Purchase_Description_Prop_Blade_Water_Blast_System_L8WC01_5-2-18.pdf

NEW PROP BLADE WATER BLAST SYSTEM, B140 (L8WC01)

Purchase Description

02 May 2018

1. Scope: This document provides the description that shall be used to acquire one (1) system. The system shall consist of one robotic waterblast system designed to remove the rubber goods and foam fairing from the shank of the C- 130/P3 propeller blade and the lead wool from inside the taper bore without eroding or damaging the blade or taper bore in any way. This system will need the capability to depaint the C-130/P3 prop pump housings and covers and the C-130/P3 valve housing covers with no damage. Dimensional drawings of these assets are shown in Appendix D.

This system will also include a waterblast cabinet that will contain the working envelope of the waterblast system. The complete system will be installed in the prop D&C area in building 140, RAFB. The existing area is approximately 19’ X 25’, see Appendix A.

1.1. The purchase price shall include the system, delivery, all listed accessories/options, installation, all building modifications (once 332 approval has been received), testing/verification, training/familiarization, and warranty.

1.2. The contractor shall provide all materials, equipment, and labor necessary to deliver and install the system.

1.3. All work shall be completed in accordance with this purchase description and subject to the terms of the contract.

1.4. The system shall be installed no later than 15 months after contract award, training and production support shall not exceed 3 months following installation. The total period of performance shall not exceed 18 months.

1.5. Certain components of this effort have been specifically called out by brand name for this purchase description. The robot, industrial control equipment, and high pressure pumps for this effort shall be of the brand Fanuc, Rockwell Automation and CESCO, respectively. “Or Equal” will not be accepted.

2. Design: The system shall be new and complete, custom built to meet our applications, and ready for immediate operation after installation, acceptance testing and training are completed.

Contractor shall provide equipment the same as Progressive Surface Model 1634 with upgrade package Q7683. The System shall have 100% operational compatibility with the current system.

3. Equipment Description: The contractor shall provide all Commercial Off-the-Shelf (COTS) Equipment Manuals for the components used in the system. (CDRL A003, Commercial Off-the- Shelf (COTS) Equipment Manual Requirements, DI-TMSS-80527C).The system shall consist of the following.

A. Blast Cabinet:

(i). The system shall have enough reach to allow waterblast of all sides of each of the assets shown in Appendix B. The water blast cabinet shall be 144 inched long, 88 inches wide, and 28.25 inches high. Appendix B shows the approximate dimensions for each asset.

The cabinet shall be a minimum of 1/2 inch steel welded construction and the inner cabinet that contains the process is stainless steel lined

(ii). The approx. dimensions of the install area are: nineteen (19) feet wide by twenty five (25) feet long for the area, see (Appendix A).

(iii). The robot shall be mounted in a fixed position to allow the robotic arm to reach the entire portion of the asset that is being water blasted. The system shall have a spindle axis that turns the parts. This axis shall be in addition to the six robot axes. This axis shall be J1 in Group 2, to be setup like the original blast cabinet. Additionally, this spindle shall be mounted to the door for ease of asset loading.

(iv). The blast cabinet shall provide the support structure for the robot. This structure shall not rely on the building structure. The structure shall be designed to minimize the impact on the work envelope.

(v). The system shall not have any structural components that will interfere with the loading of any part. Assets will be loaded onto a fixture on the inside of the water blast cabinet work door. The work door shall be 54 inches high and 66 inches long or sufficient size to load the largest asset to be water blasted. The work door shall have a fixture for holding the prop blade integrated into the spindle. The assembly shall hold 150 lbs minimum and locating the blade using the drive pin holes, and clamping it in place using four clamps on the thrust ring, that will hold the prop blade at zero orientation and rotate the blade at 2 rpm minimum and mounting locations to hold the fixtures for the valve housing cover, pump housing, and pump housing covers. The work door will have a door stop with shock absorber and magnet to hold door in the open position. The work door shall have a pneumatic clamping system to keep door shut and securely sealed during blasting operations.

(vi). There shall be two personnel doors, one on the left side as facing the front of the equipment and one on the back with step that provides walk–in access to the inside of water blast cabinet. The system shall have safety mechanisms that prevent personnel from entering during robot operation. The doors shall have windows to allow viewing during operation.

