Purchase Specification.pdf

PRODUCT SPECIFICATION

for

MAGNETIC PARTICLE INSPECTION BOOTH SYSTEM

709TH MAINTENANCE SUPPORT SQUADRON NONDESTRUCTIVE INSPECTION FLIGHT (709 MXSS)

Hill AFB, UT

May 18, 2021

Specification for the

Magnetic Particle Inspection Booth Large Parts

1. SCOPE.

The facility has one large part landing gear Magnetic Particle Inspection Booth (MPI). This purchase description is a two-phase approach. The contractor shall install a new MPI Booth in the north space while the existing MPI booth is operational. Once the contractor is complete with the first phase MPI booth, the contractor shall move to the second phase and install the second MPI booth. The contractor shall provide a mock part for acceptance and commissioning at contractor’s location before materials can be delivered to Hill AFB. MPI Booths shall include all components, parts, and features necessary to meet the performance requirements specified herein.

2. APPLICABLE DOCUMENTS.

2.1. General. The contractor shall supply and integrate the requirements as specified herein to provide a complete large aircraft part MPI Booth in accordance with this specification, which include the documents listed below and the attached drawings and listed drawings in Appendix D.

2.1.1. Department Of The Air Force – Applicable documents listed

2.1.2. Department of the Air Force/Government Publications

2.1.3. NDIMPO-4027 Fluorescent Magnetic Particle Order

2.1.4. Non-Government Publications. Applicable documents listed below:

2.1.5. ASTM E1444 Standard Practice for Magnetic Particle Testing

2.1.6. ASTM E3022 Standard Practice for Measurement of Emission Characteristics and

Requirements for LED UV-A Lamps Used in Fluorescent Penetrant and Magnetic Particle Testing

2.1.7. ASTM E709 Standard Guide for Magnetic Particle Testing

2.1.8. SAE AMS 2641 Vehicle, Magnetic Particle Inspection Petroleum Base

2.1.9. SAE AMS 3044 Magnetic Particles, Fluorescent Wet Method, Dry Powder

3. SYSTEM REQUIREMENTS.

3.1. System Basic Requirements. The Contractor shall use, when available, Commercial-of-the-Shelf

(COTS) items that are new and current components. A current component 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 has published catalogue or brochures. The contractor shall not use products such as experimental units, which do not qualify as meeting the requirements specified herein. The MPI System and design shall inherently not cause damage to any aircraft components at any point including but not limited to the pre and post-handling processes, intermediate MPI steps, or final inspection processes. The system design shall integrate with the existing overhead crane system, which has capability for adding drop stations and programmable stop and drop schedules.

3.1.1. All systems attached to the MPI System including piping, electrical, and mechanical equipment shall be routed within the footprint of the system in order to prevent damage from traffic in the surrounding areas. Concept Design and Installation Drawings shall be submitted for approval Government Project Manager prior to installing any equipment (CDRL A005). All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and/or repair. Ancillary equipment may be placed within the area with prior notice and advance government approval. For concept of the hydraulic lifting devices, see attached Drawing

001,002,003.

3.1.2. The contractor shall demo the existing curtains on the north side and structure to allow the contractor to install a below ground sump structure to hold the landing gear part handling equipment and the floor grading. This concrete enclosure shall be constructed to a minimum depth of 30 inches with a 304 Stainless Steel pan, reinforced walls to form the support for grading, and part support fixture, accessories, and walls. The minimum stainless- steel thickness shall be 7-gauge for this support structure. The contractor shall design and install using reinforcement rebar for the enclosure. The rebar shall support the stainless-steel sump pan, part handling equipment, and booth structure. The concrete and composite grading shall match the current floor elevation. Once phase 1 is complete, the contractor shall duplicate the same requirements for the South booth. Once the South booth is complete, the contractor shall install the new mag table (provided by the Government) and install in the North Booth.

3.1.3. The pit shall maintain a sloped bottom to a filtered drain preferably in one corner to provide access to the pit for ease of cleaning. This drain shall supply the return oil and particles back to the tank. The carrier fluid with particles shall be constantly agitated within a minimum

100-gallon tank. The tank agitation system shall suspend the particles at all times, but not break down the particle and oil viscosity. The Magnetic particle oil shall pump from the minimum 100-gallon tank and deliver the fluid to technician to cover parts during processing at a minimum 1 and ½ to 3 gallons a minute through a 5/8’’ hose at 15 PSI. The contractor shall verify the delivery pump pressure and flow as to eliminate particles from washing away during the process. Filtering of the carrier fluid, shall be accomplished to remove contaminants from the carrier fluid while leaving the particles. The pump and hose that delivers the fluid to technician to cover parts during processing must be compatible with the fluid.

