Performance_Specifications_26_Mar_2015_.pdf

Performance Specifications Modernization of

Two (2) Drive-Through Blast Booths (DTBB) Located in Buildings 844 and 847

Hill Air Force Base, Utah 26 Mar 2015

1. GENERAL

1.1. PURPOSE.

This specification is to modernize two (2) existing Drive-Thru Blast Booth (DTBBs) systems. The contractor shall remove existing Blast Booth Support Equipment, and replace with new as identified within this Purchase Specification. The DTBB is corrosion control equipment that uses high pressure air and abrasive media to remove paint and corrosion. The requirement shall include all freight and handling charges, incidental on-site demolition, removal and disposal of related equipment, complete design showing integration of all new equipment to existing blast booths, full turn-key assembly, retrofit of existing equipment, facility and utilities, installation of new components and manufacturer start-up of the DTBBs into the following address:

581st MMXS/MXDPABC 7563 Wardleigh Road, Buildings (Bldg.) 844/847 Blast Shop Hill Air Force Base, Utah 84056

1.2. EQUIPMENT REMOVAL AND INSTALLATION PLAN.

The Contractor shall meet the following:

1.2.1. GENERAL REQUIREMENTS

1.2.1.1. The Contractor shall provide all parts, tools, equipment, transportation, labor, management and supervision necessary to successfully accomplish the project.

1.2.1.2. The Contractor shall provide all basic facilities and accommodations required for its workers if the Government cannot provide, with the exception of any facilities and/or accommodations that the request-for-proposal identifies as being provided by the Government.

1.2.1.3. The Contractor shall provide all required Personal Protective Equipment (PPE) to all employees.

1.2.1.4. The Contractor shall handle all equipment being removed as if it is potentially contaminated with a minimal amount of Chromates, Cadmium or Lead Paint residue.

The Contractor shall follow all applicable OSHA Regulations regarding handling of hazardous materials and shall ensure that appropriate PPE is available and used by all personnel.

1.2.1.5. The Contractor shall acquire all necessary identifications, badges as well as legal permits and provide a copy to the Government before commencing any work.

1.2.1.6. Contractor’s schedule will be approved and/or disapproved by the Project Manager (PM) The Contractor shall provide a project schedule before commencing any work. Request Government approval of such schedule prior to commencement of work.. CDRL A001/DI-MISC-81382.

1.2.1.7. The Contractor shall submit to the Government a list of all major components to include: dust collector, exhaust fan, electric motors, booth controller screw conveyor, bucket elevators, blast pots, and media hopper with adequate detail to allow government PM to verify that all equipment meets PS requirements. This list shall be submitted to the PM. The contractor shall obtain written notification of Government PM approval prior to purchase and installation of any component.

CDRL A002/DI-MISC-80071E

1.2.1.8. Government review of any equipment submittals is for general conformance of the submitted equipment of the project specification; in no way does such review/approval relieve the Contractor of its obligation to furnish equipment and materials that comply in detail to the specification, nor does it relieve the Contractor of obligation to determine actual field dimensions and conditions which may affect work.

1.2.1.9. The Contractor shall field verify all utility hook-up requirements and equipment fitment. All additional concrete pads required for equipment placement is the responsibility of the contractor.

1.2.1.10. The equipment layout provided by the Government is an estimate only. The Contractor shall ensure all equipment fits within the actual area or space allowed verses estimated equipment layout and shall provide allowance for operation and maintenance standard requirements. The Contractor shall take full responsibility for space and utility requirements for equipment installed.

1.2.1.11. The Contractor shall attend all training for Burn Permit: Contractor shall obtain a BURN PERMIT from Hill Air Force Base Fire Department. A required burn permit class is taught by the base fire department on a monthly basis. Classes are conducted on the first (1st) Thursday of every month.

1.2.1.12. The Contractor shall observe and follow all current Federal, State and Local Building Codes, National Electric Code (NEC) and Plumbing Codes.

1.2.1.13. The Contractor shall refer to posted Asbestos and Lead Base Paint surveys for the project and follow all procedures on how to handle such materials.

1.2.1.14. The Contractor shall ensure the project site is cleaned, maintained, secured and kept safe for all workers as well as building occupants at all times.

1.2.1.15. The Contractor shall provide its own refuse dumpster.

1.2.1.16. The Contractor shall not deviate from any part of this Purchase Specification

(PS). Any proposed deviation shall be requested through the Contracting Officer for approval.

1.2.1.17. The Contractor shall coordinate all efforts, questions and concerns through the PM and Contracting Officer.

1.2.1.18. All installation requirement shall be in accordance with (IAW) manufacturer installation procedures or IAW PS if manufacturer procedures do not exist.

1.2.2. ELECTRICAL SERVICE AND BRANCH CIRCUITS

1.2.2.1. Size and install circuit overcurrent protection per equipment manufacturer’s spec and NEC.

1.2.2.2. Size and install new electrical equipment (i.e. transformers, VFD motors line/load reactors, etc., to support all booth related equipment). All wiring and conduits as per NEC.

1.2.2.3. Size and install all required equipment grounding as per NEC.

1.2.2.4. If required by the manufacturer, provide dedicated earth ground for the equipment using a copper rod driven through the building floor and into the ground.

1.2.2.5. Size and install service disconnects as per NEC Code (disconnects shall also disable all motor variable drives). All variable frequency drives (VFDs) shall have 3% line reactors installed.

1.2.2.6. Use only insulated copper wiring rated for industrial applications.

1.2.2.7. Do not feed any electric motors/equipment with conductors smaller than #12

American Wire Gauge (AWG).

1.2.2.8. Use only Electrical Metallic Tubing (EMT), or rigid metallic conduit.

1.2.2.9. Support all conduits as per NEC.

1.2.2.10. No conduit runs should be a tripping hazard or interfere with other machines or equipment in the shop.

1.2.2.11. Where mounting heights are not detailed or dimensioned, install mechanical services and overhead equipment to provide the maximum headroom possible while still meeting all other specification requirements.

