PD 22-40-1004.pdf

22-40-1004 14 November 2024

PURCHASE DESCRIPTION FOR THE SOLE SOURCE

ACQUISITION OF THE C2 CLEANING LINE

SCOPE.

1.1 Scope. The content of this specification describes the minimum requirements for the sole source acquisition of a C2 cleaning system that includes the removal, design, fabrication and installation of tanks, and equipment to support the cleaning processes of the C2 cleaning system. This system includes the titanium cleaner, metal spray stripping, stainless steel passivation, & alkaline metal stripping wet process. The contractor, Engineering and Software System Solutions, Inc. (ES3) shall be responsible for the complete removal of existing equipment, installation of all new equipment, all the qualified personnel and auxiliary and ancillary equipment detailed herein to provide a fully functional system. This equipment is to be installed in Building 472, located at Naval Air Station North Island.

APPLICABLE DOCUMENTS. The documents listed in this section are cited in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed in section 2.

Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

Government Documents.

Specifications, Standards, and Handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein.

STANDARDS – FEDERAL

FED-STD-H28B: Screw Thread Standards for Federal Service

U.S Department of Labor, Occupational Safety and Health Administration

(OSHA)

29 CFR 1910: General Industry, OSHA Safety and Health Standards

29 CFR 1926: Safety and Health Regulations for Construction

(Application for copies should be addressed to the OSHA Publications Superintendent of Documents P.O. Box 37535 Washington, D.C. 20013-7535)

MILITARY STANDARDS

OPNAVINST 5100.23: Navy Safety and Occupational Health Program Manual

(Application for copies of the OPNAVINST should be addressed to Office of the Chief of Naval Operations, The Pentagon, Washington, DC 20350-2000 or to Commander, Naval Safety Center 375 A Street Norfolk, VA 23511 or on the internet at http://www.public.navy.mil/navsafecen)

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property Item Unique Identification Marking (IUID)

(Application for copies should be addressed to Air Force Product Data Systems Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg. 262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257- 0870 or 0853 or https://quicksearch.dla.mil/qsSearch.aspx)

Other Government Documents, Drawings, and Publications. The following other

Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

LOCAL FACILITY DOCUMENTS

Attachment A -- EQUIPMENT MATRIX

Attachment B -- COURTESY LAYOUT

Attachment C -- FRCSW Plant Maintenance Energy Control Procedures

Non-Government Publications, Specifications, Standards, and Handbooks. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

American Conference of Governmental Industrial Hygienists (ACGIH)

Industrial Ventilation: A Manual of Recommended Practice for Design, specifically §13.70 Open Surface Tanks and §13.72 Push-pull Ventilation

(Address application for copies to: American Conference of Governmental Industrial Hygienists, 1330 Kemper Meadow Drive, Cincinnati Ohio 45240.)

American Society of Mechanical Engineers (ASME)

ASME Y14.100: Engineering Drawing Practices

ASME Y14.5: Dimensioning and Tolerancing http://www.public.navy.mil/navsafecen https://quicksearch.dla.mil/qsSearch.aspx

(Applications for copies should be addressed to ASME International Three Park Avenue New York, NY 10016-5990 or www.asme.org)

American Society of Safety Professionals (ASSP)

ANSI/ASSP Z9.1 Ventilation and Control of Airborne Contaminants During Open- Surface Tank Operations

(Applications for copies should be addressed to American Society of Safety Engineers, 520 N. Northwest Highway, Park Ridge, Il 60068)

International Organization for Standardization (ISO)

ISO 4414: Pneumatic Power-General rules and safety requirements for systems and their components

(Application for copies should be addressed to the International Organization for Standardization (ISO) 1 rue de Varembé, Casepostale56, CH211Geneva 20, Switzerland)

National Electrical Manufacturers Association (NEMA)

NEMA 250: Enclosures for Electrical Equipment (1000 V Maximum)

NEMA ICS 1: Industrial Control and Systems General Requirements

NEMA ICS 6: Industrial Control and Systems: Enclosures

NEMA MG 1: Motors and Generators

NEMA Z535.4: Product Safety Signs and Labels

(Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Rosslyn, VA 22209)

National Fire Protection Association (NFPA)

NFPA 70: National Electrical Code

NFPA 79: Electrical Standard for Industrial Machinery

(Applications for copies should be addressed to the National Fire Protection Association, ATTN: Support Services, 11 Tracy Drive, Avon, MA 02322)

National Institute for Occupational Safety and Health (NIOSH) http://www.asme.org/

NIOSH 75-145 Health and Safety Guide for Electroplating Shops

Centers for Disease Control and Prevention (CDC) and NIOSH Guide

Pocket Guide and Occupational Safety and Health Administration standards

(OSHA)

San Diego Air Pollution Control District (SDAPCD)

SDAPCD Rule 67.61 Cold Solvent Cleaning and Stripping Operations

Sheet Metal and Air Conditioning Contractors’ National Association (CAL

SMACNA)

SMACNA 1108-2008 Accepted Industry Practice for Industrial Duct Construction

Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulation unless a specific exemption has been obtained.

