L1WA28 B59D PCPDS PD 17 May 21.pdf

PURCHASE DESCRIPTION (PD)

Plural Component Paint Dispensing Systems (PCPDS) CIP Tracking #L1WA28

17 May 2021

1. The Contractor shall provide to the 402 Aircraft Maintenance Group (AMXG), Robins AFB, GA, all parts, labor, equipment, tools, materials, and transportation to deliver and install 2-Component/ Plural Component High Flow Paint Dispense System (PCPDS) for 1) MIL-PRF-85285 topcoat and

2) MIL-PRF-23377 or MIL-PRF-32239 primer. This includes verifying the accurate operation and interfacing of all items and providing operator familiarization training to Government personnel.

These systems shall conform to current WR-ALC/ 402AMXG/ MXDE Corrosion Control equipment standards to ensure compatibility and be approved by the MXDE Corrosion Control prior to Government acceptance. All systems are standalone and require no base network access.

2. Equipment Description

2.1. Design: The systems, including the basic systems and any options exercised, shall be new and complete, custom-built to meet the Government’s applications, and ready for immediate operation after installation, acceptance testing, and training are completed. Equipment must meet OSHA regulations (OSHA 29 CFR 1926) for the design and construction of PCPDS.

Designs and installation will be specific to each location. NO construction shall begin without Government approval of FDR. All coordination/approval with Robins AFB will be handled by government personnel not the Contractor.

2.1.1. No later than 30 days after award, the Contractor shall provide a single Gantt chart showing the project schedule on a biweekly basis from contract award through final inspection and acceptance of the system. Updates to this chart shall be made at least weekly and provided to the CMXG as updates occur. (CDRL A001, Project Planning Chart, DI-MGMT-80507C Project Planning Chart)

2.1.2. Prior to the close-out of the project, the Contractor shall provide all Commercial Off the Shelf (COTS) equipment manuals and associated documents including but not limited to Operator/Maintenance Manuals, As-Built Drawings of all process components, Spare Parts Lists, schematics, wiring diagrams, and design documentation. (CDRL A002, Commercial Off-the-Shelf (COTS) Equipment Manual Requirements, DI-TMSS- 80527C)

2.2. Locations for the basic contract systems and options are buildings 59P, 89, 50, 54, and 59D, as described below. Projected layouts shown in the PD appendices are subject to change. All components within the paint mixing, dispensing area and paint loading area must be Class 1, Div 1 rated. Each building location will require a drum roller to be installed. These can be either electric motor or pneumatic. This will allow for mixing of 55 gallon drum prior to loading into dispensing tanks. Government will provide CADD drawing for each location within 10 days of award. Government will provide TDS for all primer/topcoat paint products within 10 days of award.

3. Government Furnished Property (GFP): None.

4. Building 59P System

4.1. The interior dimensions of the PCPDS shall fit into an area approximately twelve (12) feet wide by ten (10) feet high by eighteen (18) feet long (see PD Appendix A) unless a more suitable area is otherwise provided by WR-ALC/402AMXG/MXDEA. The Government will be responsible for the removal of the current equipment within the room. Room size will be sized to meet each system requirements for safe access, operations and maintenance. Maximum size estimated at 20’x25’.

4.2. The PCPDS in building 59P shall have the ability to dispense a two-part top coat in one color.

4.3. To maintain compatibility with existing WR-ALC/402AMXG CCF systems, the MIL-PRF- 85285 dispense system shall consist of:

4.3.1. Two (2) each Dual Control (DC) Electric Circulating pump assemblies to dispense a 2-component (2K/ Base + Catalyst) paint on ratio at a high flow rate (10gpm). System must also have the capability to produce small batches (1qt) if required from the same tanks.

Loading of paint product into tanks shall accommodate closed head drums.

4.3.2. In order to maintain required consistent mixing ratio, the system shall meet the following specifications.

4.3.3. The resin/base pump shall have:

4.3.3.1. 1500cc lower (1 HP motor, 1400lb maximum force)

4.3.3.2. OUTPUT AT 20 CPM: 7.9 gpm (30 lpm)

4.3.3.3. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

4.3.3.4. Sealed 4-Ball Lowers

4.3.3.4.1. No Throat Seal Liquid (TSL) required

4.3.3.4.2. Ultralife Series ceramic coating

4.3.3.4.3. Completely sealed fluid section

4.3.3.4.4. Carbide Outlet Checks

4.3.3.4.5. Compatible with Bulldog, NXT, President, Viscount, E-Flo, and E-Flo DC motors

4.3.3.4.6. Maximum fluid working pressure: 2.07 MPa, 20.7 bar (Metric)

4.3.3.4.7. Maximum potential fluid pressure: 1500/v (volume of lower in cc) bar

4.3.3.4.8. Maximum continuous cycle rate: 20 cpm

4.3.3.4.9. Maximum Flow: 7.9 gpm

Building Primer 1 Primer 2 Top Coat 1 Top Coat 2 Top Coat 3 Top Coat 4 59P X X 89 X X X X X X

50 X X 54 X X

59D X X X X X X

OPTION 1

OPTION 2

4.3.3.4.10. Input voltage: 100–250 Vac, single phase, 50/60 Hz

4.3.3.4.11. Input current: 20 A maximum

4.3.3.4.12. Power inlet port size: 3/4–14 npt(f)

4.3.3.4.13. Ambient temperature range: 0–40°C

4.3.3.4.14. Maximum sound level: Less than 70 dB(A)

4.3.3.4.15. Oil capacity: 1.4 liters

4.3.3.4.16. Oil specification: silicone-free synthetic gear oil

4.3.3.4.17. Weight: Pump package (motor, 1500cc lower, stand, and tie rods) approximately 100 kg, or equivalent necessary to remove and replace pumps without the use of large equipment

4.3.3.4.18. Fluid inlet size: 1–1/2 npt(f)

4.3.3.4.19. Fluid outlet size: 1 npt(f)

4.3.4. The catalyst pump shall have:

4.3.4.1. 750cc lower (1 HP motor, 1400lb maximum force)

4.3.4.2. OUTPUT AT 20 CPM: 4.0 gpm (15 lpm)

4.3.4.3. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

4.3.4.4. Sealed 4-Ball Lowers

4.3.4.5. No TSL required

4.3.4.6. Ultralife Series ceramic coating

4.3.4.7. Completely sealed fluid section

4.3.4.8. Carbide Outlet Checks

4.3.4.9. Compatible with Bulldog, NXT, President, Viscount, E-Flo, and E-Flo DC motors

4.3.4.10. Maximum fluid working pressure: 2.07 MPa, 20.7 bar (Metric)

4.3.4.11. Maximum potential fluid pressure: 1500/v (volume of lower in cc) = bar

4.3.4.12. Maximum continuous cycle rate: 20 cpm

4.3.4.13. Maximum Flow: 4.0 gpm

4.3.4.14. Input voltage: 100–250 Vac, single phase, 50/60 Hz

4.3.4.15. Input current: 20 A maximum

4.3.4.16. Power inlet port size: 3/4–14 npt(f)

4.3.4.17. Ambient temperature range: 0–40°C

4.3.4.18. Maximum sound level: Less than 70 dB(A)

4.3.4.19. Oil capacity: 1.4 liters

4.3.4.20. Oil specification: silicone-free synthetic gear oil

4.3.4.21. Weight: Pump package (motor, 750cc lower, stand, and tie rods) approximately

100 kg, or equivalent necessary to remove and replace pumps without the use of large equipment