1.2.2.12. All materials must be new and Underwriters Laboratories (UL) or Electrical Testing Laboratories (ETL) listed.

1.2.2.13. All equipment circuits must be labeled.

1.2.3. PLUMBING, PIPING AND COMPRESSED AIR REQUIREMENTS

1.2.3.1. Size and install each run with minimum joints and couplings, but with adequate and accessible union, flanges, etc., for disassembly and maintenance/replacement of valves and equipment.

1.2.3.2. Reduce sizes as required by use of reducing fittings.

1.2.3.3. Align piping accurately at connections, within 1/16" misalignment tolerance.

1.2.3.4. Install service/shut-off ball valves per equipment inlet connections.

1.2.3.5. Install inline coalescing air filters, pressure gauges and regulators for all equipment inlet connections.

1.2.3.6. Feed all compressed air requirements from the booth’s main shop air supply.

1.2.3.7. Use only new type K copper or schedule 40 black pipe for all piping runs.

1.2.3.8. Insulate all pipe located outside the building with 1.5” wall thickness

HT/Armaflex, or Government approved equivalent, closed cell elastomeric foam tube insulation.

1.2.3.9. Install new low voltage heat tape between the pipe and the closed cell foam insulation for any piping run located outside the building.

1.2.3.10. Piping runs shall not be a tripping hazard or interfere with other machines or equipment in the shop.

1.2.3.11. Where mounting heights are not detailed or dimensioned, install mechanical services and overhead equipment to provide the maximum headroom possible while still meeting all other specification requirements.

1.2.3.12. Label all pipes using oil-resistant vinyl labels and following American National Standard Institute (ANSI)/American Society of Mechanical Engineers (ASME) A13.1 standards.

1.2.3.13. Provide temporary equipment for testing. Test each natural section of each piping system independently but do not use piping system valves to isolate sections where test pressure exceeds valve pressure rating.

1.2.3.13.1. Pressure test piping in accordance with ANSI B31.

1.2.3.13.2. Test each piping system at 125% of operating pressure indicated, but not less than 25 pound per square inch test pressure. Required test period is two (2) hours.

1.2.3.13.3. Observe each test section for leakage at end of test period. Test fails if leakage is observed or if pressure drop exceeds 5% of test pressure.

1.2.3.14. Repair piping systems sections that fail the piping test, by disassembly and re-installation, using new materials to extent required to overcome leakage. Do not use chemicals, stop-leak compounds, mastics, or other temporary repair methods.

1.2.4. MECHANICAL SYSTEMS REQUIREMENTS

1.2.4.1. Coordinate the installation of all mechanical equipment and materials with existing and new equipment, as well as building requirements. All dimensions shall be field verified.

1.2.4.2. Where mounting heights are not detailed or dimensioned, install mechanical services and overhead equipment to provide the maximum headroom possible while still meeting all other specification requirements.

1.2.4.3. Install mechanical equipment to facilitate maintenance and repair or replacement of equipment components. Connect equipment for ease of disconnecting, with minimum of interference with existing equipment and building.

1.2.4.4. Anchor all machines to the floor following manufacturer’s recommendations in so far as the anchoring system is suitable to the existing slab thickness.

1.2.4.5. Provide suitable shoring material if existing floor does not meet equipment flatness requirement.

1.2.4.6. Provide seismic restraints suitable for Seismic Zone 3 (i.e. structural angles or channels) for all applicable equipment.

1.2.4.7. Seismic restraints may be supported from the building or blast booth structure.

1.2.4.8. Provide suitable vibration mounts for dust collector, fans, bucket elevators, and evaporative coolers.

1.2.4.9. All machines must be leveled and plumbed.

1.2.4.10. Follow all equipment manufacturer’s installation recommendations.

1.2.4.11. All abandoned floor anchors must be cut flush to the concrete floor.

1.2.4.12. Use all precautions and care to ensure that no buried utilities are affected or damaged by any anchoring or excavation method.

1.2.4.13. Components must be accessible without removing or disturbing other items, with the exception of wiring and piping connections or minor tubing. All required maintenance and operational activities, shall be capable of being performed without the need to over reach past three (3) feet if possible.

1.2.4.14. Gauges and other instruments shall be visible from a normal standing position.

1.2.4.15. All mechanical equipment which requires adjustment for maintenance or replacement shall have access panels and shall be accessible to maintenance workers.

1.2.5. STRUCTURE PENETRATIONS

1.2.5.1. New building wall penetrations are required for exhaust air ductwork, return air ductwork, compressed air piping, electrical conduits and fire suppression piping.

1.2.5.2. Provide caulked and sealed sleeves through the wall into dry rooms that are flush with the wall.

1.2.5.3. All sleeves shall allow for movement of the pipe/duct caused by expansion and contraction.

1.2.5.4. Walls and roof penetrations shall be made weather-tight using flashings, counter-flashings and sealants. (Standard water leak test is required prior to acceptance).

1.2.5.5. Provide new structural reinforcement if any penetrations result in a weakened original structure.

1.2.5.6. A written request from the Contractor shall be submitted to the Contracting Officer for approval to modify building’s structural components.

1.3. QUALITY ASSURANCE OF MATERIALS AND EQUIPMENT. The Contractor shall meet the following:

1.3.1. All equipment shall be UL or ETL labelled/listed where available

1.3.2. All equipment/components shall be new and of the manufacturer's current production models, which, on the date of this solicitation, is designed, engineered, sold, and currently offered for sale through advertisements or manufacturer's published catalogs or brochures. Wording on all components and sub-components, such as electrical motors, diagrams, mechanical components, safety, and other information shall be written in American English. All installation diagrams, operator and maintenance manuals, software, and other data supplied as part of this specification shall also be written in American English.

1.3.3. All equipment shall be furnished complete with all accessories normally supplied with catalog items listed, and all accessories required for a complete and satisfactory installation.

1.3.4. At the completion of work, fixtures, equipment and materials shall be cleaned and delivered in a factory new condition for Government’s acceptance. Damage and defects occurring before acceptance of the work shall be corrected at the Contractor's expense.

1.4. QUALIFICATIONS OF WORKMEN. The Contractor shall meet the following:

1.4.1. All tradesmen shall be capable journeymen, skilled in the work assigned to them.

Apprentices may be used with appropriate direction.

