 and a velocity rate of at least 2,000 fpm. It shall be located at the product exit of the oven. It shall be installed with two (2) product openings to reduce heat escaping the oven. Each air seal shall be designed with a Plug Fan which captures the air in the enclosure and circulates it into the duct surrounding the outer product opening. The ductwork shall be designed with an adjustable air orifice to provide a pressurized airstream to create a seal inside the enclosure in order to reduce the amount of escaping heat. The motor horsepower shall be at least 3 hp.

5.1.6 CONSTRUCTION: The oven walls shall be constructed of dual 20-gauge aluminized steel panels that are 4” thick, with at least a 4-pound density constructed with mineral wool industrial insulation or equivalent. The 4” oven panels are to be covered with 2” thick mineral wool insulation and then skinned with corrugated metal. The oven roof shall be constructed of dual 20-gauge aluminized steel panels with 4” thick, at least 4-pound density, mineral wool industrial insulation or equivalent. The oven floor shall be constructed of dual 20-gauge aluminized steel panels with 4” thick, 4-pound density, and mineral wool industrial insulation or equivalent. All installations of the insulation will be firmly secured in a way to prevent settling to avoid an uninsulated space at the top of the panels. This will allow for minimum heat loss through the panel. All of the panel joints shall be filled with strip insulation and all corners shall be covered by a trim strip for safety and appearance. Structural steel shall be included where necessary to support the oven and other structures such as the conveyor and fans. The oven shall include an insulated personnel door with safety latches. The contractor shall provide and install an entrance vestibule with a gravity hood. All exhaust stacks, and any roof collar with flashing shall be provided by the contractor. To be equivalent means that the provided oven shall meet the performance, safety, and business best practice standards as the one listed in this section as well as meeting the desired appearance with the use of trim pieces etc.

5.1.7 BURNER BOX AND DUCTING: The plug fan shall be installed in a burner box constructed from 10-gauge hot rolled plate on the inside and the outside is covered with 20-gauge steel over mineral wool insulation or equivalent. The exterior walls shall be skinned with the same corrugated metal as the oven walls. The burner box shall be insulated using 6” thick, 6-pound density mineral wool industrial insulation or equivalent. The burner box shall include one (1) insulated access door for maintenance of the fan and burner. The oven shall include supply distribution ductwork that is connected to the discharge of the burner box. The oven shall include adjustable blades to provide a constant velocity of air to maximize curing. To be equivalent means that the provided oven shall meet the performance, safety, and business best practice standards as the one listed in this section.

5.1.8 HEATER: The oven shall have a gas burner. The burner shall have a U.V. Scanner and

Ignitor. The heater shall include a ¾” Pilot Style Gas Train to include all necessary shutoff cocks, regulators, gas pressure switches, motorized main gas valves, low gas pressure trim regulator, pre-assembled with nipples and unions.

5.1.9 CONTROLS: The burner shall have a flame safety controller as well as a high temperature limit controller. The burner shall have air flow switches on the exhaust and combustion blower. The burner shall have a temperature controlled PID Loop PLC. The controls shall include a fast acting thermocouple as well as a 6000 Volt ignition transformer modulating control or equivalent motor with a 4:20 MA rating.

5.1.10 ACCESS: The contractor shall be responsible for the fabrication and installation of a landing for access to the Oven Burner Box. The landing will have ladder access and include safety rails around the perimeter in accordance with safety regulations and industry best practices.

5.2 Conveyor Turns

The existing conveyor turns located after the current IR Heaters shall be replaced with (6) new turns rated for the new environment and shall tie-into the existing conveyor system. The turns shall be supported by either existing steel framing or by framing that is used to support the new cure oven being installed. 4 of these turns shall be located in the oven as well as replacing the (2) turns located on the lower tier of the line.

