Attachment 1_Statement of Work.pdf

DESCRIPTION/WORK STATEMENT/SPECIFICATION

LARGE CAPACITY AQUEOUS TURNTABLE WASHER (Building 475)

1. SCOPE

This specification establishes the requirement for one (1) aqueous‐based cabinet‐style turntable spray washer hereafter referred to as the “Equipment,” “washer” and “cleaning machine”, to be provided to

Anniston Army Depot, Anniston, Alabama. The intended application is for final cleaning of transmission components that have been disassembled. Most of the components will be internal parts from inside the transmission that have been exposed to oil and grease. The Equipment will be used primarily for cleaning of the larger transmission components that are too large to be cleaned in the flow through conveyor washer. Most components will be loaded in baskets to be cleaned. The Equipment shall remove oil, grease, dirt and organic materials from the transmission components. The Equipment shall be designed and fabricated by the Contractor with all functionality, capabilities and features as described herein. The Contractor shall provide all resources necessary to design, manufacture, deliver, demonstrate functional operation, and provide operator and maintenance training and installation for the equipment.

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

CODE OF FEDERAL REGULATION (CFR)

29CFR 1910 Occupational Safety and Health Administration (OSHA) Safety and Health

Standards

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI 14.3 Fixed Ladders ‐ Safety Requirements

ANSI AS35411 Fittings and Lubrication

ANSI B93.114M Pneumatic Fluid Power Systems ‐ Standard for Industrial Equipment and

Machine Tool Applications

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C2 (2007) National Electrical Safety Code

IEEE STD 142 (1992) Recommended Practice for Grounding of Industrial and Commercial

Power Systems

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 4414:1998 Pneumatic Fluid Power ‐ General Rules Relating to Systems

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 (2007) Standard for Motors and Generators

NEMA ICS 1 (2000; 2005) Standard for Industrial Control and Systems General Requirements

NATIONAL FLUID POWER ASSOCIATION (NFLPA)

NFLPA/JIC T2.24.1 R1 Hydraulic Fluid Power ‐ Systems Standard for Stationary Industrial

Machinery

NFLPA T2.25.1 R2‐200X Pneumatic Fluid Power‐Systems Standards for Industrial Machinery ‐

Supplement to ISO 4414:1998

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2007; 2008) National Electrical Code ‐ 2008 Edition

NFPA 79 (2007) Electrical Standard for Industrial Machinery (Department of Defense (DOD) adopted)

1.2 ORDER OF PRECEDENCE

In the event of a conflict between the text of this Equipment specification and the references cited herein, the more stringent regulation or specification shall take precedence, unless a specific exception to this, order of precedence, is noted in this Equipment specification. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained by the Government.

1.3 GENERAL REQUIREMENTS

1 Manufacturer's part numbers referenced herein are intended to be descriptive and not restrictive;

and are not intended to preclude the use of any item otherwise conforming to this specification.

2 Materials and Equipment shall be standard unmodified products of a manufacturer regularly engaged in the manufacturing of such products. Units of the same type of equipment shall be products of a single manufacturer. Items of the same type and purpose shall be identical and supplied by the same manufacturer.

3 The Equipment (as defined in this specification) includes the engineering, selection, procurement, design, manufacture, assembly, testing, delivery, installation, training and commission, and includes all related equipment, spare parts, materials, supplies, components, documentation, and all other items required to make a production ready system.

1.3.1 Mechanical General Requirements

The contractor shall not install ventilation or exhaust systems in a manner or location that interferes with equipment, or interferes with personnel access to equipment for operation or maintenance. The contractor shall not install ventilation or exhaust systems in a manner or location that interferes with the direct access to work‐in‐process (WIP), component containers and racking. The contractor shall not install ventilation or exhaust systems in a manner or location that interferes or in any way limits the full design motion of any crane.

1.3.2 Electrical Requirements

1 Equipment located outdoors. Equipment not provided with climate‐controlled enclosure, shall be capable of operating in the weather conditions indicated in Appendix Q Weather Data, unless otherwise specified. Equipment and wiring must be in accordance with NFPA 70 and NFPA 79, with proper consideration given to environmental conditions such as moisture, dirt, corrosive agents, and hazardous area classification.

2 All electrical work shall comply with IEEE C2, NFPA 70 and, unless outdoors or in an electrically hazardous classified area, shall be installed to meet NEMA 13 rating. All materials used in the installation shall conform to applicable National Electrical Manufacturers Association (NEMA) and

Underwriters Laboratory (UL) listings. Workmanship shall be in accordance with standard commercial practices. All wire shall be copper; no aluminum wire shall be used. Conduit feeds to the process equipment shall be intermediate metal conduit (IMC) or rigid conduit. Conduit runs shall be installed perpendicular and parallel to facilities and the equipment to be installed.

3 The contractor shall not install conduit in a manner or location that interferes with equipment, or interferes with personnel access to equipment for operation or maintenance. The contractor shall not install conduit in a manner or location that interferes with the direct access to work‐in‐process (WIP), component containers and racking. The contractor shall not install conduit in a manner or location that interferes or in any way limits the full design motion of any crane.

