Attachment 1 - SOW C-130 Blast and Paint Booth.pdf

Statement of Work (SOW), for C-130 Blast and Paint Booths

1.0 Scope.

1.1 Scope. The content of this specification describes the minimum requirements for the design, manufacture, delivery, and acceptance testing of a mobile blast system, and mobile paint system for the C-130 aircraft nose, right-wing and left-wing wheel wells.

The mobile blast booth enclosures shall include a blast, no sweep floor recovery system, and a corresponding mobile trailer mounted recovery and filtration unit. The mobile paint booth enclosure shall include an Alodine wash, paint, and floor recovery system, and a corresponding mobile trailer mounted filtration unit.

The blast system is used to clean the paint and debris from the wheel wells and recover the blast media. The blast system shall be an airtight sealed system to the nose, right-wing, and left-wing wheel well bays.

The paint system is used to prep and paint the C-130 wheel wells. The paint system shall be an airtight sealed system to the nose, right-wing, and left-wing wheel well bays.

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

2.0 Applicable Documents. The documents listed in this section are cited in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

2.1 Government Documents

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

STANDARDS – FEDERAL

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

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

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

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

OSHA guidelines 29 CFR 1910.1000 Table Z-1.

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

Environmental Protection Agency (EPA)

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

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

DEPARTMENT OF DEFENSE

U.S. NAVY

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

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

MILITARY STANDARDS

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property Item Unique Identification Marking (IUID)

(Application for copies should be addressed to Air Force Product Data Systems Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg.

262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257-0870 or 0853 or https://quicksearch.dla.mil/qsSearch.aspx)

2.2 Other Government Documents, Drawings, and Publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract.

LOCAL FACILITY DOCUMENTS

FRCE Information Brochure

FRCE Contract Performance Requirements

(Applications for these documents should be addressed to the contracting officer) https://quicksearch.dla.mil/qsSearch.aspx

2.3 Non-Government Publications, Specifications, Standards, and Handbooks. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract.

American Gear Manufacturers Association (AGMA)

ASME Y14.100: Engineering Drawing Practices

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

22314-1581 USA)

American National Standards Institute, Inc. (ANSI)

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

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

American Society of Mechanical Engineers (ASME)

ASME Y14.100: Engineering Drawing Practices

ASME Pressure Vessel Code BPVC Section VIII

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

International Organization for Standardization (ISO)

ISO 4414: Pneumatic Power-General rules and safety requirements for systems and their components

(Application for copies should be addressed to the International Organization for Standardization (ISO) 1 rue de Varembé, Casepostale56, CH211Geneva 20, Switzerland)

National Electrical Manufacturers Association (NEMA)

NEMA 250: Enclosures for Electrical Equipment (1000 V Maximum)

NEMA ICS 1: Industrial Control and Systems General Requirements

NEMA ICS 6: Industrial Control and Systems: Enclosures http://www.asme.org/

NEMA MG 1: Motors and Generators

NEMA Z535.4: Product Safety Signs and Labels

(Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Rosslyn, VA 22209)

National Fire Protection Association (NFPA)

NFPA 70: National Electrical Code

NFPA 79: Electrical Standard for Industrial Machinery

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

3.0 REQUIREMENTS.

3.1 Design. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

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

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

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

3.1.3.1 Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded part, and shall be easily removed to facilitate inspection, maintenance, and repair of the parts.

3.1.4 Audible Noise Level. In accordance with OPNAV M-5100.23, Chapter 18, audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

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

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

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

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

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

3.1.6 Lubrication. The machine shall be equipped with a system that provides lubrication (oil, grease, coolant, etc.) for all moving parts in accordance with manufacturer requirements.

Recirculating lubrication systems shall include a filter that is cleanable or replaceable. Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low lubrication condition. When a low lubrication condition occurs, the machine shall complete the current operation and come to a complete stop. The machine shall indicate that lubrication is required. All oil holes, grease fittings, and filler caps shall be easily accessible.

