Tube_Cleaning_Station_Purchase_Spec.pdf

DEPARTMENT OF THE AIR FORCE

HILL AIR FORCE BASE, UTAH

PURCHASE DESCRIPTION/SPECIFICATION FOR

Tube Cleaning Station Tanks for

Fabrication of Critical Aircraft Components

4 April 2017

Table of Contents

DEPARTMENT OF THE AIR FORCE

1. Scope

2. Equipment and Tooling

3. Applicable Documents

4. Design

5. Components & Features

6. Labeling Plates

7. Sizes and Capacities

8. Ancillary Equipment and Supplies

9. Requirements of the Proposal

10. Requirements After the Award of the Contract

12. Acceptance of the Equipment

13. Warranty

1. Scope

This purchase specification covers the general design and performance requirements for procurement of a Tube Cleaning System with equipment and accessories as described herein. This includes all costs associated with manufacturing, handling, and shipping as defined in this document.

2. Equipment and Tooling

This purchase specification describes the requirements for a single station consisting of two independent tanks and accessories.

3. Applicable Documents

The equipment described in this Purchase Specification shall be manufactured in accordance with these documents. The latest dated document shall be the one applicable to this Purchase Specification.

3.1 Government Publications

The following Government documents, drawings, and publications form a part of this

Purchase Specification to the extent specified herein:

STANDARDS – FEDERAL

OSHA 1910 General Industry, OSHA Safety and Health Standards (29

CFR 1910), 2011 EDITION

3.2 Other Publications

The following documents form a part of this Purchase Specification. Since the details of the designs of potential suppliers were unknown at the time this specification was written, it shall be the responsibility of the contractor to ascertain which sections of these standards are applicable to their product and to comply with those requirements. Subsequent references in this purchase specification to these standards shall not be construed as overriding any design feature required elsewhere in these standards. Nor shall such reference be construed to be the only applicable portion of the standard because it was specifically referenced and others were not. The most recent revision of these documents at the time of the issue of this contract shall be considered as binding during the performance of this contract.

INDUSTRY STANDARDS

NFPA 70 Specification for Electrical system installation.

NFPA 79 Electrical Standard for Industrial Machinery. (2012)

NEMA ICS 6 Enclosures for Industrial Controls and Systems. (R2011)

NEMA 250-2008 Enclosures for Electrical Equipment

NEMA MG 1 Motors and Generators. (2011)

ASTM A967/A967M Standard Specification for Chemical Passivation

Treatments for Stainless Steel Parts

LOCAL INSTRUCTIONS

Hill AFB Instr. 91-302 Control of Hazardous Energy (Lockout/Tagout)

3.3 Order of Precedence

In the event of a conflict between the text of this Purchase Specification and the references cited herein, the text of this Purchase Specification shall take precedence. Nothing in this

Purchase Specification shall supersede applicable laws and regulations unless a specific exemption has been obtained.

3.4 Technical Proposal

A team including process engineering, management, operations, and the contract administrator as a minimum will evaluate technical aspects of the proposals. Additional team members may be included as required at the option of the Government.

4. Design

The equipment shall be new and shall be of new construction and shall include no used or refurbished components. The equipment shall include all components parts and features necessary to meet the functional and performance requirements specified herein. Manufacturers shall submit documentation that the offering meets the requirements of this specification and how each requirement will be met.

4.1 Use of American English

Wording on all components and sub-components such as electrical motors, diagrams, hydraulic components, safety and informational charts/plates shall be written in American English. All installation diagrams, operator/users manuals, brochures, performance evaluation reports and any other data supplied, as part of this Purchase

Specification shall also be written in American English and use U.S. customary units of measure.

4.2 Safety and Health Requirements

4.2.1 Guarding

“One or more methods of machine guarding shall be provided to protect the operator and other employees in the machine guarding area from hazards such as those created by point of operation, ingoing nip points, and rotating parts. Examples of guarding methods are—barrier guards, two-hand tripping devices, electronic safety devices, etc.”