The windows shall also have a method to not become soiled with the debris and water from blasting.

(vii). The system shall have high output LED lamps to illuminate the blast cabinet interior. A minimum 2000 lux.

(viii). The blast cabinet will have feet to support and allow leveling of the machine.

(ix). The system noise level shall not exceed 75 db, slow measured, 3 feet from the equipment during normal operation.

(x). The contractor shall be responsible for tying into the existing industrial waste water drain.

(xi). There shall be a water blast debris catching trench underneath that will use a conveyor to transfer the foam, rubber, and lead wool sludge to a cabinet waste hopper for disposal.

This system shall be able to capture larger debris and lead wool particles/strands with sizes greater than 1/16 inch. The debris removal system shall have a capacity of at least 500 lbs and a conveyor speed between 1 and 10 inches per minute. A perforated plate will be underneath the conveyor that will allow water and small debris to flow into a sump that will pump into an industrial waste drain. The sump that removes the dirty water laden with small process debris shall operate automatically. A grating shall be installed over the trench to support up to 3 personnel inside the blast cabinet. The grating shall be in sections easily replaceable by maintenance personnel.

(xii). A mist collector shall be provided to remove mist from process air and drain condensate to process cabinet. This shall have a manual and automatic operation.

(xiii). A hand operated manual rinse nozzle with water hose shall be provided for manually cleaning the inside of the cabinet.

(xiv). A hand operated compressed air manual blow off nozzle with coil hose to blow debris and media off parts and equipment inside the cabinet shall be provided.

(xv). The contractor shall provide a 500 lb capacity hoist for loading and unloading parts on the work door fixture. The hoist shall be a jib configuration mounted to the outside top of the blast cabinet with the correct reach to load all parts on the door to be water blasted. The structure of the blast cabinet shall support the hoist fully loaded.

B. Water Blast Pumps:

(i). The system shall have two (2) electric motor driven CESCO model E75-II aquamiser water pumps. The pumps shall be capable of 40,000 psi water blasting to the output nozzle. The system will only operate on one aquamiser pump, but can be switched to the other pump as a backup. The system shall have the ability to set the pressure from the pump controls as well as from the robot controller/tp program.

(ii). The aquamiser pumps shall run on water flow of 4gpm @ 30 psi, compressed air of 30 cfm @ 100 psi and electrical input of 480 volt, 3 phase, 60 hz, 150 amps.

(iii). The aquamiser pumps shall have 3 step water filtration system: primary filtration using a high capacity 10 micron cartridge, secondary filtration using a high capacity 2 micron cartridge, and final filtration using a high capacity 2 micron cartridge.

(iv). There shall be 2 ea high pressure water blast heads mounted on the robot. The heads shall be selectable and settable through the robot controller/tp programs.

1. One (1) rotary, four nozzle: two .017, one .012, and one .008 ruby tips, to remove the rubber goods and foam fairing from the shank of the blade, depaint the prop pump housings and covers and depaint the valve housing covers. The rotary nozzle shall rotate at a minimum of 1500 rpm using high pressure water supplied to the four ruby tips.

2. One (1) stationary, one nozzle: .026, for removal of the lead wool inside the taper bore of the prop blade.

(v). There shall be one (1) high pressure pump transfer system with Rockwell Automation controller interface. This system will allow the blast cabinet to utilize either pump.

(vi). High pressure water tubing and fittings capable of handling water pressures up to 40,000 psi shall be installed between the aquamiser pumps, transfer system, and the water blast heads.

C. Robot Hardware/Software:

(i). The system shall consist of a Fanuc robot with a payload that will handle the blasting forces.

(ii). The robot shall have enough reach to remove the rubber goods and foam fairing from the shank of the C-130/P3 propeller blade and the lead wool from inside the taper bore. The robot shall have enough reach to depaint the C-130/P3 prop pump housings and covers and the C-130/P3 valve housing covers. The dimensions of each of the assets listed in Appendix B.

(iii). The system shall employ Handling Tool.

(iv). The robot controller shall be of type R-30iB or later with an i pendant.

(v). The robot controller shall not be located in the water blast cabinet. The robot controller shall be installed such that it is protected from the water used in the operation and kept at the proper operation temperature.

