Attachment 0001 - SOW-RIPD E4000-19-1-04 Wash Booth 299.pdf

ROCK ISLAND ARSENAL RIPD: E4000-19-1-04

PURCHASE DESCRIPTION DATE: 11-JAN-21

WASH BOOTH

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 Dimensions:

4.2 Part Capacity

4.3 Planned Operation

4.4 Spray Booth/Cabinet:

4.5 Water Recycling and Filtration System

4.6 Spray Equipment

4.7 Controls

5. APPROVAL/SHIPPING

5.1 Shipping

5.2 Installation

5.3 Testing

5.4 Completion

6. TRAINING

6.1 Schedule

6.2 Location

6.3 Type

7. SERVICE

7.1 Service/Support Requirements

1. GENERAL SYSTEM DESCRIPTION

The purpose of this turnkey project is to add an additional wash booth system with new equipment to RIA-JMTC’s current Paint Operations in Bldg. 299. The new equipment will be located in a common area with blasting and painting processes to facilitate lean manufacturing processes. The booth will be used to wash parts and weldments prior to painting and/ or prior to assembly. The system will be a turnkey project with the vendor solely responsible from design through installation and training except for responsibilities specifically identified in this purchase description as belonging to Rock Island Arsenal Joint Manufacturing and Technology Center

(RIA-JMTC).

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 is a standard product of the manufacturer and shall require either no change or minor design changes to meet requirements of these specifications. Therefore, ownership of the design will remain with the manufacturer.

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) http://dodprocurementtoolbox.com/site/uidregistry/ https://wawftraining.eb.mil/ 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 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 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.

3.2.22.1 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 HYDRAULICS: The system shall not include hydraulic equipment.

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 FOUNDATION: The requirement for a separate foundation or floor alteration is not permissible. The system shall be capable of being installed on an existing concrete floor without modification to the system or the floor, except for installation of anchor bolts. The existing floor is XX-in thick reinforced concrete.

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-2021 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.

3.3.17 AUDIBLE NOISE: The equipment noise level during normal operation shall not exceed

85-dbs, “A” scale. Tests shall be conducted around the entire equipment 60-in to 65-in above the floor within 3-ft of any major sound source. Metal removal equipment shall comply with the standard noise requirement while making a midrange horsepower cut on rigidly clamped mild steel. The contractor shall furnish shields, baffles, enclosures, or other devices necessary to bring the equipment into conformance. Any such device shall not interfere with the proper operation of the equipment and shall be designed to preserve the visibility necessary for safe operation of the system.

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 Dimensions:

4.1.1 DOOR ACCESS: The equipment shall be shipped either assembled or disassembled to pass through a door 14-ft wide by 14-ft high, and shall not exceed 25-ft in length.

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

25,000-lbs.

4.2 Part Capacity

4.2.1 MAXIMUM WORK ENVELOPE: The system shall be capable of processing components at least 12-ft wide x 35-ft long x 14-ft tall. The maximum weight of a single piece to be processed will be 40,000-lbs (20,000-lbs per axle) with a total payload capacity of 80,000-lb.

4.2.2 TEMPERATURE: The maximum temperature of the parts to be processed will be

150°F.

4.2.3 MATERIALS TO PROCESS: The primary material that will be processed through the system is steel from welding and machining operations. Other steel parts and possibly gray iron parts may be processed through this system. Refurbished parts from the field may be washed in this booth as well.

4.2.4 DUTY CYCLE: The system shall be designed to operate up to 16-hrs per day, 5-days per week. Actual part washing will be approximately 40-min of each hour.

4.3 Planned Operation

The intended service method for this unit will be equipment entering through the equipment access door. These parts will enter the room on a pallet carried by a forklift with up to a 10,000-lb payload capacity. Heavier parts will be mounted on a trailer or cart and towed/pushed into the room by a forklift (the cart would be included in the maximum work envelope listed above.

4.4 Spray Booth/Cabinet:

4.4.1 SIZE: The inside dimensions shall be at least 20-ft wide x 47-ft long x 18-ft tall. The outer dimensions of the booth shall be no larger than 28-ft wide x 50-ft long x 22-ft 8 inches tall.

4.4.2 SHELL CONSTRUCTION: The booth shall be constructed of at least 11-ga steel material or use I-beam support frame skinned with at least 18-ga steel. All exposed (wetted) surfaces shall be constructed of non-corrosive materials or shall be sufficiently protected to prevent corrosion. The floor surface shall be constructed of material designed to be non-slip when wet. The shell shall be designed with sufficient structure to support catwalks for equipment and personnel on top of the outside surface (roof) without significant sway or deflection. When assembled, the structure shall be such that there is less than 1-in of sway while under full load operation (normal loading). This shall be measured at the highest structural point on the system. Knee bracing inside the booth shall not be acceptable as it will reduce interior working envelope. External bracing is acceptable so long as the maximum outer dimensions are not exceeded. The roof shall include as a minimum catwalks and guard rails around the perimeter. Also catwalks and guard rails as necessary for maintenance of the system.