3.1.7 Replacement Parts. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts.

3.2 Construction. The machine shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the machine to its maximum rating and capacity without distortion.

3.2.1 Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, filling with solder or paste shall be used for reclaiming any defective part.

3.2.2 Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

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

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

3.2.5 Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function.

The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

3.2.6 Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

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

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

3.2.9 Workmanship. Workmanship of the machine shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

3.3 Components. The machine shall consist of not less than the following components:

3.3.1 New Portable Blast Booth System.

The C-130 Wheel Well Blasting System shall consist of the following items:

a. One Abrasive Blast System consisting of:

a. 1-Nose Blast Booth and Media/Dust Recovery/Ventilation Unit

b. 1-Right Blast Booth and Media/Dust Recovery/Ventilation Unit

c. 1-Left Blast Booth and Media/Dust Recovery/Ventilation Unit

See Section 3.3.1.1 for Media/Dust Recovery/Ventilation Unit specifications.

b. The C-130 Blast booths shall be mobile mounted on heavy duty casters with wheel locks that will hold personnel and all of the painting gear. Each booth shall have a pintle hitch mount. Casters shall be of the type that can traverse uneven pavement. Each booth shall have manual leveling jacks on all four corners to raise it so it can mate up with the aircraft.

c. Each Booth shall have rubber gaskets that mate up to the C-130 wheel wells with an airtight seal. Contractor to provide description of gasket material and durometer of seal at the time of proposal to show how their gasket will provide an airtight seal.

d. The Booths shall be fabricated out of minimum 18-gauge steel and powder coated white inside and out. Minimum personnel space interior size for the Right wing and Left wing booths shall be no less than 82” wide x 136” long. Maximum size of Right wing and Left wing booths mounted on movable cart shall be no more than 88” wide x 180” long x 81” tall when in raised position. The top of the Right wing and Left wing Blast Booths adjacent to the maintenance stands shall be no more than 18” wide. Minimum personnel space interior size for nose booth shall be no less than tapered 97”-51” wide x 115” long.

e. Interior explosion proof 4000 lumens LED lighting Class 1, Div 1with limit switches.

Lights shall illuminate the entire work area.

f. One (1) man door at each end with limit switches.

g. Four (4) viewing windows (one each man door, and two on each side of the booth) shall be installed in each booth.

h. Bulkhead hose connections for blast hose, breathing air hose, media deadman controls, and compressed air equipment blow off hose. Fittings to have unique connections differentiating between compressed air and breathing air.

i. Hose system consisting of 10 feet of 1-1/4” ID x 1-7/8” OD media hose and 10 feet of 3/4” ID x 1-1/2” OD “whip” hose with quick disconnects for operator ease and maneuverability.

j. Each Blast Booth shall have a control panel. The control panel shall have all the items required for the full operation of the blast system, which will include:

i. Ventilation start and stop

ii. Recovery start and stop

iii. Blast booth light on and off switch

iv. Emergency shut down

v. Carbon Monoxide audible and visual alarm mounted on top of the control panel.

vi. Supervisor re-set key for the Broken Filter Detector

vii. Man door open light

viii. Blast booth sealing light warning

k. Contractor will provide all necessary electrical and pneumatic connections between equipment trailer and blast booth.

l. Contractor shall provide a total of four (4) “Grade D” breathing air connections. Of these four breathing air connections, two (2) shall be compatible with 3M respirator hoses and two (2) shall be compatible with Nova Air respirator hoses. Contractor shall provide breathing hoses for both 3M and Nova Air connections.

m. All equipment shall be powder coated including the trailer.

n. Booths shall have accompanied heavy duty covers.

3.3.1.1 New Portable Blast Booth Media/Dust Recovery/Ventilation Unit Contractor shall provide Three (3) Media/Dust Recovery/Ventilation Units, one for the Nose blast booth, one for the Right blast booth, and one for the Left blast booth. Ventilation unit shall be a cross-draft design with minimum 100 FPM face velocity. Ventilation unit shall meet or exceed ANSI 29.7 as per requirements of NFPA33; Chapter 7.5.2. Ventilation unit shall meet EPA requirements for Method 319 Ventilation.