1.4.2. Proof of license for journeyman level plumber, welder, electrician and control technician shall be submitted to the Contracting Officer. CDRL A003/DI-MGMT-81954

1.5. PERIOD OF PERFORMANCE.

The Contractor shall use the following schedule to deliver to the Government the DTBBs and all associated components, tools, manuals, drawings and support equipment, including complete system installation, balancing, testing, commissioning and acceptance.

1.5.1. Phase 1 (Bldg. 844): 210 calendar days from date of award:

1.5.1.1. Complete Required Design for both blast booths in Bldgs. 844 and 847. Contractor shall conduct 35%, 65%, 95% and Final design reviews and provide corresponding drawings and specifications for each design reviews to the Government Engineer.

The Government Engineer will participate and be the approving official for all design reviews and drawings.

1.5.1.2. Obtain Government Engineer’s Review/Approval for Completed Designs.

1.5.1.3. Forward to the Government Engineers all Required Equipment Submittals for bucket elevators, screw conveyor, dust collector, blast pots, control system, evaporative cooler, grating system and heating and ventilation system.

1.5.1.4. Purchase and deliver all long-lead time equipment for both Bldgs. 844 & 847 blast booths.

1.5.1.5. Accomplish all project requirements for Bldg. 844 DTBB.

1.5.2. Phase 2 (Bldg.847): 3300 calendar days from date of award

1.5.2.1. Accomplish all project requirements for Bldg. 847 DTBB.

1.5.3. Work hours shall be between 0600 to 1600 hours, Monday thru Friday.

1.5.4. Recognized Holidays. The Contractor shall not be granted access to HAFB on the following recognized holidays: New Year's Day, Martin Luther King Day, Presidents' Day, Memorial Day, Independence Day, Labor Day, Columbus Day, Veterans' Day, Thanksgiving Day, and Christmas Day. If the holiday falls on Saturday, it is observed on Friday. If the holiday falls on a Sunday, it is observed on Monday.

2. REFERENCE DOCUMENTS

2.1. AF FORM 332. (Civil Engineering Work Request). Attachment 1 and attachment 2

3. BUILDING 844 SPECIFIC REQUIREMENTS:

3.1. BUILDING 844 EQUIPMENT REMOVAL AND RE-USE PLAN.

3.1.1. The DTBB Contractor shall remove, palletize, cover, and place in a staging area determined by the Government Engineer the following items:

3.1.1.1. Air wall dust collector system

3.1.1.2. Manual purge dust collector system

3.1.1.3. Cyclone/vacuum recovery system

3.1.1.4. Pneumatic in-floor recovery system

3.1.1.5. Bulk media storage hopper system

3.1.1.6. Booth exhaust fans

3.1.1.7. Booth exhaust ducting system

3.1.1.8. Booth lights

3.1.1.9. Booth control panel and complete electrical

3.1.1.10. Abrasive blast pots

3.1.1.11. Floor trench steel support system

3.1.1.12. Booth steel grating system

3.1.1.13. Compressed air supply to all dust collectors and in-floor vacuum lines

3.1.2. The following equipment will remain and shall be integrated into the design and modernization of the new DTBB system:

3.1.2.1. Fire suppression and alarms

3.1.2.2. Booth enclosure and doors

3.1.2.3. HVAC equipment

3.1.2.4. Shop Air and Personnel Breathing Air System and alarms

3.1.2.5. Existing roof ladder (relocate as shown in attachment 1)

3.2. BLAST BOOTH EXISTING AND CONCEPTUAL MODERNIZATION LAYOUTS.

3.2.1. See attachments 1

3.3. SYSTEM REQUIREMENTS.

3.3.1. Blast Booth Configuration. The DTBB Blast Booth Configuration shall meet the following:

3.3.1.1. Booth enclosure seams and gaps shall be resealed with abrasive resistant polyurethane sealant and all hole damages (i.e. corrosion holes, puncture holes) repaired to match existing booth.

3.3.1.2. Install a new personnel door on the booth’s west wall (to match existing doors).

3.3.1.3. Install new 0.25 inch thick rubber liner along booth interior wall (minimum five

(5) feet starting from floor).

3.3.1.4. Modernize two (2) existing product bi-fold doors with new rubber seals, heavy duty latches, and hinges.

3.3.1.5. Reuse all personnel doors.

3.3.1.6. Install new screw conveyor and bucket elevator media recovery system.

3.3.1.7. Lengthen the two (2) concrete floor trenches to provide 60 feet of full booth coverage (See attachment 1). The contractor shall dispose all excavated concrete and dirt at the Hill AFB landfill. The Contractor shall re-route all existing above floor and underfloor utilities and drains that will be impacted by any required excavations.

3.3.1.8. Size and build new reinforced concrete pits for the new bucket elevator and main cross screw conveyor systems. The contractor shall dispose all excavated concrete and dirt at the Hill AFB landfill. The Contractor shall re-route all existing above floor and underfloor utilities and drains that will be impacted by any required excavations.

3.3.1.9. All new concrete shall be reinforced and have a minimum compressive strength of 4,000 psi. A stamped drawing from a registered professional engineer is required for all new concrete work.

3.3.1.10. Install new welded galvanized steel floor gratings with perforated plates, and steel plate trench covers system. Use H-25 load criteria from the American Association of State Highway and Transportation Officials (AASHTO). All gratings shall be designed and certified by a registered professional engineer and fabricated IAW ANSI/NAAMM Standard 532-09 (or latest edition).

3.3.1.11. Install new floor hoppers out of 14 gauge (ga) steel minimum (designed to fit in existing trench four (4) feet wide x four (4) feet deep).

3.3.1.12. Replace all existing light fixtures with all new four (4)-tube 32 Watts T8 fixtures, 277 volts, polished aluminum mirrored reflectors (Class 2 Division 1 or 2 if applicable) and abrasive resistant glass. Booth lighting shall have operator selectable five (5) individual switched zones (i.e. NE, NW, SE, SW and ceiling).

3.3.1.13. Minimum booth uniform lighting required: 110 foot-candles measured at three feet from the floor.

3.3.1.14. Minimum of eight (8) light fixtures shall be modified to function as emergency lighting during building power outages (must have minimum rated run time of 60 minutes per light).

