Monorail SOW.docx

1. General Project Scope:

1.1. Scope:

This purchase description establishes design criteria, performance, and acceptance criteria for the overhead monorail system for inert preparation of bomb bodies.

1.2. Classification:

The equipment and services supplied under this purchase description shall be performed by a contractor regularly engaged in the design and integration of material handling equipment and conveyance systems. The contractor shall have a minimum of five (5) years of experience providing such equipment and services to industry other than for its own use. Unless otherwise specified in the contract, or purchase order, the contractor will be required to provide a product that meets all drawing details and requirements.

2. Applicable Documents:

2.1. Standards and Regulations:

The following documents form a part of this purchase description to the extent specified herein. Unless otherwise specified, the issues currently in effect on the date of the solicitation shall be applied.

i. OSHA 29 1910 CFR – Occupational Health and Safety Administration standards and regulations.

ii. Department of the Army Pamphlet (DA Pam) 385-64 Ammunition and Explosives Safety Standards.

iii. National Fire Protection Association (NFPA) 70 National Electrical Code (NEC).

iv. NEMA – National Electrical Manufacturers Association Standards.

v. ISO 9001:2000 – Quality Management System.

vi. TB 43-0142 – Safety Inspection and Testing of Lifting Devices

2.2. Additional Documents:

The following documents shall be in effect on the date of invitation for bids or requests for proposals and form a part of this purchase description.

i. 5166 - Monorail Concept Flow for B190 East Inert Preparation Operations

ii. D3035 - Hanger Assembly for 2,000lb Bombs

iii. D4486 - Bomb Rail Cart Assembly

iv. B2695 - Bomb Cart General Assembly

v. B2696 - Bomb Cart General Assembly & MK82 Attachments

vi. B2697 - Bomb Cart General Assembly & MK83 Attachments

vii. B2698 - Bomb Cart General Assembly & MK84 Attachments

viii. B2699 - Bomb Cart General Assembly & Penetrator 2000lb Attachments

3. Requirements:

3.1. Design:

3.1.1. Prior to final design the contractor shall verify and confirm building column locations, all integral facility features, critical dimensions, and equipment locations with government personnel.

3.1.2. System shall meet all applicable OSHA standards and regulations.

3.1.3. Elimination of pinch points is to be considered during design of the monorail system. Guards and plaques will be added where needed.

3.1.4. Only open frame members (S-beam, C-channel, L-angle, etc.) shall be used in the construction of the framework. Tubular members shall not be used. All exposed materials shall be coated/painted or made of non-ferrous materials to prevent corrosion.

3.1.5. Ease of maintenance shall be a design consideration for all portions of the monorail system.

3.1.6. The design should utilize commercial-off-the-shelf items whenever possible to facilitate repair and replacement of worn and/or damaged parts.

3.1.7. Monorail shall be primarily of the manual (free) type with some short sections which are powered.

3.1.8. Monorail shall follow the path as shown in drawing 5166 – Monorail Concept Flow for B190 East Inert Preparation Operations. Any changes or variations must be approved by McAAP engineering and management.

3.1.9. Monorail shall have a clearance from the facility floor to the bottom of the monorail trolley of eleven feet and six inches (11’ 6”).

3.1.10. Overall height of the monorail system shall not exceed fifteen feet (15’) except over the cart loading area.

3.1.11. Monorail must be made to fully integrate with existing monorail system on the west side of the specified facility as shown on 5166. The conveyors and trolleys must function seamlessly, run in either direction throughout the system, and be fully versatile to run on either track without component changeout. Existing monorail track is a 6” rolled formed design. (Further referenced in 3.1.22.2)

3.1.12. Modifications to the existing monorail must also be made to add a rail connection between the east rail heading north to the hanger holding loop as indicated on the process flow drawing, 5166. Existing monorail track is a 6” rolled formed design.

3.1.13. The addition of four trolley/hanger holding rails must be included as stated and shown on the included process flow drawing, 5166.

3.1.14. Items moved along monorail shall range from a length of ninety-nine inches (99”) with a diameter of eighteen inches (18”) to a length of forty-five inches (45”) with a diameter of nine inches (9”).

3.1.15. Monorail trollies shall have a minimum capacity of two thousand (2,000) pounds. The distance from center line to center line between trollies when placed directly next to each other on the rail shall not exceed twenty four (24) inches.

3.1.16. A minimum of sixty (60) trollies will be provided.

3.1.17. Overall minimum load capacity for the monorail shall be such that any section will be able fully capable of supporting fully loaded trollies placed directly next to one another across the section. This shall hold true for the entire monorail except for those sections designated for empty trolley return and storage and those sections which are powered.