Each Media/Dust Recovery/Ventilation Unit shall have the following:

a. One (1) Military Grade Trailer shall be all wheel steering for mounting the Blast Booth Ventilation/Recovery Unit. Each Trailer shall have a pintle hitch mount. Trailers shall be rated for the load of the Blast Booth Ventilation/Recovery unit.

b. No Sweep media recovery floor system

c. All equipment shall be powder coated including the trailer.

d. One (1) Media Reclaim Cyclone

e. One (1) Rotary Air Lock

f. One (1) Magnet Separator

g. One (1) Plastic Media Static Ionizer

h. One (1) Shaker Media Classifier

i. One (1) AFG Specifically Build Dense Particle Separator

j. One (1) Clean Media Motor/Blower

k. One (1) Clean Media Cyclone

l. One (1) Clean Media Storage Hopper

m. One (1) Pressure vessel with 60-degree bottom cone, 20’ blast hose, couplings and #8 double venturi blast nozzle.

n. One (1) Media Recovery Dust Collector. Dust Collector shall include:

i. Cartridge filters rated at 99.7% @ 0.5 microns with reverse pulse cleaning.

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ii. HEPA filters rated at 99.97% Efficiency @ 0.3 microns. integral to the dust collector.

iii. Broken Filter Detector that shuts blast system down and gives a red warning light.

Warning light is resettable by using supervisor key on main control panel.

iv. Dust Collection unit shall include sensor for monitoring differential pressure (DP). The sensors shall have a means for collecting visual (DP) readings.

o. One (1) Blast Ventilation Dust Collector. Dust Collector shall include:

i. Cartridge filters rated at 99.7% @ 0.5 microns with reverse pulse cleaning.

ii. HEPA filters rated at 99.97% Efficiency @ 0.3 microns. integral to the dust collector.

iii. Broken Filter Detector that shuts blast system down and gives a red warning light.

iv. Dust Collection unit shall include sensor for monitoring differential pressure

(DP). The sensors shall have a means for collecting visual (DP) readings.

3.3.2 Portable Paint Booth System.

The C-130 Wheel Well Painting System shall consist of the following items:

a. One Paint System consisting of:

i. 1-Nose Paint Booth and Ventilation Unit

ii. 1-Right Paint Booth and Ventilation Unit

iii. 1-Left Paint Booth and Ventilation Unit

See Section 3.3.2.1 for Ventilation Unit specifications.

b. The C-130 paint booth systems shall be fully mobile mounted on easy to move heavy duty casters with wheel locks. Each booth will have manual leveling jacks on all four corners to raise it to so it can mate up with the aircraft. Each booth shall have a pintle hitch mount. Casters shall be of the type that can traverse uneven pavement.

c. Each Booth shall have rubber gaskets that mate up to the C-130 wheel wells with an airtight seal. Contractor to provide description of gasket material and durometer of seal at the time of proposal to show how their gasket will provide an airtight seal.

d. The Booths shall be fabricated out of minimum 18-gauge steel and powder coated white inside and out. Minimum personnel space interior size for the Right wing and Left wing booths shall be no less than 82” wide x 136” long. Maximum size of Right wing and Left wing booths mounted on movable cart shall not be more than 88” wide x 180” long x 81” tall when in raised position. The top of the Right wing and Left wing Paint Booths adjacent to the maintenance stands shall be no more than 18” wide. Minimum personnel space interior size for nose booth shall be no less than tapered 97”-51” wide x 115” long.

e. Each Paint Booth shall have a control panel. The control panel shall have all the items required for the full operation of the blast system, which will include:

i. Ventilation start and stop.

ii. Paint booth light on and off switch

iii. Emergency shut down

iv. Carbon monoxide audible and visual alarm mounted on top of the control panel.

v. Supervisor re-set key for the Broken Filter Detector

vi. Man door open light.

