FPI SOW 17May23.docx

Fluorescent Penetrant Inspection (FPI) System Statement of Work

1. General

1.1. Objective: The Contractor shall manufacture, deliver, and install a turnkey Non-Destructive Testing (NDT) Fluorescent Penetrant Inspection (FPI) System.

1.2. Corpus Christi Army Depot (CCAD) Mission: CCAD performs overhaul, repair, modification, retrofit, and modernization of aircraft systems and other systems as assigned; maintains a mobilization and training base to provide capability for mission support during any contingency; provides maintenance support services for special projects as assigned; exercises command control over assigned activities; and provides on‐site technical assistance in the inspection, maintenance, and repair of customer aircraft, engines, and components.

1.3. Background: CCAD is currently having Building 1700.3 constructed via a military construction/Army authority project. This building is being built adjacent to Building 1700.2, which currently houses shops to assemble and test transmissions for various aircraft. Building 1700.3 will contain shops that directly support activities in Building 1700 such as: bearing shop, machine and grinding shops, workstation requirements kitting areas, non‐destructive inspection shop, shot peen shop, paint prep and paint shop.

1.4. Completion Date: The Contractor shall deliver and install the FPI system is within thirty-six (36) months from contract award.

1.5. Occupancy date: The targeted occupancy date is anticipated by May 2023. This date represents the day that non‐ construction personnel, to include Government and Contractor personnel, can enter the building and begin work related activities. CCAD does not have any control or authority on the occupancy date.

1.6. Building 1700.3 Utilities: CCAD anticipates that building utilities (air, water and electricity) will be provided when the building is released for occupancy. The event of extended power outages due to continued building construction efforts and upgrades, the Contractor shall be prepared to provide air and electricity to continue uninterrupted installation efforts. The Contractor shall not connect any external power source to building facilities infrastructure for distribution under any circumstance.

1.7. Operational procedures:

Christmas Day

1.7.2. CCAD Closure: CCAD may schedule a shutdown period of approximately 40 working hours between Christmas Day and New Year’s Day holiday. CCAD may schedule a shutdown period at other times. The Contractor shall comply with administrative closing procedures for CCAD. Announcements of closures will be made through the KO and COR.

1.7.3. CCAD Core Hours: Core hours of operation at CCAD are Monday through Thursday from 0600 to 1600, and every Friday 0600 to 1500, except on United States holidays or when the Government facility/installation is closed due to local or national emergencies, administrative closings, or similar Government directed facility/installation closings.

1.7.4. Non‐Personnel Services Statement: Contractor employees performing under this contract shall be controlled, directed, and supervised at all times by management personnel of the Contractor. Contractor employees shall perform their duties independent of, and without the supervision of, any Government official.

1.7.5. Location of Delivery and Installation: All items shall be delivered and install at Building 1700.3 on Naval Air Station Corpus Christi (NASCC). Corpus Christi, TX is located by the Gulf of Mexico in south Texas, approximately 210 miles southwest of Houston, 150 miles south of San Antonio, and 150 miles north of Mexico. CCAD is a 154‐acre industrial complex located within the confines NASCC.

1.7.6. Trash And Debris Removal: The Contractor shall keep the work area free of waste materials and rubbish accumulations at all times. The Contractor shall leave the work area and premises in a clean, neat and organized condition and provide a dumpster for all metallic materials, shipping containers, or other materials generated during the equipment relocation and installation phase. The Contractor shall place dumpsters in an area designated by the Government.

1.7.7. Contractor Provided Equipment Requirements: The Contractor shall use only propane, electric, hydraulic or pneumatic equipment inside Government buildings. Gasoline driven equipment is not permitted inside any Government building under any circumstance. All forklifts shall have an on-board portable fire extinguisher. The Contractor shall be required to obtain all cutting and welding permits required by the NASCC Fire Protection Inspector: 361‐961‐3491/3492. The Contractor shall notify the Navy Fire Department to obtain necessary permits for each working day. If gasoline generators are required, the Contractor shall place them in an area designated by the Government.

1.7.8. On and Off-Loading Equipment: The Contractor shall be responsible for offloading all equipment and tools in Building 1700.3. The Contractor shall be responsible for on and off loading of all tools and equipment required for new equipment machines from CCAD sites to DCRF.