4.3.4.22. Fluid inlet size: 1–1/2 npt(f)

4.3.4.23. Fluid outlet size: 1 npt(f)

4.3.5. High pressure red alert filter with inlet & outlet manual ball valves and drain ball valve so operator can easily change out the filters

4.3.6. 4 each day tank assemblies

4.3.7. 2 each 150 gal tank assembly for resin/base with an electric agitator, high/low level transmitter and a fill pump assembly on a 55 gallon lid with elevator

4.3.8. 2 each 80 gal tank assembly for catalyst with a high/low level transmitter and a fill pump assembly on a 55 gallon lid with elevator.

4.4. One (1) each high flow mix manifold will be made with large ports and a static mix tube on the outlet.

4.4.1. The inlet of the mix manifold will have two 3-way automatic ball valves, one for the resin/base and one catalyst

4.4.2. When not in dispense mode, the resin/base will circulate at lower flow rates back to the corresponding day tank.

4.5. Integration panel for system control

4.5.1. Panel will be located in a non Class 1, Div 1 safe area.

4.6. Pneumatic operator panel in the Class 1, Div 1 hazardous area for system operation in the hazardous area.

4.6.1. The operator panel may be located outside of the hazardous area provided there is an observation window to ensure proper operation of the system while filling paint carts.

4.6.2. Panel will include operator information, paint batch number and lot number of paint product loaded into system and AC tail number.

5. The PCPDS in building 59P shall have the ability to dispense primer. System must also have the capability to produce small batches (1qt) if required from the same tanks. Loading of paint product into tanks shall accommodate closed head drums. To maintain compatibility with existing WR-ALC/402AMXG CCF systems, the MIL-PRF-23377 or 32239 dispense system shall consist of:

5.1. Two (2) ea Dual Control (DC) Electric Circulating pump Assemblies to dispense a 2K (Base +

Catalyst) paint on ratio at a high flow rate (10gpm).

5.1.1. Resin/base pump shall have a 1500cc lower

5.1.1.1. OUTPUT AT 20 CPM: 7.9 gpm (30 lpm)

5.1.1.2. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

5.1.1.3. Sealed 4-Ball Lowers

5.1.1.4. No TSL required

5.1.1.5. Ultralife Series ceramic coating

5.1.1.6. Completely sealed fluid section

5.1.1.7. Carbide Outlet Checks

5.1.1.8. Compatible with Bulldog, NXT, President, Viscount, E-Flo, and E-Flo DC motors

5.1.1.9. Maximum fluid working pressure: 2.07 MPa, 20.7 bar (Metric)

5.1.1.10. Maximum potential fluid pressure: 1500/v (volume of lower in cc) = bar

5.1.1.11. Maximum continuous cycle rate: 20 cpm

5.1.1.12. Maximum Flow: 7.9 gpm

5.1.1.13. Input voltage: 100–250 Vac, single phase, 50/60 Hz

5.1.1.14. Input current: 20 A maximum

5.1.1.15. Power inlet port size: 3/4–14 npt(f)

5.1.1.16. Ambient temperature range: 0–40°C

5.1.1.17. Sound data: Less than 70 dB(A)

5.1.1.18. Oil capacity: 1.4 liters

5.1.1.19. Oil specification: silicone-free synthetic gear oil

5.1.1.20. Weight: Pump package (motor, 1000cc lower, stand, and tie rods) less than 100 kg, or equivalent necessary to remove and replace pumps without the use of large equipment

5.1.1.21. Fluid inlet size: 1–1/2 npt(f)

5.1.1.22. Fluid outlet size: 1 npt(f)

5.1.2. Catalyst pump shall have a 750cc lower (1 HP motor, motor, 1400lb maximum force)

5.1.2.1. OUTPUT AT 20 CPM: 4.0 gpm (15 lpm)

5.1.2.2. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

5.1.2.2.1. Sealed 4-Ball Lowers

5.1.2.2.1.1. No TSL required

5.1.2.2.1.2. Ultralife Series ceramic coating

5.1.2.2.1.3. Completely sealed fluid section

5.1.2.2.1.4. Carbide Outlet Checks

5.1.2.2.1.5. Compatible with Bulldog, NXT, President, Viscount, E-Flo, and E-Flo

DC motors

5.1.2.2.1.6. Maximum fluid working pressure: 2.07 MPa, 20.7 bar (Metric)

5.1.2.2.1.7. Maximum potential fluid pressure: 1500/v (volume of lower in cc) = bar

5.1.2.2.1.8. Maximum continuous cycle rate: 20 cpm

5.1.2.2.1.9. Maximum Flow: 4.0 gpm

5.1.2.2.1.10. Input voltage: 100–250 Vac, single phase, 50/60 Hz

5.1.2.2.1.11. Input current: 20 A maximum

5.1.2.2.1.12. Power inlet port size: 3/4–14 npt(f)

5.1.2.2.1.13. Ambient temperature range: 0–40°C

5.1.2.2.1.14. Sound data: Less than 70 dB(A)

5.1.2.2.1.15. Oil capacity: 1.4 liters

5.1.2.2.1.16. Oil specification: silicone-free synthetic gear oil

5.1.2.2.1.17. Weight: Pump package (motor, 1000cc lower, stand, and tie rods) approximately 100 kg, or equivalent necessary to remove and replace pumps without the use of large equipment

5.1.2.2.1.18. Fluid inlet size: 1–1/2 npt(f)

5.1.2.2.1.19. Fluid outlet size: 1 npt(f)

5.1.2.2.2. Each pump assembly will include a high pressure red alert filter with inlet & outlet manual ball valves and drain ball valve so operator can easily change out the filters.

5.1.3. 4 each day tank assemblies

5.1.3.1. 2 each 150 gal tank assembly for resin/base with an electric agitator, high/low level transmitter and a fill pump assembly on a 55 gallon lid with elevator

5.1.3.2. 2 each 80 gal tank assembly for catalyst with a high/low level transmitter and a fill pump assembly on a 55 gallon lid with elevator.

5.1.4. 1 each High Flow mix manifold will be made with large ports and a static mix tube on the outlet.

5.1.4.1. The inlet of the mix manifold will have two 3-way automatic ball valves, one for the resin/base and one catalyst

5.1.4.2. When not in dispense mode, the resin/base will circulate at lower flow rates back to the corresponding day tank.

