SOW_with_App_C.pdf

SOW Monitoring and Controls – Dec 05, 2014

STATEMENT OF WORK

For

MONITORING AND CONTROLS SYSTEMS FOR

PAINT, BLAST, and SCUFF BOOTHS

05 December 2014

Oklahoma City Air Logistics Center

Tinker Air Force Base

Table of Contents 1 Scope

1.1 Background

2 Applicable Documents 3 Detailed Requirements

3.1 Wet Spray Paint Booths

3.1.1 Overview of Paint Booths

3.1.2 Monitoring and Controls

3.2 Blast Booths

3.2.1 Overview of Blast Booths

3.2.2 Monitoring and Controls

3.2.3 Breathable Air System ............................................... Error! Bookmark not defined.

3.3 Installation

3.3.1 Location of Work Site

3.3.2 Contractor Responsibilities

3.3.3 Utilities Interconnection

3.3.4 Utilities Considerations

3.3.5 Safety

3.4 Operational Test

3.4.1 Vibration Analysis

3.5 Training

3.6 Documentation

3.6.1 Drawings

3.6.2 Electrical Schematics

3.6.3 User Manual

3.6.4 Bearing Information

3.6.5 . Fans

3.7 Design Review

3.7.1 25% Review

3.7.2 65% Review

3.7.3 100% Review

3.8 Warranty

3.9 Acronyms

1 Scope The contractor shall supply all engineering, labor, materials, parts, tools, equipment, supplies, transportation, software and incidentals necessary to design, assemble, and install real time process monitoring and controls system for two (2) existing Aircraft Parts Paint Booths, two (2) existing blast booths, and two (2) existing surface pretreatment Scuff Booths in the Aircraft

Structural Repair Facility located in building 9001 in Tinker Air Force Base, Oklahoma City, OK. The Contractor shall also provide Personal Protective Equipment (PPE) and clothing, to include reflective clothing (belt, vest, etc.); hearing and eye protection, to include prescription safety glasses; safety harnesses; fall protection equipment; lifting equipment and any incidentals necessary to perform the requirements of this Statement of Works (SOW). The Contractor shall be responsible for insuring all services, parts and Original Equipment Manufacturer (OEM) components provided under this contract are in accordance with (IAW) the terms and conditions outlined herein, conform to the manufacturer’s equipment specifications and this SOW.

The monitoring system must have the capabilities for visual and/or audible alarms, email alerts, and/or shut down the process when critical limits are breached. This system will have data storage and trending capabilities as well. The controls system must be closed looped with the monitoring system to adjust the process so that the process operates within the required limits.

The contractor will evaluate the existing equipment, and make the necessary upgrades/replace the existing equipment to meet the requirement of this SOW as described below. The contractor shall also provide training in the operation and maintenance of the new systems. The contractor shall have 120 days after contract approval to complete this SOW.

1.1 Background

The Aircraft Structural Repair Facility is located in Building 9001 in the Oklahoma City Air

Logistics Center (OC-ALC), Tinker Air Force Base (TAFB), Oklahoma City, Oklahoma. The paint, blast, and scuff booths are needed to support the expected process workload for the repair of sheet metal related airborne accessories such as engine cowlings, doors, tabs, rudders, elevators, hatches, flaps, ailerons, fairings, and spoilers.

2 Applicable Documents These specifications refer to the latest applicable revisions of the specified documents.

** NOTE: THE CONTRACTOR IS REQUIRED TO FOLLOW TI 32-7004 REGARDING

HAZARDOUS WASTE MANAGEMENT WHILE ON TAFB**

Document No. Title

TAFBI 32-7001 Hazardous Material Management Program

TAFBI 32-7004 Hazardous Waste Management Program

AFOSH 91-17 Air Force Occupational Safety and Health (AFOSH) Standard

– Interior Spray Finishing

AFOSH 91-43 Flammable and Combustible Liquids (storage)

NFPA 13 Standard for the Installation of Sprinkler Systems http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp

_of_NFPA_documents/list_of_folders.asp

NFPA 30 Flammable and Combustible Liquids Code (storage) http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List

_of_NFPA_documents/list_of_folders.asp

NFPA 33 Standard for Spray Application Using Flammable or

Combustible Materials http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List

_of_NFPA_documents/list_of_folders.asp

NFPA 70 National Electric Code http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List

_of_NFPA_documents/list_of_folders.asp

NFPA 72 National Fire Alarm Coda http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List

_of_NFPA_documents/list_of_folders.asp

NFPA 86 Standard for Ovens and Furnaces http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List

_of_NFPA_documents/list_of_folders.asp

NFPA 91 Standard for Exhaust Systems for Air Conveying of Materials http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List

_of_NFPA_documents/list_of_folders.asp

NFPA 101 Life Safety Code http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List

_of_NFPA_documents/list_of_folders.asp

NFPA 664 Standard for the Prevention of Fires and Explosions in Wood

Processing and Wood Working Facilities http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List

_of_NFPA_documents/list_of_folders.asp

NFPA 654 Standard for the Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible

Particulate Solids.

http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List

_of_NFPA_documents/list_of_folders.asp

ICS6-1993 Enclosures for Industrial Control Systems (NEMA) http://www.nema.org/index_nema.cfm/1260/