4 Equipment Service Voltage. The Equipment shall be wired to draw all of its electrical power from a single circuit. If the Equipment's single circuit amperage exceeds the requirement of a 20‐amp circuit, the Equipment shall be designed to operate on 460/480‐volt, 60‐Hertz (Hz) input power. The

Equipment shall be equipped with a manual, fused, or breaker type disconnect switch, readily accessible to the operator, that will deactivate the entire Equipment.

5. Electrical Noise. The electrical power at Government Facility may be subject to electrical noise. If the Equipment requires clean electrical power for proper operation, a properly sized power‐conditioning unit shall be included with the Equipment. If the Equipment is subject to interference from adjacent machinery, the Equipment shall include the proper shielding to prevent malfunctions.

6. Electrical Connections. Connections to screw‐type terminals shall be mechanically secured with means to prevent loss of tightness. All other electrical connections shall be mechanically secured and soldered or brazed. Rosin base fluxes shall be used in all soldering operations.

1.3.3 Motors

Motors shall be rated for continuous duty and shall have ball or roller bearings of the sealed and permanently lubricated type. All motors, unless otherwise specified, shall conform to the requirements of NEMA MG 1. Motors shall be alternating current (AC), 60‐Hz, or direct current (DC) industrial‐type motors with drip proof enclosures. Each motor control shall conform to the requirements of NEMA ICS

1. All motors 10 horsepower (HP) or greater shall have soft start controller.

1.3.4 Pneumatic System

If the Equipment requires a pneumatic system, the pneumatic system shall conform to the requirements of ANSI B93.114M (Non‐breathing Air Type)" applies to this section. The pneumatic system shall comply with ISO 4414:1998 and NFLPA T2.25.1 R2‐200X.

The contractor shall not install pneumatic systems in a manner or location that interferes with equipment, or interferes with personnel access to equipment for operation or maintenance. The contractor shall not install pneumatic systems in a manner or location that interferes with the direct access to work‐in‐process (WIP), component containers and racking. The contractor shall not install pneumatic systems in a manner or location that interferes or in any way limits the full design motion of any crane.

1.3.5 Hydraulic System

1 If the Equipment requires a hydraulic system, the hydraulic system shall conform to the requirements of NFLPA/JIC T2.24.1 R1. The hydraulic system shall be complete including all pumps, valves, piping, cylinders, and pressure controls. Overpressure protection shall be provided in the high‐pressure line to prevent damage to components. A filter system shall be provided to ensure delivery of clean fluid. The hydraulic reservoir shall have means for determining fluid level, a provision for draining, and a cleanout access plate if the reservoir is not removable.

2 The contractor shall not install hydraulic systems in a manner or location that interferes with equipment, or interferes with personnel access to equipment for operation or maintenance. The contractor shall not install hydraulic systems in a manner or location that interferes with the direct access to work‐in‐process (WIP), component containers and racking. The contractor shall not install hydraulic systems in a manner or location that interferes or in any way limits the full design motion of any crane.

3 The system shall be equipped with a hydraulic fluid requirements plate attached to the

Equipment at the hydraulic reservoir fill point. The plate shall contain the Type of fluid (Society of

Automotive Engineers) or Military or Federal specification number) and Type of filter.

1.3.6 Plumbing, Drainage and Waste

1 The contractor shall not install plumbing, drainage or waste systems in a manner or location that interferes with equipment, or interferes with personnel access to equipment for operation or maintenance. The contractor shall not install plumbing, drainage or waste systems in a manner or location that interferes with the direct access to work‐in‐process (WIP), component containers and racking. The contractor shall not install plumbing, drainage or waste systems in a manner or location that interferes or in any way limits the full design motion of any crane.

1.3.7 Safety and Health Requirements

1 The Equipment shall comply with OSHA limitations and control of noise levels, radiation, electromagnetic emission, noxious vapors, heats etc, as applicable.

2 The Equipment shall be equipped with safety devices to adequately protect the operator from all hazards incident to its operation.

3 The Equipment shall be in compliance with Occupational Safety and Health Administration 29CFR

1910. The Equipment shall include warning lights/indicators to alert the Equipment operator to unsafe operating conditions. The Equipment shall include a manual emergency shutdown switch and shall have the ability to automatically shut down when under automatic control. All parts, components, mechanisms, and assemblies furnished on the Equipment, whether or not specifically required herein, shall conform to all requirements of 29 CFR 1910. Covers, guards, or other safety devices normally furnished as standard on the manufacturer's commercial Equipment supplied to the commercial market shall be provided for the point of operation and all other parts of the Equipment that present safety hazards. All special guarding shall meet 29 CFR 1910. The safety devices shall not interfere with the operation of the Equipment. All guards shall allow access to the guarded part(s).

4 Safety devices shall be provided for all parts of the Equipment presenting safety hazards.

Guards shall be removable to provide easy access to the guarded parts. The Equipment shall comply with the standards promulgated under 29 CFR 1910 that are applicable to the Equipment itself.

5 Protection against electric shock shall be incorporated. All front access panels and doors shall be furnished with electrical interlocks to remove power from the cabinets while panels or doors are open.

6 Corrosion resistant "Caution" or "Warning" plates shall be securely attached to the equipment, visible to maintenance personnel and permanently marked.