5.1.5. Integration panel for system control

5.1.5.1. Panel will be located in a non Class 1, Div 1 safe area.

5.2. Pneumatic operator panel in the Class 1, Div 1 hazardous area for system operation in the hazardous area. The operator panel may be located outside of the Class 1, Div 1 hazardous area provided there is an observation window to ensure proper operation of the system while filling paint carts.

5.3. 2 ea. Material dispense mechanisms capable of dispensing material into existing paint carts (Must be able to automatically adjust to accommodate different paint cart tank sizes) 2 ea. Automated Solvent Flush systems to clear system of materials that may have adhered within the dispense system.

5.4 Panel will include operator information, paint batch number and lot number of paint product loaded into system and AC tail number.

6. Building 89 System

6.1. The interior dimensions of the PCPDS of the fit into an area approximately twelve (12) feet wide by ten (10) feet high by eighteen (18) feet long unless a more suitable area is otherwise provided by WR-ALC/402AMXG/MXDEA. (see PD Appendix B). The Government will be responsible for the removal of the current equipment within the room.

6.2. The PCPDS in building 89 shall have the ability to dispense a two-part top coat in four (4) colors.

6.3. System must also have the capability to produce small batches (1qt) if required from the same tanks. Loading of paint product into tanks shall accommodate closed head drums.

To maintain compatibility with existing WR-ALC/402AMXG CCF systems, the MIL-PRF- 85285 dispense system shall consist of: Eight (8) each Dual Control (DC) Electric Circulating pump assemblies to dispense a 2-component (2K/ Base + Catalyst) paint on ratio at a high flow rate (10gpm).

6.4. In order to maintain required consistent mixing ratio, the system shall meet the following specifications. Loading of paint product into tanks shall accommodate closed head drums.

6.4.1. The resin/base pump shall have:

6.4.1.1. 1500cc lower (1 HP motor, 1400lb maximum force)

6.4.1.2. OUTPUT AT 20 CPM: 7.9 gpm (30 lpm)

6.4.1.3. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

6.4.1.4. Sealed 4-Ball Lowers

6.4.1.4.1. No Throat Seal Liquid (TSL) required

6.4.1.4.2. Ultralife Series ceramic coating

6.4.1.4.3. Completely sealed fluid section

6.4.1.4.4. Carbide Outlet Checks

6.4.1.4.5. Compatible with existing Bulldog, NXT, President, Viscount, E-Flo, and E-

Flo DC motors

6.4.1.4.6. Maximum fluid working pressure: 2.07 MPa, 20.7 bar (Metric)

6.4.1.4.7. Maximum potential fluid pressure: 1500/v (volume of lower in cc) = bar

6.4.1.4.8. Maximum continuous cycle rate: 20 cpm

6.4.1.4.9. Maximum Flow: 7.9 gpm

6.4.1.4.10. Input voltage: 100–250 Vac, single phase, 50/60 Hz

6.4.1.4.11. Input current: 20 A maximum

6.4.1.4.12. Power inlet port size: 3/4–14 npt(f)

6.4.1.4.13. Ambient temperature range: 0–40°C

6.4.1.4.14. Maximum sound level: Less than 70 dB(A)

6.4.1.4.15. Oil capacity: 1.4 liters

6.4.1.4.16. Oil specification: silicone-free synthetic gear oil

6.4.1.4.17. Weight: Pump package (motor, 1500cc lower, stand, and tie rods) approximately 100 kg, or equivalent necessary to remove and replace pumps without the use of large equipment

6.4.1.4.18. Fluid inlet size: 1–1/2 npt(f)

6.4.1.4.19. Fluid outlet size: 1 npt(f)

6.4.2. The catalyst pump shall have:

6.4.2.1. 750cc lower (1 HP motor, 1400lb maximum force)

6.4.2.2. OUTPUT AT 20 CPM: 4.0 gpm (15 lpm)

6.4.2.3. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

6.4.2.4. Sealed 4-Ball Lowers

6.4.2.5. No TSL required

6.4.2.6. Ultralife Series ceramic coating

6.4.2.7. Completely sealed fluid section

6.4.2.8. Carbide Outlet Checks

6.4.2.9. Compatible with existing Bulldog, NXT, President, Viscount, E-Flo, and E-Flo

DC motors

6.4.2.10. Maximum fluid working pressure: 2.07 MPa, 20.7 bar (Metric)

6.4.2.11. Maximum potential fluid pressure: 1500/v (volume of lower in cc) = bar

6.4.2.12. Maximum continuous cycle rate: 20 cpm

6.4.2.13. Maximum Flow: 4.0 gpm

6.4.2.14. Input voltage: 100–250 Vac, single phase, 50/60 Hz

6.4.2.15. Input current: 20 A maximum

6.4.2.16. Power inlet port size: 3/4–14 npt(f)

6.4.2.17. Ambient temperature range: 0–40°C

6.4.2.18. Maximum sound level: Less than 70 dB(A)

6.4.2.19. Oil capacity: 1.4 liters

6.4.2.20. Oil specification: silicone-free synthetic gear oil

6.4.2.21. Weight: Pump package (motor, 750cc lower, stand, and tie rods) approximately

100 kg, or equivalent necessary to remove and replace pumps without the use of large equipment

6.4.2.22. Fluid inlet size: 1–1/2 npt(f)

6.4.2.23. Fluid outlet size: 1 npt(f)

6.4.3. High pressure red Alert filter with inlet & outlet manual ball valves and drain ball valve so operator can easily change out the filters

6.4.4. 4 each day tank assemblies

6.4.5. 8 each 150 gal tank assembly for resin/base with an electric agitator, high/low level transmitter and a fill pump assembly on a 55 gallon lid with elevator

6.4.6. 8 each 80 gal tank assembly for catalyst with a high/low level transmitter and a fill pump assembly on a 55 gallon lid with elevator.

6.5. Four (4) each High Flow mix manifold will be made with large ports and a static mix tube on the outlet.

6.5.1. The inlet of the mix manifold will have two 3-way automatic ball valves, one for the resin/base and one catalyst

6.5.2. When not in dispense mode, the resin/base will circulate at lower flow rates back to the corresponding day tank.

6.6. Integration panel for system control

6.6.1. Panel will be located in a non Class 1, Div 1 safe area.

6.7. Pneumatic operator panel in the Class 1, Div 1 hazardous area for system operation in the hazardous area.

6.7.1. The operator panel may be located outside of the hazardous area provided there is an observation window to ensure proper operation of the system while filling paint carts.

6.7.2. Panel will include operator information, paint batch number and lot number of paint

6.8. The PCPDS in building 89 shall have the ability to dispense two (2) types of primer. System must also have the capability to produce small batches (1qt) if required from the same tanks.

Loading of paint product into tanks shall accommodate closed head drums.

To maintain compatibility with existing WR-ALC/402AMXG CCF systems, the MIL- PRF-23377 or 32239 dispense system shall consist of:

6.9. Four (4) ea Dual Control (DC) Electric Circulating pump Assemblies to dispense a 2K (Base +

Catalyst) paint on ratio at a high flow rate (10gpm).