4.4.3 INTERIOR COLOR: The interior of the booth shall be colored white or have a highly reflective (non-dulling) surface to enhance the lighting.

4.4.4 DOORS: The booth shall include at least at least two man doors, one equipment access door, and any other doors necessary to meet OSHA and industry safety requirements.

4.4.4.1 Equipment Access Door Location: The equipment access door shall be centered on one short side of the booth.

4.4.4.2 Equipment Access Door Type: The equipment access door shall be a powered roll-up type.

4.4.4.3 Equipment Access Door Size: When open, the door shall have a clear and free opening at least 16-ft wise x 14.5-ft tall.

4.4.4.4 Equipment Access Door Seals: When closed the booth shall be water tight with channels designed to direct and materials away from the opening (water vapor discharge should be minimal due to ventilation and cooling system operation).

4.4.4.5 Equipment Access Door Controls: The equipment access door shall include a set of control buttons on the inside and a separate set of control buttons on the outside. There shall also be a hanging cord control for use by fork lift operators. The inside set of controls shall be located on the booth wall near the man-door at the access door end, the outside set of controls shall be located on the booth wall near the man-door at the access door end and such that the operator can see both the controls and the access door at the same time. The hanging cord control shall extend at least to the end of the ramp. The door shall include a timer that will prevent opening until all spraying has been inactive for time sufficient to clear the air of vapor. The timer shall be adjustable from zero to at least 5-minutes. This is to minimize the amount of vapor that escapes from the equipment access door. There shall be a labeled LED type light to indicate that the door control is active. (Note: spraying cannot begin when the door is open due to the interlock switches.)

4.4.4.6 Equipment Access Door Interlock: The equipment access door shall be interlocked with the spray equipment. This will prevent spraying while the equipment access door is open.

4.4.4.7 Man Door Locations: There shall be at least two man doors into the booth. One shall be located on the long sidewall near the equipment access end of the booth. The second door shall be on the opposite long side wall near the end of the booth opposite the equipment access door.

4.4.4.8 Man Door Interlocks: Each man door shall be interlocked with the spray equipment.

This will prevent spraying while a door is open. Therefore if spraying is in progress when a man door is opened, the equipment will stop but the ventilation equipment will continue to operate. Once the door is closed, the spraying equipment may be restarted.

4.4.4.9 Man Door Size: Each man door shall be at least 32-in wide x 82-in tall and meet all national and safety standards.

4.4.4.10 Panic Hardware: Each man door shall include panic hardware to allow operateors to evacuate the room. The doors shall NOT have key locks. This room shall be accessible at all times.

4.4.4.11 Man Door Windows: Each man door shall have a clear lexan viewing window at least 24-in x 24-in.

4.4.5 LIGHTS:

4.4.5.1 Lighting Type: The system shall include Fluorescent Light fixtures. The lights shall be appropriate for the environment inside the booth (high pressure hot water and vapor).

4.4.5.2 Locations: The fixtures shall be located on the ceiling and side walls of the booth.

This will provide at least 100-foot candles of light at 3-ft above the floor. Fixtures need to be located on both the ceiling and the walls to prevent significant shadowing by the work-piece or the operator(s).

4.4.5.3 Switch Locations: The system shall include 3-way switches next to each man door.

4.4.5.4 Emergency Lighting: The system shall include emergency lighting with battery back-up and lighted exit signs above each man door. The lighting shall be sufficient for an operator(s) wearing standard PPE (personal protective equipment) to safely exit the booth in the event of a power outage.

4.4.6 VENTILATION: The system shall be designed to maintain a safe and efficient operating environment.

4.4.6.1 Recirculation: Inlet air shall be drawn from inside the existing building, pass through the system and be returned to the inside of the building. Roof and wall penetrations shall not be allowed. Air may be recirculated up to in accordance with national health, hygiene, and safety regulations to allow better control of the inlet air properties. (Ref. ACGIH)

4.4.6.2 Velocity: The booth shall include baffled inlet and outlet plenums arranged to provide laminar air flow of at least 50-fpm. Note: Measured at all points within the work envelope with the booth empty.

4.4.6.3 Cooling: The booth shall have sufficient cooling to maintain a temperature range of

75°F ± 10°F assuming an inlet air temperature ranging from 65°F to 90°F. Note: Additional heating is not permitted for energy conservation.