7 Noise Level. Noise emitted by the Equipment shall be no greater than 80 decibels. The 80‐decibel limit is absolute. Techniques such as sound level averaging or exposure time weighing shall not be used in meeting this requirement. Any shields, baffles, enclosures or other devices required to bring the equipment into conformance with this requirement shall not interfere with visibility needed for safe operation of the Equipment. Operators shall be able to use this equipment without the need for hearing protection.

8 There shall be a sound barrier surrounding the pump motor.

9 Ergonomics. The equipment shall be ergonomically designed to prevent the occurrence of repetitive stress injuries.

10 A platform with stairway and safety railing shall be provided by the contractor with the equipment.

All ladders and railing shall meet ANSI 14.3.

1.3.8 Environmental Compliance

The Equipment provided under this contract shall meet all applicable Environmental Protection Agency

(EPA) and Alabama Department of Environmental Management (ADEM) regulations and restrictions in effect on the date of the contract.

1.3.9 Energy Efficiency

The Equipment and its components that directly consume energy in normal operation shall be designed and constructed for energy efficiency in accordance with the developments available within the industry. Pneumatic circuits shall be designed for minimum air consumption.

1.3.10 Documentation

The contractor shall provide all documentation with the Equipment as specified herein. Reference 1.4

1.3.11 System of Units

The equipment shall display all units of measure in the U.S. Customary System of Units "English", not

Metric.

1.3.12 Nameplates

1 The Equipment shall have the manufacturer's name and address, and the model and serial number in a conspicuous place.

2 A nameplate shall be attached to the Equipment and shall contain, at a minimum, the following information:

a. Nomenclature.

b. Original Equipment Manufacturer's name, Address and Phone Number.

c. Serial number.

d. Model designation.

e. Power input (volts, total amperes, phase, and frequency).

f. Facility Circuit Breaker or Buss Duct Switch Location Reference Number

g. Short‐circuit/over current rating.

h. Contract number or purchase order number.

i. National stock number (if applicable).

j. Date of manufacture.

1.3.13 Maintainability and Interchangeability

The Equipment shall be constructed using commercial off‐the‐shelf components to the maximum extent possible to ensure the prompt availability of repair parts. All replaceable parts shall be designed and manufactured to such standards as shall permit replacement and adjustment without the need for modification of the parts or the Equipment. All replacement parts shall be available domestically.

1.3.14 Workmanship

Standards of workmanship shall assure that the Equipment shall have the stability, strength, safety, and efficient operating characteristics found in state of the market commercial units.

1.3.15 Tools

All tools, other than common hand tools, required for normal operation and maintenance of the

Equipment shall be provided.

1.3.16 Construction

1 The Equipment shall be so constructed as to be capable of performing the operations specified herein. All surfaces shall be clean and free of extraneous materials. External surfaces shall be smooth and free from sharp edges, rounded or beveled, unless sharpness is required for performance. All screws, pins, and similar parts shall be installed to prevent loss of tightness. Parts subject to adjustment or removal shall not be permanently installed or deformed. The Equipment shall be constructed of parts, which are new, without defects, and free of repairs. The structures shall withstand all forces encountered during operation of the Equipment to its maximum rating and capacity without permanent distortion or failure.

2 Materials shall conform to the applicable specifications and shall be as specified herein and on the applicable drawings. Materials which are not covered by applicable specifications or standards shall be of the best quality, and entirely suitable for the purpose intended.

3 The Equipment shall be constructed of corrosion resistant material or material with a finish to resist corrosion to the maximum extent possible. Equipment materials not specifically designated herein or in the contract shall be of a quality commensurate with commercial practice within the applicable machine industry. When dissimilar metals are used in contact with each other, suitable protection against galvanic corrosion shall be applied.

4 Unless suitably protected against electrolytic corrosion, dissimilar metals shall not be used in intimate contact with each other.

1.3.17 Lubrication

1 A lubrication plate shall be attached to the Equipment. The information provided on the plate shall include:

a. Points of lubricant application.

b. Servicing interval.

c. Type of lubricant(s) with SAE number or lubricant identifier.

d. Viscosity

e. Federal or Military Specification Number (if applicable)

2 All bearings (except sealed‐for‐life type), mating gears, and sliding parts shall be provided with standard means for lubrication. Oil holes, grease fittings, and filler caps shall be accessible. Lubrication reservoirs, if applicable, shall have means for checking levels. Means shall be provided to ensure lubrication for all moving parts. Re‐circulating lubrication systems shall include a cleanable or replaceable filter. Means for determining oil level in each reservoir shall be by an oil level sight gauge, a low oil level warning light or similar device and shall be in clear view of the operator's normal workstation. An automatic lubrication system shall be provided for all ways and axis screws. Each lubricant reservoir shall have at least a 24‐hour capacity and means for determining fluid level. Any greases, oils, or fluids used to initially charge the lubricant system shall be free of contaminants known to be hazardous to human health.

3 Grease fittings conforming to ANSI AS35411 Fittings & Lubrication shall be provided in accessible positions at all necessary lubrication points. Pressure relief fittings shall be provided where use of high‐ pressure lubrication equipment could cause damage.

1.3.18 Drive Train Gears

The 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 Equipment. Gears in the drive train shall be hardened and ground steel. Working surface hardness shall be not less than Rockwell C‐48.