3.1.4 After the sump and structure is in place, floor grading shall be installed at the same elevation as the existing floor. This floor grading will be a composite type non-slip grading that will not degrade under the constant saturation of the magnetic particle oil. The contractor shall provide testing of the material, then receive approval from the Government Project Manager.

The test shall consist of the floor grading material submerged in the oil for 21 days. After 21 days, the contractor shall provide a visual degrading inspection and strength testing for

Government approval. This inspection and test shall prove that the material will hold up to the oil. The contractor must provide all oil and material for this inspection and test.

3.1.5 The contractor shall design both new north and south booth. The contractor shall design the structure to support all equipment and maintenance platforms for workers that need access to all areas. The contractor shall consider placing the converters above the booths, keeping the footprint inside the proposed area. The contractor shall install structure for a 16-gauge wall panel on both North and South walls of each booth. The contractor shall install a 12-gauge ceiling panel. The East and West walls of both booths shall be a heavy black out curtain. Curtain shall be installed in a way that no landing gear part will catch on the curtain. Once parts are inside the booth, the curtain must fall into place blocking out all light. All new structural supports and exposed steel shall be painted to prevent corrosion.

3.1.6 The contractor shall provide all new Mag Particle equipment for the bay including:

Two new DC/AC Mag converters that feed both the coil, and directly to the part at 100 amps minimum & 10,000 amps maximum.

New start stop controls, including de-mag process, new cable and clamps, new coils, new shop aid components, and new clamping type coil.

New white lights and black inspection lights to include overhead and handheld.

Overhead white and black light to be 100-foot candles to floor level. For handheld intensity of the white and black light at the part surface shall be a minimum of 100 microwatts per centimeter squared at the surface of the parts.

All new components, shall be attached overhead and on wall racks to prevent tripping hazards. All cord reels and equipment provided will have maintenance in mind for easy replacement and repair.

3.1.7 Overhead Conveyor Interaction. Parts for MPI testing shall be taken off the existing facility overhead conveyor (at designated points just outside the east wall), and loaded directly on to the landing gear parts fixture. After the MPI process, parts that are ready shall be loaded back on the overhead conveyor at a designated point inside the booth.

3.1.8 The conveyance system through the MPI process shall be composed of individually driven chain conveyors to handle the system carriers. All powered system conveyor sections shall hold one and only one system carrier and each section shall have its own individual conveyor drive motor. All conveyance gear motors shall be the same across all drive chain conveyor sections. Individual part manipulation is very important to meet inspection needs throughput requirements. Conveyor drive gear motors shall be coupled to the conveyor with jack shaft chain drives, shaft couplings with polymer linings, or outfitted with torque arms to ensure that slight mounting misalignments shall not overload the gear box bearing and cause premature gear box failure. Reference the attached drawing #001 for an example of the conveyor construction.

3.1.9 Landing gear part handling fixture or large landing gear parts cradles. The existing workload consists of technicians handling all parts. Some parts are 1200 lbs. currently these large parts sit in cradles to inspect. The technician is required to lift the parts, re-hook them, and then lift it again to achieve each inspection which is a time-consuming process. The contractor shall propose a new design with a hydraulic handling fixture and controls that would have separate cradles that move up and down on all four sides that could also drop in and out. This would manipulate the parts in all directions for a more efficient, ergonomic testing process. The cradles shall maneuver in a way to allow large, heavy parts to be supported and preventing any drops jeopardizing the safety condition for workers. Each cradle shall be removable so cradles can be re-coated with the insulation rubber. Hydraulic cradle lifts shall be rated for 1200 lbs.

Each cradle shall be high enough to accept parts from the existing trolley chain. Each cradle shall lift to an ergonomic height plus 30 inches to allow parts to be lifted at all different angles.