3.3.1.15. Install all new lighted exit sign above each personnel door (Class 2 Div 1 or 2 if applicable).

3.4. PERFORMANCE CHARACTERISTICS.

3.4.1. Air Flow and Temperature. DTBB Air Flow and Temperature shall meet the following:

3.4.1.1. Minimum booth air velocity of 110 feet per minute from front to back and uniformly across the effective booth cross section (16 feet high x 20 feet wide).

3.4.1.2. Booth space temperature range; 65-90 degrees (deg.) F (operator adjustable, monitored).

3.4.1.3. 70-100% air recirculation, 0-30% outside air electronically monitored/controlled.

3.4.1.4. Booth static pressure, 0.05” ± .02” electronically monitored/controlled.

3.4.2. Booth Air Exhaust and Ventilation System. The DTBB shall meet the following:

3.4.2.1. Install a new 40,000 cubic feet per minute (cfm) minimum, belt or direct drive centrifugal fan (rated for outdoor use), equipment mounted or floor mounted.

3.4.2.1.1. 85 decibel (DBA) or less average sound rating.

3.4.2.1.2. Variable frequency driven, high efficiency Energy Policy Act (EPACT) fan motors, 480 volts, 3 Phase (Ph), 60 Hertz (Hz) totally enclosed fan-cooled (TEFC) motor (Class 2 Div I or II if applicable per NEC), outdoor rated.

3.4.2.1.2.1. Motors shall be sized so the driven load will not require the motor to operate in the service factor range.

3.4.2.1.2.2. Motors shall be rated for 104°F environment with maximum 194oF temperature rise for continuous duty at full load (Class B Insulation).

3.4.2.1.3. Fan shall be sized and selected to accommodate static pressures and flow variations of +/-15% of scheduled values including approximately ten (10) inches of water column total pressure drop from all inline equipment, ducting and total system effect losses (the Contractor shall verify total system pressure drop and make equipment selection adjustments).

3.4.2.1.4. Fan housing shall be completely welded and powder coated with a minimum of four (4) mils of polyurethane paint. Finish color is factory standard.

3.4.2.1.5. Fan impeller shall be manufactured with continuously welded steel airfoils non-sparking blades (conform to Air Movement and Control Association

(AMCA 99).

3.4.2.1.6. Bearings shall be self-aligning, heavy duty, grease lubricated with extended lube lines and fittings, flanged mounted with minimum basic rating fatigue life L(50) in excess of 200,000 hours (hrs) at maximum operating speed for each pressure class.

3.4.2.1.7. Bearings shall be fixed to the fan shaft using concentric mounting locks.

Bearings that use set screws are not allowed.

3.4.2.1.8. Housing and bearing supports shall be constructed of welded structural steel members to prevent vibration and rigidly support the shaft and bearings.

3.4.2.1.9. Welded steel vanes in fan housings to straighten airflow.

3.4.2.1.10. Removable/hinged access and maintenance panels.

3.4.2.1.11. Built-in lockable power disconnect.

3.4.2.1.12. Built-in lifting lugs.

3.4.2.1.13. UL or ETL listed and labeled.

3.4.2.2. Motorized balancing dampers for airflow, temperature and static pressure control.

3.4.2.3. Field installed airflow and temperature sensors and transmitters integrated into the main control panel.

3.4.2.4. Complete new ducting package (as a minimum but not limited to mixed air flow boxes, fittings, straights, transitions, cones, balancing and backdraft dampers, gates, vanes, rain stacks, curbs, flashings, bird screens, transverse reinforcements and supports, etc.,) for the exhaust air, recirculated air and fresh air/make-up air systems.

3.4.2.5. Provide hinged access doors in ductwork or plenums to maintain fire or explosion isolation devices, dampers, and controls. Doors shall conform to Sheet Metal and Air Conditioning Contractors National Association (SMACNA) standards.

3.4.2.6. All ductwork shall be G90 galvanized steel.

3.4.2.7. All round ducts shall be spiral lock-seam, smooth interior.

3.4.2.8. All exterior ductwork shall be double walled and have two (2) inches thick of thermal insulation sandwiched in between the inner and outer duct walls (thermal insulation density shall be three (3) pounds per cubic feet).

3.4.2.9. Provide and install new baffled air exhaust abrasive resistant plenums and ducting system sized for the required booth air flow and duct air velocity (pressure rating is four (4) inches negative, seal class A).

3.4.2.10. Provide and install new baffled air inlet plenums and ducting system sized for the required booth air flow and duct air velocity (pressure rating is three (3) inches positive, seal class A).

3.4.2.11. Exhaust and inlet plenum openings inside the booth shall have 1-1/2” #9 standard expanded metal guards (76% open area).

3.4.3. Heating, Cooling and Make-Up Air. The DTBB shall meet the following requirements:

3.4.3.1. Integrate existing HVAC equipment for the booth’s make-up air and cooling requirements.

3.4.3.2. Integrate existing HVAC controls to the booth’s new HVAC controls.

3.4.3.3. Size and install one (1) new steam distribution/non freeze coil across the main recirculation duct (see attachment 1).

3.4.3.4. Size and install new steam lines, control valves, pressure gauges, universal style thermostatic steam traps, drains, pilot-operated regulator and control valve stations and a complete steam condensate system for the new steam coil(s) and the building’s existing condensate system (see attachment 1).

3.4.3.5. All new steam lines shall be insulated (to match bldg. steam insulation).

3.4.3.6. All new steam system controls shall be electric/electronic.

3.4.4. Dust Collector System (Cartridge Type). The DTBB Dust Collector System shall meet the following requirements:

3.4.4.1. 40,000 cubic feet per minute (minimum) outdoor unit sized to match booth required air flow.

3.4.4.2. Vertical, aspirated, single point seal cartridge filter configuration (filter collection efficiency 99.99% at 0.5 micron particulates).

3.4.4.3. Standard cartridges shall have continuous, double-seal, cast urethane gaskets.

3.4.4.4. High Efficiency Particulate Air (HEPA) filter post filtration system.

3.4.4.5. Heavy duty abrasive inlet plenum and baffles (top or side access).

3.4.4.6. Pulse-jet system with the lowest compressed air consumption, while still achieving highest efficiency filter surface area cleaning.