1.3.19 Castings and Forgings

Castings shall be free of visible blowholes, porosity, hard spots, shrinkage, defects, cracks, scale, mismatching or other defects. Forgings shall be free of visible scale, inclusions, cold shuts, mismatching, or other defects. Mechanical and chemical properties of the castings and forgings shall be adequate to meet the performance requirements of this specification. No processes such as welding, peen, plugging, or filling with solder or paste shall be used for reclaiming any defective part. Such processes may be used only for enhancing surface finish and appearance.

1.3.20 Welding, Brazing, and Soldering

Welding, brazing, and soldering shall be of a quality, which shall sustain the performance requirements of the welded, brazed, or soldered part. These operations, however, shall not be employed as repair measures for defective parts. Welding, brazing, or soldering shall be employed only where specified in the original design. Any material used for such operations shall be thoroughly removed from the part(s) upon completion of the operations.

1.4 SUBMITTALS

All documentation shall be furnished in the English language only. The Contractor shall provide three (3) printed copies and (3) three electronic copies of all documentation. The electronic documentation shall be provided on compact discs (CD). Electronic copies of the documentation shall be in Microsoft Office format (Word, Excel) or Adobe Portable Document Format (PDF). Drawings and schematics may be provided in PDF. All documentation the Contractor deems to be proprietary in nature shall be clearly marked. The Government shall have the right to print additional hard copies of all documentation from the CD or DVD as required. The following shall be submitted:

1.4.1 Preconstruction Submittals

1 Contractor shall provide Original Equipment Manufacturer's references as required in the specification of previous projects similar to the proposed equipment in both function and production capability and capacity.

2 Contractor shall provide the Original Equipment Manufacturer's descriptive and technical literature and performance charts for the equipment. Product specific catalog cuts shall be in booklet form, indexed and shall consist of data sheets that document compliance with the specification. Where multiple components are shown on a catalog cut, the application specific component shall be marked.

3 A visit to ANAD will be authorized to validate floor space for said equipment. It is the contractor’s responsibility to ensure adequate spacing for the equipment in the dedicated location in Bldg. 475 to include any and all setback dimensions. The visit shall be made within 15 days of the award date and be coordinated with authorized government representative.

1.4.2 Drawings Submittals

1 Detail drawings containing complete Equipment floor plan layout, mechanical assemblies, mechanical details, piping, wiring, schematic, flow diagrams and any other details required to demonstrate that the system will properly function as a unit and the equipment construction, the physical arrangement, layout and orientation and support services and waste streams are coordinated with factory plant floor layout. Drawings shall include, as appropriate; a drawing index; a list of symbols;

a series of drawings for each control system using abbreviations, symbols, nomenclature and identifiers.

Instruction for Installation Plan.

2 The Contractor shall provide an Installation Plan for the Equipment that includes utility and space requirements of the proposed equipment. The Contractor shall provide the written Plan to the

Government in an adequate advance notice to allow the Government to approve the Plan, prior to the delivery of equipment to Government Facility. This Instruction for Installation Plan shall include, but not be limited to, the following detail design specifications and drawings of the Equipment:

a. Scaled, dimensioned Floor plan drawing of the Equipment and major Equipment components showing floor space required.

b. Space required around the machine after installation for maintenance purposes and storage of chemicals being used.

c. Approximate location of utility connections on the machine.

d. Equipment electrical, pneumatic and hydraulic schematics

e. Mounting requirements

f. Maximum overall length, width, and height dimensions

g. All utility requirements including electrical, air, water, steam, drains, etc. Include consumption requirements of Amps, gallons per minute (GPM), cubic feet per minute (CFM), etc.

h. Minimum doorway opening requirements to move equipment into the building.

i. Approximate weight of the equipment, both with solution and without.

j. Approximate shipping weight.

k. Industrial waste disposal requirements l Ventilation requirements

m. PLC programs with all addresses, registers and rungs fully commented

3 Detailed layout drawings shall be submitted to the Contracting Officer for approval showing the layout of the components prior to detailed design of the equipment. Drawing must include locations of all connections to utilities and drains. Drawing shall be submitted to the Contracting Officer 20 days after the award date.

1.4.3 Product Data

1 The Product Data documentation shall include, at a minimum, the following: product specific catalog cuts, operator's manuals, maintenance manuals, calibration, specifications and procedures, spare parts lists, consumable material and parts lists, Material Safety Data Sheets (MSDS) and programming/software manuals. Maintenance manuals shall include electrical, hydraulic and pneumatic schematics, as applicable, parts lists, trouble‐shooting procedures, preventative maintenance requirements, lubrication schedule, etc.

2 All product data shall be furnished in the English language.

3 Schematics shall show and identify all parts and components down to and including components on circuit boards. Catalogs shall fully describe all special tooling, fixtures and attachments available for the

Equipment. Schematic diagrams showing equipment utilized, including motor horsepower and voltage;

starter; isolators; manual by‐passes; tubing sizes; drain piping and drain traps; reducing valves; and data on manufacturer's names and model numbers, mounting, access, and clearance requirements.

4 Control drawings shall be provided for equipment furnished and for interfaces to other equipment.

5 The recommended spare parts lists shall be complete with part numbers descriptions and recommended quantities for each item along with prices and normal deliver time for each item.