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vii. Paint booth sealing light warning.

f. The Paint Booths shall have a drain system with a drain basin with Qty (5) gallon liquid capacity in the sump of the enclosure, sloped floor with center drain piped to outside edge of booth with drain valve. This drain will be plumbed so the drain line runs to the outside edge of each booth. The drain line will have a ¼” turn ball valve to allow for floor drainage. Valve shall have a means of locking so only designated personnel can initiate drainage. Contractor shall provide a pump to evacuate waste.

g. Interior explosion proof 4000 lumens LED lighting Class 1, Div 1 with limit switches.

Light shall be mounted so Artisan has optimal illumination of work area.

h. One (1) Man Door at each end with limit switches.

i. Four (4) viewing windows (one each man door, and two on each side of the booth) shall be installed in each booth.

j. Carbon Monoxide monitor with yellow visual and audible warning device in the booth

k. One Fire warning device red visual and audible warning in and out for each booth

l. One outside manual fire pull station on each booth.

m. Built in bulkhead hose connections for the compressed air hose, breathing air hose, water hose, and blow off hose. Fittings to have unique connections differentiating between compressed air and breathing air.

n. Paint Booth shall have industrial standard ¾" water hose with spray nozzle for washing parts within the booth with cutoff valve.

o. The operator hoses, water hoses, and ventilation hose shall have quick disconnect for storage while moving the booth.

p. The paint booth booths shall be fitted with limit switches to only allow painting if the booth is fully sealed against the airframe and all doors closed.

q. Contractor shall provide a total of four (4) “Grade D” breathing air connections. Of these four breathing air connections, two (2) shall be compatible with 3M respirator hoses and two (2) shall be compatible with Nova Air respirator hoses. Contractor shall provide breathing hoses for both 3M and Nova Air connections. Contractor shall perform initial Grade D air certification with acceptance testing. The booths shall have an audible and visual carbon monoxide alarm that will shut down the compressed air feeding the paint guns and activate an audible and visual alarm when set off.

r. All equipment shall be powder coated including the trailer.

s. Booths shall have accompanied heavy duty covers.

t. Contractor will provide all necessary electrical and pneumatic connections between equipment trailer and Paint system.

Paint gun kit shall consist of the following:

i. Wrench adjustable 8” OAL

ii. Sander disc pneumatic 5” dia. Central vac dynorbit 3/16 orbit.

iii. Wrench power tool 7/16 x 1/2

iv. Case Milwaukee 22-1/8 x 16-1/4 x 11-1/8

v. Case Milwaukee 22-1/8 x 22-1/8 x 25-5/8

vi. Case Milwaukee 22-1/8 x 16-1/4 x 6-1/2

vii. Plate mounting Milwaukee 18-3/8 x 23-1/4 x 1-1/4

viii. Paint gun 3M 26832

ix. Regulator pressure paint for 3M gun

x. Arbor sanding disc screw on for 3

xi. Wrench power tool 11/16

xii. Collet router dbl. angle 300 series 1/4

xiii. Pliers diagonal cutting 7-1/2 w/grip

xiv. Router pneumatic 90 deg 0-20000 rpm (3 pcs.)

xv. Arbor sanding disc screw on for 1-1/2

xvi. Knife utility single locking blade

xvii. Flashlight mini high performance 50-900 lumens (4 pcs.)

3.3.2.1 Paint Booth Ventilation Unit. Contractor shall provide Three (3) Ventilation Units, one for the Nose paint booth, one for the Right paint booth, and one for the Left paint booth.

Ventilation unit shall be a cross-draft design with minimum 100 FPM face velocity.