29 CFR 1910.106

& .107

OSHA Spray Finishing Using Flammable and Combustible

Materials http://www.osha.gov/pls/oshaweb/owastand.display_standard_ group?p_toc_level=1&p_part_number=1910&p_text_version=

FALSE

40 CFR 63

Subpart GG

National Emissions Standard for Hazardous Air Pollutants

(NESHAP)

http://www.tnrcc.state.tx.us/air/opd/63/

TI 32-7004 Hazardous Waste Management Instruction

UFC 3-600-01 Unified Facilities Criteria (UFC) Fire Protection Engineering for Facilities http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nfpa.org/Codes/NFPA_Codes_and_Standards/List_of_NFPA_documents/list_of_folders.asp http://www.nema.org/index_nema.cfm/1260/ http://www.osha.gov/pls/oshaweb/owastand.display_standard_group?p_toc_level=1&p_part_number=1910&p_text_version=FALSE http://www.osha.gov/pls/oshaweb/owastand.display_standard_group?p_toc_level=1&p_part_number=1910&p_text_version=FALSE http://www.osha.gov/pls/oshaweb/owastand.display_standard_group?p_toc_level=1&p_part_number=1910&p_text_version=FALSE http://www.tnrcc.state.tx.us/air/opd/63/ http://www.wbdg.org/ccb/DOD/UFC/ufc_3_600_01.pdf

UFC 3-410-04N Unified Facilities Criteria (UFC) Industrial Ventilation

Book Industrial Ventilation by AHGIH, Chapter 5,10,&13

ANSI Z358.1 ANSI standard for emergency showers and eyewashes

1926.501 OSHA Fall protection regulation

1926.1053 OSHA Ladder regulation

3 Detailed Requirements The contractor shall provide a turnkey monitoring and controls systems that work seamlessly with the existing paint, blast, and scuff booths. The services performed by the contractor shall include, but not limited to the following items. In some cases, the contractor must upgrade/replace the existing equipment to satisfy the requirements identified in this SOW.

3.1 Wet Spray Paint Booths

3.1.1 Overview of Paint Booths

The paint booths (East Paint, OC19407, G42, and West Paint, OC19408, G40) are of the down-draft type design. All ventilating and conditioned make-up air equipment for each paint booth are roof mounted. Inlet and outlet air are drawn and discharged from the building exterior via roof penetrations. Each booth includes a breathing air system fully capable of supporting up to eight (8) personnel working in the booths. The paint guns have an air dryer and oil separator for the compressed air lines running to them.

The operating temperature range inside the paint booth is 70 o F to 120 o F year round. The heating/cooling systems have the capability of heating outside air from 30 o F to the temperature specified up to 120 o F and cooling outside air from 120 o F down to 85 o F for year-round operation.

The system also has an accelerated cure feature, which allows the booth to heat to 120 o F. The booth shall be capable of reaching this cure temperature inside the booth within 25 minutes. The cooling of the booth from 120 o F to 85 o F shall be accomplished within 25 minutes. The accelerated cure feature and the normal temperature control of the booth utilize 100% fresh air make up.

The conditioned make-up air / exhaust system equipment utilizes natural gas for heating and electricity for cooling using a close loop heat exchanger with the chilled water that is available.

The system is to provide a minimum airflow velocity of 100 feet per minute (FPM). This measurement is to be taken in the cross section of the booth with all doors closed. The contractor shall verify and make sure that the make-up air unit be interconnected with the fire alarm system. The make-up air system shall shut off in the event of a fire, so make-up air does not feed the fire.

The make-up air unit must have humidity control. For painting operations the humidity must be controlled between 30% and 80%, so humidity control is required. The booth must also operate at a slightly negative pressure at all times to keep the air from getting outside of the booth.

http://www.wbdg.org/ccb/DOD/UFC/ufc_3_600_01.pdf

Inlet air goes through a 98% efficiency filter to prevent dirt and other airborne debris from contaminating the workload. Outlet (exhausted) air utilizes HEPA filters to comply with applicable regulatory requirements. The exhaust filtration system is a 3-stage system with

99.97% efficiency down to 0.3 micron particle size. There are magnehelic differential pressure gauges to monitor pressure differential across the filters for each filtration system. When the differential pressure reaches certain point, it is time to change the filters.

3.1.2 Monitoring and Controls

The contractor is responsible for installing any metering device as well as the monitoring software to collect process data, monitor that data real time and either alert production by emailing, flashing light/audible alarms and/or shut the process down. The monitoring system must have storage capabilities and enough capacity to enable historical trending for up to 6 months. This system must get the necessary approval with BCE to access the Tinker local area network, and will also have the capability to display the charts on the web site. The contractor is also responsible for installing/upgrading equipment, which may include, but not limited to variable frequency drive, higher capacity equipment, to ensure the process parameters being monitored operate within the limits. The control system must be closed loop with the monitoring system. The following table summarizes the parameters to be monitored along with the desired operating range and alerting strategy.