6 Operating instructions explaining preventive maintenance procedures, methods of checking the

Equipment for normal safe operation and procedures for safely starting and stopping the system manually shall be provided.

2.1 REQUIREMENTS FOR LARGE TURNTABLE WASHER

1 The large capacity turntable type aqueous washer shall be sized for cleaning of transmissions and transmission related assemblies. The washer will remove oil, grease, dirt and organic materials from transmissions and components. The turntable size and capacity shall be designed to accommodate four

(4) parts baskets with the dimensions of 35 inches wide, 40 inches long, and 35 inches high. The turntable shall have a weight capacity of 10,000 pounds (lbs.). The turntable shall allow loading by overheard or Jib crane. The contractor is solely responsible for coordinating the equipment construction, the physical arrangement, layout and orientation and support services and waste streams to factory plant floor layout. The machine used for the basis of design is Jenfab Model HDS‐12060SS2F or equivalent.

2 The washer shall include, one re‐circulating wash solution tank, one re‐circulating rinse solution tank, wash chamber with turntable, automatic sludge conveyor, two chemical feed pumps, electrical control system, oil coaleser, and a platform with stairway and safety railing shall be provided by the contractor with the equipment.

2.2 GENERAL REQUIREMENTS & SALIENT FEATURES

a. The overall washer dimensions to include the safety platform and railings shall not exceed the space envelope of 31 feet +/‐ 6 inches in length, 23 feet +/‐ 6 inches in width and 13 feet +/‐ 6 inches in height. This space envelope shall accommodate all setback distances for maintenance, operation, and safety requirements stated in this specification. Refer to Sections 1.3.7 and 1.4.1

b. Washer and washer chamber shall be constructed at a minimum of 7 gauge (ga) stainless steel.

c. Washer chamber shall have a minimum work height of 60 inches and a useable turntable of 120 inches minimum.

d. The rotating turntable shall have positive engagement drive system constructed of stainless steel and weight capacity of 10,000 lbs. The turntable shall also be equipment with stainless surface (i.e. expanded metal) to support parts baskets used to process parts as mentioned in

2.1.1. The expanded metal shall be sized to support the weight of each parts basket and allow the legs of the parts baskets to sit flush on the turntable surface.

e. Side by side swing‐out v‐notched doors with constructed of stainless steel. Dual doors opening from center to the left and to the right with overhead access.

f. The Washer shall have two re‐circulating solution stages (WASH and RINSE)

g. Stainless Steel Swing down spray bar

h. Oil Coaleser

i. Low water shut off and auto water fill combination

j. Stainless steel wash nozzles

k. Electric heating elements with programmable logic controller (PLC) controlled thermostats.

l. NEMA 12 rated electrical enclosure

m. Supply Voltage requirement: 460/480 AC, 3 Phase, 60 Hertz

n. Platform with stairway and safety railing shall be provided by the contractor with the equipment. All ladders and railing shall meet ANSI 14.3.

2.2.1 STAINLESS STEEL WASH SYSTEM

a. Tank capacity shall be 2,200 gallons minimum

b. Wash Pump system shall be at a minimum equipped with a dual 30 HP pumps with pump output of 200 pounds per square inch (PSI) at 250 gallons per minute (GPM).

c. Filter System with gauges, a Dual 150 GPM, stainless steel, canister type, and sock filter system with stainless steel inner basket using 8” diameter by 30” long sock type filters.

d. Heated closed loop wash system. Rinse system shall provide heating system to maintain system temperature. The contractor shall provide a stainless‐steel pump to recirculate rinse water back to wash tank. While in wash mode, water is diverted to wash tank. Dedicated wash solution spray manifolds are located in washer cabinet.

e. The solution tank floor shall be sloped to tank drain connection point. The solution tank volume shall be a minimum of twice the pump GPM flow. The tank shall be provided with an overflow piping connected to the drain system.

f. The tank shall be capable of heating to 185 degrees Fahrenheit (F). The maximum heat up time from ambient (70 to 170 degrees F) for all tanks shall be 4 hours and the tanks shall maintain the specified temperatures during washer operation to within +/‐15 degrees F.

2.2.2 STAINLESS STEEL RINSE SYSTEM

Heated closed loop rinse system. Rinse system shall provide heating system to maintain system temperature. The contractor shall provide a stainless‐steel pump to recirculate rinse water back to rinse tank. While in rinse mode, water is diverted to rinse tank. Dedicated rinse spray manifolds will located in washer cabinet.

2.2.3 FLOAT SHUTOFF

Washer shall be equipped with a low water shut off with an adjustable 2” diameter, stainless steel float switch mounted above the heater. In case of a low water condition, the low water shut off will turn off the heater and/or pump circuit(s) to protect the heater and the pump. The shutoff shall disable the heat source and washer operation to reduce the fire hazard, and disable the pump system to prevent damage.

2.2.4 CHEMICAL SOLUTION METERING PUMPS

TWO (2) each Dosatron Liquid Chemical Injectors or equivalent to be included on the water make‐up lines. One chemical injector pump shall be required for both the wash and rinse systems. These pumps will automatically inject the proper amount of liquid chemical and rust inhibitor every time that water is added to the solution.