(vi). The robot teach pendant shall reach all areas in the blast cabinet for teaching/programming parts.

(vii). The robot shall employ Fanuc Dual Check Safety (DCS) and Collision Guard.

D. Subsystem Hardware:

(i). The water blast system shall be controlled by a single Rockwell Automation/Allen-Bradley

PLC (Logix 5000 family).

(ii). The communication protocol used for communication between the robot, PLC, HMI, and any remote I/O shall be Ethernet/IP

E. Subsystem Software:

(i). The Government shall be provided and shall own the PLC and HMI source code (.ACD and .APA files) and no parts of the code shall be password protected, unless the

Government will be given the password. This code will not be sold/given to 3rd parties unless the original developer goes out of business, no longer supports the system, or gives written permission to do so. The Government does reserve the right to use the code for troubleshooting, re-installing/downloading in case of program loss, or program modify if required.

F. Programming:

(i). The system shall allow for the addition of future part programs and recipes.

(ii). The contractor shall provide a total of three (3) non-consecutive weeks of programming support.

(iii). All programs shall be interchangeable and fully compatible with the current system.

G. Part Mounting Fixtures (i). The contractor shall provide the following fixtures to hold the parts on the inside of the work door during water blasting.

1. One (1) C-130/P3 prop blade mounting fixture, dimensions of both prop blades shown in Appendix D. One (1) spare set of hardware (studs and knobs) included.

4. Acceptance Testing

4.1. The complete factory and site acceptance plan for the system shall be developed by the contractor; reviewed and modified/approved (as appropriate) by the Government contract technical representative; and mutually agreed upon prior to conducting any test. Documentation verifying the acceptance testing and verification shall be provided to the Government.

4.2. New Prop Blade Water Blast System (L8WC01) - Factory Acceptance Testing (CDRL A006, Factory Acceptance Test Plan, DI-QCIC-80553)

A. The contractor shall assemble system and completely setup the water blast system including:

cabinet, high pressure aquamiser pumps, HMI, PLCs, robot hardware/software, subsystem hardware/software, data recording, and in-process testing at their facility.

B. Once the setup is completely assembled, working and the Government has approved the test plan, the contractor shall notify the Government POC via email and within thirty (30) days the Government shall send representative(s) to verify the following:

(i). The contractor shall demonstrate the ability to automatically and completely process the parts, including fairing removal, lead wool removal and depaint of all the appropriate parts called out in this document.

(ii). The contractor shall demonstrate how the water blast pressure to the nozzle can be adjusted to different values.

(iii). The Government representative(s) shall verify the robot hardware/software and subsystem hardware/software.

C. Upon successful demonstration of the above, the Government will give approval to ship the system to Robins AFB for installation.

4.3. Site Acceptance Testing (CDRL A007, Site Acceptance Test Plan, DI- QCIC-80553)

A. Once installation at Robins AFB is completed and the Government has approved the test plan, the contractor shall notify the Government POC via email and within one (1) week the Government representative(s) shall verify the following:

(i). The contractor shall demonstrate the ability to automatically and completely process the parts, including fairing removal, lead wool removal and depaint of all the appropriate parts called out in this document.

(ii). The contractor shall also demonstrate how the water blast pressure to the nozzle can be adjusted to different values.

(iii). The contractor shall demonstrate the creation of program.

(iv). The Government representative(s) shall verify the robot hardware/software and subsystem hardware/software.

5. Installation:

5.1. The systems shall be installed by the contractor/vendors qualified representative(s) in the government’s designated facilities/locations on Robins AFB, GA. All items shall be assembled and installed utilizing best commercial practices and manufacturer’s installation procedures. The government shall supply all required utilities within ten (10) feet of the installation site. To have the utilities installed and ready for connections, the contractor shall provide a list of all required utilities along with the required quantity and description, within the initial project planning chart (CDRL A004, Project Planning Chart, DI-MGMT-80507C).

6. Training:

6.1. Within fifteen (15) days of installation and site acceptance testing completion, operator and maintenance training will be provided for up to 10 Air Force civilian equipment operators and service technicians by the contractor’s qualified representative at no additional cost to the government. The listed training shall be provided for the system installed and a training manual for the system installed. (CDRL A005, Training Materials, DI-ILSS- 80872).