Equipment maintenance shall be designed into all of the hydraulic lift system. All equipment inside booth must be magnetic particle oil resistant and be sealed to prevent pooling on oil around the fixture. All cradles and hydraulic lifting systems shall be rated to a minimum of 1500 lbs. During excavation, the contractor shall keep in mind that utilities are below ground. The contractor shall be responsible to re-route the industrial waste line that is known to be inside the digging area

3.1.10 Fire protection, the contractor shall design a fire protection system for the new booths.

The contractor shall define the booth hazards classification using a certified Fire Protection

Engineer (FPE). The FPE shall design the system in accordance with UFC, any state and local codes. All fire protection shall include wet and electronic devices.

3.1.11 Landing gear cradle controls shall be programmed for the 12 of the largest landing gear parts control system and shall manipulate the parts for a MPI inspection and have a manual override to give technicians more control of manipulating parts without personally lifting the parts. The contractor shall have safety controls always to hold the parts. No parts can tip or be unsupported during the inspection. The controls system screen shall be positioned for the technician, but also away from direct splashing of fluid. This screen shall show the fixture as it moves and provide the manual manipulation diagram to aid workers in manually moving parts.

The contractor shall do all control system programming of the 12 large landing gear parts on site. No landing gear parts can be shipped to the contractor.

3.1.12 Inspection, testing and commissioning of the new system shall be at the contractor’s location. The contractor shall build a mockup to the C-5 Bogie Beam to use during the Inspection testing and commissioning at contractor’s location, and then at Hill AFB for testing and commissioning. This mock up Bogie Beam shall be the same size, shape, and in weight. See PDF files for Bogie Beam design (attached drawings #004-015).

3.1.13. The contractor shall install all components that will be sustainable using MPI liquid. This liquid can be very corrosive to rubber and other materials. Hydraulics, seals, and bearings shall be of a composition to allow for long lifespan and be resistant to this MPI liquid. The MPI cradle will have a constant flow of this material all over the components. The components shall be aluminum, stainless steel, or epoxy painted carbon steel. The contractor shall design the MPI cradle system that will not allow pooling fluid. All fluid coating the parts must return to the sump and then to the holding tank.

3.1.14. The gear motor speed for conveyance and fabric door opening/closing shall be controlled over Ethernet using a variable frequency drive with managed Ethernet switches. The conveyance chain shall utilize a UHMW (Ultra High Molecular Weight) plastic wear surface integral with the frame rails.

3.1.15. Operator Safety considered at the Operator Interaction Points (OIP). These areas are protected with safety rated devices such as Safety Rated limit Switches. The safety component rating shall be at a minimum IEC 61508 SIL 3 Category 4.

3.1.16. All pressure gauges, shall be joined to the unit with quick couplers for easy removal for calibration. All analog gauges attached to the system shall have a corresponding sensor that shall read out on the system HMI (Human-Machine Interface). All system alerts, shall be displayed on the HMI in real time so the operator may rectify the situation for out of process specification of pressures, space temperatures or time. The system HMI gauge readouts shall have the ability to be calibrated to the certified analog gauges.

3.1.17. The MPI system shall be designed ergonomically such that operators are not required to lift parts exceeding 25 pounds within a vertical plane, 15 inches forward of the operator’s waist.

This is extremely important around the operator fixture loading/unloading zones. Any additional weight within this zone and non-reduced weights outside this zone are considered awkward and unsafe. The contractor could also provide specific part fixtures/handling to accommodate parts to be processed ensuring safe handling, prevent liquid pooling, enable 100% visual inspection of part surfaces, and also enable complete coverage of fluid. The entire system shall be designed to minimize part handling by the system operator. The system shall maintain greater than 75% open area on the fixture bottom to allow for sprays of fluids application and inspections from underneath the landing gear holding system. The mag particle booth shall be designed to inspect the entire part. Any places the cradle touches will need to be coated and then tested.

3.1.18. Equipment Footprint. The entire MPI system shall fit within the area boundary (see attached drawing #003). The footprint of the MPI Line shall include all equipment, machinery, controls, guards, and a complete operator footprint. At no point shall normal MPI operations produce an event to cause a MPI Line device (e.g. actuated devices, fabric doors, overhead cranes, etc.) to protrude outside of the design space (See attached Design Space drawings

#003). These drawings show the example system position in the plant.

3.1.19. Pneumatic cylinders selected shall have specifications that match or are equivalent to

Parker 2A or 2AN series of Pneumatic Cylinders.

3.1.20. No lines smaller than 1-1/4 inch, drains shall run from the pan to the tank. They may have a pump to assist the fluid to the holding tank.