3.2 Scuff Booths

3.2.1 Overview of Scuff Booths

The scuff booths (East Scuff, OC19273, H43, and West Scuff, OC19410, K41) are on a complete raised floor and of the down-draft type design. All ventilating and conditioned make-up air equipment for each paint booth are roof mounted. Inlet and outlet air are drawn and discharged

Equipment Parameter Range Alarm type

Failure

Mode Comment

Booth Booth pressure < 0 Email High Per OSHA/BEF regulations

Booth Booth temp Per PO Email Range Paint and cure effectiveness

Booth Air flow >= 100 FPM Email Low Per OSHA/BEF/Fire regulations

Booth Filter DP TBD Email Range Proactively plan for filter changes

Booth

Utilities consumption N/A N/A N/A Monitoring --> cost

Booth VOC controls Per Regs Shut down High Safety/fire prevention

Blower RPM Monitor Email

Outside normal Monitor health of blower

Blower Incoming CFM Monitor N/A N/A Monitor

Blower Exhaust CFM Monitor N/A N/A Monitor

Glycol Temp in Monitor N/A N/A Monitor for efficiency of process

Glycol Temp out Monitor N/A N/A Monitor for efficiency of process

Coil Presure drop Monitor N/A N/A Monitor health of process

Breathing air

O2 and CO concentrations

Per BIO limits Email

Outside limits Health requirements from the building exterior via roof penetrations. Each booth includes a breathing air system fully capable of supporting up to eight (8) personnel working in the booths. The booth can accommodate 3 chemical applications. The booth has a pit sloped to a collection point of a 2” diameter drain with a vacuum pump to pump the waste mixture into a 1000 gallon double walled tank with leak detection.

The operating temperature range inside the paint booth is 70 o F to 120 o F year round. The heating/cooling systems have the capability of heating outside air from 30 o F to the temperature specified up to 120 o F and cooling outside air from 120 o F down to 85 o F for year-round operation.

The system also has an accelerated cure feature, which allows the booth to heat to 120 o F. The booth shall be capable of reaching this cure temperature inside the booth within 25 minutes. The cooling of the booth from 120 o F to 85 o F shall be accomplished within 25 minutes. The accelerated cure feature and the normal temperature control of the booth utilize 100% fresh air make up.

The conditioned make-up air / exhaust system equipment utilizes natural gas for heating and electricity for cooling using a close loop heat exchanger with the chilled water that is available.

The system is to provide a minimum airflow velocity of 100 feet per minute (FPM). This measurement is to be taken in the cross section of the booth with all doors closed. The contractor shall verify and make sure that the make-up air unit be interconnected with the fire alarm system. The make-up air system shall shut off in the event of a fire, so make-up air does not feed the fire.

The make-up air unit must have humidity control. For painting operations the humidity must be controlled between 30% and 80%, so humidity control is required. The booth must also operate at a slightly negative pressure at all times to keep the air from getting outside of the booth.

Inlet air goes through a 98% efficiency filter to prevent dirt and other airborne debris from contaminating the workload. Outlet (exhausted) air utilizes HEPA filters to comply with applicable regulatory requirements. The exhaust filtration system is a 3-stage system with

99.97% efficiency down to 0.3 micron particle size. There are magnehelic differential pressure gauges to monitor pressure differential across the filters for each filtration system. When the differential pressure reaches certain point, it is time to change the filters.

3.2.2 Monitoring and Controls

software to collect process data, monitor that data real time and either alert production by emailing, flashing light/audible alarms and/or shut the process down. The monitoring system must have storage capabilities and enough capacity to enable historical trending for up to 6 months. This system must get the necessary approval with BCE to access the Tinker local area network, and will also have the capability to display the charts on the web site. The contractor is also responsible for installing/upgrading equipment, which may include, but not limited to variable frequency drive, higher capacity equipment, to ensure the process parameters being monitored operate within the limits. The control system must be closed loop with the monitoring

3.2.3 Hot Water Pressure Washer Systems

The Contractor shall design, propose, provide and install new hot water pressure washer systems to provide hot rinse water for the scuff booths. The fresh hot water shall be used for final part rinse. The fresh hot water pressure systems shall include, but not be limited to, the hot water pressure washer units, high temperature/high pressure hoses, fittings, clamps, brackets, pipes, electrical wiring, EMT conduit, circuit breakers, fuses, water spray wands, water spray tips, hose reels, shut off valves, fittings, fasteners, hardware, hose reel mounting hardware and other components to provide complete systems. The Contractor shall provide and install four (4) complete hot water spray wands with nozzle assemblies and spray tips for the west booth and two (2) complete hot water spray wands with nozzle assemblies and spray tips for the east booth.

The Contractor shall ensure the simultaneous use of all six (6) spray wand assemblies. The

Contractor shall ensure each discharge hot water shall have a temperature between 100 o and 120°

F, and pressure is up to 90 PSI and a minimum 4 GPM. The Contractor shall ensure each spray gun assembly is capable to rotate 360°. The temperature and pressure shall be adjustable, so that if desired, we can change the temperature and pressure of the rinse. A bypass shall be installed to allow water to enter into the booth without going through the pressure washer, this shall be a manual valve located outside of the booth. The Contractor shall ensure the pressure washer

Equipment Parameter Range Alarm type

Failure

Mode Comment

Booth Booth pressure < 0 Email High Per OSHA/BEF regulations

Booth Booth temp Per PO Email Range Paint and cure effectiveness

Booth Air flow >= 100 FPM Email Low Per OSHA/BEF/Fire regulations

Booth Filter DP TBD Email Range Proactively plan for filter changes

Booth

Utilities consumption N/A N/A N/A Monitoring --> cost

Waste tank Tank level TBD Flashing lightHigh

Not necessary to store tank level data, but must have alarming capabilities

Pit Pit level TBD Flashing lightHigh

Not necessary to store tank level data, but must have alarming capabilities

Blower RPM Monitor Email

Outside normal range Monitor health of blower

Blower Incoming CFM Monitor N/A N/A Monitor

Blower Exhaust CFM Monitor N/A N/A Monitor

Glycol Temp in Monitor N/A N/A Monitor for efficiency of process

Glycol Temp out Monitor N/A N/A Monitor for efficiency of process

Coil Presure drop Monitor N/A N/A Monitor health of process water hoses shall be minimum 50 feet in length when fully extended. The Government shall make power and fresh water connection available within 50 feet of the pressure washer systems.