4.4.6.4 Relative Humidity: The relative humidity of air being discharged back into the factory shall be within the range of 30% to 60%.

4.4.6.5 Efficiency: Filter efficiency shall be at least HEPA level (99.9% at 0.3-microns).

There shall also be a pre-filter to prevent the HEPA filter from becoming clogged with larger particulate.

4.4.7 HOIST BEAM: The booth shall include a monorail hoist beam and support structure with a 10-ton capacity. The beam shall be centered along the long axis of the booth and the length shall be from the inside front wall to within 1-ft of the ceiling slit (approximately 38ft long). The beam shall include removable trolley travel stops.

4.4.8 HOISTS AND TROLLEYS: The booth shall include (2) powered hoists and powered trolleys.

4.4.8.1 Capacity: Each hoist shall have a 5-ton capacity.

4.4.8.2 Power Source: The hoists and trolleys shall be air powered. Air distribution shall be through the use of retractable hose reels with tag lines. This will protect the air lines when not in active use. (Festooning is not acceptable.)

4.4.8.3 Lift Speed: The maximum lift speed shall be at least 7-fpm

4.4.8.4 Trolley Speed: The maximum trolley speed shall be at least 50-fpm

4.4.8.5 Hook Height Range: Each hoist shall be designed and installed to lift loads with a hook height of 6-in above the floor to the maximum hook height of at least 12-ft. The system shall include upper and lower air driven limit switches at end of travels.

4.4.9 RAMP: The ramp shall be a detachable unit that bolts to the main enclosure during normal operation. This will allow the ramp to be removed when necessary for access to the space behind the washing system. The ramp shall extend no more than 6-ft from the face of the booth/cabinet. The surface of the ramp shall be constructed of a non-slip material.

4.5 Water Recycling and Filtration System

4.5.1 GENERAL: The booth shall include a closed loop water filtering and recycling system.

There will be a water inlet, but there will be no sanitary sewer drain. This means that the system must recycle and continue to reuse water and only bring in make-up water. The system will consist of at least a trash filter screen, settling tank, coalescing tank, a staging tank, a media filtration system, a final absolute filter, a holding tank, and an ozone injection system. Media to be filtered includes, Hydraulic Fluid, Rocks, Metal Shavings, Lithium Grease etc. in large quantities.

4.5.2 BOOTH WATER COLLECTION: The filtration system will automatically start when water is present at the collection point. The system will actively remove water from the spray booth (to the filtration system) using a vacuum pump. Gravity only collection will not be acceptable. The inlet will include a screen to prevent clumps of particulate and trash from being drawn into the recycling system. The plumbing and screen must be sized to allow for proper flow to prevent starving the recycling system and to prevent flooding of the spray booth. The vendor shall determine the sizing of the mesh of the screen, but the openings may not exceed

1/8-in (this is a maximum but it may be smaller). If the vendor recommends smaller mesh to allow for proper support of the recycling system then they shall provide the smaller mesh.

4.5.3 SETTLING TANK: The system will include a settling tank for removal of large particulates. Water will come to the settling tank from the spray booth after passing through the trash screen.

4.5.3.1 Construction: The tank will be sized to allow proper settling of suspended solids.

Inclined plates shall be utilized to induce more rapid separation in a small area. The plates shall be easily removable and cleanable. The plates shall be designed to last the life of the recycling system. All wetted parts of the tank and plumbing shall be constructed of stainless steel (10-ga or thicker) with stainless steel and/or brass fittings (mild steel, iron, and PVC will not be acceptable). The tank shall be constructed to allow movement using a standard fork lift. (Note: may be mounted to a common skid with other tanks.)

4.5.3.2 Flow: Flow of water through the tank shall be laminar with a Reynolds Number less than or equal to 500.

4.5.3.3 Dwell: The dwell time shall be determined by the vendor, but in any case shall be at least 2-hrs in duration (meaning that if it is determined that the dwell time should be 3-hrs the vendor must provide this equipment, but if he determines that 1.5-hrs is sufficient the system must be upsized to provide 2-hrs of dwell time). It is the vendor’s responsibility to ensure that the system is sized appropriately.

4.5.3.4 Auto-Purge: Solids shall be directed to a collection system and automatically removed from the tank. The collection system shall gather the solids and use a “pinch valve” with an adjustable timer to purge the material from the tank. The pinch valve is required for its sealing properties and the speed. The material will be sent back to the spray booth where it will be collected in a bag filter.

4.5.3.5 Disposal: The bag filter will hold the solids while letting the water pass through back to the floor of the booth. When the bag filter is full it shall be manually disposed of by the operator(s).