6.9.1. Resin/base pump shall have a 1500cc lower

6.9.1.1. OUTPUT AT 20 CPM: 7.9 gpm (30 lpm)

6.9.1.2. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

6.9.1.3. Sealed 4-Ball Lowers

6.9.1.4. No TSL required

6.9.1.5. Ultralife Series ceramic coating

6.9.1.6. Completely sealed fluid section

6.9.1.7. Carbide Outlet Checks

6.9.1.8. Compatible with existing Bulldog, NXT, President, Viscount, E-Flo, and E-Flo

DC motors

6.9.1.9. Maximum fluid working pressure: 2.07 MPa, 20.7 bar (Metric)

6.9.1.10. Maximum potential fluid pressure: 1500/v (volume of lower in cc) = bar

6.9.1.11. Maximum continuous cycle rate: 20 cpm

6.9.1.12. Maximum Flow: 7.9 gpm

6.9.1.13. Input voltage: 100–250 Vac, single phase, 50/60 Hz

6.9.1.14. Input current: 20 A maximum

6.9.1.15. Power inlet port size: 3/4–14 npt(f)

6.9.1.16. Ambient temperature range: 0–40°C

6.9.1.17. Sound data: Less than 70 dB(A)

6.9.1.18. Oil capacity: 1.4 liters

6.9.1.19. Oil specification: silicone-free synthetic gear oil

6.9.1.20. Weight: Pump package (motor, 1000cc lower, stand, and tie rods) approximately

100 kg, or equivalent necessary to remove and replace pumps without the use of large equipment

6.9.1.21. Fluid inlet size: 1–1/2 npt(f)

6.9.1.22. Fluid outlet size: 1 npt(f)

6.9.2. Catalyst pump shall have a 750cc lower (1 HP motor, motor, 1400lb maximum force)

6.9.2.1. OUTPUT AT 20 CPM: 4.0 gpm (15 lpm)

6.9.2.2. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

6.9.2.2.1. Sealed 4-Ball Lowers

6.9.2.2.1.1. No TSL required

6.9.2.2.1.2. Ultralife Series ceramic coating

6.9.2.2.1.3. Completely sealed fluid section

6.9.2.2.1.4. Carbide Outlet Checks

6.9.2.2.1.5. Compatible with existing Bulldog, NXT, President, Viscount, E-

Flo, and E-Flo DC motors

6.9.2.2.1.6. Maximum fluid working pressure: 2.07 MPa, 20.7 bar (Metric)

6.9.2.2.1.7. Maximum potential fluid pressure: 1500/v (volume of lower in cc)

= bar

6.9.2.2.1.8. Maximum continuous cycle rate: 20 cpm

6.9.2.2.1.9. Maximum Flow: 4.0 gpm

6.9.2.2.1.10. Input voltage: 100–250 Vac, single phase, 50/60 Hz

6.9.2.2.1.11. Input current: 20 A maximum

6.9.2.2.1.12. Power inlet port size: 3/4–14 npt(f)

6.9.2.2.1.13. Ambient temperature range: 0–40°C

6.9.2.2.1.14. Sound data: Less than 70 dB(A)

6.9.2.2.1.15. Oil capacity: 1.4 liters

6.9.2.2.1.16. Oil specification: silicone-free synthetic gear oil

6.9.2.2.1.17. Weight: Pump package (motor, 1000cc lower, stand, and tie rods) approximately 100 kg, or equivalent necessary to remove and replace pumps without the use of large equipment

6.9.2.2.1.18. Fluid inlet size: 1–1/2 npt(f)

6.9.2.2.1.19. Fluid outlet size: 1 npt(f)

6.9.2.2.2. Each pump assembly will include a high pressure red alert filter with inlet & outlet manual ball valves and drain ball valve so operator can easily change out the filters.

6.9.3. 4 each day tank assemblies

6.9.3.1. 4 each 150 gal tank assembly for resin/base with an electric agitator, high/low level transmitter and a fill pump assembly on a 55 gallon lid with elevator

6.9.3.2. 4 each 80 gal tank assembly for catalyst with a high/low level transmitter and a fill pump assembly on a 55 gallon lid with elevator.

6.9.4. 1 each High Flow mix manifold will be made with large ports and a static mix tube on the outlet.

6.9.4.1. The inlet of the mix manifold will have two 3-way automatic ball valves, one for the resin/base and one catalyst

6.9.4.2. When not in dispense mode, the resin/base will circulate at lower flow rates back to the corresponding day tank.

6.9.5. Integration panel for system control

6.9.5.1. Panel will be located in a non Class 1, Div 1 safe area.

6.10. Pneumatic operator panel in the Class 1, Div 1 hazardous area for system operation in the hazardous area.

6.10.1. The operator panel may be located outside of the Class 1, Div 1 hazardous area provided there is an observation window to ensure proper operation of the system while filling paint carts.

6.11. 2 ea. Material dispense mechanisms capable of dispensing material into existing paint carts (Must be able to automatically adjust to accommodate different paint cart tank sizes)

6.12. 2 ea. Automated Solvent Flush systems to clear system of materials that may have adhered within the dispense system.

6.13. Panel will include operator information, paint batch number and lot number of paint product

7. Engineering Design Reviews: Design of the process equipment shall meet the requirements necessary to successfully conduct the corrosion control process by furnishing and installing new equipment while at the same time incorporating existing CCF equipment into the process where practical. The systems shall be new and complete, custom built as required to meet the AMXG’s applications, and ready for immediate operation after installation, acceptance testing and training are completed. The Contractor shall provide design reviews at specific points as follows.

7.1. Preliminary Design Review (PDR) - The PDR evaluates if design concepts are feasible and technically adequate. The PDR will establish if the system is ready to proceed into more detailed design. The PDR shall be conducted at Robins AFB or via a conference call, to be scheduled in advance by the Contractor with the Government point of contact (POC) (listed in paragraph 8 below). The PDR presentation material shall be delivered to the Government within 5 days of scheduled meeting. (CDRL A003, Conference Minutes – Preliminary Design Review (PDR), DI-ADMN-81250B/T)

7.2. Critical Design Review (CDR) – The CDR provides the team with an objective look at what the final design will likely be. The review shall ensure the system can proceed into production, demonstration, and test and can meet stated performance requirements within cost, schedule, and risk. The CDR shall be conducted at Robins AFB or via a conference call, to be scheduled in advance by the Contractor with the Government POC. The CDR presentation material shall be delivered to the Government within 5 days of scheduled meeting. (CDRL A004, Conference Minutes – Critical Design Review (CDR), DI-ADMN-81250B/T)

7.3. Final Design Review (FDR) – The FDR provides one last look at the entire system design before the final system is setup at the Contractor’s facility. The FDR shall be conducted at Robins AFB, to be scheduled in advance by the Contractor with the Government POC. The FDR presentation material shall be delivered to the Government within 5 days of scheduled meeting. (CDRL A005, Conference Minutes – Final Design Review (FDR), DI-ADMN- 81250B)

7.4. No construction on any system (including the basic and all options) shall begin without written Government approval following the FDR. The Government will oversee all coordination/approval with Robins AFB prior to granting written Contractor approval to proceed. All coordination/approval with Robins AFB will be handled by government personnel not the Contractor.