OSHA 1910

4.2.2.1 Guards shall be affixed to the machine where possible and secured elsewhere if for any reason attachment to the machine is not possible. The guards shall be designed so that they do not create accident hazards and shall be designed so that they can only be removed using tools.

4.2.2.2 Permanent guards shall be provided to cover all belts, gears, electric motors and any other mechanical moving parts where possible.

4.2.3 Electrical Hazards

Shockproof controls rated for use in wet working conditions for protecting the operator from mechanical and electrical hazards shall be provided. The machine shall comply with

OSHA 1910 safety standards and NFPA 70 and 79 electrical standards for spray wet environments. In addition, provision shall be made to provide for control of all hazardous energy sources when appropriate for lock out-tag out procedure Hill AFB Instruction 91-

302.

4.2.4 Pressure Equipment: Pneumatic systems shall have guarding and secure lines that do not drag across the floor or other components of the machines causing abrasion on the lines and shall be designed and installed consistent with ISO 4414 requirements for pneumatic systems.

4.2.5 Auditory Hazards

The equipment and peripheral devices together shall not exceed 75 dbA maximum noise level under a no load condition.

4.2.6 Mercury Prohibition.

The use of mercury, mercury compounds, or mercury based instruments on or in the machine is prohibited.

4.2.7 Asbestos Prohibition.

The use of asbestos and materials containing asbestos on or in the machine is prohibited.

4.3 Lubrication

All points requiring lubrication shall be equipped with easy access and a plate giving lubrication instructions. The contractor shall provide all Material Safety Data Sheets

(MSDS) for all oils or lubricants required for machine operation.

4.4 Construction

The equipment shall be constructed so that when it is installed and connected to power it is ready for operation. The equipment shall be constructed of parts, which are without defects and free of repair. The equipment structure shall be capable of withstanding all forces encountered during operation of the equipment to its maximum rating and capacity without permanent distortion. All parts subject to wear breakage or distortion shall be easily accessible for adjustment, replacement and repair.

4.4.1 Finish

This equipment will be used in a wet environment. The tanks shall be of all 304 stainless steel construction and shall be passivated to prevent corrosion at the welds. All components subject to rust shall be cleaned of all foreign matter prior to paint application and shall be painted in accordance with the manufacturer’s standard commercial practice. Exception to painting shall be made for surfaces that cannot be painted without interfering with the mechanical operation of the machine such as sliding or bearing surfaces that are otherwise protected by rust and corrosion preventing lubricants and coatings. Corrosion resistant stainless steel and plastic components may be unpainted.

4.4.2 Installation

Floor mounting and anchoring hardware shall be supplied by the vendor following the design specifications of the manufacturer. These specifications are to be included in the documentation for the equipment. Labor to install shall be provided by the Air Force.

4.4.3 Electrical power supply and electrical equipment.

All electrical equipment for the machine shall conform to the applicable requirements of

NFPA standards and shall be designed with enclosures of NEMA type 4 and liquid tight buttons and controls suitable for a water spray wet environment. The machine shall draw all of its electrical power from a single circuit having a fused safety disconnect switch supplied and installed by the Air Force. The machine's electrical system shall be wired for 480 VAC 3 phase 60 Hz. The vendor shall supply an installation diagram for the machine with the proposal showing connection points and requirements for the machine including electrical power and grounding, water, compressed air, etc. Connection to local utilities and final operational testing for acceptance will be the responsibility of the Air

Force.

The machine's electrical system shall withstand line voltage fluctuation of 10% with no damage to the machine or its related components. If DC or reduced voltage AC is required or specified for any part of the machine operation the necessary conversion or transformation equipment shall be furnished with the machine. The electrical system shall be suitable for connecting the size grounding conductor specified in NFPA 79 standards for the disconnect fuse rating. Each electric motor shall meet the applicable design standards of NEMA MG 1-2011 that are applicable to that type of motor.

