Completed Carousel Requirement Document 2012 05 31.pdf

PURCHASE SPECIFICATION

FOR

VERTICAL CAROUSEL STORAGE

FOR THE

572nd C-130 OVERHAUL SECTION

(572 AMXS/MXDPAA)

Hill AFB, UT

Revised:

31 May 2012

1. Scope:

1.1. This purchase specification covers the general design and performance requirements for the six Vertical Carousels Storage Units (four Dual Access Units and two Single

Access Units) and the installation of the Vertical Carousels Storage Units in building

225, C-130 Aircraft Docks. From this point on the Vertical Carousels Storage Units will be referred to as the Carousels throughout this Purchase Specification (PS). The

Carousel shall provide storage of parts removed from the C-130 Aircraft during the overhaul process. The contractor must include all management, supervision, engineering, design, materials, labor, fabrication, transportation, shipping, off loading, equipment, installation, utility connections, modification to existing systems

(if required) and items and activities necessary to provide completely functional carousels.

2. Overview:

2.1. There are 4 existing C-130 carousel storage systems installed on docks C1-C2-C7-

C8, building 225 and 4 more on docks E1-E2-E3-E4 in building 680 on Hill AFB, UT. For consistency with other systems currently on base, ease of operator use, standardized training, and to avoid safety issues caused by workers confusion on the proper operation of carousels made by different manufacturers, the carousel shall limit operational changes. The components, functional use, basic methodology and user operations are to be comparable to the existing system. System training already in place for existing systems which should be adequate for the new carousels. Tray sizes must match trays on existing units to allow standardized storage configuration.

3. Design:

3.1. The machines shall be new and one of the manufacturer's current production models, which on the date this solicitation has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer's published catalogs or brochures. Products such as a prototype unit, pre-production model or an experimental unit do not qualify. The machines shall include all components parts and features necessary to meet the alignment and performance requirements specified herein.

3.2. Quantity: 4 each Dual Access

3.2.1. Carousel height: 272 inches max. (Machines which are taller may be submitted, but contractor must include all costs associated with relocating utilities which are at approx. 275” high and/or truss brackets which are at 286” high and/or structural cross members which are at 290” high.)

3.2.2. Footprint width: 174” min. to 177.5” max. (Machines which are outside this range may be submitted, but contractor must include all costs associated with modifying steel railing on existing C-130 MX stands. Modifications must be made by stand manufacture, to same standards and honor current warranty. Vendor must also field verify that wider units do not hit hangar trusses.)

3.2.3. Footprint depth: 82” min. to 104” max. (Machines which are outside this range may be submitted, but contractor must include all costs associated with modifying utilities which are 105” away from the C-130 MX stands and/or the walls of the 2 nd level mezzanines which are 110” away from the MX stands.)

3.2.4. Protrusions: Any protrusions (motor boxes, light boxes, etc.) which extend outside the footprint specified must be field verified by the contractor to not conflict with existing MX stand columns, existing walkways or other existing conditions.

3.2.5. Machine Capacity: 35000 lb min.

3.2.6. Speed: 30 ft/minute min.

3.2.7. Pans: 10 min.max

3.2.8. Pan Clear Height: 36 inches min. (Pans must include a full width back panel 36” tall to support parts stored at an angle to keep parts from falling off shelves).

3.2.9. Pan Depth: 36 inches (clear) min.

3.2.10. Pan Width: 144 inches (clear) min. (Pans must include full coverage side walls to prevent parts from falling off side of pans).

3.2.11. Pan Capacity: 1000 lb min.

3.2.12. Intermediate Shelves: 5 each 12’ x 3’ bolt-in-place, 1/8” max deflection @ 400 lbs distributed load, clear span with no intermediate supports, installed @ 12” and 24” spacing in pans.