1.7.8.1. The Contractor shall be responsible for preservation, packing, shipping, un‐packing, on‐site placement at CCAD and storage in accordance with the manufacturer’s commercial practices. The Contractor shall provide an on‐site, fully authorized representative for all receipt of goods. The Government will not provide storage for shipped equipment and materials. The Contractor shall be responsible for the storage and handling of equipment and materials.

1.7.9. Travel Expenses: The Contractor shall be responsible for all travel expenses associated with this requirement.

1.7.10. Standards and Procedures: Applicable building, safety, construction, federal and process standards and procedures are listed in Appendix C: Standards and Regulations.

1.7.10.1. Approvals: Government approvals for any product, design, specification or document does not negate the Contractor’s ultimate responsibility for meeting standards, codes and regulatory agency requirements.

1.7.10.2. Standard by Reference: When a reference in this document is made to an industry specification, a manufacture, trade or trade association, an industry, or other generally recognized source, such are hereby made a part of the specification and shall have the same force and effect as though referenced in this document.

1.7.10.3. Competing Regulations: In the event of competing regulations and requirements for this installation, the strictest shall be enforced.

2. Equipment Specifications

2.1. Non-Destructive Inspection (NDI) Area: The Contractor shall provide and install equipment as stated in Table 1: NDI Area New Equipment List in accordance with FPI industry standards. The Contractor shall provide verification that specialty equipment for FPI (such as booth lighting, FPI machines, curtain enclosures, LED UV lamps) are rated for such applications. The Contractor shall provide such documentation in the product drawings and associated lists for the equipment.

Table 1: NDI Area New Equipment List

Workbench stools

2.1.8.

Solvent booths

2.1.9.

Workbench, 36” x 96”

2.1.10.

Jib boom with air hoist

2.1.11.

2.1.1. Booth Curtain and Structures: The Contractor shall install curtain enclosure at locations indicated in section 3.2 Drawings. The Contractor shall determine the final size of the curtain enclosure based on the NDI equipment final locations and estimated sizes as indicated in section 3.2 Drawings. Each booth shell shall consist of an independent structure and an NDI curtain. Under no circumstances shall equipment inside the booth support any part of the NDI curtain or booth structure. The Contractor shall determine a suitable method of creating the structure required to support activities of the substation. The Contractor shall design the booth to be disassembled and installed quickly. The Contractor shall provide the design of the Booth Curtain and Structure in the product drawings and associated lists and provide disassembly instruction sets.

2.1.1.1. Booth Curtain Structures: The Contractor shall design the booth structures so that equipment located inside the booth can be easily removed without removing the structures. Curtain structures shall be easy to remove and not require rigging or lifting equipment (such as pallet jacks, forklifts, etc.). The design of the structure shall be self-supporting and not require any support from building columns and pillars. The Contractor shall minimize the use of solid walls and maximize curtain use. Maintenance areas of machines located within all booths shall be easily accessible and not require any removal of curtain structures to access.

2.1.1.2. Booth Inspection Lighting: The Contractor shall provide documentation that the lighting in each inspection area meets or exceeds the requirement stated in this document. The contractor shall provide results for each overhead high power light and overhead black light. The contractor shall provide results that verifies that the booth and cabinets do not allow more than 2 foot candles of outside light when booth and cabinet lights are off throughout the booth. The Contractor shall perform testing in accordance with section 1.6.11. The contractor shall provide the test method and results in the test plan of the FPI line.

2.1.1.3. Solid Overhead Roofs for Booths: The Contractor shall provide placards that indicate the roof is not a load bearing surface and not rated for human use. The Contractor shall permanently install the placards on all 4 sides of the booth for each booth. The location of each placard shall be easily visible from the floor and non-obstructed. All equipment fixed to the roof (such as lighting fixtures, ducting, fans, switches, etc.) shall be easy to reach and replace from the outside edges of the booth or from the inside of the booth.

2.1.2. Roller System: The process flow of the roller system w/ FPI substations are provided in the drawings section 3.2. The Contractor shall design all entry and exit points of the substations so that the process flow is maintained. The Contractor shall provide the necessary quantities of substations to complete the process flow of FPI production lines as indicated by the drawings in section 3.2.

2.1.3. Air Hoist, Trolley and Crane Systems: The Contractor shall provide proof load certificates for each crane system. The Contractor shall paint the load capacity of the crane system onto the trolley of the crane system. The label shall be legible from the floor.

Design, installation, and testing shall be in accordance with section 3.27. Fire Protection Installation.