6. CLIN 002 NEW BATCH LINE

6.1 Design for Cure Oven

6.1.1 Air changes in Oven: 2.67 per minute

6.1.2 Design Temperature: 180 degrees Fahrenheit

6.1.3 Burner size: Appropriate burner for the system with a rating of 15,000-880,000 BTUs

6.1.4 Operating BTUs/Hr: 0.4 mbtu or equivalent

6.2 Cure Oven

6.2.1 OVEN SIZE: The convection cure oven shall not exceed 20’ W x 16’8” L x 13’ H (not including burner box). This is due to the constraints of the space allotted for this system.

6.2.2 CIRCULATION: The convection cure oven shall have a high efficiency plug circulation fan. The fan shall have a 6” thick insulated plug. The fan shall have a CFM rate of 10,000 with static pressure at 2.5 inches. The plug fan size shall be CPF-240 or equivalent. The circulation fan shall include a soft start. All of the bearings, motor, and V-belt drives shall be mounted outside of the oven.

6.2.3 EXHAUST SYSTEM: The cure oven shall include an exhaust system that has a purge/ exhaust cfm rate of at least 1,158 or equivalent in order to produce a purge time of 15 minutes.

The exhaust shall be in the form of a Centrifugal exhaust fan Static Pressure shall be at 0.5”.

The exhaust system’s motor shall be at least .75 hp. The exhaust system shall include all components/ ductwork needed to integrate the system with the oven and rest of the environment. This may include but not be limited to elbows, transitions, exhaust stacks, roof collar with flashing and any required stack termination cap.

6.2.4 CONSTRUCTION: The oven walls shall be constructed of dual 20-gauge aluminized steel panels that are 4” thick, with at least a 4-pound density constructed with mineral wool industrial insulation or equivalent. The 4” oven panels are to be covered with 2” thick mineral wool insulation and then skinned with corrugated metal. The oven roof shall be constructed of dual 20-gauge aluminized steel panels with 4” thick, at least 4-pound density, mineral wool industrial insulation or equivalent. The oven floor shall be constructed of dual 20-gauge aluminized steel panels with 4” thick, 4-pound density, and mineral wool industrial insulation or equivalent. All installations of the insulation will be firmly secured in a way to prevent settling to avoid an uninsulated space at the top of the panels. This will allow for minimum heat loss through the panel. All of the panel joints shall be filled with strip insulation and all corners shall be covered by a trim strip for safety and appearance. Structural steel shall be included where necessary to support the oven and other structures such as the conveyor and fans. The oven shall include an insulated product door with safety latches. The contractor shall provide and install an entrance vestibule with a gravity hood. All exhaust stacks, and any roof collar with flashing shall be provided by the contractor. To be equivalent means that the provided oven shall meet the performance, safety, and business best practice standards as the one listed in this section as well as meeting the desired appearance with the use of trim pieces etc. The oven shall be designed for explosion relief.

6.2.5 BURNER BOX AND DUCTING: The plug fan shall be installed in a burner box constructed from 10-gauge hot rolled plate on the inside and the outside is covered with 20-gauge steel over mineral wool insulation or equivalent. The exterior walls shall be skinned with the same corrugated metal as the oven walls. The burner box shall be insulated using 6” thick, 6-pound density mineral wool industrial insulation or equivalent. The burner box shall include one (1) insulated access door for maintenance of the fan and burner. The oven shall include supply distribution ductwork that is connected to the discharge of the burner box. The oven shall include adjustable blades to provide a constant velocity of air to maximize curing. To be equivalent means that the provided oven shall meet the performance, safety, and business best practice standards as the one listed in this section.

6.2.6 HEATER: The oven shall have a gas burner. The burner shall have a U.V. Scanner and

Ignitor. The heater shall include a ¾” Pilot Style Gas Train to include all necessary shutoff cocks, regulators, gas pressure switches, motorized main gas valves, low gas pressure trim regulator, pre-assembled with nipples and unions.

6.2.7 CONTROLS: The burner shall have a flame safety controller as well as a high temperature limit controller. The burner shall have air flow switches on the exhaust and combustion blower. The burner shall have a temperature controlled PID Loop PLC. The controls shall include a fast acting thermocouple as well as a 6000 Volt ignition transformer modulating control or equivalent motor with a 4:20 MA rating.