3.2.13. Part Sizes: Pans and shelves must be capable of storing a variety of aircraft parts removed during aircraft maintenance activities. The larger sizes range from de-icing ducts which are 120” long to APU door panels which are curved pieces approx. 51” wide x 56” long (stored at an angle on the shelf with the edge leaning against the back wall of the 3’ tall pan). Wheel doors are 122” x 36.5” x 11.5”. Other parts include engine cowlings which are 35” x 46” x 14” and 48” x 36” x 16.5”. Wing tips are 91” x

12.5” x 13” while vertical stab. tips are 59” x 12” x 27”. Other panels are 75” x 24” x

3” while kidney plates are stored in bags approximately 28” x 40” x 30”. There are a multitude of other parts and sizes being stored. Over the past several years, thousands of man hours have gone into configuring these storage carousels in a manner which is efficient for mechanics. New carousels must have identical pans sizes so as to standardize configurations between docks.

3.2.14. Pan & Shelf Coating / Polyarmor protective coating (or approved equivalent rubberized coating) on all interior surfaces of pans/shelves to prevent aircraft parts from direct contract with metal pans/shelves. Coating shall be 12-20 mil min.

3.2.15. Power requirements: A 240 volt, 3 phase, 60 hertz, 40 Amp fused disconnect is provided for power connection. The fused disconnect is located on the column of the

MX stands, next to the carousel installation location. Contractor to include connection to this disconnect or to other existing facility electrical service as required.

3.2.16. Outlet: Machine to include a min. of one 120VAC, 20 Amp, 60 Hz outlet.

3.2.17. Motor drive system: 7.5 Horse power min.

3.2.18. Load Imbalance Capability: 50%.

3.2.19. Finish: standard factory baked on paint

3.2.20. Dust cover: Dust cover on top of machine to be capable of supporting 310 lb maintenance personnel and 25 lbs of hand tools min.

3.2.21. Part Visibility: The machine must be vertical carousel type unit which allows users to easily rotate through storage pans to visually find required aircraft parts.

3.2.22. User Controls: Push button on, push button off, push button rotate up, push button rotate down. Emergency stop button on both sides of access window.

3.2.23. Automatic Safety Stop: Machine shall incorporate sensors to automatically stop carousel from rotating in either direction if an object is in a position to get pinched between the rotating carousel pans an any other part of the carousel.

3.2.24. RS232 Port : The controller shall be a command driven interface with asynchronous responses communicating through an ASCII RS232C 9 pin connection.

Pan positioning shall be directed from Air Force automation control host system

MPS/D230 using ASCII commands. The controller shall respond when commands are completed and not require continuous polling to determine completion status / minimum-maximum

3.2.25. Counter: None

3.2.26. Access Doors: Lockable with same key for all doors proved in this contract.

3.2.27. Lights: Full width fluorescent light over access doors

3.2.28. Seismic rating: 4

3.2.29. Fire Protection: In Accordance With AFI 32-10141, each carousel shall provide fire sprinklers complying with guidance provided in FM Data Sheet 8-33 Carousel

Storage (latest version). As a minimum sprinklers shall consist of 2 Head internal

Sprinkling, Top mounted, 1” connection

3.2.30. Dual Window Access: Both access windows to be on same side of unit.

Openings to be 38” high x 146” wide min. Bottom of lower window to be 36” to 40” above floor. Bottom of upper window to be at 143” to 148” above floor. Windows to be installed such that the upper window is accessible from the deck of the MX stands

3.2.31. Safety light sensors are to be positioned on upper and lower pinch point areas of access windows to stop carousel motion in the event of human or obstruction .

3.3. Quantity: 2 Single Access

3.3.1. NOTE: All specifications in section 3.1 are applicable unless specifically modified below.

3.3.2. Carousel height: Approximately 402”

3.3.3. Footprint width: 198” max. (including all protrusions below 10’ high)

3.3.4. Footprint depth: 110”max.

3.3.5. Pans: 16 min.

3.3.6. Intermediate shelves: 8

3.3.7. Power requirements: Contractor to field survey existing electrical service in hangar and include connecting to existing facility electrical service as required.

3.3.8. Single Window Access: Access window opening to be 38” high x 146” wide min. Bottom of window to be 36” to 40” above floor.

4. BASIC WARRANTY:

Unless noted otherwise, contractor to provide a written warranty which warrants all products provided under this contract, under normal use, will be free from defects in materials and workmanship and that each unit/system will perform its design function for a period of no less than one (1) year. Warranty period to start from date of final acceptance of each installed unit/system. Any defects in materials or workmanship or failure of any product or component to perform its designed function during the warranty period shall be fixed by the contactor at no additional cost to the government. Warranty shall include the cost(s) of, parts, shipping and labor. Warranty repairs are to be fixed within 2 days of notice of failure.