2.4 Acronym Definitions Not Explicitly Listed in Text. The following acronyms not explicitly listed in each section text are defined as follows:

a. JIS- Japanese Industrial Standards

b. DIN- German Institute for Standardization

c. EN- European Standard

Proposal Format. Proposal shall be submitted using the following mathematical conventions:

a. Whole numbers will be expressed where one thousand is written as 1,000.

b. Decimals will be expressed where one-tenth is written as 0.1.

c. Submission of compliance statement and descriptive literature shall be in the same units as the units listed in this document.

d. In accordance with ASME Y14.5, all values listed in parenthesis will be treated as reference units and not the official proposed value in determining acceptability. For example, 300mm (11.8 inches), the 300mm will be used in determination of acceptability, and the measurement in parenthesis will not be considered in determining acceptability.

REQUIREMENTS.

Design. The item offered shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The C2 cleaning system shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

Measuring and Indicating Device Graduations. All measuring and indicating devices on the C2 cleaning system shall be graduated in the United States customary units.

An electronic control system that demonstrates switching between manufacturer standard units to United States customary units will be found acceptable.

Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located on or near the tank that they control. All controllers shall be BACnet compatible and shall connect to a Siemens data capture unit for monitoring purposes. This connection shall be provided through either Ethernet or 4-20 milliamp (mA) signal from the equipment.

Safety and Health Requirements. All parts, components, mechanisms, and assemblies furnished on the C2 cleaning system, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910, OSHA 29 CFR 1926, OPNAVINST 5100.23, ANSI/ASSP Z9.1 and NEMA Z535.4, and Centers for Disease Control and Prevention (CDC) and NIOSH Guide, “Pocket Guide and Occupational Safety and Health Administration standards” (OSHA) or equivalent ISO/EN/DIN/JIS standards. During the installation of the C2 cleaning system, the contractor shall conform to all safety regulations of NIOSH 75-145. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements. The contractor shall provide a Safety and Health plan.

Safety Guarding. Covers, guards, thermal or electric insulators, or other safety devices shall be provided on the cleaning line. The safety devices shall not interfere with the operation of the line. The safety devices shall prevent unintentional contact with the guarded part, and shall be easily removed to facilitate inspection, maintenance, and repair of the parts.

3.1.3.2 Lockout/Tagout Energy Control Procedures. The contractor shall create an Energy Control Procedure (ECP) for all assets installed per standards 29 CFR 1910:

OSHA Safety and Health Standards and OPNAVINST 5100.23 Navy Safety and Occupational Health Manual (The Control of Hazardous Energy Lockout/Tagout).

The ECP shall follow the format per Attachment C. The contractor shall submit the ECP(s) to the Technical Point of Contact (TPOC) for review.

Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

Hazardous Material Exclusions. Supplies or materials being provided as part of the equipment shall be free of known hazardous materials. These materials shall not be brought on site without prior approval of the Government. Radioactive materials or instruments capable of producing ionizing radiation as well as materials which contain asbestos, mercury, lithium, methylene chloride, lead (= or >0.06%), or polychlorinated biphenyls (PCB’s) are prohibited. Definitions of hazardous materials are specified in the latest version, including revisions adopted during the term of the contract, of FED-STD-313F.

Nickel Metal Hydride and lithium batteries are permissible for memory backup. Class I Ozone Depleting Substances as defined in 40 CFR 82 shall not be used in the performance of this contract or be provided as part of the equipment. Exceptions to the prohibition of these materials must be referred to the Contracting Officer in writing, for consideration, not later than 60 calendar days after effective date of contract and prior to any work being performed.

Environmental Protection. The completed installation shall meet all applicable Environmental Protection Agency (EPA) and Occupational Safety Health Association (OSHA) restriction for materials classified as hazardous to the environment in effect on the date of contract. During the operation of the equipment at their final location, all equipment shall comply with all applicable EPA and OSHA regulations in effect on the date of contract regulating the emission of material hazardous to the environment. The contractor shall coordinate with FRCSW and Naval Air Station, North Island (NAS) regarding installation site approvals and environmental permits required by Federal, State, County, and Local Laws. For additional information, the contractor is instructed to contact the TPOC within thirty (30) days from contract award. The contractor shall provide in writing the make, model, capacity, footprint, mechanical, and electrical requirements of the equipment to the TPOC and Designated Government Representative (DGR).