5. Components & Features

The bid shall address each of the following parameters. If the bid does not adequately address the line item, it may be considered an insufficient characteristic. The machine shall meet and may exceed any of the minimums but shall not exceed specifications listed as maximums. The contract shall cover providing two (2) stainless steel process tanks:

5.1 Tank #1: Washing Tank

5.1.1 Construction

The tank shall hold DI water with Brulin 815GD alkaline detergent with a 10% concentration at 120ºF±10ºF (ph:11.5) without equipment degradation or tank leakage for at least 5 years. It shall be equipped with ultrasonic transducers to generate sweeping waves of 10 kw of cleaning power at no less than 30 kHz and generators and controls to process tubes for variable time periods controlled by the operator according to the degree of cleaning required for each batch. The tank shall be insulated and shall have 2 half-length lids that drain condensate and splash-water back into the tank. They need not open under program control but must be stable in either the open or closed position when moved by the operator. The tank shall be constructed of no less than 12 ga. thick 304 stainless steel and shall be penetrant tested and hydrostatically tested for leaks. Sheet welds shall be external to the wetted side where possible with plumbing penetrations welded both inside and out. All internal welds shall be passivated per ASTM A967. The tank shall be insulated with mold resistant insulation fiber with a stainless steel outer sheet protecting the insulation. Controls for the ultrasonic generators, filter system, and temperature controls and displays shall be front mounted. Access to all components for maintenance shall be either from the ends or the front, allowing placement against a wall to minimize floor space required. Lifting points shall be provided for transport and placement.

5.1.2 Solution Handling

The equipment shall be plumbed to move the detergent solution through a weir-filter system capable of skimming oil and collecting particulates and to heat the solution to the process temperature with a 20 kw heater and digital temperature control with overtemp protection for the heating elements. Water level, as well as the concentration and condition of the solution, shall be manually maintained by the operator.

5.2 Tank #2: Rinse / Test Tank

5.2.1 Tank Construction

The rinse tank shall be separate and independent from the wash tank for flexibility of arrangement. The rinse water will not be held in the tank but shall drain to one end and out the drain line. The tank need not be insulated and shall have 2 half-length lids that drain condensate and splash water back into the tank. They must be stable in either the open or closed position when positioned by the operator and shall have a latching mechanism for use during pressure testing of tubes. The tank shall be constructed using

12 gage 304 stainless steel with exterior seam welds and double sided welds for all plumbing penetrations. All internal welds shall be passivated per ASTM A967.

5.2.2 Rinse / Test Tank Functions

The rinse tank shall be designed for DI water for spray rinsing outside and flushing inside with a pistol grip hand nozzle and an inverted elastomer cone to align and seal the end of tubes from ¼” to 3” diameter. It shall be equipped with a manifold for attaching the tubes to DI water for leak testing of welded tube assemblies at up to 70 psi using DI water pressure controlled by a pressure regulator and shall be equipped with ball valves for isolation of the tube and gage from the system for leak detection by static leak rate. The

Air Force will be responsible for the connection between the tube and the manifold for this low pressure test. The tank shall also be designed with supports 8” above the bottom at each end to support the baskets at a 20º slope for drainage. See pp 8.

The rinse tank shall also be equipped with a manifold for connecting individual tubes with aircraft fittings for hydro-testing stainless steel tubes from ¼” to 1” in diameter for burst strength with an isolation ball valve and gauge capable of calibration on each tube connection, and an air over water pump to avoid compressed gas explosion in the event of failure. This test is to be performed with the lid closed and latched to catch spray in the event of a tube failure. All system gages and controls shall be front or side mounted on the outside of the tanks.

5.3 Process Description

5.3.1 Wash Cycle

Load: Lower the tubes into the wash tank individually or in a wire basket, making sure that no air is entrained.

Automated wash cycle: Ultrasonics at 32 KHz with lateral flow of detergent in tank.

Unload: Remove and tip basket to drain, then lower into rinse tank.

5.3.2 Rinse Cycle

DI Rinse: Individually spray exterior and flush inside with hand nozzle. Set aside to drain.

5.3.3 Welded Assembly Leak Test

Cap all openings but one. Fill with DI water. Attach to low pressure hose and close lid.