2.2.5 TURNTABLE JOG BUTTON

The contractor shall provide a jog button to rotate the turntable. This button shall be added on the front of the electrical enclosure which, when depressed by the operator, rotates the turntable while the door is open, which allows for easier loading and unloading. This button shall be capable of operation while the operator is on the platform with the doors open. This capability is required to load and unload parts baskets.

2.2.6 AUTOMATIC SLUDGE REMOVAL SYSTEM, STAINLESS STEEL

The contractor shall supply a 12” wide conveyor system with 304 stainless steel construction and a conveyor drive. Designed to remove the sludge from the bottom of the wash tank and discharge it a standard 55 gallon drum. A high‐level float shall be provided for the customer supplied standard 55 gallon drum container.

2.2.7 OIL COALESCER

The coalescer shall be capable to remove up to 10 Gallons of oil per hour from the wash solution. The unit size is 18” X48”X15” (45‐gallon capacity). The coalescer unit shall be furnished with a stainless steel recirculating pump, tank insulation and fluid level controls. A sparge pipe shall be installed above the wash solution and the surface solution is constantly pushed to an overflow weir that directs all of the tank surface oil to the coalescer. The coalescer shall on a stand tall enough to feed into a standard 55 gallon drum with access to lid.

2.2.8 PLC CONTROLS

Siemens Brand Logo version 8 PLC with a Siemens Logo Human-Machine Interface (HMI) (or equivalent). The PLC shall monitor the diverting flapper valves to insure the correct ones are open and closed in order to direct solution back to the appropriate wash and rinse tank. The

PLC shall also control the cycle times and pauses between stages (wash, rinse, and shop air blow off), to let wash drip and return to wash tank before switching to rinse stage of cycle. The HMI shall provide feedback to the operator of which part of the cleaning cycle the machine is in and how much time remains for the cycle. The cycle times shall be changeable on the HMI screen and have the capability to be password protected. The HMI shall display any and all fault conditions.

2.2.9 STEAM EXHAUST SYSTEM

Washer shall be equipped with an exhaust system to produce a minimum of 1000 (cubic feet per minute (CFM) to remove steam exhaust system from the washer process chamber. The system shall utilize a powder coated, mild steel tube axial type, belt driven exhaust fan, powered by a half horsepower, 1,725 revolutions per minute (RPM), three phase, totally enclosed, fan‐cooled

(TEFC) electric motor. An exhaust box shall be provided to the machine to be set up for a 12” tube axial fan connection.

2.2.10 TWO CHANNEL TIMER

A two channel timer system shall be supplied to control the on and off times of the oil skimmer and heat for both wash and rinse systems.

2.2.11 ONE CHANNEL DIGITAL THERMOSTAT

These controls shall be microprocessor based and panel mounted. This option shall have the capability to lock in the temperature settings.

2.2.12 INSULATION FOR THE MACHINE HOUSING

The entire washer shall be insulated with 1” fiberboard and 18ga stainless steel cover.

2.2.13 SHOP AIR BLOW‐OFF SYSTEM

This blow off system shall be constructed of stainless steel. This system shall be plumbed or routed into the washer to aid in dying of parts after process cycles. This system shall be plumbed with a minimum of a one ¾” air manifold, and controlled by a 1” solenoid valve.

2.2.14 VISIBLE STACK LIGHT WITH AUDIBLE ALARM

A red, amber and green stack light w/110V AC steady‐on lights shall be mounted to the top of the control box to visually indicate the status of the system. Red=Fault, Amber=In Cycle, Green=Complete.

2.2.15 STAINLESS STEEL SWING DOWN SPRAY BAR

A spray manifold shall be supplied and connected to the main plumbing of the machine to make cleaning smaller parts more efficient. When not in use, this manifold system shall be capable of move or swing when processing larger parts.

2.2.16 HYDRO BLAST DETAIL SPRAY GUN

A spray gun shall be supplied that manually operates off of shop supplied compressed air. This detailing spray gun shall siphons the cleaning solution from the wash tank and directs it onto the parts with the added force of the compressed air. This detail spray gun shall also be able to be used with the siphon function turned off to aid in manual blow off of the parts with the compressed air.

2.3 SYSTEM REQUIREMENTS

1 The washer system shall be floor installed without a pit.

2 The washer shall be provided with a minimum 50 GPM pneumatically powered diaphragm type pump to assist emptying of solution tanks to drums or other containers for either off‐site disposal. Both tanks shall be plumbed to the facility drain.

3 A safety float switch shall be provided to prevent heating system when operating under low water condition. The solution heating system shall be controlled by an automatic 7‐day timer located on the main NEMA 12 control panel. The timer will be controlled by the PLC. The heating of the tanks shall be from an electrical energy source. The water lines shall be run to the tank and shall have an automatic water level control. Make‐up water for the tank shall be automatically controlled. The make‐up water will be added at a rate and frequency to prevent the temperature from falling below the minimum temperature limit. The tanks shall be constructed in such a manner to allow addition of chemical and for ease of solution removal as well as complete draining capability and for ease of cleaning. The tanks to be provided with minimum 4 inch freeboard.

4 There shall be Cycle Timers that allow separate setting of wash, rinse, blow‐off and exhaust stages.

5 The washer shall have an overflow protection that shuts off water fill to prevent flooding of the shop.

6 An automatic water refill shall maintain the solution at a nominal operating level. The washer shall include a system to automatically provide for make‐up water as the solution evaporates. Each tank shall have its own system and be plumbed separately. Chemical pumps (2 required) to be provided for each solution stage to add chemical automatically as new water is added.