3.1.18. Every effort shall be employed to minimize the number of columns required to support the monorail as floor space will need to be clear for production operations and forklift traffic.

3.1.19. All overhead support structures (gussets, etc.) for the monorail shall be at a minimum height of nine feet (9’) to provide clearance for personnel and forklift traffic.

3.1.20. Monorail track path switches shall be pneumatically or electrically actuated and shall have individual control boxes for activating the switch located near the switches for operational use. The monorail shall have safety stops to prevent trollies from falling from monorail while switch is in motion.

3.1.21. Column design must not require new concrete piers or concrete rework to support the new monorail system.

3.1.22. Powered Sections

3.1.22.1. Monorail shall have eight (8) independent powered sections. The powered sections convey a loaded trolley through two height-shifting interconnecting sections with the existing monorail system, one empty hanger transfer section, a grit blaster in one section, two for the entry and exit out of the drop station, a heating/curing tunnel, and a heating tunnel used for melt-out operations. Conveyance speed shall be variable and controlled electronically by a variable frequency drive or similar electronic method.

3.1.22.2. The powered sections for the two height-shifting interconnecting sections are approximately 11.5’ liner feet for the North section and 35.5’ for the South section. The elevation change from one floor to the other is approximately 19”. Final design and integration to be determined during the design phase after the award and must be approved by McAAP OM, AO, and Safety departments. Full transference from the old to new monorail and back is essential to gain the redundant capabilities specified in this project.

3.1.22.3. The powered empty hanger transport section will be approximately 65.5’ long. These sections will not need to meet the high load capacities as previously stated, since only empty hangers will travel on this section.

3.1.22.4. Powered monorail section for the grit blaster shall be a minimum of eighteen feet (18’) long. It shall have spinner mechanism located at the center of the monorail section and another spinner located approximately fifty-six inches (56”) past center (verify during site visit). This section should have a means of stopping and/or dropping from the drive when a loaded trolley is in the above mentioned positions and picking back-up when the grit blaster has finished its cycle.

3.1.22.5. The powered sections for the entry and exit sections of the monorail leading into the drop station are approximately 25.0’ liner feet for the Entry section and 28.5’ for the Exit section. These areas are not easily accessible to personnel, so limited user interface must be utilized to ensure easy flow of loaded bomb hangers in and empty bomb hangers out.

3.1.22.6. The powered sections for the heat tunnel and tar melt-out heat tunnel shall be a minimum of twenty-one (21’) long each.

3.1.23. Spinner Mechanism

3.1.23.1. A total of five (5) mechanisms shall be provided that will spin the hanger suspended from the monorail trolley. Two of these shall be located in the grit blaster powered section of the monorail mentioned in section 3.1.22.4. One each of the others shall be located in the paint booth, thermal coat booth, and thermal arc booth.

3.1.23.2. The mechanism shall be designed such that it functions to spin the hanger depicted in drawing D3035 – Hanger Assembly for 2000Lbs. Bombs.

3.1.23.3. At the paint booths and the thermal arc booth the spinner shall be accompanied by actuator “kick-out” device to kick or move the carrier away from the spinner and out of the booth. This actuator should be able to move the carrier four feet (4’) for the paint booths and six feet (6’) for the thermal coat and thermal arc booths.

3.1.23.4. Mechanism shall be either electrically or pneumatically powered. The operational speed of mechanism shall be adjustable.

3.1.23.5. If required, the government can provide an example drawing of a spinner used in similar operations.

3.1.24. Cart Loading Station

3.1.24.1. The monorail system shall have a station for unloading the monorail carriers into carts. The station shall be capable of raising and lowering the fully loaded carriers as required to load the carts. The carts will be in of various configurations as shown in the cart drawings referenced in the additional documents section of this document.

3.1.24.2. Station should be capable of raising and lowering two (2) carriers simultaneously. See profile notes 1 and 2 on supplied drawing 5166 for the estimated required drop height.

3.1.24.3. Reference table below for bomb assets being loaded:

3.1.24.4. Station should be equipped with safety stops to prevent a trolley from inadvertently coming off the track.

3.1.24.5. Station should be equipped with some form of secondary stopping mechanism in the event of a failure of the primary lifting/lowering mechanism.

3.2. Electrical

3.2.1. The system will be designed to use 480 volt, 3 phase, 60 hertz alternating current power.

3.2.2. Controls

3.2.2.1. A control station for each powered monorail section, spinner mechanism, and kick-out device shall be located nearby for convenient operation.