Lubrication. Means shall be provided to ensure proper lubrication for all moving parts in accordance with manufacturer requirements. All oil holes, grease fittings, and filler caps shall be easily accessible.

Replacement Parts. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, filters, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, solenoids, solid-state devices, and level, resistivity and electrode probes. Tooling and accessories normally supplied as standard items shall also be considered replacement parts. Foreign-sourced replacement parts shall either be interchangeable with domestically supplied components or be readily available from a domestic source.

Permitting. FRCSW will be responsible for obtaining the required Authority to Construct and Permit to Operate from the San Diego County Air Pollution Control District (SDCAPCD). The contractor shall be responsible for supplying the data and calculations required to fill out the form thirty (30) days after contract award (ACA) for FRCSW to complete the application for SDAPCD evaluation of the equipment/processes and ensure the design meets all applicable rules and regulations with respect to emissions. Installation of the equipment shall not start until the Authority to Construct is received by FRCSW. Upon completion of installation the SDCAPCD shall be contacted to inspect, approve, and close out the Authority to Construct. Installed equipment shall meet all conditions listed on the Authority to Construct and Permit to Operate. Typically, an inspection is also required for final approval. Final acceptance will be contingent upon the installed equipment meeting all conditions listed on the SDCAPCD Authority to Construct and Permit to Operate issued to

FRCSW.

Construction. The C2 cleaning system shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the system to its maximum rating and capacity without distortion.

Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, filling with solder or paste shall be used for reclaiming any defective part.

Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed. All fasteners/hardware shall be made of 316 stainless steel.

Threads. All threaded parts used on the C2 cleaning system, and its related attachments and accessories shall conform to FED-STD-H28B and the applicable “Detailed Standard” section referenced therein or equivalent ISO/EN/DIN/JIS standards.

At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

Pneumatic System. Under the condition that the C2 cleaning system has a pneumatic system, the system shall conform to ISO 4414. The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls. A C2 cleaning system that does not require a pneumatic system to operate properly shall be considered acceptable.

Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

Epoxy Painting. The C2 cleaning system tanks shall be epoxy painted in accordance with the manufacturer’s commercial practice. All paint shall be of the lead-free type. Color shall be safety blue. No paint shall be applied to the inner surfaces of the tanks.

Workmanship. Workmanship of the C2 cleaning system shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

Components. The C2 cleaning system shall be used to process parts up to 83 inches long × 13 inches in diameter, and shall consist of not less than the following components:

Tanks. The C2 cleaning system consists of nine (9) outer tanks and four (4) inner tanks, which shall be fabricated from 316L stainless steel. The tanks shall have a 4 inch × 4 inch × ¼ inch angle rim and two (2) 4 inch × 4 inch × ¼ inch angle girths. All heated tanks shall be thermally insulated and electrically isolated. All unpainted tank welds shall be passivated for corrosion prevention. Tanks shall be inspected and hydrostatic tested to ensure tanks are leak free prior to delivery. See Attachment A for model numbers, tank sizes, materials, chemistry, temperatures, and required liners.

Tank Height Above Work Floor. Tanks shall be installed to maintain OSHA standards referenced in Section 2.1.1 for worker safety shall be achieved by modification to the tank support structure to raise/lower the tank lip to a safe working height from the grating per OSHA standard.

Grating, Support Structure and Toeboards. As defined in CFR 1910

Subpart D, 1910.21 walking-working surfaces (i.e. the grating walkway). The grating walkway shall not have a hole, gap or void >2 inches in its least dimension or an unprotected edge >4 feet above the lower basement level. The grating, supporting I-beams, and toeboards need to be added or modified to meet this requirement.

Modifications to the supporting I-beams require stamped drawings from a California licensed Professional Engineer showing the design can support the new line. Any new I-beam grating supports shall be coated with an epoxy primer and topcoat to match the color of the existing grating support beams. Installation of walkway shall comply with OSHA minimum walking/working surface width requirements (see OSHA standard referenced in Section 2.1.1). Grating type shall be 1-1/2-inch-thick mil finish 19-W-4 Carbon Steel Light-Duty 3/16-inch Bar Smooth. All added or expanded grating must be supported to carry a minimum load of 75 lbs./ ft2.

Inner Tank Stands. To support non-full depth inner tanks, 4 inner tank stands in accordance with Attachment A shall be constructed of 316L stainless steel and welds passivated for corrosion prevention.

Air Agitation System. Low pressure air agitation piping shall be installed on all rinse tanks in accordance with Attachment A. Low pressure air shall be provided by existing facility blower equipment. Air agitation materials shall be constructed to withstand the tank chemistry and operating temperatures in accordance with Attachment A. The agitation system shall be equipped with ball and diaphragm valve controls. The system shall be sized to provide the proper agitation turnovers in accordance with Attachment A.