8. Delivery

8.1. For each system to be delivered, the Contractor shall provide FOB destination delivery to the following address and Government point of contact.

DoDAAC: FP8038

402 AMXG/MXDEA

92 Phantom Street, Bldg. 125 Warner Robins, GA 31098 Attn: Todd Lavender, leighton.lavender@us.af.mil, (478) 222-8086 Alternate: Attn: Mike Robertson, michael.robertson.17@us.af.mil, (478) 222-4903

8.2. Each system shall be installed no later than 12 months after contract award or option exercise.

9. Acceptance Testing: The following procedures apply to each system installed, including the basic and any options exercised. The complete factory and site acceptance plans for the system shall be developed by the Contractor; reviewed and modified/approved (as appropriate) by the Government contract technical representative; and mutually agreed upon prior to conducting any test.

Documentation verifying the acceptance testing and verification shall be provided to the Government at least thirty (30) days prior to testing, which is to be scheduled in advance by the Contractor with the Government POC. The Government will notify the Contractor in writing within fifteen (15) calendar days of receipt if they comply with the test plan. If revisions are required, the Contractor shall provide revisions within ten (10) calendar days for Government review and approval. (CDRL A006, Acceptance Test Plan, DI-QCIC-80553)

10. Training

10.1. Contractor shall provide operator familiarization training for up to 10 operators on 3 to 5 aircraft, approximately 2 days each, not to exceed a total of 10 8-hour days per system.

Contractor shall schedule training with the Government POCs listed above. This training shall be provided for the basic system and any options exercised. A virtual reality plural component paint dispensing system training will be developed matching the operation and safety warning for a typical system.

10.2. Contractor personnel providing training shall be fluent in the English language, capable of meeting requirements to access Robins AFB, and comply with all base security requirements and applicable federal and state environmental regulations.

10.3. Contractor shall supply an operator/trainer for 30 days post start up.

10.4. Contractor shall supply 6 months of service post start for any issues that may arise.

11. The Contractor shall provide a PCPDS operator’s manual for each specific location, to include the basic requirement and any options exercised. (CDRL A002, Commercial Off-the-Shelf (COTS) Equipment Manual Requirements, DI-TMSS-80527C/T) The manual shall include at a minimum the following topics:

11.1. Agitation of primer and topcoat components

11.2. Paint component transfer

11.3. PCPDS operation and paint dispensing

11.4. Initializing the control system

11.5. Primer side operations

11.6. PCPDS checks prior to running system

11.7. Setting fill rate and batch size

11.8. Positioning paint cart and dispensing mixed paint and/or primer

11.9. Topcoat side operations

11.10. PCPDS checks prior to running system

11.11. Setting fill rate and batch size

11.12. Positioning paint cart and dispensing mixed paint and/or primer

11.13. PCPDS monitoring instructions

11.14. PCPDS spare parts inventory

12. OPTIONS: Contract options, if exercised, shall be separately priced and available to exercise for up to five (5) years from the time of basic contract award.

13. OPTION 1

13.1. The Contractor shall provide system design and installation for Building 50 and

Building 54 system specific to paint operation and will include:

13.2. Building 50: The interior dimensions of the PCPDS of the fit into an area approximately twelve (12) feet wide by ten (10) feet high by eighteen (18) feet long unless a more suitable area is otherwise provided by WR-ALC/402AMXG/MXDEA. (see PD Appendix C). The Government will be responsible for the removal of the current equipment within the room.

13.3. The PCPDS in building 50 shall have the ability to dispense a two-part top coat in one color. System must also have the capability to produce small batches (1qt) if required from the same tanks. Loading of paint product into tanks shall accommodate closed head drums. To maintain compatibility with existing WR-ALC/402AMXG CCF systems, the MIL-PRF-85285 dispense system shall consist of:

13.3.1. Two (2) each Dual Control (DC) Electric Circulating pump assemblies to dispense a 2-component (2K/ Base + Catalyst) paint on ratio at a high flow rate (10gpm). In order to maintain required consistent mixing ratio, the system shall meet the following specifications.

13.3.2. The resin/base pump shall have:

13.3.2.1. 1500cc lower (1 HP motor, 1400lb maximum force)

13.3.2.2. OUTPUT AT 20 CPM: 7.9 gpm (30 lpm)

13.3.2.3. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

13.3.2.4. Sealed 4-Ball Lowers

13.3.2.4.1. No Throat Seal Liquid (TSL) required

13.3.2.4.2. Ultralife Series ceramic coating

13.3.2.4.3. Completely sealed fluid section

13.3.2.4.4. Carbide Outlet Checks

13.3.2.4.5. Compatible with existing Bulldog, NXT, President, Viscount, E-Flo, and E-

Flo DC motors

13.3.2.4.6. Maximum fluid working pressure: 2.07 MPa, 20.7 bar (Metric)

13.3.2.4.7. Maximum potential fluid pressure: 1500/v (volume of lower in cc) = bar

13.3.2.4.8. Maximum continuous cycle rate: 20 cpm

13.3.2.4.9. Maximum Flow: 7.9 gpm

13.3.2.4.10. Input voltage: 100–250 Vac, single phase, 50/60 Hz

13.3.2.4.11. Input current: 20 A maximum

13.3.2.4.12. Power inlet port size: 3/4–14 npt(f)

13.3.2.4.13. Ambient temperature range: 0–40°C

13.3.2.4.14. Maximum sound level: Less than 70 dB(A)

13.3.2.4.15. Oil capacity: 1.4 liters

13.3.2.4.16. Oil specification: silicone-free synthetic gear oil

13.3.2.4.17. Weight: Pump package (motor, 1500cc lower, stand, and tie rods) approximately 100 kg, or equivalent necessary to remove and replace pumps without the use of large equipment

13.3.2.4.18. Fluid inlet size: 1–1/2 npt(f)

13.3.2.4.19. Fluid outlet size: 1 npt(f)

13.3.3. The catalyst pump shall have:

13.3.3.1. 750cc lower (1 HP motor, 1400lb maximum force)

13.3.3.2. OUTPUT AT 20 CPM: 4.0 gpm (15 lpm)

13.3.3.3. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

13.3.3.4. Sealed 4-Ball Lowers

13.3.3.5. No TSL required

13.3.3.6. Ultralife Series ceramic coating

13.3.3.7. Completely sealed fluid section

13.3.3.8. Carbide Outlet Checks

13.3.3.9. Compatible with existing Bulldog, NXT, President, Viscount, E-Flo, and E-Flo DC motors

13.3.3.10. Maximum fluid working pressure: 2.07 MPa, 20.7 bar (Metric)

13.3.3.11. Maximum potential fluid pressure: 1500/v (volume of lower in cc) = bar

13.3.3.12. Maximum continuous cycle rate: 20 cpm

13.3.3.13. Maximum Flow: 4.0 gpm

13.3.3.14. Input voltage: 100–250 Vac, single phase, 50/60 Hz

13.3.3.15. Input current: 20 A maximum

13.3.3.16. Power inlet port size: 3/4–14 npt(f)

13.3.3.17. Ambient temperature range: 0–40°C

13.3.3.18. Maximum sound level: Less than 70 dB(A)

13.3.3.19. Oil capacity: 1.4 liters

13.3.3.20. Oil specification: silicone-free synthetic gear oil

13.3.3.21. Weight: Pump package (motor, 750cc lower, stand, and tie rods) approximately

100 kg, or equivalent necessary to remove and replace pumps without the use of large equipment