6.2. Training shall include:

A. Two (2) weeks of operator training, to include production runs on assets and review of the operation manual.

B. One (1) week of maintenance training, to include a complete preventive maintenance cycle, basic troubleshooting, review of the electrical/mechanical drawings and maintenance manual, and review of the HMI/PLC code.

C. Two (2) weeks of programming/engineering training, to include a complete part creation sequence and review of the programming manual.

7. Additional Requirements:

7.1. Contractor shall have robotic de-paint experience and depot level experience.

7.2. The contractor shall provide three (3), nonconsecutive, one (1) week production support visits, to be scheduled as required throughout the first initial year. The contractor shall be onsite within two (2) weeks of being notified that onsite support is required.

7.3. A final walk through inspection shall be conducted with the Government Technical Representative after the installation has been completed. Any components damaged, missing, or installed improperly will be identified and corrected by the contractor in a timely manner prior to completion of the contract. Only the Contracting Officer is authorized to make changes to the resulting award document and/or contract on behalf of the Government.

7.4. SAFETY REQUIREMENTS:

A. The contractor shall establish and maintain a safety and health program in accordance with the elements listed in the Appendix C (Safety Requirements). The contractor shall submit a Safety and Health Plan 10 days after award for review and acceptance by the WR-ALC/SE (Safety Office). The contractor shall ensure their Safety and Health Plan addresses, in detail, the items listed in the Appendix C. If task specific procedures are incorporated into a company local document, ensure those procedures are included/attached to the company's Safety and Health Plan. Referencing the company's local procedure/ document in the safety plan is not adequate. If the company's local procedure/document is not attached; Safety Plan will be returned "Not acceptable". (Safety and Health Plan CDRL A001-DI-MGMT-81580/T, Contractor's Standard Operating Procedures)

B. The contractor Safety Plan shall address in detail the items listed in the Contract Appendix C, Part II through Part IV as applicable. For task specific procedures identified in the Contract Appendix C, the contractor's internal procedures for those tasks must be identifiable within the submitted Safety Plan or shall be provided in an amendment or addendum to the company's Safety Plan. If task specific procedures identified in the Contract Appendix C, are not submitted with the contractor's Safety Plan, the submitted Safety Plan will be returned as NOT ACCEPTED. The contractor will have 5 working days to resubmit the Safety Plan, amendment or addendum to address or correct issues identified for non-acceptance. The WR- ALC Safety Office will provide acceptance or non-acceptance of the resubmission within 5 workings days of receipt to the COR who will notify the CO.

C. Mishap/Incident Reporting. The contractor shall report all mishaps/incidents in accordance with the contract Appendix C. The contractor shall immediately secure the mishap scene and damaged property and impound pertinent maintenance and training records until released by the Government's Safety Office (WR-ALC/SE). Such release shall be accomplished through the CO. The contractor shall cooperate and assist Government personnel in the investigation of the incident and submit an Accident/Incident Report within 24 hours of the accident/incident. The Contractor shall require all subcontractors to comply with required safety, health and fire standards. (CDRL A002, Accident/Incident Report, DI-SAFT-81563/T)

7.5. Contractor shall provide signs, barricades, and lights as required to protect base personnel.

7.6. Schedule. The contractor shall schedule and perform the work as to minimize negative impacts on production.

7.7. The contractor shall perform the required work during the following normal business hours:

6:00 AM – 6:00 PM, Monday – Friday. Work performed on weekends and holidays shall be approved by the Contracting Officer before work commences. A Government Representative shall be present in the event of weekend/holiday work schedule.

7.8. The contractor shall remove all packing materials and residue from the area and properly dispose of these off base. The work area shall be maintained in an uncluttered and safe condition at all times or work will be terminated until the conditions are corrected.

7.9. Under no circumstances shall the contractor use Government equipment such as forklifts, ladders, stools, tools, etc., during equipment installation.

7.10. The systems shall include all of the necessary consumables required for initial operation.

7.11. Three (3) months after contract award, the contractor shall provide a single Gantt Chart showing the project schedule from contract award through final inspection for the system.