Air spargers shall be located at the bottom of the tanks and anchored one (1) to three (3) inches from bottom of tank inner surface to prevent debris and sludge from clogging the lines. All air agitation piping shall be anchored and remain static during operation. The piping shall direct the airflow upwards for proper solution circulation throughout the tank.

The air volume provided is approximately one (1) cubic foot per minute (CFM) per linear foot of length.

Mechanical Agitation System. Mechanical agitation shall be provided for tanks in accordance with Attachment A. Pumps shall be hardwired at the tank. The pump, eductors, and any piping materials shall be constructed to withstand the tank chemistry and operating temperatures in accordance with Attachment A. The agitation system shall be equipped with on and off switches to control the pumps. The contractor shall assess and determine an optimal agitation design taking into consideration the turnover rates in accordance with Attachment A and the ideal agitation rates in accordance with industry standards for the tank sizes and contents. The mechanical agitation shall provide for proper solution circulation throughout the tank.

Eductors. The eductor nozzles shall be distributed in a manner that provides uniform agitation throughout the full volume of the tank. The eductors shall be anchored at intervals along the bottom of the tank to provide turnovers of the solution in accordance with Attachment A, agitation rates in accordance with industry standards for the tank sizes and contents, and not allow debris or sludge to build up.

See Attachment A for materials and tanks requiring eductors.

Pumps and Filters. Pumps and filters shall be located at the tank and provide sufficient circulation and filtration for the processing tanks. The pumps shall be compatible with the tank solution, chemistry and operating temperatures. In addition, the pumps shall include filters mounted internal to the tank that are compatible with the tank solution chemistry and operating temperatures and are equipped with slide-in filter cartridge adaptors to ease filter replacement. Filters shall provide filtration down to 5-30 microns in accordance with Attachment A. The filtration system shall show flow pressures before and after the filter media in order to demonstrate filter usage.

See Attachment A for pump material, turnover values, and filtration values.

Heating Coils & Heaters. In-tank heat exchangers and associated controls shall be installed in accordance with Attachment A and are to be sized to reach the tanks operating temperature from ambient temperature in a maximum of six (6) hours. Heating source shall be hot water (205°F ± 5°F) or 480V, 60Hz, 3-Phase power in accordance with Attachment A. The electric heater design shall be equipped with a safety disconnect shut off. All heating coils/heaters shall be manufactured from chemically compatible materials as required in Attachment A. All heated tanks shall be equipped with temperature control and level control systems. (Refer to Attachment A for tank, temperature and model requirements).

Hot Water Piping Insulation. The contractor shall provide new insulation on all hot water and return lines up to working envelope of each tank.

Tank Thermal Insulation. The contractor shall provide thermal insulation on all tanks. Insulation shall be applied to the internal baffles/dividers in all heated tank sections.

. Electrical Control and Level Monitoring System. All controllers shall be BACnet compatible and connect to a Siemens Data Capture Unit for monitoring purposes. This connection shall be provided through either Ethernet or 4-20 milliamp (mA) signal from the equipment. Modify, add or replace existing tank control and monitoring systems as required to provide digital controls that will integrate with FRCSW’s existing Direct Digital Control (DDC) system. Connect new equipment control and monitoring systems to nearby DDC control panel. Create requisite control points within DDC control system and update graphics within front-end operating system, Desigo, for remote monitoring and control of new equipment. DDC system remote monitoring to include all monitoring visible at local DDC controllers, and any additional points identified by manufacturer as indicative of equipment operational status. DDC system remote controls to include tank systems enable/disable, tank temperature setpoint, and tank level controls. Coordinate integration to DDC system with DDC system operators. Provide as-built DDC controls drawings. The control systems and level monitoring system shall include the following items.

Temperature Control with Automatic Level Control. The heating coil digital temperature control system shall include a thermostat, temperature sensor, stack light, 5-probe level sensor, and redundant solenoids (1 NO and 1 NC). There shall be an electrical control unit with stack-light that has a twist-lock female receptacle to plug into the electrical control unit. The level control probe shall be compatible with the temperature and tank solution in accordance with Attachment A.

Analog Temperature Gauge. All tanks with a digital temperature controller shall have a separate analog temperature gauge mounted at the tank with a probe compatible with the tank’s chemistry.

Conductivity Monitoring System. A conductivity monitor with local display and solenoid valve shall be installed at all rinse tanks in accordance with Attachment A to monitor water quality. The setpoint for makeup shall be adjustable to meet water quality requirements. The conductivity monitoring system shall consist of a conductivity/resistivity module, probe, indicating transmitter, dual relay module, and a NEMA 250 type 4X enclosure. The conductivity probe shall be compatible with the temperature and tank solution in accordance with Attachment A.

pH Monitoring System. A pH monitor with local display shall be installed at tanks in accordance with Attachment A to monitor chemistry pH level. The pH monitoring system shall consist of a pH measuring electrode, reference electrode and a high input impedance meter, indicating transmitter, dual relay module, and a NEMA 250 type 4X enclosure. The pH electrode shall be compatible with the temperature and tank solution in accordance with Attachment A.