6.3 Paint Booth

6.3.1 DESIGN: The paint booth shall have inside dimensions of at least 20’-6” wide x 41’-8” deep. The end opening dimensions of the booth shall be 12’tall x 12’ wide. The design velocity of the system shall be 60 fpm. Due to the space allotted for this batch line, the exterior dimensions of the booth shall not be more than 30’10” W x 42’10” L x 16’2” H. The booth shall be a side downdraft style spray booth.

6.3.2 DRY BOOTH: The paint booth shall have 20” x 20” Pad type filters. All maintenance and cleaning shall be done from the front side of the booth with the filter media being designed for easy removal. The booth shall be equipped with a manometer mounted on the booth side wall panel to indicate pressure drop across the filters and will therefore indicate to the operators that the filters need to be changed.

6.3.3 INTAKE: The booth shall be equipped with a pressurized intake plenum that receives its air from a make-up air unit. The intake plenum shall consist of diffusion type air filters designed to evenly distribute supply air to the spray booth.

6.3.4 LIGHTING: The booth shall include LED lighting that is rated for paint booth environments. At minimum, they shall be vapor tight units certified by NFPA rated at Class 1, Division 2. The booth shall include 24 of these units or equivalent amount to provide sufficient lighting for the booth.

6.3.5 EXHAUST: The booth shall include an integrated exhaust system. There shall be included exhaust fans to connect to ventilation ductwork leading to the exterior of the building.

The exhaust air shall be filtered prior to passing through the fan. The CFM rating shall be determined by the contractor but will allow for the appropriate exhausting and air changeover within the booth while following all standards, codes, and business best practices. The system shall include a set of filters. The motor, drive and bearings shall be isolated from the exhaust air stream. The ventilations system shall produce sufficient air flow through the booth.. The exhaust system shall be driven by VFD motors/controls. These will be connected to the spray gun controls. When the spray guns are idle for an adjustable amount of time, the exhaust fans will reduce to a minimal speed to conserve energy.

6.3.6 MAKE-UP AIR: The booth shall include a make-up air system rated at a sufficient CFM and capable of up to a 90 degree temperature rise. CFM rating shall be determined by the contractor but shall conform to all applicable codes and safety standards as well as following business best practices. The unit shall be constructed of rust resistant material. It shall include a

V-bank filter section with 2” filter frames and cleanable filters. The unit shall include a natural gas burner designed for 5 psi input gas pressure with a BTU/HR rating of at least 223,423 up to at least 5,585,580 or equivalent range in order to meet the other performance specifications listed. The contractor shall be responsible for the provision of the intake hood with bird screen as well as low fire start and high gas pressure switch. The unit shall have a VFD with vent package. The air handler shall be ducted directly to the spray booth.

6.3.7 COATING: The booth shall be coated inside and outside. The inside of the booth shall be coated white to increase the effectiveness of the lighting within. The outside of booth shall be coated in order to prevent corrosion and enhance appearance of the booth.

6.3.8 VENTILATION: Intake vent air filters shall be rated by UL as Class 2 and EPA registered as environmentally safe. The filter shall be rated at no less than 98% efficient. A filter holding grid shall be provided by the vendor for each filter cell. This unit shall include one set of filters

6.3.9 MANOMETER: A manometer shall be provided with the unit to monitor the filter resistance and thereby the filter’s life and efficiency.

6.3.10 CONNECTION: The vendor shall be responsible for design, construction, and installation of ductwork necessary for safe and proper ventilation of the batch line in its entirety.

The vendor shall provide all labor and materials for this effort. This effort may include exhaust stacks, roof collars, flashing and any other components to make operation of the system safe and efficient.

6.4 Manual Pull Trolley Line

A manual overhead Enclosed Track Conveyor System with Overhead manual Cross-Transfers will be provided to move the product through the Spray Booth and the Batch Ovens. A Cross-

Transfer will be located before and after the Spray Booth and will provide transfer from the three

(3) tracks in the Spray Booth to the three (3) tracks in both ovens.