Ventilation unit shall meet or exceed ANSI Z9.7 as per requirements of NFPA33; Chapter

7.5.2. Ventilation unit shall meet all OSHA guidelines and requirements for 29 CFR

1910.1000 Table Z-1and EPA requirements for Method 319 Ventilation. Contractor shall provide copies of the EPA Method 319 certification to the government upon delivery.

Each Ventilation Unit shall include the following:

a. Each Ventilation unit shall have One (1) Military Grade Trailer. Trailers shall be all wheel steering for mounting Paint Booth Ventilation Unit. Each Trailer shall have a pintle hitch mount. Trailers shall be rated for the load of the Paint Booth Ventilation unit.

b. Filtration system shall have multistage filtration with a minimum of 3 stages, using filters that meet EPA Method 319 certification requirements, and including HEPA filters rated at 99.97% Efficiency @ 0.3 microns integral to the ventilation unit.

Ventilation unit shall have interlocking fan and spray air so the unit will not allow the user to spray contaminants unless the fan is running. Filtration system shall include a Volatile Organic Compound (VOC) monitor. Filtration system shall include sensors to monitor the differential pressure across all filter stages. Gauges that shall be provided with means for capturing visual readings. Contractor to provide test certification (EPA Method 319) for all filters prior to production of booths.

c. Filtration system shall have dry fire suppression system to meet all OSHA requirements. Each booth shall have its own standalone dry chemical fire suppression system. The unit will have audible and visual warning lights and horns on the inside and outside of each booth. Unit shall be engineered to accept hard wiring to the facilities alarm system.

d. All equipment shall be powder coated including the trailer.

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

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

3.3.4 Electrical System. All paint, blast and ventilation systems shall conform to NFPA 79. The existing source power available at the facility is 460 volt, 3-phase, 60 Hertz (Hz). The machine’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete, including any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated, and fused, single disconnect device shall be utilized on the machine with means of lockout in the off position only. Electrical plug shall be able to connect to a 600VAC, 3 Phase, 4 Pole, 60 Amp receptacle, Appleton Powertite, PN ADR6044.

3.3.4.1 Electrical Enclosures. Construction of the electrical enclosures shall conform to NEMA ICS 6 standards and NEMA 250. The enclosure shall be a NEMA type 12 and shall provide for ventilation of components and shall be designed for an indoor non-hazardous location. All electrical components shall conform to applicable NEMA ICS 1 standards. The machine shall be provided with interlocks on its electronic cabinet that shall instantly remove power from the equipment when the door is opened in accordance with NFPA 79.

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

3.3.5 Controller Features. The machine controllers shall consist of an Allen Bradley PC with Human-Machine Interface (HMI).

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

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

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

3.3.5.4 Software. Programming by contractor to meet the requirements for the blast booth controls and, Paint booth controls to meet system requirements (Section 3.3.1 and 3.3.2).

3.3.5.5 Hardware. Allen Bradley PLC with HMI.

3.3.6 Motors. Motors shall be rated for continuous duty. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG 1. Each motor shall have an identification plate in accordance with paragraph 3.5 to identify manufacturer, model number, serial number, voltage, amperage, horsepower, phase, frequency, and frame number.

Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

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

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

3.3.9 Hour Meter. The machine shall be equipped with a non-resetting type, analog hour meter to display accumulated operating time of the drive motor(s), mounted on the main electrical panel visible from the outside, sealed to prevent the entrance of dust and moisture, and shall be mounted to withstand shock and vibration generated by the machine. The meter shall have a range of 0 to 99,999.9 hours in increments of one (1) tenth of one (1) hour. A CNC control that tracks and displays total machine on time (a non-resetting type), controller on, program runtime, and run time of the servo motor(s) run time shall be considered to meet this requirement. The meter shall be sealed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by the machine.

3.4 Standard Tooling and Equipment. All standard tooling and equipment required for proper operation of the machine (such as special tools needed for maintenance) shall be furnished. A list of these items shall be furnished at time of proposal, reference CDRL A004 Product Drawings and Associated Lists.