13.3.3.22. Fluid inlet size: 1–1/2 npt(f)

13.3.3.23. Fluid outlet size: 1 npt(f)

13.3.4. High pressure red alert filter with inlet & outlet manual ball valves and drain ball valve so operator can easily change out the filters

13.3.5. 4 each day tank assemblies

13.3.6. 2 each 150 gal tank assembly for resin/base with an electric agitator, high/low level transmitter and a fill pump assembly on a 55 gallon lid with elevator

13.3.7. 2 each 80 gal tank assembly for catalyst with a high/low level transmitter and a fill pump assembly on a 55 gallon lid with elevator.

13.4. One (1) each High Flow mix manifold will be made with large ports and a static mix tube on the outlet.

13.4.1. The inlet of the mix manifold will have two 3-way automatic ball valves, one for the resin/base and one catalyst

13.4.2. When not in dispense mode, the resin/base will circulate at lower flow rates back to the corresponding day tank.

13.5. Integration panel for system control

13.5.1. Panel will be located in a non Class 1, Div 1 safe area.

13.6. Pneumatic operator panel in the Class 1, Div 1 hazardous area for system operation in the hazardous area.

13.6.1. The operator panel may be located outside of the hazardous area provided there is an observation window to ensure proper operation of the system while filling paint carts.

13.6.2. Panel will include operator information, paint batch number and lot number of paint

14. The PCPDS in building 50 shall have the ability to dispense primer. System must also have the capability to produce small batches (1qt) if required from the same tanks. Loading of paint product into tanks shall accommodate closed head drums. To maintain compatibility with existing WR-ALC/402AMXG CCF systems, the MIL-PRF-23377 or 32239 dispense system shall consist of:

14.1. Two (2) ea Dual Control (DC) Electric Circulating pump Assemblies to dispense a 2K (Base

+ Catalyst) paint on ratio at a high flow rate (10gpm).

14.1.1. Resin/base pump shall have a 1500cc lower

14.1.1.1. OUTPUT AT 20 CPM: 7.9 gpm (30 lpm)

14.1.1.2. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

14.1.1.3. Sealed 4-Ball Lowers

14.1.1.4. No TSL required

14.1.1.5. Ultralife Series ceramic coating

14.1.1.6. Completely sealed fluid section

14.1.1.7. Carbide Outlet Checks

14.1.1.8. Compatible with existing Bulldog, NXT, President, Viscount, E-Flo, and E-Flo DC motors

14.1.1.9. Maximum fluid working pressure: 2.07 MPa, 20.7 bar (Metric)

14.1.1.10. Maximum potential fluid pressure: 1500/v (volume of lower in cc) = bar

14.1.1.11. Maximum continuous cycle rate: 20 cpm

14.1.1.12. Maximum Flow: 7.9 gpm

14.1.1.13. Input voltage: 100–250 Vac, single phase, 50/60 Hz

14.1.1.14. Input current: 20 A maximum

14.1.1.15. Power inlet port size: 3/4–14 npt(f)

14.1.1.16. Ambient temperature range: 0–40°C

14.1.1.17. Sound data: Less than 70 dB(A)

14.1.1.18. Oil capacity: 1.4 liters

14.1.1.19. Oil specification: silicone-free synthetic gear oil

14.1.1.20. Weight: Pump package (motor, 1000cc lower, stand, and tie rods) approximately

100 kg, or equivalent necessary to remove and replace pumps without the use of large equipment

14.1.1.21. Fluid inlet size: 1–1/2 npt(f)

14.1.1.22. Fluid outlet size: 1 npt(f)

14.1.2. Catalyst pump shall have a 750cc lower (1 HP motor, motor, 1400lb maximum force)

14.1.2.1. OUTPUT AT 20 CPM: 4.0 gpm (15 lpm)

14.1.2.2. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

14.1.2.2.1. Sealed 4-Ball Lowers

14.1.2.2.1.1. No TSL required

14.1.2.2.1.2. Ultralife Series ceramic coating

14.1.2.2.1.3. Completely sealed fluid section

14.1.2.2.1.4. Carbide Outlet Checks

14.1.2.2.1.5. Compatible with existing Bulldog, NXT, President, Viscount, E-Flo, and E-Flo DC motors

14.1.2.2.1.6. Maximum fluid working pressure: 2.07 MPa, 20.7 bar (Metric)

14.1.2.2.1.7. Maximum potential fluid pressure: 1500/v (volume of lower in cc) = bar

14.1.2.2.1.8. Maximum continuous cycle rate: 20 cpm

14.1.2.2.1.9. Maximum Flow: 4.0 gpm

14.1.2.2.1.10. Input voltage: 100–250 Vac, single phase, 50/60 Hz

14.1.2.2.1.11. Input current: 20 A maximum

14.1.2.2.1.12. Power inlet port size: 3/4–14 npt(f)

14.1.2.2.1.13. Ambient temperature range: 0–40°C

14.1.2.2.1.14. Sound data: Less than 70 dB(A)

14.1.2.2.1.15. Oil capacity: 1.4 liters

14.1.2.2.1.16. Oil specification: silicone-free synthetic gear oil

14.1.2.2.1.17. Weight: Pump package (motor, 1000cc lower, stand, and tie rods) approximately 100 kg, or equivalent necessary to remove and replace pumps without the use of large equipment

14.1.2.2.1.18. Fluid inlet size: 1–1/2 npt(f)

14.1.2.2.1.19. Fluid outlet size: 1 npt(f)

14.1.2.2.2. Each pump assembly will include a high pressure red alert filter with inlet & outlet manual ball valves and drain ball valve so operator can easily change out the filters.

14.1.3. 4 each day tank assemblies

14.1.3.1. 2 each 150 gal tank assembly for resin/base with an electric agitator, high/low level transmitter and a fill pump assembly on a 55 gallon lid with elevator

14.1.3.2. 2 each 80 gal tank assembly for catalyst with a high/low level transmitter and a fill pump assembly on a 55 gallon lid with elevator.

14.1.4. 1 each High Flow mix manifold will be made with large ports and a static mix tube on the outlet.

14.1.4.1. The inlet of the mix manifold will have two 3-way automatic ball valves, one for the resin/base and one catalyst

14.1.4.2. When not in dispense mode, the resin/base will circulate at lower flow rates back to the corresponding day tank.