4.5.4 COALESCING TANK: The system will include a coalescing tank with an oil/water separator and skimmer for removal of oils from the water. Water will come to the coalescing tank from the settling tank.

4.5.4.1 Construction: The tank will be sized to allow proper removal of oils. Water will pass through a cleanable coalescing material with at least 400-ft2 of surface area. The material shall be designed to last the life of the recycling system. The configuration of the material shall not have horizontal surfaces or pockets that will allow oil to become trapped. All wetted parts of the tank and plumbing shall be constructed of stainless steel (10-ga or thicker) with stainless steel and/or brass fittings (mild steel, iron, and PVC will not be acceptable). The tank shall be constructed to allow movement using a standard fork lift. (Note: may be mounted to a common skid with other tanks.)

4.5.4.2 Flow: Flow of water through the tank shall be laminar with a Reynolds Number less than or equal to 500.

4.5.4.3 Oil/Water Seperator: As the oil coalesces it will float to the surface where it will be accumulated using a separator and removed by a high efficiency skimmer. The skimmer will include an adjustable timer and will remove the oil from the tank to a removable collection container (a bucket). Periodically the operator(s) will dump the removable container into the

RIA-JMTC oil recycling collection point. Water will pass to the next tank by way of an under-current stainless steel weir system that will allow water to pass beneath a barrier (while holding back the oil floating on the surface prior to skimming). The weir shall be adjustable.

4.5.5 STAGING TANK: The system will include a staging tank that will accumulate water until there is sufficient volume to efficiently push through the media filter while maintaining the life and efficiency of the pump system. Water will come to the staging tank from the coalescing tank. All wetted parts of the tank and plumbing shall be constructed of stainless steel (10-ga or thicker) with stainless steel and/or brass fittings (mild steel, iron, and PVC will not be acceptable). The tank shall be constructed to allow movement using a standard fork lift. (Note:

may be mounted to a common skid with other tanks.) While it is the responsibility of the vendor to properly design the size of the tank, it shall be at least 85-gal. If the vendor determines that the tank must be larger for efficient operation of the system provided, then he shall provide an appropriately sized tank, but in any case it may not be smaller than indicated above. This tank will also allow a delay in water going to the media filter during the backflush process.

4.5.6 MEDIA FILTER: The system will include a high pressure media filtration vessel to remove suspended solids, heavy metals, hydrocarbons, and conversion of ammonia and nitrogen to safe materials. Water will come to the filter vessel from the staging tank.

4.5.6.1 Construction: The vessel shall be constructed of materials rated for use with pH levels ranging from 2 to 11. The vessel shall be rated to withstand pressures up to 170-psi with wide ranges of slow pressure fluctuations. The flow of water shall pass from the top of the vessel, through the media, and exit at the bottom of the vessel (bottom-up flow is not acceptable).

The vessel shall be designed with an access port in the top to allow for loading of new media, unloading of expended media, and for triple rinsing at the end of the systems life (This will prevent the need to cut up the tank for disposal). The vessel shall be constructed to allow movement using a standard fork lift.

4.5.6.2 Media: The 750-lb or larger filter vessel shall include at least (3) types of media:

small gravel, sand, and Zeolite. The system shall be sized and designed so that the media will have a life expectancy of at least 2-yrs before needing replacement. This vessel shall filter out all particulates (solids) 20-microns or larger.

4.5.6.3 Auto-Backflush: The system shall include an adjustable timer to automatically backflush the media filter. During the backflush cycle no water will come from the staging tank. Water will be pushed from the bottom of the tank and removed near the top of the tank.

The “dirty” water will be returned to the spray booth through the bag filters.

4.5.7 ABSOLUTE FINAL FILTER: The system shall include a final absolute oil absorbing particulate filter that will remove solids 5-microns or larger before the water is discharged into the holding tank. This filter will protect the downstream high pressure pumps. Since this filter will become clogged with small particles and will catch any residual oil it will be a disposable filter. This must include easy access for scheduled maintenance to replace (difficult access means that it won’t get changed as often as necessary). The absolute filter system shall include a monitor to notify the operator(s) when the pressure differential is great enough to require the filter to be changed. The system shall be designed to shut-down prior to failure of the filter to prevent damage to other components. The system shall include at least one spare set of disposable filters and any additional filters necessary for 2000-hrs of planned usage.