3.4.4.7. Adjustable on-demand (with Photohelic Gauge) pulse rate system based on pressure drop measured across the filter cartridges.

3.4.4.8. Modular bolted construction, structural steel framed, minimum 10 (ga) steel panels, fully powder coated finish with minimum of four (4) mils of polyurethane paint. Finish color is factory standard.

3.4.4.9. Factory fully assembled with built-in lifting lugs.

3.4.4.10. Extended tubular steel legs to fit 2000 pounds super sack collection bags (fully powder coated finish to match dust collector. Incorporate welded steel tabs/hooks to support collection bag ears.

3.4.4.11. Free flow pyramid hoppers (maximum of two (2) designed to eliminate dust bridging or build-up.

3.4.4.12. Explosion proof motorized rotary air lock valves (Class 2 Div I or 2 if applicable).

3.4.4.13. Explosion vent and future fire suppression per NFPA.

3.4.4.14. Wind load rated for 100 mph and seismic rated for seismic Zone 3.

3.4.4.15. Lockable power disconnect.

3.4.4.16. UL or ETL listed and labeled.

3.4.4.17. Class 2 Div 1 or 2 (if applicable pre NEC) for selection and installations of all electrical devices.

3.4.4.18. OSHA/ANSI compliant fixed access ladders and maintenance platforms with railings (primed and painted, color is Industrial Safety Yellow).

3.4.4.19. Smallest footprint available with all of the above accessories considered.

3.4.4.20. Minimum 10 year standard manufacturer warranty.

3.4.5. Floor Media Reclaim System. The DTBB Floor Media Reclaim System shall meet the following requirements:

3.4.5.1. Factory assembled, match mark complete units.

3.4.5.2. Component selection Group three (3), bearing selection Group H.

3.4.5.3. New in-floor hoppers and angle flanged 10 ga. U-troughs with flange foot supports.

3.4.5.4. Double bearing trough ends with feet.

3.4.5.5. Standard discharge spouts with plain openings.

3.4.5.6. 10 ga. trough covers on sections outside booth walls.

3.4.5.7. Nine (9) inch diameter helicoid screw conveyor system with two (2) inch diameter hardened shaft couplings and trough-end mounted screw driver reducers.

3.4.5.8. Flight edge thickness: 3/8 in. (inner) and 3/16 in. (outer).

3.4.5.9. Minimum 5.0 hp, 3ph, 460 VAC, 60 hz, heavy duty TEFC motors (Class 2 Div 1).

3.4.5.10. Double rollers and thrust bearing thrust force absorption design.

3.4.5.11. Design for a 15% trough loading and reclaim throughput of 120 cubic feet/hr.

3.4.5.12. All flights shall be hard surfaced to be suitable for use with garnet and/or Quick-

Strip G 10/20 media (180 lbs/ft³ bulk density) abrasive media (abrasiveness class:

extremely abrasive.)

3.4.5.13. Shall be designed to withstand corrosion, erosion, and abrasion impact and wear from previously specified abrasive media.

3.4.5.14. Provide hardened shafts, super-pack seals, hangers, fully sealed self-lubricating industrial duty long life hanger and end bearings that will accommodate four (4) degrees of shaft misalignment (L50 fatigue life rating) and all other related conveyor components.

3.4.6. Bucket Elevator. The DTBB Bucker Elevator shall meet the following:

3.4.6.1. Provide and install a Link-Belt™ Type 1 centrifugal discharge bucket elevator (or Government approved equivalent).

3.4.6.2. Service required is intermittent: 10 hours per day, six (6) days a week minimum.

3.4.6.3. Belt mounted buckets.

3.4.6.4. Suitable for use with garnet and/or Quick-Strip G 10/20 (180 lbs/ft³ density) abrasive media.

3.4.6.5. Shall withstand corrosion, erosion, and abrasion impact and wear from previously specified abrasive media.

3.4.6.6. Allow proper height for gravity feed into the abrasive air wash enclosure or chute (maximum clear height is 18 feet measured from building floor to lowest obstruction).

3.4.6.7. Non-sparking components (must be zone 20 compatible).

3.4.6.8. Class 2 Div 1 (if applicable per NFPA) for selection and installations of all electrical devices.

3.4.6.9. Electrical devices shall have a temperature class of Group II/T4 (<135 deg. F).

3.4.6.10. Designed to handle a reclaim throughput (discharge rate: 120 ft³/hr.)

3.4.6.11. Inlet chute designed to eliminate media to build back.

3.4.6.12. Designed to eliminate bucket drag by not allowing buckets to be dragged through a fully plugged boot.

3.4.6.13. Industry standard heavy duty wear resistant belt and steel bucket system

3.4.6.14. Fixed head shafts with foot shaft take-ups.

3.4.6.15. Bearings shall be self-lubricating and be fully sealed from dust or dirt at all times.

3.4.6.16. Bearings shall be fixed to the fan shaft using concentric mounting locking;

bearings that use set screws are not allowed.

3.4.6.17. Bearings shall be self-aligning, heavy duty, flanged mounted with minimum basic rating fatigue life L(50) in excess of 200,000 hrs at maximum operating speed for each pressure class.

3.4.6.18. Elevator casing with 12 ga steel hood and 7 ga. steel head and intermediate sections shall be rigid, with flange bolted connections; boot section shall be ¼ inch steel totally enclosed; large maintenance/inspection doors on the boot , body and hood sections.

3.4.6.19. Elevator enclosure shall be designed to minimize if not eliminate buckling or vibration under full operational load.

3.4.6.20. All seams shall be sealed, hinged maintenance access panels must be provided with rubber gaskets for a dust tight fit.

3.4.6.21. Factory applied primer and paint standard coatings are required.

3.4.6.22. Shall be secured to the floor and shall have seismic braces and supports designed for seismic Zone 3.

3.4.6.23. OSHA/ANSI compliant fixed access ladders and maintenance platforms with railings shall be provided for the hood and head sections of the bucket elevator (primed and painted, color is Industrial Safety Yellow).