3.1.21. Maintenance access shall be provided to the area between the two booths and in the floor for the sump.

3.2. Components. The MPI System shall fully perform MPI ASTME1444 NDI, and 809 MXSSOI

Fluorescent Magnetic Process Order NDIMPO-4027 V2-1. The new MPI system shall be able to accommodate all required aircraft parts for inspection (see Table 1 below for minimum and maximum part dimensions and weight, and the attached Appendix B for part geometry).

Table 1

Parts Size and Weight Parameters

Largest parts size 8’L X 8’W X 12”D

Smallest parts size 8’ L X 6’W X 8” D

Heaviest Part 1200 lbs.

Lightest Part 600 lbs.

3.2.1 An example layout of the MPI Line components, are shown in the attached Appendix D, drawings. System stations are shown in an example layout in the attached Drawings # 001, 002,003. Wetted Stations shall be constructed out of the appropriate corrosion resistant materials. SSPC-SP10, and then a prime and top coat of Devran 224HS, Macropoxy 646 High

Build Epoxy or equivalent shall be used. Stations are shown as an example to satisfy the MPI system requirements to achieve the required processing flow rate. Stations are to be sized to accommodate parts for processing and fit in the design space as shown in the attached

Drawings #003

3.2.2 Control System. The contractor shall provide a control system that allows for partially automated process and parts tracking, starting from when a part is loaded into the system holder to when the part is removed from the system holder.

3.2.2.1 The control system shall operate in such a way to ensure position feedback of each landing gear part during the MPI process. Feedback may include but is not limited to; proximity sensors, contacting a limit switch, or barcode scanners.

3.2.2.2 The state of the entire system shall pick up where it left off, in the event of:

• Loss of power

• Manual control override

• Safety Muting

• Emergency stop

3.2.2.3 The control system shall be based upon an Allen-Bradley PLC (or equivalent) interfaced by (3) Allen-Bradley (or equivalent) Panel View 5510 Human Machine

Interface (HMI) touchscreens. Touch screens shall be a minimum of 15” screen size. The

HMI touchscreen shall allow for part selection, part manipulating process overview, trends, error logging, reset of alarms and process control errors. The HMI system shall provide everything the operator needs to control and utilize the MPI system. The process sensors such as space temperature shall be displayed on the HMI. The HMI shall display trends and a record for part selection. The HMI shall allow the user to select and change the specific part position that each part shall follow as it is processed through the booth. This position cannot be editable once the process has started. Each part shall be scanned in the PLC that stores all the necessary processing alarms. All alarms shall log into a database on the HMI that shall be available for download as needed in csv format.

The Control system is also required to log processing data for each different part and have capacity to store this data for up to 10 years. For each part that is processed, a report shall be generated, and the information shall be stored for each part. Unique parts can be set and stored and shall include options for; manual intervention until process starts, and process times. This control design shall allow for a different positions to be selected for each part into the system for the twelve (12) specific parts.

3.2.2.4 HMI Screens: Process overview screen shall show all parts and current state of each part. There shall be part specific screens that exist for all parts and shall show the current state of all devices as well as analog data associated with that part. All devices show up as green on the HMI when engaged. Motors are shown running under a faulted shall be red. A motor shall be manually on, manually off, or in automatic mode. HMI shall show each mode on the screen. Actuated valves, are shown in their current open or closed states. Valve modes, are indicated on the HMI screen. A valve can be manually open, manually closed, or in automatic mode. Fluid levels, Air pressure, water pressure, and temperatures shall also be displayed. The HMI shall have trend screens that show time signal trend lines of system variables like space temperature. Two (2) weeks of trend data shall be available on each system HMI. Descriptive error log screens shall be included and used for diagnostics to understand reported errors. The primary control network used shall be Ethernet with Allen-Bradley safety I/O (Input/Output) cards used for safety and Allen-Bradley I/O cards used for sensors and instrumentation I/O. The safety control system integrates seamlessly with the mechanical design of the machine.

Area guarding is used where possible. For areas of the machine where it is not possible, the safety control system is used. Typically, this is on the areas of the machine that the operator can interact with parts. The safety control system shall be IEC 61508 SIL Level

2, Category 3. It includes emergency stop and push buttons inside the booth, and safety output modules to control safety components. Safety muting in the area of operator interaction shall be accomplished with a separate safety control network. IEC 61508 SIL3

Category 4 components shall be used on the stations that required manual intervention.