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

3.5 Marking on Instruments, Control Panels, and Plates. All words on plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

3.5.1 Lubrication Plate. A lubrication plate shall be permanently and securely attached to each machine. The plate shall contain the following information:

Points of Lubricant Application Servicing Interval Type of Lubricant Viscosity Military or Federal Specification for Each Lubricant (If available) Size and Type of Each Lubricant Filter

3.5.2 Identification Marking of Military Property. An Item Unique Identification Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text. At a minimum this tag shall contain the information listed below.

3.6 Technical Data. Technical data shall contain technical information, specifications, instructions for the operation, maintenance of the machine, and recommended spare parts list. All copies of technical data shall be legible and written in the English language, reference CDRL A004 Product Drawings and Associated Lists. The first draft Technical Data Package (TDP) shall be submitted to the Government 15 calendar days prior to the Preliminary Design Review.

The second draft TDP shall be submitted to the Government 15 calendar days prior to the Final Design Review. A working draft TDP shall be submitted to the Government 15 calendar days prior to the start of installation. The final TDP shall be submitted to the Government no later than 10 calendar days after the completion of equipment installation.

3.6.1 Manuals. Two (2) complete printed sets and one (1) electronic copy (CD-ROM) of the Blast and Paint Booth systems shall be provided to the TPOC, reference CDRL A001 Operation and Maintenance Manual. The manuals shall include the following:

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

b. All original software manuals and registration keys/codes shall be provided, along with original software installation disks, reference CDRL A005 Software Media and A006 Software Documentation. Both Software Media and Software Documentation shall be delivered upon completion of the Final Acceptance Test.

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

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

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

f. The contractor shall submit all technical manuals no later than 60 calendar days prior to the start of installation for review by the Government. A working draft shall be submitted 10 calendar days prior to the start of installation. Final manuals are due no later than 10 calendar days after the completion of installation.

g. Manuals shall include operating VOC ranges per OSHA guidelines 29 CFR 1910.1000 Table Z-1.

h. Manuals shall include recommended differential pressure ranges for filter maintenance.

3.6.2 Plan of Action and Milestones (POA&M). The contractor shall provide a Plan of Action and Milestones (POA&M) to identify contractor performance dates of all major events from contract award to completion of all contract requirements, reference CDRL A007 Plan of Action & Milestones. The initial POA&M shall be delivered at the time of proposal. The milestones shall be prepared using a recognized project management technique (preferably Microsoft Project). The final POA&M shall be submitted at the Post Award Conference. The Government and the contractor shall review the report monthly. The contractor shall notify the Government prior to making any changes to the POA&M. All changes to the POA&M must be approved in advance by the Government. The POA&M shall detail such items as system design concept, system development, software design concept, software development, engineering, procurement of major hardware, assembly, operational debug, factory acceptance, shipment, installation, training, and final acceptance test.

3.6.3 Control of Hazardous Energy (Lockout/Tagout) Procedures. A written procedure for locking out all energy sources shall be provided by the contractor in accordance with 29 CFR 1910.147, reference CDRL A002 Lockout and Tagout Procedure. The contractor shall submit draft copies to the Government 60 calendar days prior to the start of installation. Working drafts are due at the start of equipment installation, and final copies shall be submitted no later than 10 calendar days after completion of system installation and shall incorporate marked-up changes from installation. The contractor shall provide an electronic copy of the procedure in Microsoft Word to the Government as well as include the procedure in the technical manuals.

3.6.4 Instrument and Calibration Procedures. Calibration procedures and/or tooling requiring operator verification or recalibration as part of a production run or on a daily or periodic basis shall be provided to the Government, reference CDRL A003 Calibration Procedure. The contractor shall provide and comply to the following items listed below:

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

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

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

d. An example calibration procedure will be provided by the Government at the request of the contractor. Government calibration personnel will advise the contractor in producing a suitable calibration procedure. A first draft calibration procedure shall be provided to the Government 15 calendar days prior to the Preliminary Design Review. A second draft calibration procedure shall be provided to the Government 15 calendar days prior to the Final Design Review. A working draft shall be provided to the Government 15 calendar days prior to the start of installation. A final procedure shall be submitted within 7 calendar days of the completion of the Final Acceptance Test.