3.2.4 Wastewater Drain System

For each booth, the contractor shall design pumping system and run piping from the 1000 gallon collection tank to the closest IWTP drain opening. There will be 2 level sensors in the tank. The lower sensor will signal the pump to come on and pump the liquid to IWTP. In case the pump malfunctions or couldn’t keep up that the level rises to the upper sensor, a flashing light will go off at the tank, and in the booth and stay flashing until the water level retreats. Also, when the water level reaches the upper limit, the pump feeding the tank at the pit must be interlocked and shut of automatically and stop feeding the tank. The drain system will have valves and pump shut off capabilities so that when turned off, there will be nothing going to the IWTP, and the level can rise to the upper sensor. Flashing lights and shutting off pit pump must still operate per normal protocol at all times.

The same concept must be true for the pump at the pit. The contractor will determine if the existing pump is suited for the job and make the necessary upgrades if need be. There will be two level sensors as well. The lower one will turn on the pump to pump into the collection tank, and the upper one will turn on the flashing light at the pit and in the booth.

3.3 Blast Booths

3.3.1 Overview of Blast Booths

The two media blast booths (North booth, OC19545, P41, and South booth, OC19629, N41) are an in-out configuration (one work entrance) each be sized at 12’Wide x 15’Length x 16’Height

(interior working dimension). The north booth, plastic media (20/30), and the south booth, glass media (type 10 & 13), each has a full-floor recovery and collection system. The booth pressure must be at least 1/2" water gauge (w.g.) (nominal) and the minimum air flow velocity in the booth is 100 cubic feet per minute (CFM) per square foot of cross sectional area. The blast booths are equipped with a pneumatic type recovery system for capturing media during blasting operation and moving it to a reclamation unit. The pneumatic recovery system utilizes no moving parts to convey the blast media to the cleaning and reclamation system. Spent media is conveyed through this system using controlled high velocity airflow

The media reclaim separation system is an air centrifugal (cyclone) type, highly balanced separator, which receives all media and debris conveyed from the blasted work piece through a vacuum conveying duct. The reclaiming system centrifugally separates the blast media from the conveying air stream and collects oversized debris in the filter screen and deposits reusable media into the storage hopper section. The dust and broken media is pulled through the center vortex tube along with air to the dust collection system that we will call the general environment

(GE). The system contains a removable strainer for separating unwanted material before it reenters the blasting system. The reclaimed media is powered by a 5 horsepower heavy-duty motor mounted on top of the reclaim. The system does allow minor adjustment in the reclaim system to be made by adjusting static pressure, which in turn adjusts the air flow through the system. Major adjustments are made by an adjustable pipe inside the vortex tube which is standard on all pull through dust collection systems.

The dust collection systems consist of a first stage self-cleaning cartridge filter and a second stage

HEPA filter unit that will capture 99.97% of particles 0.3 micron in size or larger. Both systems have a minimum airflow velocity of 100 feet per minute for every square foot of cross section of the booth. Cartridge cleaning shall be automatic on a pressure cycle (as determined by a set pressure differential) by a reverse pulse jet nozzle arrangement. A differential pressure control

(DPC) gauge monitors the pressure difference between the dirty and clean side of the filters. The

DPC gauge shall be used to control the proper sequencing of the reverse pulse jet filter cartridge cleaning cycle.

3.3.2 Monitoring and Controls

software to collect process data, monitor that data real time and either alert production by emailing, flashing light/audible alarms and/or shut the process down. The monitoring system must have storage capabilities and enough capacity to enable historical trending for up to 6 months. This system must get the necessary approval with BCE to access the Tinker local area network, and will also have the capability to display the charts on the web site. The contractor is also responsible for installing/upgrading equipment, which may include, but not limited to variable frequency drive, higher capacity equipment, to ensure the process parameters being monitored operate within the limits. The control system must be closed loop with the monitoring

Equipment Parameter Range Alarm type Mode Comment

Booth Booth pressure < 0 Email High Booth must stay negative relative to outside

Booth Nozzle pressure Per PO Light Outside range

To prevent damage to asset and potential safety concerns

Booth Air flow >= 100 FPM Email Low Per OSHA/BEF/Fire regulations

Booth

Utilities consumption Monitor N/A N/A Monitor for cost effectiveness

Blower Blower RPM Monitor N/A N/A Monitor for health of equipment

Blower Run Hour Per MFG Email High Monitor for PM

Cartridge reclaim DP Range TBD Email High To ensure pulse cycle is activated and cleaning

HEPA reclaim DP Range TBD Email High To proactively change HEPA filters

Cartridge (GE) DP Range TBD Email High To ensure pulse cycle is activated and cleaning

HEPA (GE) DP Range TBD Email High To proactively change HEPA filters

Pulse cycle Status On/Off Email Off To ensure pulse cycle is activated and cleaning

Particle dectection Size and qty TBD Shut down High Stop the line when the first stage filter is breached

3.4 Installation

3.4.1 Location of Work Site

The location of the work site is within TAC (Building 9001), at the post locations identified in sections 3.1.1, 3.2.1, and 3.3.1 above.

