Attachment 01 - DFP Grit Blaster_20Aug2020.docx

DESCRIPTION FOR PURCHASE (DFP) for GRIT BLASTER August 20, 2020

Preface: The Crane Army Ammunition Activity (CAAA) has a new requirement to apply a metalized coating, thermal arc spray, to MK 80 series and BLU series bombs. For the metalized coating to adhere to the surface of the bomb, a specific surface profile must be created. This profile shall be created by grit blasting. CAAA has a renovation facility in which unserviceable bombs are processed through the facility and put back into serviceable conditions. The current process includes, but not limited to, removal of current exterior coating, reapplication of primer, then reapplication of topcoat. The new process will include removal of current exterior coating, create desired surface finish profile on the exterior of bomb via grit blasting, application of metalized coating (thermal arc spray) in lieu of primer, then reapplication of topcoat. This Description for Purchase (DFP) is to identify the requirements for purchasing, installation, and training for a grit blasting cabinet to create necessary surface profile, on the bomb surface, to promote adhesion of the metalized coating (thermal arc spray.)

Bombs are moved via a Richard-Wilcox power and free conveyor system into the ‘work-cell’ that will accommodate the grit blasting process. Bombs hang on either a single carrier or a dual carrier set-up. Bomb sizes of 500-lb and 1000-lb hang on a single carrier (approximate carrier length 2ft-3in) and bombs weighing 2000-lb hang on a dual carrier set-up (approximate carrier length 4ft – 8 3/4in). Since this work cell has a single stop assembly and due to the different carrier lengths, the 500-lb/1000-lb bombs will have a different centerline while in the stop compared to the 2000-lb Dual carrier. Single Stop assemblies will yield different bomb centerlines, See attachment FIG 03. There is a stop assembly prior to the Grit Blast cabinet work-cell that queues bombs up from previous processes. The aforementioned stop only allows one bomb at a time into the work-cell to be processed. A bomb rotator is in place that rotates bombs at 2-34 rpm (variable, manual selection). The work-cell has an operator interface button that enables the operator to toggle rotator on and off. This operator interface also houses an operator interface button that allows operator to release a bomb from the work-cell once the grit blast process is complete. Once a bomb is processed and manually released by the operator, the conveyor automatically releases a bomb from the staging queue into the Grit Blast work-cell. Bomb sizes are not intermingled on the line. A production run consist of running one size bomb. The grit blast operation is required to create the necessary surface profile required for adhesion of the metalized coating at the next operation, Thermal Arc Spray.

The following items are in-place and are not included in the Grit Blast requirement:

(1) Power and Free conveyor system.

(2) Bomb rotator in place.

(3) Current Rotator rotates bomb at 2 - 34 rpm (variable, manual selection).

(4) Bomb rotation on/off switch.

(5) Carrier/trolley release button.

REQUIREMENTS:

(1) Grit blast system that will clean and prepare the exterior surface of all MK 80 series and BLU series bombs for thermal Arc Spray coating. See attachment FIG 01-A & FIG 01-B.

(2) The system shall clean the surface to an SPC-SP 10 (NACE 2) minimum near-white metal with an angular profile to promote coating adhesion.

(3) The system shall prepare the bomb surface with a minimum anchor-tooth profile depth of .002 minimum, when measured in accordance with ASTM D 4417, Method C, prior to receiving the metallized coating.

(4) The system provided shall be ‘turn-key’, including, but not limited to, all power supplies, head/spray nozzle(s), and articulating arm (if applicable) that will traverse each bomb from surface x to surface z cleaning and creating required profile. See attachment FIG 02-THERMAL ARC SPRAY COVERAGE. Note, the surface area that is sprayed with metalized coating is the same area that shall be grit blasted to create the acceptable profile.

(5) The system shall have a reciprocating arm, at a minimum, or an equivalent process, that will traverse the bomb from surface ‘x’ to surface ‘z’ and/or from surface ‘z’ to surface ‘x.’ Start/Stop points shall be easily adjustable to change to accommodate varying lengths and diameters bombs.

(6) The grit blast shall consist of a cabinet that houses the bomb and contains the sand/grit while the bomb is being blasted. The cabinet shall be designed in a manner to not obstruct the flow of bombs on the conveyor while the bombs are in transit. The cabinet shall not house the bomb rotator or the power and free conveyor.

(7) The system shall have a single “cycle start” button that can be initiated to start an automatic ‘production’ cycle that cleans/profiles from surface x to surface z, or vice versa, of appropriate size bomb. This ‘cycle start’ button shall be in close proximity to the current operator control buttons (rotator on/off, carrier release, etc…)

(8) Cycle Time: The system shall clean and profile, from start to finish, less than or equal to 3 minutes on a 500-lb (Mk-82) bomb and less than or equal to 9 minutes for a 2000-lb (MK-84) bomb.

(9) The system shall have a 100% duty cycle, or a duty cycle percentage high enough not to interrupt production flow.

(10) All functions that are instigated to complete an auto-cycle shall have individual button(s), for each function, that can be utilized in ‘manual mode’ for set-up and troubleshooting.

(11) The system shall be installed at CAAA and fully functional within 45-days after receipt at Crane.

(12) Supply air (if required) will be provided within 15ft of equipment by the US government. Air requirement shall be communicated to the Government 45-days prior to equipment installation.

(13) Electrical power will be provided by US government from government’s building supply to a separate disconnect or directly to equipment’s power panel only. All other ancillary field electrical wiring, to include, but not limited to, push buttons, sensors, and limit switches will be the responsibility of the contractor. Supply electrical requirements shall be given to the government 45-days prior to equipment installation.

(14) If a Programmable Logic Controller is utilized, it shall be an Allen-Bradley and use Allen Bradley RSLogixTM Ladder Logic Programming software.

(15) The awardee shall notify the Government 45 calendar days prior to installation, of any items that need removed or redirected. These items include air lines, electrical lines/conduit, overhead lighting and fire suppression lines.

(16) Grit/Sand/Garnet shall be provided. Quantity provided shall be enough for set-up and testing, and to clean and profile a Proof of Production quantity of 200-each MK82 (500 lb.) bombs. The Proof of Production quantity (200 units) shall pass the quality grit blasting criteria, requirements (2), (3), and (4), with no more than 4 rejects. The awardee shall be on-site for the entire Proof of Production run and shall provide technical and mentorship to achieve the required 200 units with no more than 4 rejects.

(17) All high wear or consumable parts shall be identified. The identified parts shall be provided as spare parts in a quantity acceptable to process approximately 200-each, MK 82 (500 lb.) bombs.

(18) Grit Blast equipment shall perform its function and integrate with the current conveyor system, building structure, and monumental process equipment.

(19) In-person training shall be given to CAAA:

A. Production operators. Training shall consist of, but not limited to, daily operation, daily operational checks, set-up, and adjusting of equipment and settings. Approximately 5 operators shall be trained and training may be performed as a group.

B. Maintenance personnel. Training shall consist of, but not limited to, preventive maintenance, replacement of high wear items (if any exist), and overall maintenance of the equipment. Approximately 5 maintenance personnel shall be trained and training may be performed as a group.

This training shall coincide with Proof of Production run.

(20) 3 sets of complete manuals shall be provided no later than the first day of the Proof of Production run.

(21) 3 sets of complete drawings shall be provided no later than the first day of the Proof of Production run.

(22) If a PLC is utilized, 3 sets of the ladder logic program shall be provided shall be provided no later than the first day of the Proof of Production run.

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