3.4.7. Air Wash Module:

3.4.7.1. New gravity type air wash module.

3.4.7.2. Service required is intermittent: 10 hours per day, six (6) days a week minimum.

3.4.7.3. Shall be suitable for use with garnet and/or Quick-Strip G 10/20 (180 lbs/ft³ bulk density) abrasive media.

3.4.7.4. Shall be resistant to heat, corrosion, erosion, abrasion, hardness and flow characteristic properties of the above mentioned abrasive media.

3.4.7.5. Designed to fit in same space where old air wash system is located.

3.4.7.6. Shall have an adjustable rotating drum with perforated plate screen assembly to remove debris from the reclaimed media.

3.4.7.7. Shall include ductwork/pipe/hoses to transport separated dust, debris and recovered media (including 55 gal drums, covers and transition fittings).

3.4.7.8. Shall be designed to function utilizing the new dust collector fan.

3.4.7.9. Cascade plates/baffles shall ensure a measured uniform curtain stream of media to efficiently accomplish dust removal.

3.4.7.10. Shall have high abrasive and erosion resistant collecting chutes/funnels for debris and media.

3.4.7.11. Shall have non-sparking components (must be zone 20 compatible).

3.4.7.12. Class 2 Div 1 (if applicable per NFPA) for selection and installation of all electrical devices.

3.4.7.13. Electrical devices shall have a temperature class of Group II/T4 (<135 deg. F).

3.4.7.14. Shall be designed to clean a media reclaim throughput of 120 ft³/hr.

3.4.7.15. Enclosure shall be constructed the same method and materials as the bucket elevator described in 3.4.6.

3.4.7.16. Finish color shall match bucket elevator.

3.4.7.17. Shall be designed to handle full operational load and shall have seismic braces for seismic Zone 3.

3.4.7.18. Shall have same hinged maintenance access panels as bucket elevator.

3.4.7.19. OSHA/ANSI compliant maintenance platform and fixed ladder shall be installed.

3.4.8. Storage Hopper:

3.4.8.1. New free flow pyramid storage hopper shall be installed.

3.4.8.2. Holding capacity shall be 120 cubic feet, 21,000 lbs.

3.4.8.3. Free standing using structural grade steel columns/tubing.

3.4.8.4. Floor anchored and supported for seismic Zone 3.

3.4.8.5. Fully welded hopper walls constructed out of 3/16" thick steel (minimum) with steel frame reinforcement.

3.4.8.6. Prime and painted; finish color shall match bucket elevator.

3.4.8.7. Bolt-on observation port (30 square inches minimum) with structural grade shatter proof scratch resistant glass with rubber gasket seals shall be installed on the front hopper wall.

3.4.8.8. Provide a 30" x 30" hinged access hatch installed on the top of the hopper.

3.4.8.9. Hopper’s pyramid sections shall be designed to allow for a smooth free flow of media to the blast pots below.

3.4.8.10. Two (2) each independent discharge ports made out of 6.0" diameter steel pipe schedule 80 and one (1) each 8 inch diameter Schedule 80 clean out port shall be installed on the lowest section of the hopper.

3.4.8.11. Manual ball valves installed in series with discharges and clean-out ports.

3.4.8.12. Fall protection railings along the top of hopper and one (1) fixed ladder shall be installed to provide access to the top of the hopper and the air wash maintenance platform (OSHA/ANSI compliant), finish color is safety yellow.

3.4.9. Blast Pots and Accessories. The DTBB shall meet the following requirements:

3.4.9.1. Install two (2) new Axxiom/Schmidt, or Government approved equivalent, eight

(8) cubic feet capacity dual chambered blast pots complete with all required automatic electro-mechanical control system, control valves, control transformers, timers, safety switches, combo valves, service valves, gauges, regulators, all required piping, high attenuation silencers, screens, and flange mounted bolt-on steel plate lids with gaskets.

3.4.9.2. Each blast pot shall have fully integrated automatic flow control (dipper) valves that control the media flow from the storage hopper into the blast pots allowing for proper pop-up valve seal within the blast pot chambers.

3.4.9.3. Fully integrated NEMA 4 lockable control box for each blast pot.

3.4.9.4. New blast hoses, nozzles, and nozzle safety switches for two (2) operators.

3.4.9.5. Provide high air pressure related safety devices.

3.4.10. Control Panel. The DTBB Control Panel shall meet the following requirements:

3.4.10.1. User selectable/adjustable booth temperature set-points.

3.4.10.2. Fully integrated to run all booth support equipment plus all booth lighting, shop air, ventilation, heating and cooling.

3.4.10.3. Illuminated indicator lights and/or push-buttons switches for booth lights, evaporative cooling, heating, dust collector, floor augers and bucket elevator.

3.4.10.4. Control panel mounted Dwyer Photohelic gauge or Government approved equivalent, for booth static pressure control and monitoring.

3.4.10.5. Two (2) each panel mounted Dwyer Magnehelic, or Government approved equivalent, differential pressure gauges to indicate pressure drops across dust collector cartridge filters and HEPA filters.

3.4.10.6. Digital display showing graphical images of all booth equipment and their status including all booth operating set-points but not limited to the following:

3.4.10.6.1. Booth space temperature and static pressure

3.4.10.6.2. Booth temperature set points

3.4.10.6.3. Outside air temperature

3.4.10.6.4. Countdown timers settings and total booth run times

3.4.10.6.5. All doors open/close status

3.4.10.6.6. Shop-air on/off status

3.4.10.7. Automatic control capability to balance booth static pressure, temperature and airflow regardless of filter loading.

3.4.10.8. Emergency shut-off push button for entire booth.

3.4.10.9. Cabinet must be NEMA4, lockable, powder coated (color: industrial gray).

3.4.10.10. Control cabinet must actively dissipate internal heat build-up by the use of cooling fans.

3.4.10.11. Must house all controllers, micro-processors, motor drives, starters, control voltage transformers, fuses and other related electrical devices.