Tank Electrical Isolation. The vendor shall provide electrical isolation on all tanks. Isolation shall be applied between the tank and the basement support beams, between copper bussing plates, and between the tank and the cathode and anode buss bar mounts as required.

Push-Pull Ventilation. The C2 cleaning system tanks that utilize a ventilation exhaust system in accordance with Attachment A shall use a push/pull design equipped with ventilation hoods on the pull side and a pipe with holes or slot that is mounted on the opposite side of the tank as the ventilation hood for the push side. Push-pull system calculations and design shall be performed by the contractor and results must comply with the San Diego Air Pollution Control District (SDAPCD) Rule, SDAPCD Rule 67.61, “Cold Solvent Cleaning and Stripping Operations”; American Conference of Governmental Industrial Hygienists (ACGIH) Standard, “Industrial Ventilation: A Manual of Recommended Practice for Design”, (specifically §13.70 Open Surface Tanks and §13.72 Push-pull Ventilation); and the American Society of Safety Professionals (ASSP) Z9.1 Standard, “Ventilation and Control of Airborne Contaminants during Open-surface Tank Operations”. Authority to Construct (ATC)/Permit to Operate (PTO) application must be filed with the SDAPCD per paragraph 3.1.9.

Ventilation Hoods (Pull Side). The ventilation hoods shall be connected to the existing plenum located in the B472 basement of the plating shop, and shall be Type II, Grade I made of 3/8-inch-thick impact resistant PVC. The hoods shall have a baffle to allow for adjustability in the flow rate including the ability to close the opening completely and a Magnehelic differential pressure indicating transmitter with a scale range of 0 inches to 2.0 inches WC (± 0.5% electrical accuracy and ± 2% mechanical accuracy) and shall be BACnet compatible and connect to a Siemens Data Capture Unit to indicate the pressure differential across the ventilation hood. This connection shall be provided through either Ethernet or 4-20 milliamp (mA) signal from the equipment.

Push-Side Piping. The push side pipe shall be mounted with a union fitting to allow for rotation adjustability, an inline diaphragm valve for adjustability of the flow rate and a ball valve providing an on/off switch for the push-side at the tank location.

This pipe system shall be connected to the existing low-pressure blower in the basement of the B472 plating shop. Hole size and spacing is calculated per section

3.3.6 Push-Pull Ventilation.

Plenum Ducting. Existing ventilation system ducting shall be removed and replaced by redesigned ducting taking into consideration CFM, FPM and static pressure requirements created with the design of the new tank configuration.

Plenum ducting shall be constructed of PVC. Fabricated from 3/16’’ and ¼” thick PVC and designed per the SMACNA reference in Section 2.2 for the most efficient air flow.

Exhaust Stack. The existing exhaust stacks shall be removed and replaced by the contractor. New stacks must be designed to handle the CFM requirements and achieve an exit air velocity between 3000-4000 feet per minute (FPM). Stack shall not have any cap or obstruction that would interfere with the exhaust air from traveling vertically from the stack. Stack shall reach a minimum height of 65 feet from grade and fabricated from 3/16’’ and ¼” thick PVC.

3.3.6.4 Exhaust Fans. Contractor shall remove and provide replacement exhaust fans for ventilation stacks C1-C4, new fans shall be relocated on rooftop of building 472.

The exhaust fans shall be sized to accommodate the CFM and static pressure requirements per the ACGIH reference in Section 2.2. Fans shall connect to a Siemens Data Capture Unit for monitoring purposes. This connection shall be provided through either Ethernet or 4-20 milliamp (mA) signal from the equipment.

New exhaust fans shall be connected to the newly constructed plenum located below the ventilation hoods of the plating shop and shall be designed to handle emission from full exhaust loads. It shall also be designed for variable loading to the extent practical for energy conservation.

3.3.6.5 Mist Eliminators. Each ventilation system shall have a mist eliminator ahead of the fan. This mist eliminator shall remove 98% of droplets 20 microns or greater.

Electrical System. The C2 cleaning system shall conform to NFPA 79. The existing source voltage available at the facility is 110/120 Volt, Single-phase, 60 Hertz (Hz) and 3- Phase 460/480 VAC, 60 Hz. The equipment’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete and shall include any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device shall be utilized on the machine with means of lockout in the off position only. All electrical enclosures shall conform to the requirements of NEMA ICS 6. Electrical connections made to the facility electrical system shall conform to NFPA 70. PVC conduit shall be used for all items requiring wiring connections.