7 The equipment shall be equipped with suitable grounding devices for static discharge.

8 The filter system shall monitor the amount of solids deposited into the cleaning solution. The filtration system monitors the different differential pressure across the filter and provides an alarm when the volume of solids in the solutions is too high. This indicates that a filter change is required.

9 Any non‐metallic material that is affected by contact with cleaning compounds shall not be used. If requested, the specific chemical solutions can be provided to the contractor.

10 The equipment shall have a door seal that is maintenance free and traps spray and steam inside the cabinet. The washer shall have a drip tray to keep the floor dry and safe.

11 A sound enclosure shall be provided on all pump motors.

12 The washer shall have chemical metering pumps that inject rust inhibitor or other chemical treatment into the make‐up water. The chemical shall be mixed with rinse water and applied to the wash load at the end of the wash cycle.

2.4 ADDITONAL DESIGN CRITERIA

1 Spray Enclosure Design‐ Easy access to the washing jets shall be provided so that jets and jet positioning can be easily and quickly inspected. Doors shall be provided with safety latches and switches to prevent pump operation when in the open position. Manifolds shall be designed for quick replacement of nozzles or nozzle assemblies. Manifolds and nozzles shall be built from stainless steel.

2 Plumbing System‐ the plumbing system shall have adequate filters to prevent nozzles from becoming clogged even after dirt and debris have been removed from large quantities of parts.

Chip trays and screens shall be provided to "pre‐filter" solution returning to the solution tank. A type stainless steel mesh screen will be the primary filter in the solution tank system. A clogged filter fault indicator indicating need to change filter bags shall be provided on the main electrical panel. Bag filter units shall be provided with safety switches to prevent pump operation while bag filter units are being serviced. A pressure gage will be provided in the output side of both the wash and rinse pump outputs. The filter shall permit removal and replacement of the filter element without draining the re‐circulating system or the cleaning chamber. Means shall be provided to automatically shut off the re‐circulating pump and the cleaning solution heater in the event the filter element becomes clogged.

3 Instrumentation‐ A PLC shall control the washer. Instrumentation shall be provided so that the cleaning solutions can be easily monitored and means of corrective action can be taken care of within minutes. A 7‐day timer controlled by the PLC is to be provided so that the system can accommodate changes in work shifts. An indicator light and alarm shall be provided to warn the operator if the solution temperature has fallen below the minimum specified level. It must be in a convenient place for the operator to see.

4 Electrical Panel‐ Electrical panel to be provided with minimum following controls.

a. On/off switch for table drive motor, pump motors, sludge conveyor, exhaust motor, oil skimmer motor and heating elements.

b. Temperature indicator and temperature controller for each solution stage

c. 7‐day timer control for heating system, oil/sludge removal operations.

d. Operator/PLC interface panel with system status and troubleshooting messages. (example):

bag filter clogged, wash door open, sludge conveyor jam, low temperature, low water level, etc.)

e. An emergency stop button shall be furnished on the equipment located conveniently for the operator. It will be marked for emergency use only.

5 PLATFORM‐A grated platform and stairs shall be provided and constructed to allow operators load work pieces at ergonomic working height. Handrails shall be provided. This shall meet all applicable OSHA safety requirements. The platform shall must not obstruct any operator or maintenance function of the washer.

2.5 Ventilation/Exhaust

1 There shall be an automatic steam exhaust system that removes steam from the cabinet during the cleaning cycle and evacuation at the end of the cycle, prior to opening the door. There shall be a timer that that is adjustable to prevent the door from opening before the majority of steam has been exhausted from the cabinet after the rinse cycle is complete. The timer shall control the amount of time the steam exhaust blower runs after the door is opened.

2 An exhaust blower shall be included to remove steam from the washer. This will be vented through the roof. The exhaust blower capacity shall be a minimum of 1000 CFM. After the washer door has been opened the PLC shall shut the blower down to prevent exhausting additional air from the building.

2.6 SAFETY

1 Emergency stop buttons shall be furnished on the equipment conveniently located for the operator near the loading/unloading positions as well as one near the filter maintenance area. They shall be marked for emergency use only.

2 A sound enclosure shall be provided over motors and other devices that create noise. The sound level shall be 80 dba MAX. Absolute.

3 The floor around the equipment must be dry at all times to prevent operators from slipping.

The washer shall have a drip tray to keep the floor dry and safe.

3.1 INSPECTIONS & VALIDATIONS

1 The Government or Government representative shall have the right to visit Original Equipment

Manufacturer's plant to inspect work in process at reasonable times and in a reasonable manner by notifying Contractor in advance. Any approval during any inspection, or the failure to inspect at all, shall not be deemed to be a waiver of any of Government's rights.

2 Government may require written reports from Contractor on the progress of the design and construction of the Equipment. These reports shall at a minimum include a statement of the major components and parts purchased, the percentage of the design or Equipment completed as of the date of the report, a narrative of any problems or difficulties encountered, and a statement of any difficulties then contemplated and a statement of the procedure to be taken by Contractor to remedy the reported difficulties.