3.2.2.2. The track switch controls shall be located so that they can be easily accessed by an operator pushing the trollies.

3.2.2.3. The control station for the loading station shall be mounted to and accessed from a work platform provided by the government.

3.2.2.4. All control components near or above the paint, stripping, and thermal coating booths are to be rated for hazardous environments.

3.3. INSTALLATION, CERTIFICATION, AND TRAINING

3.3.1. Installation

The monorail shall be installed by the contractor in the designated building and extension between the dates of April 2028 and March 2029. The government will provide supply power to the main panel location, but the contractor shall be responsible for all electrical installation of the monorail. This will include tie-in’s with the existing monorail as required by the design to make a fully integrated system.

Contractor shall verify building column locations, elevation changes, dimensions, and any other design altering facility characteristics before installation. All estimated dimensions given by this document and on the supplemental drawing are for reference only.

3.3.2. Certification

In the event any component requires certification upon final installation, then this will be considered part of the installation of the system. Any certification shall be the responsibility of the contractor. As such, final acceptance will not be made until certification is complete. It is the sole purview of the MCAAP Engineering Office personnel to waive the necessity of these certifications.

3.3.3. Training

The contractor shall provide a factory representative to train all necessary personnel in operation and maintenance.

4. After Award Reviews:

After an award, the contractor shall provide the government with, at minimum, a 30% progress/status update, a 60% progress/status update, a 90% progress/status update, and a notification when the item is shipped. If there are any unforeseen delays the government contract officer should be notified immediately. It is the sole purview of the MCAAP Engineering personnel to waive the necessity of these progress/status updates. The progress/status updates shall take the form of design reviews as necessitated by the procurement type and determined by government personnel. The design reviews shall have the minimum listed requirements below:

4.1 30% Concept Design and Data Review:

A 30% conceptual design review will be held between the contractor and MCAAP personnel within four (4) months of the award. Contractor shall supply preliminary drawings related to the construction and final assembly as specified by this purchase description to the MCAAP Operations Management, Planning Division, Engineering Branch for approval. Any specific facility, mechanical, or controls requirements that McAAP will need to fulfill must be openly conveyed and accepted at this point. These drawings should include installation and/or operational envelope dimensions, utility requirements, and connection locations along with any other pertinent data. If there is a picture of the equipment or portions of the equipment, such as from a brochure, then that picture(s) should be included with the data. It is advantageous for the contractor to supply as much data as possible as the government will use this to approve the proposed equipment, as related to this purchase description, for production and/or purchase. This set of drawings/data shall be in electronic format. The preferred format is “.dwg” or “.dxf” for 2-D data and Solid Works (.sldprt, .sldasm) format or STEP (.stp) format for 3-D data. All drawings/data shall be authorized for reproduction and distribution to end users of the equipment.

4.2 60% Preliminary Design and Review:

A 60% design review will be held between the contractor and MCAAP personnel upon the date agreed upon during the 30% design review. Contractor shall supply in-process drawings related to the construction and final assembly as specified by this qualifying statement to the MCAAP Operations Management Planning Division for approval. These drawings should include finalized installation and/or operational envelope dimensions, utility requirements, and connection locations along with any other pertinent data. All equipment the government must procure to support the item in this procurement that would constitute a “long lead time” should be identified at this time. Any changes to the design from the previous review should be incorporated. If there is a picture of the equipment or portions of the equipment, such as from a brochure, then that picture(s) should be included with the data. It is advantageous for the contractor to supply as much data as possible as the government will use this to approve the proposed equipment, as related to this purchase description, for production and/or purchase. This set of drawings/data shall be in electronic format. The preferred format is Solid Works (.sldprt, .sldasm) format or STEP (.stp) format 3-D data and “.dwg” or “.dxf” for 2-D data if 3-D data is not available. All drawings/data shall be authorized for reproduction and distribution to end users of the equipment.

4.3 90% Detailed Design and Review:

A 90% design review will be held between the contractor and MCAAP personnel upon the date agreed upon during the 60% design review. Contractor shall supply in-process drawings related to the construction and final assembly as specified by this qualifying statement to the MCAAP Operations Management Planning Division for approval. A 90% design package should only require minimal changes at this point. Examples of this would be cleaning up of drawings, incorporating redlines, and finalizing bill of materials. No changes to the scope should be made at this time. This set of drawings/data shall be in electronic format. The preferred format is Solid Works (.sldprt, .sldasm) format or STEP (.stp) format 3-D data and “.dwg” or “.dxf” for 2-D data if 3-D data is not available. All drawings/data shall be authorized for reproduction and distribution to end users of the equipment.