2.1.5. Substation and Booth Control Systems: If automated controllers, such as PLC’s and HMI’s, are required for controlling functions of the machine, Allen-Bradley’s PLCs and HMI products is preferred, but equal or like products that meets the following qualifications listed below is acceptable:

The Contractor shall provide logic diagrams for all PLC’s and control architecture diagrams for HMI’s when the manuals are delivered. All logic diagrams shall have inputs and outputs clearly identified. The Contractor shall provide an overview of inputs and its relationships to outputs as part of the product drawings for each substation.

2.1.6. All components of the roller system w/ FPI substations shall be similar in color schemes.

2.1.7. Utility Distribution for the FPI Roller Systems and Substations: The Contractor shall design the utility distribution system to the substations to minimize the use of vertical unitstrut and maximize the use of areas underneath the roller system. Utility distribution to wet areas of the roller system and substations shall be designed in accordance with standards in section 1.6.11.

· Lighting must be from outside and above sealed cabinet and provide a minimum illumination of 100 foot-candles

· Light panels shall be of heat treated glass

· One straight flow nozzle

· One right angle flow nozzle

· One “V” pattern wide angle nozzle

· Leak proof door shall not drip material when opened.

2.1.11. Jib Boom with Rolling Air Hoist

· Jib Boom

· 360-degree rotation travel with adjustable stop

· Working height: shall lift AH64 main housing from floor to 10 feet

· At least 3x greater than air hoist capacity

· Working span dependent on application and location. Jib boom spans throughout DCRF range from 4’ to 8’.

· Base mounted, steel construction

· Air hoist

· 90 PSI rating

· 500 pound capacity

· Manual trolley: easy to push/pull on jib boom span, no binding

· Control pendant to be level to operator

· Hardened steel load chain with hook and latch 360 swivel end

· 1-1/8” hook opening

· Maximum chain length: hook shall touch the floor plus 1 foot

· Disk brake for zero load drift

· Lubrication free

· Variable lowering and lifting speed and precise positioning by control pendant

· Emergency stop button

2.2. FPI Area: The Contractor shall provide and install equipment as stated in Table 2: FPI Area New Equipment List in accordance with FPI industry standards. The Contractor shall provide verification that specialty equipment for FPI (such as booth lighting, FPI machines, curtain enclosures, LED UV lamps) are rated for such applications. The Contractor shall provide such documentation in the product drawings and associated lists for the equipment.

Table 2: FPI Area New Equipment List

Jib Boom with Rolling Air Hoist

2.2.1.

Worktable, 36” x 60”

2.2.2.

Scissor Lift

2.2.4.

Mini Computer Workstation

2.2.5.

2.2.1. Jib Boom with Rolling Air Hoist

· Jib Boom

· 360-degree rotation travel with adjustable stop

· Working height: shall lift AH64 main housing from floor to 10 feet

· At least 3x greater than air hoist capacity

· Working span dependent on application and location. Jib boom spans throughout DCRF range from 4’ to 8’.

· Base mounted, steel construction

· Air hoist

· 90 PSI rating

· 500 pound capacity

· Manual trolley: easy to push/pull on jib boom span, no binding

· Control pendant to be level to operator

· Hardened steel load chain with hook and latch 360 swivel end

· 1-1/8” hook opening

· Maximum chain length: hook shall touch the floor plus 1 foot

· Disk brake for zero load drift

· Lubrication free

· Variable lowering and lifting speed and precise positioning by control pendant

· Emergency stop button

2.2.6. Roller System with FPI Substations: Design of this roller system and substation shall not require any modification to the foundation except for mounting. All booths and substations shall be moveable.

2.2.6.1. General requirements for all components of the roller system and FPI substations:

· 304 stainless steel construction of all wetted surfaces unless stated otherwise and applies to developer powder or any fluid

· All cabinet designs:

· Shall have a minimum load capacity of 500 LBS.

· Shall be capable of handling and processing FPI baskets with 30” tall aircraft parts unless specified

· Booths shall have entry and exit doors (The below immediate requirements do not apply to the vapor degreaser substation entry and exit doors.)

· Shall allow operator to lower door manually with no manual disengagement of mechanism

· Shall automatically engage every time the door is opened manually or automatically

· Shall have roller sections pass through cabinet unless specifically stated

· All gauntlets shall:

· Be compatible with chemicals listed for FPI substations

· Not crack or deform

· Be easily replaceable

· If electronic devices are required, the system on/off shall be controlled by a pushbutton at the operator’s panel. A pilot light shall be provided to indicate the system is turned on.