CDRL A001, DI-SESS-81639

5. DELIVERY, STORAGE & HANDLING:

Contractor to make all arrangements necessary, provide all equipment necessary, and cover all costs to deliver and off load all job related equipment, supplies, materials, fabrications, etc. to the job site at Hill Air Force Base, Utah. Contractor to coordinate delivery and off-loading with AMXG as required.

6. INSTALLATION REQUIREMENTS:

6.1. INSTALLATION SITES:

6.1.1. Installation sites for the four shorter, dual window units:

6.1.1.1. The four shorter units are to be incorporated into the existing C-130 MX stands on docks C3, C4, C5 and C6. Space for these units were designed into the stands. Two stands are mirror image of the other two stands.

6.1.1.2. Aircraft will be vacated from each dock during the carousel installation.

6.1.1.3. Units must be installed within 1” of the deck of the stands on two sides.

6.1.1.4. Overhead speakers are to be relocated as required.

6.1.1.5. Contractor to remove temporary railing system installed and provide OSHA approved fall protection methods for their employees during entire installation process. (Contractor may use existing overhead fall arrest system if desired, but must provide their own harnesses).

6.1.1.6. Existing roof truss system, second level mezzanines and existing utilities are in very close proximity to the installation site.

6.1.1.7. Offerors are urged and expected to field survey each site, examine limited available space and existing site conditions, and include all work required to adapt the site to accommodate the carousel as well as all equipment and labor needed to perform the installation and erection of the machines. In no event shall the failure to inspect the sites constitute grounds for a claim after the contract award.

6.1.2. Installation Sites for the two taller units:

6.1.2.1. The two taller units are to be installed in the North East and South East corners of B225.

6.1.2.2. Units must be installed similar to the units currently in docks C1, C2, C7 and

C8 with the back of the units approximately 6” away from the truss system above and the side of the units within 1” of the yellow walkway without protruding into the walkway.

6.2. WORK SCHEDULE COORDINATION:

6.2.1. PRE-INSTALLATION MEETING:

Before any of the “on site” work within the scope of the contract is started, the

Contractor shall initiate and conduct a pre-installation meeting. Meeting shall:

6.2.1.1. Require attendance of persons directly supervising the on-site installation work.

6.2.1.2. Review schedule of installation, installation procedures and conditions, and coordination with related work.

6.2.1.3. Review safety requirements; FOD (Foreign Object Damage) control requirements; controlled area access and badge requirements; means of access to premises and building; delivery of materials and use of approaches; use of corridors, stairways, elevators, and similar means of communications; the location of fences, partitions and eating spaces for Contractor’s employees; sequence of procedure; work hours; schedule for completion, commissioning and training; and the like.

6.2.2. LIMITED SITE AVAILABILITY: The carousel sites will be cleared of aircraft by AMXG prior to the beginning of the Installation Time Period. Prior to that time the contractor will have limited access to the site, must request access to the site, and may have to conduct site surveys and perform other pre-installation activities around aircraft and equipment currently on the site. AMXG will make every effort possible to make the site available at the time/date requested by the contractor. However, site availability is not guaranteed. Any government caused delays to site availability will extend the completion and/or installation time periods on a day for day basis. Delays to site availability will be at no cost to the government. AMXG will provide outside staging space approximately 40’ by 40’. Contractor will be responsible for providing weather protection for material stored outside.

6.2.3. COORDINATION WITH PRODUCTION: Contractor must coordinate all on-site work and installation schedules with AMXG and schedule all on-site work around aircraft production activities. Contractor shall submit a proposed schedule to the PM for approval prior to commencing work on any site. The contractor must adapt their schedule to match site availability as granted by the PM. AMXG may alter schedules as needed and at no cost to the government. CDRL A002, DI-MGMT-80033A

6.2.4. PHASED INSTALLATION: Contractor must have first unit available for installation within 4 months of contract award. Subsequent units to be available at a rate of 2 weeks per unit following the delivery of the first unit

6.2.5. INSTALLATION TIME REQUIREMENTS: Contractor shall complete the installment of each carousel within two weeks of each carousel site being released to them.