Electrical Enclosures. Construction of the electrical enclosures shall conform to NEMA ICS 6 standards. The enclosure shall be a NEMA 250 type 12 and shall provide for ventilation of components and shall be designed for an indoor non-hazardous location. All electrical components shall conform to applicable NEMA ICS 1 standards. The C2 cleaning system shall be provided with interlocks on its electronic cabinet that shall instantly remove power from the equipment when the door is opened in accordance with NFPA 79.

Arc Flash Protection. The C2 cleaning system enclosures shall be marked for arc flash in accordance with NFPA 79 Paragraph 16.2.3 “Safety Signs for Electrical Enclosures” for arc flash safety. or current equivalent ISO/EN/DIN/JIS/IEC standards for arc flash safety. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

Solid-State Components. Electrical devices used to power electrical servo and spindle motors of control voltage delivered to solid-state electrical components shall be solid-state devices. Such devices shall be equipped to handle the electrical load imposed by operation of the C2 cleaning system to its maximum potential. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

Motors. Motors shall be rated for continuous duty. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG-1. Each motor shall have an identification plate in accordance with paragraph 3.7.2 to identify manufacturer, model number, serial number, voltage, amperage, horsepower, phase, frequency, and frame number. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

Process Line Accessories. The following items shall be provided in the quantities listed as per Attachment A and Table I below. Attachment A takes precedence over Table I, if quantity inconsistencies exist.

Table I: Process Line Accessories

DESCRIPTION COMMENTS QTY

Tank Covers lightweight, durable bi-fold type covers compatible with tank chemistries 1

RO Water Spray Rinse Guns/Lance with appropriate hosing installed in accordance with Attachment A 2

Filtered Shop Air (Compressed Air) Guns with appropriate hosing installed in accordance with Attachment A 3

Outlet Enclosure NEMA 250 type 4X, 2-Gang Vertical While-In-Use Self-Closing Flip Lid Cover Plates

(one at each tank)

Duplex Outlet Receptacle

NEMA 250 type 5-20R, 120V 20A Receptacle, GFCI

(one at each tank)

Duplex Outlet Receptacle

NEMA 250 type 5-20R, 120V 20A Receptacle, Non-GFCI

(one at each tank) Billboards on sides facing walkways of each tank to Display Tank Chemistry and Material Information see attachment A; 316L stainless steel mounted on Uni-strut; welds passivated for corrosion prevention

(Includes four

(4) 8.5 inch × 11 inch slots)

Tolerance Characteristics. The tolerances of the system shall be as specified in Table II below.

Table II: Tolerance Characteristics

EQUIPMENT /

SPECIFICATION REQUIREMENT

Conductivity 10 to 10000µS/cm ± 2% of reading; 5 to 5,000 ppm Maximum Heat Up Time To Operating Temperature

Must reach operating temperature (see attachment A) within ≤6 hours, unless otherwise noted in Attachment A pH Monitor/Control System ±0.02

Pump & Eductor System

Pump head safety factor = 10% Pump, eductors and associated plumbing equipment shall be sized appropriately to allow adequate flow of solution to meet turnover requirement as listed in Attachment A

Tank Chemistry Temperature

See attachment A for temperature range for each tank ± 10°F, unless otherwise noted in Attachment A

Tank/liner dimension See Attachment A for tank/liner dimensions ± .75 inches Tank Height above Grating 42 ± 3 inches above walking working surface (i.e. grating)

Turnovers See Attachment A for tank turnover requirement

Work Envelope See Attachment A for work envelope dimensions ±1”, unless otherwise specified

UTILITIES REFERENCE INFORMATION

Source Hot Water Temperature 205°F± 5°F

Standard Tooling and Equipment. All standard tooling and equipment required for proper operation of the C2 cleaning system and maintenance shall be furnished. A list of these items shall be furnished at time of proposal.

Marking on Instruments, Control Panels, and Plates. All words on plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

Lubrication Plate. A lubrication plate shall be permanently and securely attached to each C2 cleaning system. The plate shall contain the following information.

• Points of Lubricant Application

• Servicing Interval

• Type of Lubricant

• Viscosity

• Military or Federal Specification for Each Lubricant (If available)

• Size and Type of Each Lubricant Filter

Nameplate. A nameplate shall be permanently and securely attached to each rectifier, pump, conductivity and pH controller, and autofiller in the C2 cleaning system. The nameplate shall contain the information listed below. If the C2 cleaning system is a special model, the model designation shall include the model number of the basic standard cleaning system and a suffix identified in the manufacturer's permanent records.