· All clean air guns shall have nozzles designed to deliver air and provide chip guarding that meet standards in section 1.6.11.

· Incoming air to the clean air blow gun shall not exceed 100 PSI.

· The contractor shall provide documentation that the nozzle meets standard

· All clean air guns and nozzles located inside cabinets shall have a hanging method:

· Locations shall be easily accessible from the gauntlets if present

· Shall not interfere with any motions of the aircraft parts or baskets

· All pump and nozzle combinations for spraying shall not atomize the solution

· All pumps used for circulation, filtration, spraying and pumping material out of tanks shall have a minimum of 3 HP unless stated otherwise

· Cabinets and booths shall have easily removable access panels around the perimeter. No swinging access panels shall be allowed.

· All lighting over booth inspection areas on the rollers shall be designed in accordance with section 1.6.11. If requirements stated in this section conflict with other standards referenced, then the strictest shall be enforced.

· All valves, pumps, cylinders, tanks, and piping shall be easy to access. dis-assembly of any component of the machine shall not require any special tools

· All materials and equipment used for the roller system w/ FPI substations and baskets shall be compatible with the following:

· Magnaflux ZL-67

· Magnaflux ZL-37

· Magnaflux ZL-56

· Magnaflux ZP-4B

· Magnaflux ZP-14A

· Tectyl 894, grade 3 material and fumes

· Vertrel SDG solvent and fumes

· Tergo MCF solvent and fumes

· DI water

· Transition points between sections of the roller system, turning tables, bridge gates and substations shall be smooth and continuous. No misalignments, steps or interference points allowed

· Equipment that utilizes water shall be provided DI water:

· Each DI water drop for equipment shall have a canister type 5 micron filter

· Contractor shall provide at least 6 spare filters

· Plumbed to provide at least 5 GPM

· All elements of the substations shall be leak free: doors, cabinets, piping, tanks, drip rails, drip pans, gloves, windows etc.

· No part of the roller system, turning tables, bridge gates and substations shall have sharp edges

· Sound levels of any substation and supporting equipment shall not exceed 60 DB.

· All air hoists, trolleys and crane systems:

· System shall be rated for 500 LBS.

· The below requirements does not apply to linear gantry systems

· System shall provide side to side and front to back motion with trolley hook centered on basket

· Side to side movement: distances determined per substation

· Front movement: distances determined per substation

· Back movement: distances determined per substation

· System shall lift the FPI basket 9 feet from the ground (with no aircraft part)

· Air hoist:

· 90 psi rating

· Manual trolley and crane movement: easy to push/pull on rails, no binding

· Control pendant to be level to operator

· Hardened steel load chain with hook and latch 360 swivel end with no resistance with load

· 1-1/8” hook opening

· Maximum chain length: hook shall touch the floor plus 1 foot

· Disk brake for zero load drift

· Lubrication free

· Variable lowering and lifting speed and precise positioning by control pendant

· Emergency stop button

· If system is not integrated into a cabinet, crane mounting shall be to floor

· If trolley system is integrated with cabinet, the cabinet shall:

· Be constructed and rated for the hoist load

· Not deform or shake under load

· Mounting shall not interfere or require any modifications to the roller system

· Exhaust from the air hoist shall not contaminate the aircraft part. A check shall be performed by the contractor to confirm contaminates are not contaminating the part. Acceptable mitigation methods:

· Route exhaust away from booth or cabinet

· Provide a properly sized filter system for incoming air to the air hoist

· Provide a properly sized exhaust filter

2.2.6.2. Roller system:

· Working width: 48”

· Working height: 36”

· Have a minimum load capacity of 500 LBS.

· Rust free and easy to maintain

· Equipped with guard rails along entire length of roller system

· Working width and height shall be equal along entire path of roller system

· Roller turning sections:

· Shall be ball transfer tables

· Equipped with guard rails

· Match dimensions of roller system

· Shall be mounted to floor

· Roller system stainless steel catch pans:

· All roller sections shall have catch pans to include turning sections:

· Shall be easy to access, removable and easy to clean

· Pans shall not leak when butted up against machine or other pans

· Catch pans shall not be installed inside of machines or stations that have cabinets unless stated

· FPI secondary baskets has the same requirements as FPI baskets except for the following:

· 1.5” tall walls

· Outer dimensions of secondary basket shall be smaller than the base of the FPI baskets by 3/16”

· Shall be compatible with Magnaflux ZR-10B Hydrophilic Emulsifier

2.2.6.3. Bridge gates:

· Equipped with a mechanism for raising bridge with a touch button

· Equipped with a mechanism for manually raising the bridge gate. Unloaded weight of the bridge gate shall be less than 35 LBS.