14.1.5. Integration panel for system control

14.1.5.1. Panel will be located in a non Class 1, Div 1 safe area.

14.2. Pneumatic operator panel in the Class 1, Div 1 hazardous area for system operation in the hazardous area.

14.2.1. The operator panel may be located outside of the Class 1, Div 1 hazardous area provided there is an observation window to ensure proper operation of the system while filling paint carts.

14.3. 2 ea. Material dispense mechanisms capable of dispensing material into existing paint carts (Must be able to automatically adjust to accommodate different paint cart tank sizes)

14.4. 2 ea. Automated Solvent Flush systems to clear system of materials that may have adhered within the dispense system.

14.5. Panel will include operator information, paint batch number and lot number of paint product

15. Building 54: The interior dimensions of the PCPDS of the fit into area approximately twelve (12) feet wide by ten (10) feet high by eighteen (18) feet long unless a more suitable area is otherwise provided by WR-ALC/402AMXG/MXDEA. (see PD Appendix D). The Government will be responsible for the removal of the current equipment within the room.

15.1. The PCPDS in building 54 shall have the ability to dispense a two-part top coat in one color. System must also have the capability to produce small batches (1qt) if required from the same tanks. Loading of paint product into tanks shall accommodate closed head drums. To maintain compatibility with existing WR-ALC/402AMXG CCF systems, the MIL-PRF-85285 dispense system shall consist of:

15.1.1. Two (2) each Dual Control (DC) Electric Circulating pump assemblies to dispense a 2-component (2K/ Base + Catalyst) paint on ratio at a high flow rate (10gpm). In order to maintain required consistent mixing ratio, the system shall meet the following specifications.

15.1.2. The resin/base pump shall have:

15.1.2.1. 1500cc lower (1 HP motor, 1400lb maximum force)

15.1.2.2. OUTPUT AT 20 CPM: 7.9 gpm (30 lpm)

15.1.2.3. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

15.1.2.4. Sealed 4-Ball Lowers

15.1.2.4.1. No Throat Seal Liquid (TSL) required

15.1.2.4.2. Ultralife Series ceramic coating

15.1.2.4.3. Completely sealed fluid section

15.1.2.4.4. Carbide Outlet Checks

15.1.2.4.5. Compatible with existing Bulldog, NXT, President, Viscount, E-Flo, and E-

Flo DC motors

15.1.2.4.6. Maximum fluid working pressure: 2.07 MPa, 20.7 bar (Metric)

15.1.2.4.7. Maximum potential fluid pressure: 1500/v (volume of lower in cc) = bar

15.1.2.4.8. Maximum continuous cycle rate: 20 cpm

15.1.2.4.9. Maximum Flow: 7.9 gpm

15.1.2.4.10. Input voltage: 100–250 Vac, single phase, 50/60 Hz

15.1.2.4.11. Input current: 20 A maximum

15.1.2.4.12. Power inlet port size: 3/4–14 npt(f)

15.1.2.4.13. Ambient temperature range: 0–40°C

15.1.2.4.14. Maximum sound level: Less than 70 dB(A)

15.1.2.4.15. Oil capacity: 1.4 liters

15.1.2.4.16. Oil specification: silicone-free synthetic gear oil

15.1.2.4.17. Weight: Pump package (motor, 1500cc lower, stand, and tie rods) approximately 100 kg, or equivalent necessary to remove and replace pumps without the use of large equipment

15.1.2.4.18. Fluid inlet size: 1–1/2 npt(f)

15.1.2.4.19. Fluid outlet size: 1 npt(f)

15.1.3. The catalyst pump shall have:

15.1.3.1. 750cc lower (1 HP motor, 1400lb maximum force)

15.1.3.2. OUTPUT AT 20 CPM: 4.0 gpm (15 lpm)

15.1.3.3. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

15.1.3.4. Sealed 4-Ball Lowers

15.1.3.5. No TSL required

15.1.3.6. Ultralife Series ceramic coating

15.1.3.7. Completely sealed fluid section

15.1.3.8. Carbide Outlet Checks

15.1.3.9. Compatible with existing Bulldog, NXT, President, Viscount, E-Flo, and E-Flo DC motors

15.1.3.10. Maximum fluid working pressure: 2.07 MPa, 20.7 bar (Metric)

15.1.3.11. Maximum potential fluid pressure: 1500/v (volume of lower in cc) = bar

15.1.3.12. Maximum continuous cycle rate: 20 cpm

15.1.3.13. Maximum Flow: 4.0 gpm

15.1.3.14. Input voltage: 100–250 Vac, single phase, 50/60 Hz

15.1.3.15. Input current: 20 A maximum

15.1.3.16. Power inlet port size: 3/4–14 npt(f)

15.1.3.17. Ambient temperature range: 0–40°C

15.1.3.18. Maximum sound level: Less than 70 dB(A)

15.1.3.19. Oil capacity: 1.4 liters

15.1.3.20. Oil specification: silicone-free synthetic gear oil

15.1.3.21. Weight: Pump package (motor, 750cc lower, stand, and tie rods) approximately

100 kg, or equivalent necessary to remove and replace pumps without the use of large equipment

15.1.3.22. Fluid inlet size: 1–1/2 npt(f)

15.1.3.23. Fluid outlet size: 1 npt(f)

15.1.4. High pressure red alert filter with inlet & outlet manual ball valves and drain ball valve so operator can easily change out the filters

15.1.5. 4 each day tank assemblies

15.1.6. 2 each 150 gal tank assembly for resin/base with an electric agitator, high/low level transmitter and a fill pump assembly on a 55 gallon lid with elevator

15.1.7. 2 each 80 gal tank assembly for catalyst with a high/low level transmitter and a fill pump assembly on a 55 gallon lid with elevator.

15.2. One (1) each High Flow mix manifold will be made with large ports and a static mix tube on the outlet.

15.2.1. The inlet of the mix manifold will have two 3-way automatic ball valves, one for the resin/base and one catalyst

15.2.2. When not in dispense mode, the resin/base will circulate at lower flow rates back to the corresponding day tank.

15.3. Integration panel for system control

15.3.1. Panel will be located in a non Class 1, Div 1 safe area.

15.4. Pneumatic operator panel in the Class 1, Div 1 hazardous area for system operation in the hazardous area.

15.4.1. The operator panel may be located outside of the hazardous area provided there is an observation window to ensure proper operation of the system while filling paint carts.

15.4.2. Panel will include operator information, paint batch number and lot number of paint

16. The PCPDS in building 54 shall have the ability to dispense primer. System must also have the capability to produce small batches (1qt) if required from the same tanks. Loading of paint product into tanks shall accommodate closed head drums. To maintain compatibility with existing WR-ALC/402AMXG CCF systems, the MIL-PRF-23377 or 32239 dispense system shall consist of:

16.1. Two (2) ea Dual Control (DC) Electric Circulating pump Assemblies to dispense a 2K (Base +

Catalyst) paint on ratio at a high flow rate (10gpm).