3.4.2 Contractor Responsibilities

3.4.2.1 Emergency POC

An Emergency and Project Point of Contact Telephone List shall be jointly developed. A list of emergency and project telephone list shall be provided by the contractor to the government inspector.

3.4.2.2 Installation

The contractor shall provide all personnel, equipment, tools, supervision, transportation, materials, structural installation requirements, field testing, site oversight, waste handling/transportation/disposal and any other incidentals necessary to install a monitoring and controls system to the existing paint booths and blast booths. The contractor will also make any necessary additions and/or upgrades to the existing equipment to satisfy the requirements in this

SOW. The contractor shall have one-hundred twenty (120) calendar days to complete the installation of the new monitoring system and any upgrades to the equipment.

3.4.2.3 Clean up

The contractor shall be responsible for daily and final project clean-up of all areas, including but not limited to, the interior work site, utilized road way, utilized facility aisles, utilized ramps and outside lay down area. All generated debris, waste materials; trash shall be swept up and removed.

3.4.2.4 Chemicals

All chemicals utilized during the project must be approved by TAFB’s HAZMAT office prior to the contractor bringing chemicals on base. The Material Data Safety Sheets (MSDS) of proposed chemicals must be furnished to the government representative ten (10) days after contract award to obtain the necessary authorization of proposed chemicals. These chemicals must be stored in their appropriate locations when not in use.

3.4.2.5 Transportation

The contractor shall provide for the “tarped” transportation of the equipment components to a secured warehouse in Oklahoma City, OK for storage and staging prior to delivery to the installation site at Tinker AFB, if necessary.

3.4.2.6 Off-Loading

The contractor shall furnish all labor and material handling equipment required for off-loading the equipment and components both at the designated storage warehouse (if necessary) and the final destination in TAC. The contractor shall be responsible for the disposal of all crating, skids and packing materials. The contractor shall furnish all personnel, equipment, tools and materials necessary to off-load, clean, set on-site equipment components and the associated assembly of said components with the supervision of factory representatives.

3.4.2.7 Leveling

The contractor shall furnish all personnel, equipment, tools and materials necessary to level the booths on the contractor installed pad IAW manufacturer’s direction.

3.4.2.8 Alignment/Accuracy Tests

The contractor shall provide all labor, equipment and materials necessary to insure the alignment and accuracy of the booths IAW manufacturer’s standard requirements. Test showing the booth meets specifications shall be provided by the contractor.

3.4.2.9 Initial System Charging

The contractor shall provide all fluids including but not specifically limited to hydraulic oils, way and lube oils IAW manufacturer’s instruction. MSDS shall be provided to the Government representative ten (10) days after contract award to obtain the necessary authorization of chemical use. TAFB shall provide the paint and primers.

3.4.3 Utilities Interconnection

Utilities shall include water, fire sprinkler water, compressed air, eye wash water, water, natural gas. The contractor shall furnish all personnel, equipment and materials necessary to connect the booths to TAFB provided “rough-in” utilities that are available within twenty-five (25) feet of final connection points. All utility interconnections shall be performed by personnel who are licensed in their field of activity.

3.4.4 Utilities Considerations

3.4.4.1 Outages

Outages for utility interconnections shall be coordinated with the Government. This usually requires three week notice.

3.4.4.2 Contractor Utility Usage

Electricity and compressed air for power tools will be available for use by the Contractor at the work site. The Contractor shall provide extension cords and compressed-air extension hoses with fitting and valves.

3.4.5 Safety

The contractor is advised that natural gas piping is in the work area. The contractor is advised that electric service and steam are in the work area. Fall protection, PPE, and any other safety related material needed shall be provided by the contractor for contract employees. Hard hats shall be required in the facility, due to the ongoing construction, as well as hearing and eye protection and safety glasses.

3.5 Operational Test

After installation, the contractor shall apply power and perform a checkout of all installed systems. If necessary, the contractor shall make changes to achieve correct operation of the systems at no additional cost to the Government. After the system checkout, the point of contacts for the Government and the contractor shall jointly inspect all deliverables. The contractor, at no additional cost to the Government, shall correct deficiencies. All blowers and motors shall be base lined.

3.5.1 Vibration Analysis

Vibration analysis shall be performed on the equipment. All analysis and base line information/results shall be given to the Government.

Data Gathering Points—For all rotating equipment provided under the contract, the contractor shall provide vibration monitoring points using the following guidelines:

The contractor has the option of machining the equipment case in order to achieve a flat and smooth spot of 1" diameter with a surface finish of 32 micro-inches

RMS, or installing magnetic accelerometer pads either by welding or stud mount.

The accelerometer pads must meet the size and finish requirements of the machined spot face.