· Opening shall be completed with no sudden movement. Movement shall be uniform

· Equipped with guard rails to prevent a load from falling

· Shall be integrated with the building fire alarm system for automatic opening in case of fire

· Shall provide a minimum of 36” of clearance when opened. Absolutely no obstructions of any kind (such as sensors, wiring, anchor bolts, roller supporting structures, rollers, etc.) allowed within this 36” wide zone. The depth of zone shall be the width of the roller system.

2.2.6.4. Vapor degreaser substation

· 460 VAC, 3 phase, 60 HZ system

· Enclosed batch type machine

· Machine shall use the following solvents:

· Vertrel SDG solvent

· Tergo MCF solvent

· Immersion in vapor zone with spray configuration with vapor recycling by primary and freeboard vapor trap cooling coils

· Design shall minimize air disturbances internal to machine to maintain cooling blankets

· Tank:

· Compatible with FPI baskets

· 1” thick insulation minimum all around and bottom

· Capable of bringing solvent to a boil in 10 minutes or less from cold start, 30 KW minimum power

· Heaters shall be easily removable and accessible

· Base of sump and opening of sump to be square

· Vapor zone above boiling solvent shall be a minimum 36” to 38” tall as measured above the stationary, unheated solvent surface to the center of the primary cooling coils. The unheated solvent surface to the bottom of the tank shall be approximately 12” to 13” (approximately 90 gallons of solvent).

· Solvent shall be transferred using threaded or other leak-proof couplings and the end of the pipe in the solvent sump shall be located beneath the liquid solvent surface (standard reference 40 CFR 63.463 d8)

· Provide sight glass to determine height of solvent without looking inside of machine:

· Shall be graduated (with units in gallons and quarts) to provide accurate measurements of volume in tank

· Contractor shall minimize the freeboard height but maintain at least 80% freeboard ratio

· Shall have a lid:

· Automatic, powered open and close

· Shall remain closed except when part are moved into and out of the degreaser

· Cover can remain open during the cleaning process

· Cover to remain closed during idle

· Does not disturb the vapor zones when opened and closed

· Shall not have gaps or openings around the perimeter

· Standard reference: 30 TAC 106.454 4B and 4C

· Shall be sealed

· Fixed sprays:

· Located on opposite sides of tank in vapor zone holding area

· 2 spray headers per side

· Positioned to spray unheated distillate from a spray tank onto part

· Independent, stainless steel pump ½ HP minimum

· Stainless steel spray nozzles with flow control with pressure gauge

· Spraying operations shall be done within the vapor zone

2.2.6.5. Chiller system:

· Primary cooling coils:

· Minimum of 3 cooling coils around the perimeter of tank

· Temperature shall be maintained such that coils provide continuous condensation of rising solvent vapors creating a concentrated vapor zone:

· If water cooled coils are used, temperature and flow requirements for chilled water shall not exceed building supply. Four HP minimum for water cooled pump.

· The contractor shall provide the air temperature between the cooling coils. The contractor shall provide a method for this measurement.

· Cooling capacity boost for larger thermal masses

· Finns shall be used to increase heat transfer efficiency

· Freeboard condenser cooling:

· Temperature of coils shall maintain a -10 to -25 degrees Celsius or colder during normal operation and:

· The chilled air blanket temperature measured at the center of the air blanket shall not be greater than 30% of the solvents boiling point (standard reference: 40 CFR 63.463 e2(i)) and

· Contractor shall provide method and verification of this requirement

· Cooling capacity boost for larger thermal masses

· Water cooled compressor/condenser unit: temperature and flow requirements for chilled water shall not exceed building supply

· Minimum of 3 paired cooling coils around the perimeter of tank

· Automatic defrosting system. Shall maintain subzero cooling temperature during defrosting.