Apply 70 psi water and check for leaks for 30 seconds, unload.

5.3.4 High pressure test

Cap one end of each tube and fill with water. Attach with aircraft fittings to manifold up to 4 tubes. Open isolation valve on each tube and apply pressure. Close isolation valve and hold 3 minutes, watching for any sign of leakage or pressure drop. Unhook, uncap and drain.

6. Labeling Plates

All markings on the plates shall be permanent and legible on a contrasting non-glare background.

6.1 Lubrication Chart or Plate

If lubrication is required, a lubrication chart or plate shall be permanently and securely attached to the equipment. The following information shall be furnished on the chart or plate:

Points of application

Service interval

Type and viscosity of lubricant

6.2 Nameplate

A Corrosion-resistant nameplate shall be securely attached to the machine.

The nameplate shall contain the information listed below:

Noun (description)

Manufacturer’s name

Manufacturer’s serial number

Manufacturer’s model number

Power input (volts total amperage phases frequency)

Contract number or order number

Date of manufacture (day month and year)

6.3 Caution Plate

The manufacturer shall furnish a corrosion-resistant plate secured to the equipment in a visible location with all important cautions to be observed by the operator. The plate shall be permanently marked. If more than one plate is required to alert the operator and/or maintenance personnel in one or more areas caution plates shall be furnished.

7. Sizes and Capacities

The machine shall conform to the requirements of Table I.

TABLE I (Sizes and capacities for the Machine)

Feature Specification Description

Tube diameter 0.25” to 3.0” Minimum diameter range

Tube length 120” Maximum

Tank working area 120” x 24” x 20” LxWxD water filled area, each tank min

Leak test pressure 10 lb to 70 lb Manifold min / max range

Burst test pressure 1,000 lb to 6,000 lb Manifold min / max range

Tube material Aluminum, Stainless Steel, Titanium

NOTE: Requirements are not less than those shown. Where a range is indicated, the required performance is from the stated minimum or greater, and to the stated maximum or less.

8. Ancillary Equipment and Supplies

Two 36” x 4” high racks the full width of the tank for loading and unloading, washing, rinsing, and draining small tubes. They shall be made from stainless steel. The hook high side does not require the 4” sidewall and should be open on that side to accommodate handling up to 5’ lengths. They shall have handles for lifting such that the grips are above the surface of the water in the wash tank when lowered into place and shall be used in both the wash and rinse tanks. Typical basket loads will be 10 lbs. or less but shall be designed for a maximum distributed load of 20 lbs. without permanent deformation.

9. Requirements of the Proposal

Offerors shall submit (in duplicate) as part of their proposal brochures, photographs, illustrations, drawings, and narratives which clearly show that the design, construction, capacities, and operation of the equipment being offered will meet all of the requirements set forth in this Purchase Specification. Literature displaying more than one model or size machine shall be clearly marked to indicate the model or size being offered.

Proposals shall include a response to each numbered paragraph of this Purchase

Specification indicating compliance or non-compliance with the paragraph's particular requirements. Each paragraph shall be numbered using the Purchase

Specification paragraph numbers. Response to each paragraph shall state if the requirement will be met AND specifically how it will be met. Where the proposal exceeds requirements or exceptions are taken, bid submittals shall provide specific information so the impact of the over-compliance or exception can be evaluated.

All narratives shall be in American English and all sizes and capacities of the range being offered shall be stated in the U.S. customary system of units.

This equipment shall be installed on an existing 8 inch thick steel reinforced concrete floor.

Drawings of the foundation (if a foundation is required) to support the equipment and all utility requirements shall be furnished as part of the Offerors proposal.

Offers which do not include sufficient information to permit a complete compliance review by Air Force personnel shall be rejected.