The contractor shall ensure monitoring locations are positioned on structural members. Installation of accelerometer pads on bolted cover plates or other non-rigid members are not acceptable.

Data gathering points are to be located in a horizontal, vertical and axial orientation with respect to component bearing/shaft centerline.

Blowers & Fans—Motors on blowers and fans shall have accelerometer pads installed in the radial (2ea) and axial (1 ea) directions as previously described. Fan bearings shall be monitored radially in the vertical direction.

3.5.2 Test and Acceptance

As part of Test and Acceptance, the Contractor shall develop an Acceptance Test Plan (ATP) to demonstrate the full operability of the monitoring and controls systems. The ATP shall demonstrate full compliance of all installed equipment with the performance criteria specified by all referenced Standards and Publications listed in section 2 of this SOW and the approved design. The contractor shall submit the ATP and obtain an approval from the Government at the

100% design review. Test and Acceptance shall be conducted IAW the ATP and with the presence of the Government contract monitor.. The tests shall be conducted upon the paint and blast booths after completion of the work required by this SOW. The tests shall be coordinated with the Government and conducted at the installation site. The Contractor, at no additional cost to the Government, shall correct all deficiencies. The point of contacts for the Government and the Contractor shall jointly inspect all deliverables.

3.6 Training

The contractor shall provide the following on-site training: four (4) days, two (2) sessions/day

(one for day shift, and one for swing shift) of operator and maintenance training, review of system documentation, operation procedures, trouble shooting, preventative maintenance, operator maintenance and daily check sheet, optimal performance adjustments (rules of thumb for balancing the system). On-site training shall be conducted during the respective shop’s operating hours and be scheduled to not conflict with Government holidays. Training shall be conducted after successful completion of operational (3.5) testing. Anticipate four (4) government personnel to attend each training session. The contractor shall provide all training materials in the English language.

3.7 Documentation

The contractor shall provide system documentation IAW the following specifications.

3.7.1 Drawings

Shop drawings” shall mean drawings submitted by the Contractor or sub-contractor showing in detail either or both of the following as listed in the SOW:

(1) The proposed fabrication and assembly of structural elements.

(2) The installation (i.e., form, fit, and attachment details) of materials or equipment.

“Shop drawings” shall be defined as drawings and associated data, submitted to the Government by the Contractor or sub-contractor pursuant to this SOW and Contract, showing in detail: (1) the proposed fabrication and assembly of structural elements, and; (2) the installation (i.e., fit, and attachment details) of materials or equipment. It shall include drawings, diagrams, layouts, schematics, materials list, descriptive literature, illustrations, schedules, performance and test data, and similar materials furnished by the Contractor to explain in detail the specific portions of the work identified in this Contract or SOW requiring Shop Drawings. The contractor shall provide both D-size scale drawings and electronic (CD) drawings to the Government. The

Government will retain all rights to Shop Drawings and may duplicate, use, and disclose in any manner and for any purpose shop drawings delivered under this contract.

3.7.2 Electrical Schematics

The contractor shall supply electrical schematics for all installed systems.

3.7.3 User Manual

The contractor shall supply a user manual as follows. The user manual shall include an overall description of the paint system (all booths, rooms, tanks, and equipment). The user manual shall include the basic operational characteristics of the prep (scuff) and paint booth systems. The user manual shall include a description of the control panel features, operation, and maintenance guide. All monitoring, thermocouples, and measurement devices/equipment shall include the manufactures user manuals, technical data, calibration technical data, and verification of calibration. User Manual(s) shall be delivered in electronic (CD) and three (3) copies in hard form. In addition, the contractor shall provide a list of recommended or long lead items that the

Government may want to keep spares in the event of parts failure. Include the price and suggested sources for each item.

3.7.4 Bearing Information

The contractor shall provide to the procuring organization section drawings that show the component arrangement for all rotating equipment supplied under the contract. The section drawings shall accurately depict the bearing support structural arrangement, be drawn to scale, and show the dimensions to the centerline of all rotating shafts.

The contractor shall provide the bearing manufacturer and part number for all bearings used in all rotating equipment supplied under this contract. The information shall be included on the sectional drawings for each bearing location.

The contractor shall provide the operating speed for constant speed units and the normal operating speed range for variable speed equipment.

3.7.5 Fans

The contractor shall provide the following information on all fans supplied under the contract:

Type of fan or blower

Number of rotating fan blades/vanes

Number of stationary fan blades/vanes

Rotating speed(s)

The contractor shall provide the following additional information if the fans/air handlers are belt driven:

Number of belts

Belt lengths

Belt Part Number

Diameter of the drive sheave at the drive pitch line

Diameter of the driven sheave at the drive pitch line

For all fans supplied under the contract, the contractor shall ensure sufficient access to the fan is present in order to allow for cleaning and in-place balancing of the fan.

3.8 Design Review

3.8.1 25% Review

The 25% design review shall take place within 2 week of contract signing. This review shall show equipment location (to include foot prints of all major pieces), any roof penetrations needed to be ready prior to installation, and utility drops. Also, a timeline that shows major milestone dates, such as design reviews, fabrication dates, delivery, installation, training, design reviews, and completion of each booth. The Government shall have 1 week to review and respond to the contractor regarding the proposal.