6.3. TOOLS, MATERIALS, AND EQUIPMENT CONTROL:

6.3.1. CONTRACTOR WORK ZONE: The contractor must establish a dedicated and secure Contractor Work Zone by providing a fence around the work area with appropriate, construction, keep out, and warning signs to separate the Contractor Work

Zones from the aircraft production areas. Contractor Work Zones must be completely free of all aircraft and aircraft parts. All staging areas, material storage, and work areas shall be confined to the area inside the Contractor Work Zone. The size and location of the Contractor Work Zone must be coordinated with AMXG so as to minimize the amount of disturbance to Depot production activities. The Contractor Work Zone must be at least 20’ away from any aircraft. The fence to be chain link, properly supported snow barrier, or other PM approved fencing material. Tension barriers or caution tape do NOT meet this requirement, it must be an actual fence. The contractor must maintain all tools, materials, equipment, and perform all work (as far as possible) within the fenced Contractor Work Zone.

6.3.2. LOST TOOLS: If tools, and/or equipment are lost in the aircraft maintenance area, the contractor will report the loss to the PM within 30 minutes of discovering the item is lost. Every effort shall be made to recover the item before reporting it as lost.

6.3.3. FOREIGN OBJECT DAMAGE (FOD) Safety Requirements: FOD is any foreign object which causes damage to an aircraft. To ensure no construction materials become FOD the contractor is required to; ensure all deliveries and construction vehicles are properly covered and clean prior to entering the industrial area, ensure all work areas are cleaned daily, ensure all construction debris is contained within the

Contractor Work Zone, thoroughly clean all installed products and all construction areas prior to turn over to government..

6.4. WORKING AROUND AIRCRAFT:

6.4.1. The aircraft maintenance area is defined as the entire secure (or controlled) area behind the pacer protect fence (also known as the red line area) and includes the flight line, tarmac and all facilities. No person shall enter the aircraft maintenance area without first obtaining permission, obtaining appropriate badges (or escorts), knowing the rules and agreeing to conform to the rules governing the area. WARNING: The area classified as the flight line has additional restrictions and requirements. The boundary of the flight line is indicated by a double yellow dashed line. Access to the aircraft maintenance area does NOT grant access to the flight line. All persons entering the flight line must receive additional appropriate training prior to entering.

6.4.2. When working in the aircraft maintenance area, the Contractor will be required to work in close proximity to aircraft and shall use extra caution to insure that activities do not endanger aircraft or personnel nor delay aircraft maintenance activities. Special rules and regulations exist when working around aircraft. The contractor will be required to adhere to these rules and regulations. Highlights include, but are not limited to:

- No work will be allowed over the aircraft

- Tool control requirements

- No privately owned vehicles in pacer protect area

- Contractor vehicle restrictions

- Restrictions of Driving/parking to close to aircraft

- Flight Line restrictions

- No food/beverages except in designated areas

- No smoking except in designated areas

- Restrictions on phones, cameras, and electronic devices

- Obtaining access badges and/or security escorts

- Time restrictions for unescorted work

6.4.3. SECURITY BADGES: AMXG will NOT provide government escorts for secured area. Contractor must obtain base access badges and secured area badges for the duration of the installation process. Secured area badges can take months to acquire so contractors should submit paperwork for secured area within 2 weeks of contract award..

6.4.4. NORMAL WORK HOURS: When working in the aircraft maintenance area the contractor, unless noted otherwise, is to work during normal 309 AMXG work hours whenever possible. Normal work hours for 309 AMXG are defined as 0600 to 1530

Monday through Thursday and 0600 to 1430 on every other Friday (with opposite

Fridays as off Fridays).

6.4.5. EXTENDED WORK HOURS: The contractor, at no additional cost to the government, must work extended hours (weekday evenings, nights, weekends and/or holidays) as required in order to complete the tasks within the schedule constraints defined in this contract. Contractors must be escorted by government personnel when working extended hours. Contractor must obtain approval from the PM one week prior to working extended work hours to allow the PM time to arrange for a government escort.