4.5.8 HOLDING TANK: The holding tank shall receive water from the absolute final filter and from the “point of first connection” for house water. The holding tank shall be the source for water being sprayed. This tank will include a level detection feature with an auto-fill to add make-up water as necessary to balance loss due to evaporation and due to water leaving on cleaned parts. The water inlet shall include a back-flow preventer (to be supplied by the

Contractor). The tank shall have at least a 500-gal capacity and the complete water system shall have at least an 800-gal capacity to minimize fluctuation in chemistry. All wetted parts of the tank and plumbing shall be constructed of stainless steel (10-ga or thicker) with stainless steel and/or brass fittings (mild steel, iron, and PVC will not be acceptable). The tank shall be constructed to allow movement using a standard fork lift. (Note: may be mounted to a common skid with other tanks.)

4.5.9 OZONE INJECTION: The system will continually circulate water from the holding tank through an ozone injection system back to the start of the filtration process (settling tank). The ozone injection is to prevent growth of bacteria (and odor) and the circulation prevents bacterial growth throughout the filtration system tanks and weirs (also will break down soaps). The ozone generator will utilize replaceable discharge elements with a minimum life of 2000-hrs of operation. The ozone system shall be sized to prevent bacteria growth without the need for adding chemicals or “bugs” to the system.

4.5.10 FILTRATION PUMPING SYSTEM: Pumps shall include high pressure and low flow protection.

4.6 Spray Equipment

The system shall include (2) high pressure hot water spray systems and (1) water cannon.

4.6.1 PRESSURE WASHERS: The system shall include two high pressure hot water pressure washers.

4.6.1.1 Flow: Each gun shall be capable of continuous operation of 5-gpm at 2900-psi.

4.6.1.2 Construction: Housings shall conform to NEMA-4 standards or better. The coils and housings shall be stainless steel material.

4.6.1.3 Temperature: Each washer shall have a minimum adjustable temperature range from ambient to 200°F. Heating shall be electric (no ventilation stack required, no fumes, and no flame) water to water thermostatically controlled heat exchanger to prevent exposure of the process water to the heating elements (to prevent scale build-up and damage of heating coils). The unit shall provide instant hot water with no “warm-up” time. The unit shall include an auto on/off feature that is controlled by the wand trigger.

4.6.1.4 Hold-Time: The system shall be able to hold maximum temperature through the cycle time of the parts being washed. This usually falls between 30 minutes to an hour but can also extend past the hour mark.

4.6.1.5 Wands: Each washer will include at least 75-ft of braided stainless steel pressure hose, and insulated trigger gun, and a variable pressure and angle wand with a hardened stainless steel nozzle.

4.6.1.6 Reels: Each washer will include an auto-retracting hose reel for the high pressure hoses. These will be mounted to the interior of the spray booth to allow for good access by the operator(s) to the hoses and the process area.

4.6.2 WATER CANNON: The system shall include one low pressure high volume water cannon. This shall produce at least 30-gpm @ 100-psi. It will be used for flood cleaning of large frames. The planned duty cycle for the cannon will be no more than 5-min per half-hour. It shall include at least a 30-ft hose with a retractable hose reel.

4.7 Controls

4.7.1 PLC: The system shall be controlled using a standard Programmable Logic Controller

(PLC). Note: It is not acceptable to use a PC as a system controller. This shall provide system controls and give information on monitors. It shall display the real-time state of every switch in the system including but not limited to: Pressure Switches, High/Low Water Level Sensors, Door Switches/Interlocks, etc… This will provide critical information for maintenance and trouble-shooting of the system. The control shall also have a password protected feature to allow adjustment of all of the system timers. The control shall include indicators for required maintenance (e.g. changing of the final absolute filter) when failure to perform could result in damage to the system.

4.7.2 The system shall include automatic shut-down to prevent damage to the system (e.g.

prevent pumps from being damaged due to lack of sufficient water flow). The operator(s) will then be able to determine the cause of the shut-down by checking the system control PLC.

5. OPTION- CLIN 0002 HEAVY DUTY MEDIA PRE-FILTER

The contractor shall provide with the system, a heavy duty media pre-filter to handle large quantities of grime and other contaminants. This shall either be a stand alone filtration system prior to the filtration system specified earlier in the RIPD, or a heavier duty filtration system connected to the 100% water recycling system as long it satisfies all aspects of RIPD Section 4.

5.1 Media

The contaminants and media off of the parts being washed consists of Lithium Grease, Sand, Mud, Rock, Hydraulic Fluid. Amounts of these contaminants vary. The parts/ vehicles that would be washed in this equipment are either vehicles that were in storage lots, vehicles that are in for refurbishments, or parts normally produced and manufactured that are being washed prior to painting operations. 6-8 of these vehicles are expected to be washed per day. This number may fluctuate with workload.

6. APPROVAL/SHIPPING

6.1 Shipping

6.1.1…