· Center shall be located to allow a 30” tall aircraft part to dwell within cooling coils without interference with the lid

· Finns shall be used to increase heat transfer efficiency

· Cooling coils shall be protected from aircraft parts being lowered or raised through the machine

· Vapor capture efficiency:

· Shall be capable of achieving 85% or greater control of total solvent emissions (standard reference: 30 TAC 115.412 2D(ii)) and

· Total solvent make-up, gross usage minus waste disposal, shall not exceed 1500 gallons per year (standard referen¬¬ce 30 TAC 106.454 4G(ii)).

· All condensed solvent and water formed on coils shall be directed to a water separator

· Water separator with lid:

· 20 gallon capacity

· Clean solvent shall be returned to the boil tank

· 5 gallon distillate reservoir and removable lid

· Utilizes cooling coil inside separator

· Adjustable weir

· Exhaust system:

· The exhaust stacks shall discharge vertically with no restrictions or obstructions to flow. The stack height shall extend at least 1.3 times the building height as measured from ground level (standard reference 30 TAC 106.454 4F).

· All exhaust stacks shall be designed with lightning protection in accordance with NFPA 780 and standards stated in section 1.6.11.

· Exhaust ventilation shall operate between 50 and 65 cubic feet per minute per square foot of degreaser open area. Ventilation fans or other sources of air agitation shall not be operated near the degreaser station (standard reference 30 TAC 106.454 4E).

· Lift system for baskets with Linear gantry system

· 2 axis motion:

· X axis: left and right

· Y axis: up and down

· No chains or wire rope shall be used for the gantry system

· Provide solid shafting or similar

· Provide precise lifting and lowering positioning

· Mounting legs and frame

· Jib boom style or similar

· Shall not interfere with any section of the roller system

· Shall not interfere with accessing the any part of the roller system and be compatible with FPI basket

· Contractor shall design a method for hooking the basket to the gantry system for transferring. Contractor shall be allowed to utilize attachments designed for the basket:

· Attachments:

· Shall be easy to remove from the basket

· Shall be easy to install on the basket

· Shall be light

· Easy to maintain

· Shall be rated for load capacity of the basket

· Shall not interfere with 30” aircraft part in basket

· Be capable of lifting and lowering the basket without binding, hitting or rubbing interior components of machine.

· Smooth motion during all lifting, all lowering and traversing

· Provide manual raising when input utilities, air or electricity, is cut off

· Controls and monitoring:

· Controls

· PLC with HMI

· Control interface:

· Programming different process profiles for various parts

· Display process times and alarms

· Programmable timers for dwell times in vapor zone and freeboard areas

· Temperature controls

· Indicators and readouts for chilling system

· Alarms

· 2 axis gantry system speed control and position set points

· Monitoring features:

· Low solvent level: shuts off heat if solvent in boil tank falls too low (standard reference 30 TAC 115.512 2(ii))

· Heat to solvent shuts off if either the primary or freeboard cooling fails and shall utilize a flow sensor and thermostat to detect if the condenser coolant is not circulating or if the coolant temperature exceeds machine parameters (standard reference 30 TAC 115.512 2(i))

· Vapor level sensor which will detect if the vapor level rises above acceptable design limits (standard reference 30 TAC 115.512 2(iii))

· Vapor up control: establishes ‘ready for operation’ when vapor is ready

· High temperature control to prevent heater burnout or temperature run away

· Liquid solvent temperature monitoring

· Energy saver feature:

· Heater power shall be reduced by 50% when machine is in idle mode

· Heater power shall be returned to normal when a load is introduced to vapor zone

· Machine shall utilize a dedicated thermostat for the energy saver feature

· At startup of machine, the primary condenser shall be turned on before the sump heater (standard reference 40 CFR 63.463 d6)

· At shutdown of machine, the sump heater shall be turned off and the solvent vapor layer allowed to collapse before the primary condenser is turned off (standard reference 40 CFR 63.463 d7)

· Shall have tower lights to indicate mode of machine and be clearly visible from all directions

· Automatic motions overview:

· Basket is raised from roller system by gantry lift system and moved to top of machine

· Lid automatically opens, basket is lowered into vapor zone: period of time shall be programmable

· Basket is raised into freeboard area: period of time shall be programmable

· Basket is raised to top of machine

· Lid automatically closes

· Basket is moved from top of machine and lowered to roller system opposite the start point of basket

· Motions shall be precise and programmable

· Motions shall not exceed 11 feet per minute: shall be adjustable

· Beeping sounds and patlites shall be provided for motions

· Raised work platform:

· Shall be safety yellow in color

· Horizontal platforms shall be serrated

· High enough to allow operator to view opening of degreaser at waist level

· Shall meet OSHA and ergonomic standards

· Shall have hand rails along entire length of platform

· Shall be light and portable

· Centerline of roller system shall be in line with the centerline of the tank looking top down

· Shall contain a stainless steel containment pan that extends just passed the boundaries of the machine. Shall not create an operator tripping hazard.