3.4.10.12. The controller shall be Allen Bradley Compact Logix 1769- L33ER PLC system with Ethernet processor and 2711P Panel View Plus 6 2711P-T10C4A8 terminal operator interface via touchscreen (or Government approved equivalent). The PLC system shall operate as a stand-alone system and shall include all software, hardware, peripherals, and all I/O devices as required to provide a complete operating system. Contractor shall provide a new laptop computer (Toshiba, HP, Lenovo, Dell or ASUS are acceptable manufacturers) with a padded carrying bag for remote programming and maintenance of the blast booths PLC systems. The laptop shall have a minimum of 17 inches high definition monitor, NVidia GeForce or ATI Radeon Direct 12X graphics card, 802.11 b/g/n WiFi and Blue Tooth enabled, high-speed Ethernet and USB ports, 500 Gigabyte Hard drive, 12 Gigabytes of RAM, latest generation Quad Core Processor technology minimum 3.50 GHz processor speed, CD/DVD RW drive, SD and Compact Flash memory card reader, USB optical mouse and a spare battery. The laptop shall be pre-loaded with Microsoft Windows 7 Professional 64 Bit with SP1 OS, Microsoft Office 365 Suite 2013, Adobe Acrobat XI Pro, Rockwell Automation RSLogix 5000 Professional and Factory Talk View Site Edition. The fully configured PLC programs including the screen graphical user interfaces of the two (2) blast booths 844 and 847 shall be uploaded to the laptop at the end of the project. The laptop computer and all software (including all related software discs and manuals) shall be officially licensed to and turned-over to the Government Engineer/309 MXSG/EN.

3.4.10.13. Shall be designed based on blast booth sequence of operations (see attachment 1).

4. BUILDING 847 SPECIFIC REQUIREMENTS.

4.1. BUILDING 847 EQUIPMENT REMOVAL AND RE-USE PLAN.

4.1.1. The Contractor shall remove, palletize, cover and place to a staging area determined by the Government the following items:

4.1.1.1. Cartridge dust collector system

4.1.1.2. Bucket elevator system

4.1.1.3. Screw conveyor system

4.1.1.4. Bulk media storage hopper system

4.1.1.5. Cyclone dust collection system

4.1.1.6. Catwalk maintenance platform

4.1.1.7. Booth exhaust fan system

4.1.1.8. Booth exhaust ducting system

4.1.1.9. Booth lights

4.1.1.10. Booth personnel doors

4.1.1.11. Booth control panel

4.1.1.12. Booth electrical panel (motor control center)

4.1.1.13. Booth personnel doors

4.1.1.14. HVAC/steam system and ductwork/ventilation system

4.1.2. The follow equipment will remain and shall be integrated into the design and construction of the new DTBB system:

4.1.2.1. Fire suppression and alarms

4.1.2.2. Blast Booth enclosure

4.1.2.3. Abrasive Blast Pots

4.1.2.4. Intrusion Prevention and Alarm System

4.1.2.5. Personnel Breathing Air System and alarms

4.1.2.6. Compressed Air System

4.2. BLAST BOOTH MODERNIZATION LAYOUT. (all components not shown for simplicity)

Attachment 2 Hill Air Force Base conceptual design

4.3. SYSTEM REQUIREMENTS.

4.3.1. Blast Booth Configuration. The DTBB, shall meet the following:

4.3.1.1. Modernize and reuse existing booth enclosure; all seams and gaps shall be resealed with abrasive resistant polyurethane sealant and all holes (i.e. corrosion holes, puncture holes) repaired, patch and paint all repairs to match existing booth.

4.3.1.2. Install new 0.25 inch thick rubber liners along booth interior walls (minimum 5 feet starting from floor).

4.3.1.3. Refurbish all three (3) existing product bi-fold doors with new rubber seals, mechanical, electrical hardware, hinges and latches (re-align all doors).

4.3.1.4. All four (4) personnel doors including hardware shall be new (all doors must have glass-lite windows size to match existing with protective rubber shields that can be raised/closed from outside of booth); new door material shall match old doors and finish color shall be industrial/safety yellow.

4.3.1.5. Reuse all concrete trenches and pits.

4.3.1.6. Reuse, re-align, level and fully re-weld all steel floor gratings, perforated plates and steel plates (replace damaged pieces).

4.3.1.7. New floor hoppers 14 ga welded steel minimum to fit in existing trenches.

4.3.1.8. New screw conveyor and bucket elevator system.

4.3.1.9. Remove all sharp edges on all booth panels, doors and floors.

4.3.1.10. Replace all existing light fixtures with all new four (4)-tube 32 Watts T8 fixtures, 277 volts, polished aluminum mirrored reflectors (Class 2 DIV 1 or 2 if applicable) and abrasive resistant glass. Booth lighting shall have operator selectable five (5) individual switched zones (i.e. NE, NW, SE, SW and ceiling).

4.3.1.11. Minimum booth uniform lighting required: 110 foot-candles at three (3) foot height from the floor.

4.3.1.12. Minimum of eight (8) light fixtures shall be modified to function as emergency lighting during building power outages (must have minimum rated run time of 60 minutes per light).

4.3.1.13. Install all new lighted exit sign above each personnel door (Class 2 Div. 1 or 2 if applicable).

4.4. PERFORMANCE CHARACTERISTICS.

4.4.1. Air Flow and Temperature. The DTBB shall meet the following:

4.4.1.1. Minimum booth air velocity of 110 feet per minute from front to back and uniformly across the effective booth cross section (21 feet high x 24 feet wide).

4.4.1.2. Booth space temperature: 65-90 ˚F (operator adjustable, monitored/automatic).

4.4.1.3. 70-100% air recirculation, 0-30% outside air (monitored, automatic).

4.4.1.4. Booth static pressure shall be set at 0.05 ± .02 (monitored, automatic).

4.4.2. Booth Air Exhaust and Ventilation System. The DTBB, Booth Air Exhaust System, shall meet the following:

4.4.2.1. Install a new 60,000 cubic feet per minute (cfm) minimum, belt or direct drive centrifugal fan (rated for outdoor use), equipment mounted or floor mounted fan.

4.4.2.2. 85 decibel (DBA) or less average sound rating.

4.4.2.3. Variable frequency driven, high efficiency Energy Policy Act (EPACT) fan motors, 480 volts, 3 Phase (Ph), 60 Hertz (Hz) totally enclosed fan-cooled (TEFC) motor (Class 2 Div I or II if applicable), outdoor rated.