• Nomenclature

• CAGE Code

• Manufacturer’s Name

• Manufacturer’s Model Designation

• Manufacturer’s Serial Number

• Power Input (Volts, Total Amps, Phase, Frequency)

• Contract Number

• Date of Manufacture

• Full-load current for each supply

• Ampere rating of the largest motor or load

• Short-circuit current rating of the industrial control panel

• Max ampere rating of short-circuit and ground fault protective device, where provided

• Electrical diagram number(s) or number of the index to the electrical drawings

Identification Marking of Military Property. An Item Unique Identification Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text. At a minimum this tag shall contain the information listed in paragraph 3.7.2 Nameplate.

Technical Data. Two (2) hard copies and one (1) searchable .pdf electronic copy of technical data shall be provided with the C2 cleaning system. Technical data shall contain specifications, instructions for the operation, maintenance of all the components of the C2 cleaning system and recommended spare parts list. All copies of technical data shall be legible and written in the English language. All technical data shall identify manufacturer’s name, model number, serial number and contract number. Technical Data shall include the following items.

a. Manuals/Drawings: The contractor shall furnish two (2) hard copies of all technical, OEM manuals and drawings containing all information in compliance with modifications of the C2 cleaning system. The manuals shall provide the data necessary for the programming, operation, and maintenance of the C2 cleaning system and ancillary equipment. The contractor shall also furnish one digital copy of the above technical manuals and drawings in Adobe’s Portable Document Format (*.pdf) file format or Excel on CD-ROM(S)/DVD optical drive media. The digital manuals and drawings shall be organized, indexed and referenced similar to the equivalent hardcopy format (i.e. volume, manual, section, etc.). 2D drawings shall comply with ASME Y14.100 in Solidworks (*.slddrw) file format and 3D models in Solidworks (*.sldprt, *.sldasm) file formats.

b. Training Manuals: Shall cover in detail all phases and cycles of operation such as start-up, maintenance, idle, shut down, troubleshooting, programming, running programs, printing, re-starting systems, etc. Manuals shall include the contractor’s contact information, parts list, preventive maintenance cycles, any/all information and documentation necessary to properly service, operate, maintain, adjust, and perform all functions within the equipment.

c. Maintenance Manuals: Shall properly identify in detail the extent of preventive maintenance, materials, liquids, substances, parts, and chemicals, used during preventive maintenance, repair, and/or troubleshooting of equipment. A complete list of all materials, chemicals, substances, and parts used for the maintenance and operation of the equipment shall be provided to the Government.

d. Calibration Manuals: Shall properly identify in detail the extent of calibration, part numbers, model numbers, specific calibration tools or adapters required and manufacturer used. A complete list of all materials, chemicals, substances, and parts used for the calibration, or that need to be calibrated within the equipment shall be provided to the Government.

e. Materials: A complete list of all materials, chemicals, substances, and parts used for the calibration, or that need to be calibrated within the equipment shall be provided to the Government 120 days prior to installation of equipment. Manuals shall be provided at the time of delivery and/or before acceptance of equipment.

f. Changes and Adjustments: Any and all adjustments made to the equipment during testing, acceptance, and warranty period shall be properly noted by the contractor. Updated manuals with any and all adjustments, updates, or changes made to the system shall be provided to the Government at no additional cost.

Plan of Action and Milestones (POA&M). The contractor shall provide a POA&M to identify contractor performance dates of all major events from contract award to completion of all contract requirements. The initial POA&M shall be delivered thirty (30) calendar days After Contract Award (ACA). The milestones shall be prepared and submitted using a recognized project management technique (preferably Microsoft Project). The Government and the contractor shall review the report on a monthly basis.

The contractor shall notify the Government prior to making any changes to the POA&M.

All changes to the POA&M shall be approved in advance by the Government. The POA&M shall detail such items as engineering, procurement of major hardware, assembly, operational debug, factory acceptance, shipment, loading and laydown area, installation, and final acceptance test.

Acceptance Test Plan (ATP). The Contractor shall prepare an Acceptance Test Plan (ATP). The ATP shall be a step-by-step written instruction on how to verify compliance during the Final Inspection/Acceptance Test specified in Section 4.4. The Manufacture’s standard testing procedures shall be included in the ATP. Any procedures necessary for compliance with Section 4, which are not covered by the Manufacturer’s standard testing procedures shall be identified and included in the ATP. The initial ATP shall be submitted thirty (30) calendar days ACA for Government review and approval. The Government shall respond with acceptance or recommendations within ten (10) business days. The accepted test procedures shall become part of this contract.