The manual pull trolley line shall be designed to accept wheeled mounts that carrier rigs can be mounted to. The Enclosed Track and Cross Transfer shall include floor mounted supports. The system of railing shall include space for an operator Load/Unload station to include a secondary staging location to store hanging carriers that are not in use at the time. The vision for this would be a length of trolley track parallel to that the operator load/ unload station. The main function for this would be to store spare wheeled trolley connectors, racks, parts awaiting secondary process such as taping etc. The trolley line shall be able to accommodate the designed part capacity of the batch line which is parts up to 12ft.

The wheeled mounts shall be 4-wheeled mounts with capacity to hold at least 1000lbs. A minimum of 42 of these wheeled mounts shall be provided as part of this project assuming that a

12ft part would require 2 of the 4-wheeled mounts to be stable, this would allow for 14 parts to be WIP and 7 to be being prepped/ offloaded etc. All turns/splits/ and connections of track shall be able to accommodate up to the full max part size and the 12ft carrier.

6.5 PLC Control

The system statuses shall be able to be viewed from a single control electrical cabinet. The panels shall be ETL certified. The control shall monitor the system and control the Motor starter soft starts, flame control packages with PID Temperature control. The cabinet shall include all components necessary for monitoring and controlling the system as well as following all applicable codes, standards, and business best practices for this type of equipment. The operator screen shall be used to display system managements and faults as well as any other useful information pertaining to the system. This includes but is not limited to, I/O inputs and Outputs etc.

The control shall provide the capability to read all of the operating temperatures of the ovens and the ability to input different temperature requirements as needed.

A flame controller shall be installed. The fuel fired equipment cannot be operated via a PLC however the PLC shall be used to monitor function.

6.6 CLIN 003 Second Cure Oven

The contractor shall be responsible for the provision, installation, and tie in of a second cure oven into the batch line system. The second cure oven shall follow the specifications outlined in section 6.1 and 6.2 along with all of the included sub sections. All additional overheard manual track as well as any other tie ins, material, and labor to tie in the second oven to the batch system shall be provided by the contractor.

7. APPROVAL/SHIPPING

7.1 Shipping

7.1.1 RESPONSIBILITY: The contractor is responsible for delivery of the equipment to the

Rock Island Arsenal. Adequate preserving of equipment surfaces, packing, marking, and skidding of materials for shipment shall be the responsibility of the contractor. If special lifting devices, such as hooks or eyes, are required for ease of handling, they shall be supplied with the equipment. Any special devices shall be returned to the contractor upon request only if they will not be required for future movement of the equipment, and at the contractor’s expense.

7.1.2 SHIPPING SCHEDULE: Be aware, the Rock Island Arsenal will only off-load equipment arriving between 6:00 am and 12:00 am (noon), local time on Mondays through

Thursdays except holidays. For information concerning holidays, the contractor should consult the contracting officer. There is no place to stage transporting vehicles awaiting the arrival of contractors. All equipment shall be delivered at the same time, meaning the same day (multiple trucks are acceptable) unless pre-authorized to deliver on multiple days by the RIA-JMTC contracting officer.

7.1.3 RECEIVER: All shipments to Rock Island Arsenal including installation tools and/or replacement parts, as well as the original shipment of the equipment, shall be marked “ATTN:

Mr. Robert McClure or Mr. Dave Holgorsen, TARA-IFF”. Items not correctly marked are subject to being returned at the vendor’s expense.

7.1.4 ARRIVAL INSPECTION: Upon receipt of equipment at Rock Island Arsenal, a preliminary inspection shall be performed to determine condition and/or count. This inspection shall be performed by Rock Island Arsenal personnel.

7.2 Installation

7.2.1 SITE PREPARATION REQUIREMENTS: The contractor shall be solely responsible for any necessary site inspections required for determining the specifications of work that must be completed prior to final system installation. The contractor will then provide detailed information of any preparation work that the vendor must perform prior to system installation to

Rock Island Arsenal.

7.2.2 PREPARATION EXECUTION SUPPORT: Rock Island Arsenal will support the preparation portion of the installation by providing utilities to the points of first connection.

7.2.3 LABOR AND MATERIAL: The supplier is solely responsible for providing all labor,…