4.4.2.3.1. Motors shall be sized so the driven load will not require the motor to operate in the service factor range.

4.4.2.3.2. Motors shall be rated for 104°F environment with maximum 194oF temperature rise for continuous duty at full load (Class B Insulation).

4.4.2.4. Fan shall be sized and selected to accommodate static pressures and flow variations of +/-15% of scheduled values including approximately ten (10) inches of water column total pressure drop from all inline equipment, ducting and total system effect losses (the Contractor shall verify total system pressure drop and make equipment selection adjustments).

4.4.2.5. Fan housing shall be completely welded and powder coated with a minimum of four (4) mils of polyurethane paint. Finish color is factory standard.

4.4.2.6. Fan impeller shall be manufactured with continuously welded steel airfoils non-sparking blades (conform to Air Movement and Control Association (AMCA 99).

4.4.2.7. Bearings shall be self-aligning, heavy duty, grease lubricated with extended lube lines and fittings, flanged mounted with minimum basic rating fatigue life L(50) in excess of 200,000 hours (hrs) at maximum operating speed for each pressure class.

4.4.2.8. Bearings shall be fixed to the fan shaft using concentric mounting locks.

Bearings that use set screws are not allowed.

4.4.2.9. Housing and bearing supports shall be constructed of welded structural steel members to prevent vibration and rigidly support the shaft and bearings.

4.4.2.10. Welded steel vanes in fan housings to straighten airflow.

4.4.2.11. Removable/hinged access and maintenance panels.

4.4.2.12. Built-in lockable power disconnect.

4.4.2.13. Built-in lifting lugs.

4.4.2.14. UL or ETL listed and labeled.

4.4.2.15. Motorized balancing dampers for airflow, temperature and static pressure control.

4.4.2.16. Factory or field installed airflow and temperature sensors and transmitters integrated into the main control panel.

4.4.2.17. complete new ducting package (as a minimum but not limited to mixed air flow boxes, fittings, straights, transitions, cones, balancing and backdraft dampers, gates, vanes, rain stacks, curbs, flashings, bird screens, transverse reinforcements and supports, etc.,) for the exhaust air, recirculated air and fresh air/make-up air systems.

4.4.2.18. Provide hinged access doors in ductwork or plenums to maintain fire or explosion isolation devices, dampers, and controls. Doors shall conform to Sheet Metal and Air Conditioning Contractors National Association (SMACNA) standards.

4.4.2.19. All ductwork and plenums shall be G90 galvanized steel.

4.4.2.20. All round ducts shall be spiral lock-seam, smooth interior.

4.4.2.21. All exterior ductwork shall be double walled and have two (2) inches thick of thermal insulation sandwiched in between the inner and outer duct walls (thermal insulation density shall be three (3) pounds per cubic feet).

4.4.2.22. Provide and install new baffled air exhaust abrasive resistant plenums and ducting system sized for the required booth air flow and duct air velocity (pressure rating is four (4) inches negative, seal class A).

4.4.2.23. Provide and install new baffled air inlet plenums and ducting system sized for the required booth air flow and duct air velocity (pressure rating is three (3) inches positive, seal class A).

4.4.2.24. Exhaust and inlet plenum openings inside the booth shall have 1-1/2” #9 standard expanded metal guards (76% open area).

4.4.3. Heating, Cooling and Make-Up Air. The DTBB shall meet the following requirements :

4.4.3.1. Cooling:

4.4.3.1.1. Provide new evaporative cooling module(s) installed across or prior to the booth’s fresh air intake enclosures located on the bldg. roof (fresh air volume ≥ 30% of total booth recirculated air in cooling mode).

4.4.3.1.2. Provide pre-painted steel enclosure(s) and 24 inches tall roof curb(s).

4.4.3.1.3. Cooling module shall have 316 stainless steel sump, casing and media supports.

4.4.3.1.4. Minimum of 12” thick Celdek, or Government approved equivalent, cooling media (accessible/removable through a side door).

4.4.3.1.5. Full factory pre-piped internal plumbing with schedule 80 PVC.

4.4.3.1.6. Automatic water level control, ½ hp circulating pump, motorized control valve and sump low level switch.

4.4.3.1.7. Interlock switch to prevent circulating pump from operating if exhaust fan is disabled.

4.4.3.1.8. Backwash cycle with adjustable timer.

4.4.3.1.9. Overflow and dump piped drains.

4.4.3.1.10. Overflow and dump water shall drain on building roof.

4.4.3.1.11. Automatic dump control for freeze protection.

4.4.3.1.12. All controls and electrical component and installation shall be Class 2

Div 1 only if applicable per NEC )

4.4.3.1.13. All new enclosures panels shall be primed and painted (minimum of four (4) mils of polyurethane paint). Color is industrial gray.

4.4.3.1.14. Must be structurally supported independent from any ductwork.

4.4.4. Heating:

4.4.4.1. Size and install two (2) new steam distribution coils (non-freeze) across each recirculation ducts (see HVAC equipment layout).

4.4.4.2. Size and install new steam lines, control valves, pressure gauges, universal style thermostatic steam traps, drains, pilot-operated regulator and control valve stations and complete steam condensate system for the new steam coils to replace the entire existing condensate system for the booth(see attachment 2).

4.4.4.3. All new steam lines shall be insulated equivalent to the existing steam line insulations.

4.4.4.4. All new steam system controls shall be electric/electronic.

4.4.5. Dust Collector System (Cartridge Type). The DTBB shall meet the following requirements:

4.4.5.1. 60,000 cubic feet per minute (minimum) outdoor unit sized to match booth required air flow.

4.4.5.2. Vertical, aspirated, single point seal cartridge filter configuration (filter collection efficiency 99.99% at 0.5 micron particulates).

4.4.5.3. Standard cartridges shall have continuous, double-seal, cast urethane gaskets.

4.4.5.4. High Efficiency Particulate Air (HEPA) filter post filtration system.

4.4.5.5. Heavy duty abrasive inlet plenum and baffles (top or side access).

4.4.5.6. Pulse-jet system with the lowest compressed air consumption, while still achieving highest efficiency filter surface area cleaning.

4.4.5.7. Adjustable on-demand (with Photohelic Gauge) pulse rate system based on pressure drop measured across the filter cartridges.

4.4.5.8. Modular bolted…