16.1.1. Resin/base pump shall have a 1500cc lower

16.1.1.1. OUTPUT AT 20 CPM: 7.9 gpm (30 lpm)

16.1.1.2. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

16.1.1.3. Sealed 4-Ball Lowers

16.1.1.4. No TSL required

16.1.1.5. Ultralife Series ceramic coating

16.1.1.6. Completely sealed fluid section

16.1.1.7. Carbide Outlet Checks

16.1.1.8. Compatible with existing Bulldog, NXT, President, Viscount, E-Flo, and E-Flo DC motors

16.1.1.9. Maximum fluid working pressure: 2.07 MPa, 20.7 bar (Metric)

16.1.1.10. Maximum potential fluid pressure: 1500/v (volume of lower in cc) = bar

16.1.1.11. Maximum continuous cycle rate: 20 cpm

16.1.1.12. Maximum Flow: 7.9 gpm

16.1.1.13. Input voltage: 100–250 Vac, single phase, 50/60 Hz

16.1.1.14. Input current: 20 A maximum

16.1.1.15. Power inlet port size: 3/4–14 npt(f)

16.1.1.16. Ambient temperature range: 0–40°C

16.1.1.17. Sound data: Less than 70 dB(A)

16.1.1.18. Oil capacity: 1.4 liters

16.1.1.19. Oil specification: silicone-free synthetic gear oil

16.1.1.20. Weight: Pump package (motor, 1000cc lower, stand, and tie rods) approximately

100 kg, or equivalent necessary to remove and replace pumps without the use of large equipment

16.1.1.21. Fluid inlet size: 1–1/2 npt(f)

16.1.1.22. Fluid outlet size: 1 npt(f)

16.1.2. Catalyst pump shall have a 750cc lower (1 HP motor, motor, 1400lb maximum force)

16.1.2.1. OUTPUT AT 20 CPM: 4.0 gpm (15 lpm)

16.1.2.2. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

16.1.2.2.1. Sealed 4-Ball Lowers

16.1.2.2.1.1. No TSL required

16.1.2.2.1.2. Ultralife Series ceramic coating

16.1.2.2.1.3. Completely sealed fluid section

16.1.2.2.1.4. Carbide Outlet Checks

16.1.2.2.1.5. Compatible with existing Bulldog, NXT, President, Viscount, E-

Flo, and E-Flo DC motors

16.1.2.2.1.6. Maximum fluid working pressure: 2.07 MPa, 20.7 bar (Metric)

16.1.2.2.1.7. Maximum potential fluid pressure: 1500/v (volume of lower in cc)

= bar

16.1.2.2.1.8. Maximum continuous cycle rate: 20 cpm

16.1.2.2.1.9. Maximum Flow: 4.0 gpm

16.1.2.2.1.10. Input voltage: 100–250 Vac, single phase, 50/60 Hz

16.1.2.2.1.11. Input current: 20 A maximum

16.1.2.2.1.12. Power inlet port size: 3/4–14 npt(f)

16.1.2.2.1.13. Ambient temperature range: 0–40°C

16.1.2.2.1.14. Sound data: Less than 70 dB(A)

16.1.2.2.1.15. Oil capacity: 1.4 liters

16.1.2.2.1.16. Oil specification: silicone-free synthetic gear oil

16.1.2.2.1.17. Weight: Pump package (motor, 1000cc lower, stand, and tie rods) approximately 100 kg, or equivalent necessary to remove and replace pumps without the use of large equipment

16.1.2.2.1.18. Fluid inlet size: 1–1/2 npt(f)

16.1.2.2.1.19. Fluid outlet size: 1 npt(f)

16.1.2.2.2. Each pump assembly will include a high pressure red alert filter with inlet & outlet manual ball valves and drain ball valve so operator can easily change out the filters.

16.1.3. 4 each day tank assemblies

16.1.3.1. 2 each 150 gal tank assembly for resin/base with an electric agitator, high/low level transmitter and a fill pump assembly on a 55 gallon lid with elevator

16.1.3.2. 2 each 80 gal tank assembly for catalyst with a high/low level transmitter and a fill pump assembly on a 55 gallon lid with elevator.

16.1.4. 1 each High Flow mix manifold will be made with large ports and a static mix tube on the outlet.

16.1.4.1. The inlet of the mix manifold will have two 3-way automatic ball valves, one for the resin/base and one catalyst

16.1.4.2. When not in dispense mode, the resin/base will circulate at lower flow rates back to the corresponding day tank.

16.1.5. Integration panel for system control

16.1.5.1. Panel will be located in a non Class 1, Div 1 safe area.

16.2. Pneumatic operator panel in the Class 1, Div 1 hazardous area for system operation in the hazardous area.

16.2.1. The operator panel may be located outside of the Class 1, Div 1 hazardous area provided there is an observation window to ensure proper operation of the system while filling paint carts.

16.3. 2 ea. Material dispense mechanisms capable of dispensing material into existing paint carts (Must be able to automatically adjust to accommodate different paint cart tank sizes)

16.4. 2 ea. Automated Solvent Flush systems to clear system of materials that may have adhered within the dispense system.

16.5. Panel will include operator information, paint batch number and lot number of paint product

17. OPTION 2

17.1. Building 59D: The interior dimensions of the PCPDS of the fit into area approximately twelve

(12) feet wide by ten (10) feet high by eighteen (18) feet long unless a more suitable area is otherwise provided by WR-ALC/402AMXG/MXDEA. (see PD Appendix E). The Government will be responsible for the removal of the current equipment within the room.

17.2. The PCPDS in building 59D shall have the ability to dispense a two-part top coat in four

(4) colors. System must also have the capability to produce small batches (1qt) if required from the same tanks. Loading of paint product into tanks shall accommodate closed head drums. To maintain compatibility with existing WR-ALC/402AMXG CCF systems, the MIL-PRF-85285 dispense system shall consist of:

17.2.1. Eight (8) each Dual Control (DC) Electric Circulating pump assemblies to dispense a 2-component (2K/ Base + Catalyst) paint on ratio at a high flow rate (10gpm). In order to maintain required consistent mixing ratio, the system shall meet the following specifications.

17.2.2. The resin/base pump shall have:

17.2.2.1. 1500cc lower (1 HP motor, 1400lb maximum force)

17.2.2.2. OUTPUT AT 20 CPM: 7.9 gpm (30 lpm)

17.2.2.3. MAXIMUM WORKING PRESSURE: 460 psi (31.7 bar, 3.1 MPa)

17.2.2.4. Sealed 4-Ball Lowers

17.2.2.4.1. No Throat Seal Liquid (TSL) required

17.2.2.4.2. Ultralife Series ceramic coating

17.2.2.4.3. Completely sealed fluid section

17.2.2.4.4. Carbide Outlet Checks

17.2.2.4.5. Compatible with existing Bulldog, NXT, President, Viscount, E-Flo, and E-

Flo DC motors

17.2.2.4.6. Maximum fluid working pressure: 2.07 MPa, 20.7…