Attachment 01 - DFP_Thermal Arc Spray-20Aug2020.docx

DESCRIPTION FOR PURCHASE (DFP) for THERMAL ARC SPRAY 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. 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 in lieu of primer, then reapplication of topcoat. This Description for Purchase (DFP) is to identify the requirements for purchasing, installation, and training for the metallized coating application.

Bombs are moved via a Richard-Wilcox power and free conveyor system into the ‘work-cell’ that will accommodate the Thermal Arc Spray (TAS) application process. Stop assemblies are integrated into the conveyor system, for this work-cell, that stop all bombs in a manner that the centerline of each bomb is in the same location, regardless of bomb size. There is a stop assembly prior to the TAS work-cell that queues bombs up. 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 33 rpm. 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 thermal arc spray application is complete. Once a bomb is processed and manually released by the operator, the conveyor automatically releases a bomb from the TAS staging queue into the TAS work-cell.

The following items are in-place and are not included in the Thermal Arc Spray requirement:

(1) Power and Free conveyor system.

(2) Dust collector.

(3) Bomb rotator.

(4) Current Rotator rotates bomb at 15-38 rpm (variable, manual selection.)

(5) Bomb rotation on/off switch.

(6) Carrier/trolley release button.

REQUIREMENTS:

(1) A Thermal Arc Spray system that will spray a uniform metallized coating on the exterior of MK 80 series and BLU series bombs. (See attached FIG 01-A and FIG 01-B)

(2) The bomb surface will have a surface preparation of 2 mil angular profile (via grit blasting, provided by others) prior to receiving the metallized coating.

(3) Metallized coating thickness shall be a uniform: .005 +.002/-.001 when measured in accordance with AWS C2.18.

(4) Minimal Thermal Arc Spray adhesion strength shall be 500 PSI, minimum, when tested in accordance with ASTM D4541. Method E.

(5) Metallized coating material shall be: 85% Zinc, 15% Aluminum (by weight) alloy wire 1/8” Diameter.

(6) The system provided shall be ‘turn-key’, including, but not limited to, all power supplies welding equipment, head/spray gun, and articulating arm that will traverse each bomb from surface x to surface z applying a uniform metallized coating, as required. See FIG 02, “THERMAL ARC SPRAY COVERAGE”

(7) 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 bomb diameters.

(8) The system shall have a single “cycle start” button that can be initiated to start an automatic ‘production’ cycle that applies TAS 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…)

(9) Cycle Time: The system shall apply the metallized coating, 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-ln (MK-84) bomb.

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

(11) 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.

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

(13) 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.

(14) Electrical supply 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.

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

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

(17) 85/15 Zn/Al wire shall be provided. Wire shall meet AWS C2.25. Wire quantity provided shall be enough for set-up, testing, and to coat a Proof of Production quantity of 200-each MK82 (500 lb.) bombs. The Proof of Production quantity (200 units) shall pass the quality Thermal Arc Spray criteria, requirements (3), (4), (5) and (6) of this DFP, with no more than 4 rejects. Awardee shall be on-site for the entire Proof of Production run and shall provide technical assistance and mentorship to achieve the required 200 units with no more than 4 rejects.

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

(19) Thermal Arc Spray equipment shall perform its function and integrate with the current conveyor system, building structure, and monumental process equipment.

(20) Thermal Arc Spray equipment shall be designed, or shielded, in a manner to not apply metalized coating to bomb rotator or power and free conveyor.

(21) 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.

(22) 3 sets of complete manuals shall be provided no later than the first day of Proof of Production run.

(23) 3 sets of complete drawings shall be provided no later than the first day of Proof of Production run.

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

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