3.8.2 65% Review

This review shall take place within 3 weeks of the 25% review and shall include details about type of equipment specifications, utility requirements, air flow calculations, and safety equipment locations. This review shall allow the Government to review all applicable documentation to verify compliance with all regulations noted. The Government shall have 2 weeks to review and respond to the contractor regarding the proposal.

3.8.3 100% Review

This review shall take place within 3 weeks of the 65% review to include all details necessary for the Government to verify that all changes have been made to meet the stated intent of this SOW.

The Government shall have 2 weeks to review and respond to the contractor regarding the proposal.

3.8.4 Installation Progress Review

The Contractor shall conduct a review with the Government of installation progress against the schedule on a weekly basis. During the Installation progress review, the Contractor shall formally report the results of the installation to date as well as respond to issues identified by the

Government, address design changes made during the installation process, and recommend design changes as a result of installation issues including trade-off impacts. The Contractor shall incorporate all changes approved during the Installation Review briefings into the final as-built drawings provided at project completion and buy-off. Only the CO may approve changes which the Contractor asserts, alters the scope, cost or schedule of the project contract.

3.8.5 Program Management

The Contractor shall establish and maintain management operations that include the following areas:

(a) Project Management Plan

(b) Sub-Contractor Control

The Contractor shall develop and maintain a project plan, including a schedule that clearly defines how the project will be managed and controlled. The Contractor shall take into account human interaction with the system from a safety and maintenance view. The Contractor shall ensure that supportability design criteria and characteristics are considered and incorporated into the design to meet availability requirements stated in the SOW.

3.9 Environmental Protection and Safety

Environmental Protection & Safety: The Contractor shall be knowledgeable of and comply with all applicable federal, state and local laws, regulations, instructions and requirements regarding environmental protection and occupational safety and health. The Contractor shall comply with any laws, instructions or regulation changes during the term of this contract.

Contractors shall be compliant Tinker Air Force Base (TAFB) Supplement to Air Force

Instruction (AFI) 32-7086, “Hazardous Materials Management”, Tinker AFB procedures per

Tinker Air Force Base Instruction (TAFBI) 32-7004, “Hazardous Waste Management”, and

Complex procedures per Oklahoma City Air Logistics Complex (OC-ALC) Sup to AFI 32-7086, “Hazardous Material Management” and OC-ALCI 32-101 “Air Quality Record Keeping

Procedure”. Publications are available digitally on e-Publishing website at www.e-publishing.af.mil for downloading or ordering.

Material Safety Data Sheet/Safety Data Sheet (MSDS/SDS): Upon COR receipt of the “No

HAZMAT Usage” certification, the requirements of this section no longer apply.

The Contractor shall not transport, ship or use any chemical, material or substance used in the performance of this PWS on Tinker AFB before written approval is provided by 72 ABW/CEIE, Natural Infrastructure Management (Environmental Compliance). The Contractor shall submit to the COR, ten (10) calendar days after contract award date all Material Safety Data Sheets

(MSDSs) or Safety Data Sheets (SDSs) and a completed OC-ALC Form 152, MSDS/SDS

Information Sheet. The Contractor shall receive approval from the COR prior to shipping any chemical, material or substance to Tinker AFB. A copy of the manufacturer MSDS/SDS shall accompany the shipment. Contractor shall comply with the effective dates for SDS requirements

IAW the Occupational Safety and Health Administrations (OSHA) Hazardous Communication

Standard, Title 29, Code of Federal Regulation (CFR) Part 1910.1200. The COR will forward all MSDS/SDS submittals to 72 ABW/CEIE for approval. A current manufacturer MSDS/SDS shall be submitted to the COR if the Contractor changes manufacturer or vendor for any chemicals that were prior approved. The Contractor shall maintain copies of manufacturer

MSDSs/SDSs for all chemicals and MSDSs/SDSs shall be readily accessible at all times by

Contractor personnel as well as government employees.

Hazardous Material (HAZMAT): If no HAZMAT will be brought on base or used in performance on this contract, the contractor shall certify “No HAZMAT will be brought on base” or “No HAZMAT Usage” in writing on company letterhead. This certification shall be provided to the COR within ten (10) days after award. Upon COR reciept of the certification, the requirements of this section no longer apply. Appropriate penalties for the contractor, or administrative and disciplinary action for the later shall be assessed if found in violation of above certification.

The Contractor shall not store chemicals or hazardous material (HAZMAT) on Tinker AFB.

Contractors shall be compliant with HAZMAT management procedures per Oklahoma City Air

Logistics Complex (OC-ALC) Supplement to AFI 32-7086, “Hazardous Materials

Management”. The Contractor shall maintain a log of all HAZMAT that is used on base. This usage log shall be provided to the COR monthly, the last business day of each month, or when the required work is completed. The COR will forward the records to the Unit Environmental

Coordinator (UEC) no later than the fourth (4 th

) day of the following month or the first (1 st subsequent business day.

Hazardous Waste: If no HAZWASTE will be generated during performance of this contract, the contractor shall certify “NO Hazardous Waste Generation” in writing on company letterhead.

This certification shall be provided to the COR within ten (10) days after award. Upon COR receipt of the “No Hazardous Waste Generation” certification, the requirements of this section no longer apply. Appropriate penalties for the contractor, or administrative and disciplinary action for the later shall be assessed if found in violation of above certification.