2.2.6.6. Black-Light Inspection Booth

· Roller sections shall go through the booth

· Drip pans shall have a drain that is connected to the industrial waste line. This pan shall be designed so that fluids do not accumulate during use. A shut off valve shall be installed for this drain.

· Inside working dimensions of booth:

· Wide enough to accommodate air hoist/crane vertical structures and motions

· Deep enough to allow 4 feet from entrance to rollers and allow for 1.5 feet clearance behind the rollers. Values approximate.

· Height shall be tall enough to contain the air hoist, trolley and crane system

· NDI curtain: specifications identical to MPI booth NDI curtain except for no part of the curtain shall touch aircraft parts passing through entry and exit doors

· Entry and exit doors shall have pushbuttons located inside and outside the booth for opening and closing the door

· Air circulation fans:

· One fan for venting air out of curtain booth

· Locations of circulation fans shall be on opposite sides of the booth

· One fan for cool air and circulation

· Each with on/off switch and speed control on wall

· Capacity of cooling fan to keep inside booth at same temperature as surrounding outside area

· Cool fan air shall not be directed toward FPI basket or operator

· Location of fans to be easily accessible to allow for easy replacement

· Lighting over inspection area on rollers:

· Overhead high power white light: with on/off switches. The light shall provide a minimum of 100 foot candles of visible light when measured at the roller section. One switch shall be near entrance of booth and another near the inspection area for easy operator access.

· Overhead black light, fluorescent or UV-A flood lamps: with on/off switch. The black light shall provide a minimum of 1200 microwatt/CM^2 at the roller section. Switch shall be near inspection area for easy operator access.

· Shall provide a method for easy cleaning of light fixtures and bulb maintenance

· The contractor shall design the lighting to limit the obstruction of light caused by the crane system

· General purpose lighting:

· Centered in booth between roller section and entrance to booth

· 2 each on/off switches:

· At entrance

· Near inspection area

· Booth shall not allow more than 2 foot candles of outside light when enclosure light is off throughout enclosure

· Contractor shall provide a vertical panel directly underneath where the curtain interfaces with the roller to eliminate light from entering from underneath rollers

· Air hoist, trolley and crane system:

· Side to side movement distance: shall move one FPI basket at 2 feet, 2.5 foot maximum

· Front movement distance: shall move one FPI basket forward from roller system 2 feet with a 2.5 foot maximum

· Back movement distance: shall move one FPI basket backward from roller system 1 foot with a 1.5 foot maximum

· Solid overhead roof: specifications identical to MPI booth solid overhead roof

· Booth shall have sturdy, metal framing mounted to floor and the structure shall be rigid

· Shall have 4 additional 120 VAC receptacles, approximately 3 feet from floor, for ancillary equipment throughout booth

· Shall have a penetrant spray booth

· Roller sections shall go through the booth and cabinet

· Inside working dimensions of booth

· Wide enough to accommodate spray booth cabinet

· Deep enough to allow 4 feet from entrance to cabinet, values approximate

· Height shall be tall enough to contain the cabinet

· Shall have an air filter/condensate/oil separator/desiccant dryer system in accordance with CCAD J.02 page 16 section 14.2 and shall be located in a location easily viewed and accessed by the operator

· NDI curtain: specifications identical to MPI booth NDI curtain except for no part of the curtain shall touch aircraft parts passing through entry and exit doors

· Cabinet:

· Inside working dimensions of cabinet shall have width, depth and height enough to accommodate air hoist/crane vertical structures and motions, rollers with a basket

· Entry and exit doors shall have pushbuttons shall be located inside and outside the booth for opening and closing the door

· Base of cabinet shall have a drain that is connected to the industrial waste line. The base shall be designed so that fluids do not accumulate during use. A shut off valve shall be installed for this drain.

· Exhaust system:

· Back and inside of booth cabinet shall contain an electrostatic precipitator:

· Electrical connections of the precipitator shall be in accordance with section 1.6.11.

· Any drainage from the electrostatic precipitator system shall be routed to the base of cabinet.