3.2 Conformance Validation

The Equipment shall meet the requirements of this specification and conform to the Original

Equipment Manufacturer's own drawings, specifications, standards, and quality assurance practices.

Conformance Validation shall be witnessed verified and documented by the Contractor. The government reserves the right to, at any time during the contract period; require proof of such conformance or to inspect the Equipment to determine compliance with the requirements of this specification.

3.3 DELIVERY AND SHIPMENT

1 The Contractor shall be responsible for delivering the Equipment to the Anniston Army Depot

(BUILDING 475), 7 Frankford Avenue, Anniston, Alabama, 36201.

2 The Equipment shall be protected from damage and the weather during shipment.

2 Contractor shall notify Government when the Equipment will be ready for shipment. Contractor will be responsible for dismantling, crating, and loading the Equipment aboard the carrier, shipment and unloading and uncrating at Government Facility. All delivery and freight charges shall be included in all proposals.

3.4 INSTALLATION

1 The complete installation of this equipment in Government facility shall be the sole responsibility of the Contractor.

2 The contractor shall be responsible for providing employees qualified to provide adequate supervision to perform the installation.

3 The contractor shall be solely responsible for the installing, adjusting, and performing acceptance testing of the equipment.

4 The Contractor shall be responsible for adjustment of all Equipment sensors, switches, controls, nozzles, PLC programs and settings, chemical dosing adjustments and any other adjustable components as required after the Government has completed the basic Equipment installation as specified herein.

5 The installation of this equipment shall be verified by authorized government representative. The

Contractor shall be responsible for identifying all components and functionality described in the

Specification to the Contracting Officer or Contract Officer’s Representative.

3.5 TESTING AT ANNISTON ARMY DEPOT (TRANSMISSION FACILITY BLDG 475)

3.5.1 Acceptance Test

1 The entire system shall be tested. Oil, grease, grime shall be removed and preservative added to avoid rust. All heated tanks shall be tested to verify that the temperature control is as specified herein.

The exhaust systems shall be tested. This test shall be conducted by the contractor and validated by an authorized ANAD representative.

2 If the Equipment fails to conform to the Specifications or fails to meet the requirements of the test, the Contractor shall promptly make such repairs, replacements or changes as may be necessary to correct all such nonconformities. Contractor shall continue to correct and modify the Equipment until it meets the Specifications and passes the acceptance.

3.5.2 Conformance Validation

The Equipment shall meet the requirements of this specification and conform to the manufacturer's own drawings, specifications, standards, and quality assurance practices. Conformance Validation shall be witnessed by the Government representative, verified and documented by the Contractor.

3.6 TEST FAILURES

If any of the Equipment furnished under this contract fails to operate as required, or fails to meet any of the specifications provided for in this contract; the Government will have the right to operate the equipment until such defects have been remedied, without the Government accepting the Equipment and without cost to the Government.

3.7 TRAINING

The Contractor shall provide ANAD Employees training sessions on the operation and maintenance of the Equipment to be completed after the Equipment has passed the acceptance test. The training instructors shall be the provided by the contractor personnel.

3.7.1 Maintenance Training

Maintenance training shall be provided by the contractor of the Equipment. Two (2) mechanical maintenance technicians shall be trained by a factory representative at ANAD. The training shall include:

physical layout of each piece of hardware, procedures, preventive maintenance procedures, schedules, troubleshooting, diagnostic procedures and repair instructions.

3.7.2 Equipment Operator Training

For the Equipment operator training, four (4) Equipment operators shall be trained by a factory representative in operation of the Equipment and its controls. This training shall include: general equipment architecture; functional operation of the Equipment, including workstations; operator commands; application programs, control sequences, loops and fault clearing operations.

3.8 CERTIFICATE OF SPECIFICATION COMPLIANCE

The Contractor shall provide a written certification after the conclusion of all testing, training, document submittal that the equipment meets or exceed these specification requirements.

3.9 EQUIPMENT APPROVAL

Upon the Government approval of the acceptance test delivery of all documentation to include operation and maintenance data; verification of equipment manufacturer's service and repair capability meets the specified requirements; and the delivery of the Certificate of specification the Government will approve the equipment.

4.0 WARRANTY

The Equipment shall be covered by a warranty. The warranty shall be for a period of not less than 1 year and shall begin the day following Government issuance of final acceptance of the Equipment per paragraph 3.5. The Contractor shall respond to requests for warranty service within 48 hours after requests. The warranty shall be written in the Anniston Army Depot’s name.

5.0 Required Language from the Environmental Checklist.

5.1 Compliance with Environmental Laws and Regulations. The Contractor shall comply with all applicable federal, state, and local environmental laws, statutes, regulations, executive orders, permits, Army regulations (with supplements), as well as Major Subordinate Command (MSC) and installation regulation, policy, Host Tenant Agreement, Interagency Service Support Agreement, or

Status‐of‐Forces Agreement. The Contractor shall immediately report any conflicts between applicable federal, state, local environmental laws, statutes, executive orders, and provisions of Army Regulation

200‐1, and any specifications within this contract to the Contracting Officer Representative (COR).

5.2 Compliance with Green Procurement Requirements. The Contractor shall follow Federal

EPA Comprehensive Procurement guidelines (www.epa.gov/cpg)…