Additionally, the Gantt Chart shall be provided monthly after the initial project schedule. (CDRL A004, Project Planning Chart, DI-MGMT-80507C)

8. Warranty: All standard Warranty provisions shall be included with the bid package but as a minimum shall include one (1) year parts and labor from the time of acceptance (for each system) for defects in material and workmanship.

9. Bid Package Requirements:

9.1. New Prop Blade Water Blast System (L8WC01)

A. Total Cost

B. Basic system layout, to include:

(i). High pressure water distribution system

1. One line diagram

2. Water blast heads/nozzle types (ii). Robot

1. Robot model (for example only- Fanuc R-2000iB)

2. Robot controller model (for example only- Fanuc R-30iA)

(iii). Top view layout showing:

1). HMI location for transfer valves.

2). Robot location 3). Work envelope, location and structure, including structure material and coatings 4). Work envelope 5). CESCO model E75-II aquamiser water pumps location

6). Robot control cabinet location 7). Subsystem control cabinet location

C. Animated simulation to demonstrate work envelope and robot reach

10. Data Deliverables/Contract Data Requirements Lists (CDRL):

CDRL # Ref. Para. Description A001 7.4.A, 7.4.B Contractors Standard Operating Procedures A002 7.4.C Mishap Report A003 3 Commercial Off the Shelf Equipment Manuals and Associated

Documents (Operator/Maintenance Manuals, Spare Parts List, Schematics)

A004 5.1, 7.11 Project Gantt Chart A005 6.1 Training Material A006 4.2 Acceptance Test Plan-Factory A007 4.3 Acceptance Test Plan-Government Site

11. Government Technical Representatives. The on-site Government points of contact are:

Primary: Alternates:

Charles Armstrong Shane Groves

402 CMXG/MXDEA 402 CMXG/MXDQBE

Robins AFB, GA Robins AFB, GA Comm 478-222-4080 Comm 478-335-6482

12. Security Requirements

12.1 Government Security Regulations: The Contractor shall ensure personnel, information, system, facility, and international security requirements are met in accordance with DoD 5220.22-M, National Industrial Security Program Operating Manual (NISPOM), Air Force Instruction (AFI) 31-101, Integrated Defense.

12.2 Security Clearance: The Contractor shall ensure Contractor personnel have a valid security clearance appropriate to the access required for proper accomplishment of contract/order requirements. Classified material will not be accessed as part of this contract’s performance.

Contractor personnel shall not be authorized access to classified and/or sensitive, but unclassified, information and/or materials or be permitted to work on classified and/or sensitive, but unclassified, projects and/or programs without a proper security clearance and a need-to-know. Contractor personnel whose clearances have been suspended or revoked shall immediately be denied access to classified and/or sensitive, but unclassified, information.

12.3 Communications Security (COMSEC): The Contractor shall use only secure communications methods and/or equipment to transmit or otherwise transfer classified and/or sensitive, but unclassified, information in accordance with DoD 5220.22-M.

12.4 Access to Government System: The Contractor shall ensure a CAC is obtained by all contractor/subcontractor personnel who require access to DoD computer networks/systems, for DoD facility entry control and/or for physical access to facilities and buildings to perform tasks under the contract/order. The Contractor shall provide a list of contractor/subcontractor personnel who require a CAC to the PCO. The Government will provide the Contractor instruction on how to complete a Contractor Verification System (CVS) application and notify the Contractor of approval/disapproval of contractor/subcontractor personnel application. Contractor/subcontractor personnel shall obtain the CAC from the local Real Time Automated Personnel Identification Documentation System (RAPIDS) issuing facility [usually the Military Personnel Flight PF)].

12.5 The Contractor shall immediately report a lost or stolen CAC as directed by local Government policy. The Contractor shall notify the PCO of any change to the list of contractor/subcontractor personnel who require a CAC and provide an updated list within five business days. The Contractor shall return a CAC within five business days once contractor/subcontractor personnel no longer require computer network/system access and/or facility access. The Contractor shall return an expired CAC within five business days after the expiration date. The Contractor shall return any and all CACs within five business days after completion/termination of the contract as directed by local Government policy.

13. Access to Government Facilities

13.1 The Contractor shall ensure Contractor personnel who require access to Robins AFB or other Government facilities comply with the security procedures of the facility.