Installation. The contractor shall provide all qualified personnel and equipment to ensure safe, complete installation and operability of the new C2 cleaning system. The contractor shall provide materials and tools necessary for complete installation of the C2 cleaning system. The contractor shall take into consideration the artisans’ safety with respect to OSHA Standards per Sections 2.1.1 and 3.1.3 for working surfaces and ergonomic risk factors and control methods per Sections 3.1.2 and 3.3. The contractor shall survey the cleaning facility, coordinate with stakeholders (i.e. FRCSW facilities, maintenance, and environmental personnel) to identify needs regarding the new system with respect to utilities (see section 3.9.3) and hazardous waste disposal, and shall comply with safety and environmental standards. The individual requirements for the C2 cleaning system are outlined in Attachment A and are designed to meet the needs of the chemical composition in each tank. The operational parameters of each tank have been addressed for reactivity to material, operational temperature, power requirements, filtration, agitation and required ventilation.

Removal of Existing Cleaning Line. The contractor shall provide all qualified personnel and equipment to ensure safe removal of the existing equipment. Removal of the C2 cleaning system must be done in such a manner to accommodate the installation of a new C2 cleaning system. The existing cleaning system removal and/or modification requirements will be determined upon completion of the site assessment. Contractor must provide own riggers and rigging equipment; contractor cannot use FRCSW equipment, and any forklift must be powered by propane tank.

Hazardous Waste: FRCSW shall assume all responsibility and associated liability for disposal of hazardous waste as defined in California Code of Regulations Title 22. Vendor to contact TPOC and obtain specific instructions in regard to location and latest regulation from the Government for disposal of hazardous equipment / parts. FRCSW will provide hazardous waste roll-off bins as needed. The contractor shall be responsible for the following:

a. Tanks will need to be emptied, rinsed, and dry/free of any liquid before they are removed for disposal.

b. The tanks/hardware will be disposed of as hazardous waste.

c. If necessary, tanks shall be cut apart in order to properly fit in hazardous waste disposal bins.

Non-Hazardous Waste: Disposal of non-hazardous solid waste shall be the contractor’s responsibility.

Emergencies. In the event of an emergency, including hazardous material spills, the contractor or present contractor representative who identifies the emergency shall call 911 from any FRCSW phone and relay the location of the spill to include building and specific area within the building. If calling from a cell phone, caller must state that this is a North Island Coronado Naval Base emergency at FRCSW and relay the location so they can transfer the call to our local 911. Also individual needs to notify the TPOC for the project.

Utilities. The contractor shall install the C2 cleaning system utility hookups including low pressure air, DI and RO water, hot water, electrical, and ventilation to the existing site in a way to make the finished system operational. The Government shall provide all utility connections to within twenty (20) feet of the C2 cleaning system. Contractor shall be responsible for all utilities and connections from that point to the equipment.

Loading/Laydown Area. The Government and contractor shall discuss the space requirement in the post award conference.

Work Stoppage. For unforeseen issues found during the installation of the equipment, the contractor shall notify the TPOC and DLA immediately to determine further course of action.

Installation Access. Roll up door for access to site is sized 7 feet 11 inches wide x 9 feet 6 inches high.

Training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is proficient in the English language, shall be provided for specialized training to familiarize Government personnel with the scrubber equipment and to help ensure reliable performance and maximum service life during normal usage. The training shall be for a minimum of ten (10) Government employees (to include Government contract employees) such as facility and maintenance personnel, engineering, materials engineering, and personnel working or operating the equipment.

Training shall be in the operation, maintenance, calibration, support, and programming of the air scrubber for the C2 cleaning system. The training shall be performed at the Government’s facility and shall be eight (8) hours a day for five (5) workdays or 40 hours, between 0600 and 1430 hours excluding any weekends, federal holidays, furloughs, and base closures. The course shall utilize as-built drawings and manuals provided under this contract and shall include both classroom and hands-on portions. All printed training aids shall be supplied for the course, be in the English language, and become the property of the Government. The following items shall be covered during the training:

a. Familiarization with the equipment including description of the system, description of safety and emergency features, and familiarization with related technical data to be provided

b. Demonstration by contractor personnel of all operation, safety, and emergency aspects of the equipment

c. Hands on operation by Government personnel with assistance from the contractor

d. Upon completion of training, Government personnel shall be capable of fully operating the equipment without assistance, perform the required maintenance, and calibrate the equipment

QUALITY ASSURANCE.

Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein and in accordance with the attached Quality Assurance Provision (QAP). The Government reserves the right to witness any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

Responsibility for Compliance. The Contractor shall be responsible for ensuring all items meet the requirements of sections 3 and 4.

Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. Final Inspection/Acceptance test (Destination) (see 4.4).

Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient temperature conditions in the range of 55° F to 100° F and 10% to 95% relative humidity.

Final Inspection/Acceptance Test (Destination). Final Inspection and acceptance test shall be performed on the C2 cleaning system to…