· Mist Collector:

· Inlet shall be plumbed to back wall behind the electrostatic precipitator and shall allow for evenly distributed suction across precipitator

· Shall have on/off control in front of cabinet near operator and on mist collector

· Drain of the mist collector shall be routed to the nearest industrial waste drain

· Exhaust shall be plumbed to roof penetrations

· Contractor shall determine CFM rating of mist collector, the minimum shall be 8.8K CFM:

· CFM shall be enough to prevent FPI material overspray from reaching back to operator from furthest point away from back of cabinet

· CFM shall be enough to prevent FPI material from escaping curtain areas

· CFM allow for proper application of FPI material onto aircraft parts

· Specifications:

· Self-supporting with floor mount legs

· Minimum of 3 stage filtration system

· Collects airborne mist such as FPI material

· Contains a pressure differential gauge to determine filter change

· Contain a bottom mist collector drain below the inlet

· Steel construction body and legs

· Utilizes an inlet hopper

· Tool interlock system

· Bottom open and close valve for releasing accumulated material

· Exterior finish compatible with FPI material

· External width and depth shall not exceed 45” x 70”

· Provide at least 6 filters of each type used

· Building roof exhaust fan: see section 3.20.

· Contractor shall provide an exhaust fan suitable to maintain proper flow to outside air

· Two air operated pumps for NDT fluids. Each pump shall:

· Be Ingersol Rand ARO type pump, part number to be determined by the Government

· Be located on operator side of roller system

· Have individual air pressure regulators, adjustable 20 to 90 PSI

· Have the fluid outlets connected to Government provided spray guns via a hose

· Have the fluid inlet routed to a Government provided 5 gallon container of FPI fluids. Hoses shall be long enough to reach the bottom of the container. Containers shall be located near the pumps.

· Have pump rebuild kits

· Provide installation for two Government provided spray guns: Each spray gun shall be connected to individual pressure air pressure regulators, adjustable 20 to 90 PSI

· Source of air shall be from filter/condensate/oil separator/desiccant system

· Shall have the inlet fluid hoses connected to the pump outlet. Length of hoses shall allow for use from left to right in front of the cabinet.

· Cabinet shall provide a method for securing spray guns safely while not in use. Located on left side of cabinet, operator side.

· Shall have a stainless steel pan for holding 2 five gallon, Government provided containers of FPI fluids.

· Shall have an integrated air hoist, trolley and crane system:

· Side to side movement distance: shall move one FPI basket at least 2 feet, 2.5 foot maximum

· Front movement distance: shall move one FPI basket forward from roller system at least 2 feet with a 2.5 foot maximum

· Back movement distance: shall move one FPI basket backward from roller system at least 1 feet with a 1.5 foot maximum

· Lighting over inspection area on rollers:

· Overhead high power white light: with on/off switches. The light shall provide a minimum of 100 foot candles of visible light when measured at the roller section. One switch shall be near entrance of booth and another near front of cabinet for easy operator access.

· Overhead black light, fluorescent or UV-A flood lamps: with on/off switch. The black light shall provide a minimum of 1200 microwatt/CM^2 at the roller section. Switch shall be near front of cabinet for easy operator access.

· Shall provide a method for easy cleaning of light fixtures and bulb maintenance

· The contractor shall design the lighting to limit the obstruction of light caused by the crane system

· General purpose lighting:

· Centered in booth between roller section and entrance to booth

· 2 each on/off switches

· At entrance

· Near inspection area

· Booth shall have sturdy, metal framing mounted to floor and structure shall be rigid

· Solid overhead roof: specifications identical to MPI booth solid overhead roof

· Booth and cabinet shall not allow more than 2 foot candles of outside light when enclosure light is off throughout enclosure

· Contractor shall provide a vertical panel directly underneath where the curtain interfaces with the roller to eliminate light from entering from underneath rollers

· Air circulation fans:

· On/off switch and speed control on wall

· One fan for venting air (heat) out of curtain enclosure

· One fan for cool air and circulation

· Capacity of circulation fans to keep inside booth at same temperature as outside surrounding area

· Cool fan air shall provide a cross draft from behind operator to inside and back of cabinet wall. Fan shall provide CFM to keep FPI overspray from operator

· Location of fans to be easily accessible to allow for easy replacement

· Shall have 4 additional 120 VAC receptacles, approximately 3 feet from floor, for ancillary equipment throughout booth

· Entire booth shall be considered a…