13.2 The Contractor shall ensure an ID card is obtained by all contractor/subcontractor personnel who require recurring access to a Government facility, but not local area network (LAN) access. The Contractor shall submit a letter to the PCO listing all contractor/subcontractor personnel requiring access to the facility. The PCO will approve the request and forward it to the issuing/registration office for processing. Contractor/subcontractor personnel shall report to the issuing/registration office to obtain the ID card(s).

A.

13.3 The Contractor shall submit a letter to the PCO immediately if contractor/subcontractor personnel no longer require access, upon transfer/termination of contractor/subcontractor personnel or upon completion/termination of the contract/order. The letter shall identify the name(s) and social security number(s) of the contractor/subcontractor personnel. The Contractor shall return the ID card(s) to the issuing/registration office upon expiration, upon transfer/termination of contractor/subcontractor personnel, or once contractor/subcontractor personnel no longer require access to the facility. The Contractor shall return any and all ID cards to the issuing/registration office upon completion/termination of the contract.

13.4 Operations Security (OPSEC): The Contractor shall ensure compliance with OPSEC requirements including procedures to protect classified and/or sensitive, but unclassified, Government projects and/or programs. The Contractor shall ensure Contractor personnel who perform work at Robins AFB or another Government facility comply with the OPSEC procedures of the facility.

B.

13.5 Security Incident or Violation: The Contractor shall immediately notify the Government Security Office of any potential or actual security incidents or violations including potential or actual unauthorized disclosure or compromise of classified and/or sensitive, but unclassified, information.

14. Affirmative Procurement Programs (APP)

14.1 In accordance with FAR 23.404(b)(1), 100% of purchases of Environmental Protection Agency (EPA)-designated products included in the Comprehensive Procurement Guidelines (CPG) list [https://www.epa.gov/smm/comprehensive-procurement-guideline-cpg-program] and/or United States Department of Agriculture (USDA)-designated products included in the biobased product listings [http://www.biopreferred.gov] shall, at a minimum, meet the EPA or USDA standards for recovered materials or biobased content, respectively, unless an item cannot be acquired competitively within a realistic timeframe, meet appropriate performance standards, and/or be acquired at a reasonable price.

14.2 In accordance with FAR 23.404(a)(iii), the Contractor shall provide estimates and verification of recovered material for EPA-designated CPG products and certification for both EPA-designated CPG products and USDA-designated biobased products. In accordance with the Robins Air Force Base, Georgia / Green Procurement Program (GPP) Plan, the Contractor shall provide estimates and certifications to the Government for completion of the applicable attachment(s) to be included in the Purchase Request (PR) package.

15. Environmental Management System (EMS) Awareness Training: Environmental Management Systems (EMS) Awareness Training: All contractor personnel working on Robins AFB who perform activities on the installation are required to complete Air Force-provided initial EMS Awareness Training. It is the responsibility of the Prime Contractor to ensure that all sub-contractors, vendors, and employees complete this training prior to beginning work on Robins AFB.

Notification of training completion shall be sent to both the Robins AFB Contracting Officer (CO) to be maintained in the contract file and Environmental Management, 78 CEG/CEIE, (78ceg.cev.FrontOfc@us.af.mil) for tracking purposes. Failure to provide documentation of EMS Training may result in termination of the contract.

15.1 EMS training is provided by Environmental Management at (478) 327-8104 or

(478) 926-9645. Contractors have two options to satisfy the mandatory EMS

Awareness Training requirement. Contractors that do not have a Common

Access Card must exercise Option 2.

15.2 Option 1 (Preferred Option): The Air Force version of EMS

Awareness Training is available through the Advanced Distributed Learning

Service (ADLS) website:

https://golearn.adls.af.mil/kc/rso/login/ADLS_login.asp. EMS Awareness

Training is located under the miscellaneous tab. This option is only available to contractors who have a CAC and takes approximately 10 minutes to complete.

15.3 Option 2: Contractor requests a copy of the Robins EMS Awareness

Training Power Point Presentation from Environmental Management. The request should be sent to the Environment Management Workflow Box at the following email address, 78ceg.cev.FrontOfc@us.af.mil. Once the presentation is received, the contractor is responsible for ensuring that all his/her employees view the training.

APPENDIX A

New Blast

Cabinet and

Pumps

APPENDIX B