The conveyors that are accessed from a system breach shall be stopped when an intervention occurs to allow for safe access. An Ethernet switch shall be provided to control all VFD and servo drives over Ethernet. Separate Ethernet cards shall be provided for system devices and plant integration.

3.2.2.5 At a minimum the HMI shall display:

• Part number

• Part voltage shot coil reading

• Part voltage shot direct reading

• Coil shot number

• De Mag

• Part position during process

• Space temperature

• Ventilations fan CFM

• Lighting Mode

• All fluid Pump controls and tank levels

• Gallon volume in both sump and 100 gallon tanks

• Tank Volume Tracker

3.2.2.6 Automation Programming and Visualization Computer Software Licenses, all software installed on the workstation shall be licensed and activated. All Rockwell

Software (or equivalent) licenses shall be transferred to the customer. The information to transfer all licenses shall be forwarded to the Government project manager.

3.2.2.7 Load Stops. The contractor shall provide two Load Stops that allows for loading of parts from the overhead crane into the specific parts located on the system. The

Attached Drawing #001 shows the two loads stop locations on the line. At these locations, the Contractor shall program stops in the existing overhead crane to drop parts into system carriers. The Load Stop Stations shall be at the end of the carriage return line and at the beginning of the MPI line. The facility overhead conveyor is the part source and lift assist in this station as the load stations are designed to be directly underneath the overhead conveyor line. The operator shall disconnect the parts from the overhead conveyor at one of two loads stop locations.

3.3 Support Systems Design.

3.3.1 Shop aids insert tooling. The contractor shall duplicate the 5 existing shop aids magnetic insert tooling. The contractor shall construct a rack to hang the new tooling. (see Appendix B picture labeled “Shop Aid” pg. 22.)

3.3.2 Electrical safety. Because of the high amperage used in this process, all metal parts, with the potential of touching landing gear parts and cradles, must be adequately insulated for the maximum DC amps

3.3.3 Electrical System. The Magnetic Particle Inspection System for both booths and the inspection table require three separate electrical feeds that shall be installed using the existing facility electrical buss located in the ceiling 100 feet west of the existing booth location. The existing and new booths shall be designed to operate on existing Hill AFB facility electrical systems (480-volt 3 phase 60 Hz). All power circuits within the line circuit shall be 277/480V 3 phase 60 Hz or 120/208V 3 phase 60 Hz. All control circuits within the line should be 24VDC single phase. The MPI’s electrical system shall be tolerant of fluctuation of ± 10 percent of the line voltage. The electrical system 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 MPI

System with means of lockout. Routing of power shall not interfere with the existing system, normal system operations, or existing overhead conveyance system. (See Appendix B, pictures on page 29, 30)

3.3.3.1 AC/DC power converter. Electrical devices used to power electrical servomotors control voltage delivered to solid- state electrical components shall be solid-state devices. Such devices shall be capable of handling the electrical load imposed by operation of the MPI System to its maximum capability. The use of selenium solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

3.3.3.2 Electrical Panels. A 250A main line power feed is required for the following electrical panels:

3.3.3.2.1 High Voltage Panels: Quantity: Three

Power Feed:

• The first 480V panel shall be fed from the existing the main

250A power feed.

• The second 480V panel shall be fed with a 250 Amp feed from the buss in center of building

• 3rd feed is the existing large Mag table

(See Attachments B and C for High Voltage Panel 1 and 2 details pictures)

3.3.3.3 I/O Panels: Quantity: 2

Power Feed: Shall be fed with 24V and/or 120VAC from one of the 480V panels.

3.3.3.4 HMI Panels: Quantity: 2

Power Feed: Shall be fed with 24V and/or 120VAC from a high voltage panel.

3.3.3.5 Power Isolation. The contractor shall provide and install an isolation transformer for the system and line reactors for the line’s variable frequency drives. The isolation transformer shall be sized properly and placed on the main power feed to the system.

The isolation transformer shall provide a controlled path for common mode noise current, and a consistent line to ground voltage reference in order to minimize insulation stress, and be able to accommodate for the system’s surge protection scheme. Line reactors shall be used to protect each variable frequency drive on the line and shall be sized and installed according to the manufacture’s specifications.

3.3.3.6 Facility Connections. Electrical connections made to the facility electrical system shall conform to Hill AFB Facility Design Standard Section 14

3.4 Pneumatic System. The Pneumatic system is used to actuate valves and cylinders on the stations

3.4.1 Facility Connections. Pneumatic connections made to the facility plant compressed air system shall use ProPress copper piping system, and ProPress isolation ball valve on branch line off the main. Use ProPress full port 200 psig ball valves.