5. Finalized Drawings and Data:

The contractor shall provide two (2) complete sets of as-built reproducible drawings/data. The drawings/data shall include, at minimum, the requirements of the paragraph above. One (1) complete hard copy set of finalized drawings/data shall be provided with the equipment. The other will be in electronic format. The format must be capable of being read as “.dwg” or “.dxf” for 2-D data and Solid Works (.sldprt, .sldasm) format or STEP (.stp) format for 3-D data. All drawings/data shall be authorized for reproduction and distribution to end users of the equipment. The drawings and data should hold to all pertinent industrial and government standards including, but not limited to, the following: ASME Y14.5-2018, ASME Y14.38-2019, and ASME Y14.1-2020 (or the newest revision to these standards). A copy of all software programs is included in this requirement, and the format and transmission will need to be coordinated with McAAP OMP-AIT personnel.

6. Operational, Maintenance, and Parts Manuals:

The contractor shall furnish under this purchase description two (2) sets of operational, maintenance, and parts manuals as necessitated by the equipment. The manuals shall be specific (not canned statements about the system in general) to the system supplied. There shall be a brief description concerning the purpose of the specific equipment supplied and the rated operating capacities. The manuals shall contain a complete parts list to include (at minimum) all information necessary (manufacturer’s name, address, phone number, P/N, S/N, size, model number, type, etc.) to re-order the part if necessary. The manuals shall include all preventive maintenance procedures/schedules specific to the equipment supplied. These manuals shall be applicable to the equipment provided only and shall include all safety precautions/warnings associated with the operation. All manuals shall be authorized for reproduction and distribution to end users of the equipment. One (1) set of hard copy versions of the manuals shall be provided with the equipment. One (1) set of the manuals shall be electronic in form (on CD) and must be capable of being read in either a “.pdf” or a “.doc” format.

7. Delivery:

Delivery is to be coordinated at the earliest possible convenience with the MCAAP Operations Management, Planning Division to facilitate an orderly receipt of the system. MCAAP can store the system if the contractor chooses to deliver before the April 2028 – March 2029 installation window. The final system will be offloaded at the final MCAAP destination by the contractor. If base employee equipment or personnel are required, this must be fully stated and approved prior to award acceptance.

8. Acceptance Review:

Upon shipment of components to MCAAP, an acceptance review by government personnel will be conducted. If the system or its components are found to be unacceptable, those components shall be shipped back to the contractor/manufacturer for repair and/or replacement. It is the sole purview of the MCAAP Engineering personnel to waive the necessity of these reviews.

9. Spare Parts Inventory:

A full and comprehensive spart parts list and inventory shall be provided to McAAP upon delivery. Along with this, a full maintenance and upkeep plan is to be included to assist in documenting and performing preventive maintenance actions. If changes are noted during testing and prove-out, the contractor will be required to provide updated maintenance plans, spare parts lists, and the spare parts themselves to compensate for the change. The spare parts inventory should cover items with quantities sufficient to support demil operations for one year after system prove out.

10. Quality Assurance Provisions:

110.1 Responsibility for Inspection:

Unless otherwise specified in the contract or purchase description the contractor is responsible for the performance of all inspection requirements specified herein. Except as otherwise specified the contractor may use their own facilities or any commercial laboratory acceptable to the government. The government reserves the right to witness or separately perform any of the inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements. The contractor shall notify the contracting officer at least 15 working days prior to shipment so a government representative(s) can make arrangements to be present to perform an acceptance inspection if necessary. Final acceptance of the contract shall be the responsibility of the government contracting officer.

11.2 Quality Management:

Contractor must show proof of internal quality management system in accordance with MIL-I-45208A, ISO 9001: 2000 or equivalent quality assurance programs. The contractor shall certify and maintain substantiating evidence that the product meets the provided drawing specification, and quality assurance requirements. This includes manufacturing and welding requirements. The manufacturer may use their own inspection facility or any commercial facility agreeable to the government. The government reserves the right to witness the inspections of all components of this system for conformity of specifications.

11. Warranty:

Contractor shall provide a warranty against defective material, parts, and workmanship for a period no less than 1 year from the final commissioning date.

12. Intended Use Statement:

When government drawings, specifications, or other data are used for any purpose other than in connection with related Government Procurement Operations, the Unites States Government thereby incurs no responsibility or any obligation whatsoever. The fact that the government may have furnished, formulated, or in any way, supplied the said drawings, specifications, or other data, is not to be regarded by implication, or otherwise in any manner licensing the holder or any other person, or corporation, or conveying any rights or permission to manufacture, use, or sell any patented invention that may be in any way related thereto.