10. Requirements After the Award of the Contract

NOTE - Engineering and technical support for installation requirements shall be furnished by the 309th Commodities Maintenance Group Manager. The support office at Hill AFB may be contacted at:

309 CMXG COMMODITIES MAINTENANCE GROUP PROCESS ENGINEER

7169 6th St. Bldg 510

Hill AFB, UT 84056-5228

Name: Kent Johnson

Phone: (801) 586-5330

Or

Name: Mike Adams

Phone: (801) 586-8931

Work hours: 7:00 AM to 3:30 PM MT (Monday thru Thursday)

10.1 The contractor shall provide the Engineer and Contract Administrator an estimated date for delivery of the machine at least 30 days prior to the scheduled delivery.

The Engineer’s phone number is in paragraph 10.0 above. The Contract

Administrator’s phone number will be provided after award of contract.

10.3 The contractor shall ship the equipment to Hill AFB, Utah where it will be installed and tested by Air Force personnel. The machine shall remain the property of the contractor until the Government at Hill AFB accepts it.

All costs associated with manufacture and shipping to Hill AFB shall be the responsibility of the contractor. If repairs are required to bring it into operational condition, the contractor shall either complete the repairs on site or have it returned for factory repair. In either case, the cost of material and labor to repair and any travel or shipping expense required for repair shall be the responsibility of the contractor.

10.8 All hardware required for leveling or anchoring the machine to the floor shall be furnished by the contractor.

10.9 The Air Force shall provide and install all necessary fusible disconnects, circuit breakers, circuit breaker boxes, and outlets to install the machine. If hard wire connection of the equipment to the disconnect boxes is required, wiring attachment shall be the responsibility of the Air Force. Once the equipment is connected to power, it shall be disabled during the installation process and only unlocked when required. Hill AFB

Instruction 91-302, Control of Hazardous Energy (Lockout/Tagout) shall be required to protect contract employees, as well as Government employees from electrical harm.

11. Inspection and Run-off test requirements

The machine shall be fully installed, fully connected, and fully operational at the time of the final run-off. Standard aspects of the machine and its’ performance shall be verified to the manufacturers specifications. Any deficiencies shall be corrected by the manufacturer or contractor prior to government acceptance.

11.1 Factory verification test report

The manufacturer's standard verification test report shall be prepared by the contractor and submitted to the Process Engineer at the time of factory buy-off. All reports will be in

American English with U.S. customary units of measurement.

11.2 Operational test

The equipment shall be operated at the factory for not less than 1 hour. During that test the proper operation of all controls, motors, adjusting mechanisms and other accessories shall be verified and recorded. This test shall also include a leak test of all wet surfaces and pipe connections. A report of this test shall be provided to the Process Engineer at the time of delivery. This test shall be repeated on site prior to acceptance and shall include calibration of test gages and controls by Air Force metrology lab personnel.

12. Acceptance of the Equipment

If the equipment fails to pass any test in the requirements of this Purchase Specification, it shall be rejected. After it has passed all of the tests required by this Purchase

Specification, the equipment will be accepted by the Group Manager. The Group

Manager will sign the test report indicating that the tests were witnessed by a representative of the using activity and that all of the tests were performed satisfactorily.

Acceptance shall be acknowledged by a signature sheet, including at a minimum, signatures of a Process Engineer, Production Supervisor, two operators, Quality assurance, and Maintenance.

13. Warranty

13.1 Full warranty is for one year. Items proposed shall be warranted for 1 year and shall include parts, labor, functional adjustment, and travel expenses for repairs at the installation site or shipping expense if the repairs are to be done at the factory.

Vendor shall provide an additional 1-year warranty on parts only. Government employees will complete the installation of parts after the first year.

Warranty repairs shall be conducted by factory trained repair technicians during the first year and must commence within 5 days of notification by the Air Force that repairs are needed. Delays in response time can be negotiated at the discretion of the Air Force.

Contractors shall include a copy of each applicable warranty with their response to this solicitation. The warranty period is to start when the responsible government official makes the final buy off.

Warranty against leakage of the tank for materials and workmanship shall be for 5 years.

Vendor shall make any needed weld repairs, at his discretion, either on site or at vendor’s factory where special process equipment is available. Cost of travel expense or shipment to and from the factory shall be the responsibility of the vendor. After the first year, travel or shipping cost will be at the Government’s expense.