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

f. A final calibration procedure shall be provided to the Government within 7 calendar days after final acceptance of the equipment.

3.6.5 Acceptance Test Plan (ATP). The contractor shall prepare an acceptance test plan for inspecting and a test plan for the Blast and Paint Booths, reference CDRL A009 Acceptance Test Plan. The ATP shall be a step-by-step written instruction on how to verify compliance during Contract Quality Assurance Inspection (Origin) and the Final Inspection/Acceptance Test specified in Sections 4.4 and 4.5. Acceptance test plan shall include minimum of Qty (2) Design Reviews that shall be scheduled and approved prior to acceptance. The Manufacturer’s standard testing procedures shall be included in the ATP. The ATP shall include any procedures necessary for compliance with Sections 4.4 and 4.5 that are not covered by the Manufacturer’s standard testing procedures. The initial ATP shall be submitted 15 calendar days prior to the Preliminary Design Review. The final ATP shall be submitted at the Final Design Review for review and approval. The approved ATP shall become part of the contract.

3.6.6 Design Review. The purpose of the Design Reviews shall be to review and comment on the contractor's proposed solutions, reference CDRL A010 Conference Agenda and A011 Conference Minutes. Conference Agendas shall be submitted to the Government 7 calendar days prior to any conference or scheduled meeting. Conference Minutes shall be submitted to the Government 7 calendar days after any conference or scheduled meeting. The contractor shall visit the Fleet Readiness Center East (FRCE) within 30 days after the Post Award Conference to get all necessary measurements from the C130 so they can develop and design the portable blast, paint, and ventilation booths.

3.6.6.1 Preliminary Design Review. No later than 60 days after the site visit to FRCE, the contractor shall conduct a preliminary design review that consists to the following items:

a. Design has been developed using sections 3.1 through 3.5.

b. Design shows how the blast and paint booths will connect to the aircraft with an airtight seal. All material to be used for this shall be provided by the contractor.

c. Weight of each booth

d. Weight capacity of each booth

e. Clearance for travel or rotation of any moving parts

f. Interface mounting and mating information, such as dimensions of location for attaching hardware, and meet the manufacturer vibration design requirement.

g. Interface pipe and cable attachments required for installation and co-functioning of the item to be installed with related items

h. Location, type and dimensions of cable entrances, terminal boards, electrical connectors, and ducts

i. Interconnecting and cable detail

j. Peak electrical load (Amps) requirement to support all proposed equipment in its fully configured and operational state, including all accessories

3.6.6.2 Final Design Review. Submission of final design for review by the government shall be not later than sixty (60) calendar days after Government acceptance of preliminary drawing. These final drawings shall bear a complete title block with a permanent drawing number, signature, date, and an original stamp or seal of a Professional Engineer (PE) licensed in the state of the receiving activity where the equipment will be installed. The final drawing submission shall include an engineering report with structural calculations used in the design. The engineering report shall also be stamped by a PE. The Government shall notify the contractor in writing within ten (10) working days of receipt of drawing if they comply with this specification. If revisions are required, the contractor has ten (10) working days to make revisions and resubmit for a new review. Rejection of drawings does not relieve the contractor from final delivery date of contract performance period.

3.6.7 Equipment Drawings. The Contractors proposal shall be provided with dimensioned equipment drawings in both a .PDF file and CAD file compatible with AutoCAD 2015 edition, reference CDRL A004 Product Drawings and Associated Lists. The dimensioned CAD file shall be drawn to actual size and show footprint of new equipment to include ancillary pieces, utility connection points, access doors and required maintenance clearance dimensions. The CAD file shall show side and elevation views.