Field Code Changed http://www.e-publishing.af.mil/ http://www.e-publishing.af.mil/

The Contractor shall dispose of contaminated solid waste, spent or processed chemical solutions, used rags and hazardous waste in government furnished waste containers located in the shop or area the work is being performed. The Contractor shall notify the COR if the required waste containers are not available on site.

Discharges: Any discharges into Tinker’s Industrial Waste Treatment Plant (IWTP) or sanitary sewer will be approved and done IAW Tinker Industrial Waste Water Discharge Permit as instructed by 72 ABW/CEIE, Natural Infrastructure Management (Environmental Compliance).

The COR will submit the required notice of intent documentation to the UEC for 72 ABW/CEIE approval. The Contractor shall maintain records of written approval issued by 72 ABW/CEIE for discharges into IWTP and sanitary sewer.

Off-Site Discharges: For discharges outside of Tinker AFB, the Contractor shall ensure waste water discharges, that may contain pollutants resulting from any contracted service, go to a state or federal permitted treatment facility such as a municipal Publicly Owned Treatment Works

(POTW). The Contractor shall provide a letter ten (10) calendar days after contract award date to the COR from the POTW that states the POTW is permitted for all pollutants that the

Contractor may discharge during the contracted service.

Spills: Upon occurrence of any spill that could enter the storm system or cause any harmful environment effects, the Contractor shall immediately call 911 to report the incident. When possible, the Contractor shall use a base telephone to receive help from Tinker AFB 911. If using a cell phone, the Contractor shall request Tinker AFB 911. The Contractor shall immediately report all environmental violations to the COR and UEC. The Contractor shall provide five (5) copies of a typed or written report about the incident within four (4) clock hours as follows:

One (1) copy to CO, two (2) copies to the COR, a copy for UEC and one (1) copy for record.

The format of the report shall be left up to the Contractor, but the report shall contain the following information:

1.) Name and contact number of person reporting the spill

2.) Date and time of incident

3.) Location and source of spill

4.) Substance or pollutant spilled

5.) Amount spilled and rate of discharge

6.) Any damages or injuries involved

7.) Extent of area impacted

8.) Potential hazards

9.) Actions taken

10.) Organizations contacted

11.) Remarks Section - that addresses the cause of the spill (e.g. human error, equipment, etc.) and whether 911 was called and which agencies responded.

Environmental Training: Upon COR receipt of the “No Hazardous Waste Generation” certification, the requirements of this section no longer apply.

Contractor personnel performing duties in the service of this PWS shall have training that acquaints the person with the details of Resource Conservation Recovery Act (RCRA) regulations in 40 CFR 260 through 279; applicable State Laws and regulations; DoD, Air Force and local requirements. This training can be obtained through creditable training institutions or companies. All training shall be approved by 72 ABW/CEIE, Natural Infrastructure

Management (Environmental Compliance). RCRA training is available at http://www.natlenvtrainers.com/RCRA-hazardous-waste.htm;

http://www.skillsoft.com/catalog/detail.asp?CourseCode=esh_sah_a34_sh_enus000000 and http://www.lion.com/Storing-Hazardous-Waste-for-LQGs at the Contractor’s expense. Prior to obtaining training, the Contractor shall provide the name of the training institution or company and course description to the COR for approval within ten (10) calendar days after contract award date. Once written approval is received from the COR, the Contractor shall provide the environmental training certificates for employees performing duties in the service of this PWS to the COR, within thirty (30) calendar days after contract award date. In addition to the required environmental training, Contractors shall be compliant with Tinker AFB procedures per TAFBI

32-7004, “Hazardous Waste Management”.

3.10 Warranty

The contractor shall warranty all equipment and workmanship free of defects for a period of two

(2) years from the completion date. The contractor shall be notified of defects by the

Government in writing. The contractor shall respond to all reported problems within 24 hours.

Defects shall be remedied at no cost to the Government within 10 calendar days.

3.11 Acronyms

AFOSH – Air Force Occupational Safety and Health Standard

CBD – Commerce Business Daily

CDR – Critical Design Review

CFR – Code of Federal Regulations

CFM – Cubic Feet per Minute

FPM – Feet per Minute

HVAC – Heating Ventilating and Air Conditioning

HVLP – High Volume Low Pressure

IAW – In Accordance With

IWTP – Industrial Wastewater Treatment Plant

KWH – Kilowatt-hours

MMBTU – million BTUs or million British Thermal Units

NEMA – National Electrical Manufacturers Association

NESHAP – National Emissions Standard for Hazardous Air Pollutants

NFPA – National Fire Prevention Association

NTP – Notice to Proceed

OC-ALC – Oklahoma City Air Logistics Center

OSHA – Occupational Safety and Health Administration http://www.skillsoft.com/catalog/detail.asp?CourseCode=esh_sah_a34_sh_enus000000

PDR – Preliminary Design Review pH – Measure of Acidity & Alkalinity

POC – Point of Contact

PPE – Personal Protective Equipment

RFP – Request for Proposal

SFCM – Standard Cubic Feet per Minute

STP – Submission To Procurement

TAFB – Tinker Air Force Base

TAFBI – Tinker Air Force Base Instruction

09 DECEMBER 2014

APPENDIX "C"

SAFETY SPECIFICATIONS

FOR

MONITORING AND CONTROLS…