3.7 Installation. Blast and paint booths and all ancillary equipment shall be fully assembled upon delivery. Contractor shall be responsible for all equipment (forklifts, man lifts, etc.) and qualified personnel required for unloading, rigging, installation, connecting machine to utilities, and leveling the machine in place. Contractor shall also be responsible for the Installation Responsibilities as follows:

a. Provide Booth portable tow mounting in accordance with the Manufacturer’s design requirements.

b. Furnish labor and material handling equipment for off-loading and placing booths on the ground at the facility.

c. Set and rough mount the booths to C-130 wheel wells.

d. Align booths to airtight seal to C-130 wheel wells.

e. Connect machine to the provided utilities hook-up within 20 ft. of the machines.

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

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

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

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

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

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

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

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

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

3.7.3 Site Preparation and Installation Plan. The contractor shall provide a clear and concise site preparation and installation plan, reference CDRL A008 Site Preparation and Installation Plan. The plan shall include a detailed description of all installation work, general equipment specifications (i.e. size, weight, etc.), any required utility requirements, pertinent electrical details, and any other details required for site preparation and layout. The plan shall be based on a working schedule of normal business hours (6:30 am and 3:00 pm Monday-Friday), excluding weekends and Government holidays. The site preparation and installation plan shall be submitted at least 15 days prior to Preliminary Design Review for review. The final site preparation and installation plan shall be submitted at the Final Design Review.

3.7.4 Compressed Air Connection. Cubic feet per minute (CFM) is CFM at standard conditions. The standard conditions of air are defined as 60 degrees Fahrenheit, 14.7 PSIA and relative humidity of zero. The piping installation shall meet or exceed the current Department of Defense construction criteria as defined in UFC 1-200-01. Contractor shall provide color code marking of piping/tubing conforming to ASME A13.1. Contractor shall provide pipe flow markings, warning and identification tape, and metal tags as required. Provide a single point connection to the new equipment with a lockable shutoff valve. Install adequate course and fine filtration for particle removal. Install adequate filters and separators to remove oil vapor and fine aerosols, as required. Install an air dryer if the existing compressed air is not dry enough (i.e. if the dew point of the compressed air needs to be lowered). Install adequate filters, separators to remove moisture, water particulates, water, and water vapor, as required. Design and protect the new equipment from any wet saturated compressed air conditions due to an occasional catastrophic compressed air dryer failure in the currently supplied compressed air. The Contractor shall be responsible for design and installation of new compressed air piping and associated components. The existing compressed air pressure available at the Government facility fluctuates between 83 to 93 psi. The contractor shall assume that all compressed air qualities to be of the lowest quality that is useable as compressed air. The Contractor shall make provisions to filter, dry, humidify, lubricate, amplify, and regulate the Government supplied compressed air to meet the Original Equipment Manufacturer (OEM) compressed air requirements and recommendations.

3.8 Training. The contractor shall furnish the services of competent instructor(s), fluent in the English language, who shall give full instruction to designated personnel in operation, maintenance, and pertinent safety requirements reference CDRL A012 Training Plan. The training plan shall be submitted in accordance with CDRL A012 Training Plan. The initial Training Plan shall be submitted to the Government 15 calendar days prior to the Preliminary

Design Review. The final Training Plan shall be submitted at the Final Design Review. The training shall cover the information in the Operations and Maintenance Manual, reference CDRL A001 Operation and Maintenance Manual. Each instructor shall be thoroughly familiar with all parts of the equipment and shall be trained in operation and maintenance. Instruction shall be given during the first regular work week following Government acceptance of the equipment for regular operation. Training shall be conducted at customer facility. All materials, manuals, tapes, data, etc. shall be contractor furnished and shall become the property of the Government. All Government Personnel training shall be conducted between normal business hours (6:30 am and 3:00 pm Monday-Friday), excluding weekends and Government holidays.

3.8.1 Operator Training. Operator training shall be provided at Fleet Readiness Center East.

Training shall be provided…