3.4.2 Mechanical HVAC . The contractor shall install ventilation in both north and south booth. The contractor shall design the ventilation to a minimum of 5 to maximum

7 air changes an hour with fresh air. The contractor shall maintain 65 to 75 degrees

Fahrenheit at all times. Cooling can be evaporative and heating can be electrical. The contractor shall provide and install all equipment and utilities using the facility utilities in that area. All new structural supports and exposed steel shall be painted to prevent corrosion.

3.4.3 Safety Guarding. Area guarding shall be provided to conform to 29 CFR 1910

Subpart O.

3.5 Overhead Conveyor System. The existing overhead power-free monorail conveyor shall be modified to operate in conjunction with the proposed system. Conveyor modifications shall include the removal and placement of conveyor stops and drop stations with the addition of multiple hoist controllers. Modifications also includes changes to existing overhead power-free conveyor programming to accommodate the removed and added stations, and the break- away of control for the MPI Line. All changes to this system, shall be reviewed and approved by the facility electrical engineer. Overhead conveyor load/unload stop locations are shown in the attached Appendix D, and Drawing #001

3.6. Controller Programming.

3.6.1 MPI Line Controller System shall be designed to communicate/control overhead

Monorail Conveyor System (MCS). The safety system for the MPI line shall also integrate with the monorail conveyor system. A safety stop shall be installed immediately after the load stop station. At this location, it shall be determined that there are no parts on the overhead conveyor hoist and the hoist chain is fully retracted. Both of these conditions shall be checked with appropriate sensors. The sensors shall be tied into the

MPI control system and not allow the overhead crane to advance. The contractor shall also be responsible for making the necessary program changes to the current monorail conveyor PLC to ensure proper integration with the MPI control system. All changes to the monorail conveyor PLC shall be properly documented and submitted to the

Government Program Manager for approval upon completion of installation.

3.6.2 Standalone Computer

Contractor shall provide a standalone computer with associated Allen- Bradley software that shall interface with the MPI Line PLC. This computer shall be located inside the final inspection booth. This computer shall also have the ability to have the same screen displays as the HMI displays. This computer shall access the .csv files from the data server and have the ability to copy the files to a Compact Disc. One (1) license of

Microsoft Excel shall be provided to view the .csv files and run reports. NOTE: This computer shall not be allowed on the base facility internet so all files and updates shall be installed prior to installation at the facility. The computer shall have the minimum technical specifications listed below:

• Processor: Intel i5 or Equivalent

• RAM: 8 GB

• Hard Disk: 256 GB Solid State Drive

• USB: 3 Ports (Keyboard, Mouse, Flash Drive)

• Display Port: HDMI or Display Port

• Operating System: Minimum Windows 10

• Compact Disk Reader/Writer

3.6.3 HMI Controller. HMI Touchscreens (Three included) shall be located near the load and unload stations, and in the inspection booth. (See attached Appendix G, and pictures for HMI location details)

3.6.4 Data Server. A data server to maintain long term records of processing times for each carrier in each step of the MPI line, e.g. dwell times, drying time, time between dip and rinse, date, etc. This shall be the specific computer which stores all of the information for a minimum of 10 years referenced in Section 3.6.2.

3.7 Alignment and Accuracy Tolerances. The alignment and accuracy tolerances of the MPI

Line shall permit continuous operation and be in accordance with NDI T.O 33B-1-1, ASTME1417.

3.8 Special Tools. Use of special tooling is discouraged, but any specialized tooling NOT available in normal Air Force Nondestructive Inspection (NDI) or Maintenance shops required for the operation, or maintenance of the equipment, shall be provided by the contractor. This shall include consumable items needed for start-up of the equipment. COTS parts shall be available in Contractor’s design and easily purchased from other vendors. The contractor shall use COTS parts where possible. Use of COTS parts is preferred for all parts subject to replacement and shall be manufactured to definite dimensions and tolerances. All components, that take measurements and/or require calibration of any type, to ensure proper equipment operation, shall be considered and require interchangeability. 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, and seals.

Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts.

Foreign-sourced replacement parts shall be interchangeable with domestically supplied components or be readily available from domestic sources.

3.9 All measuring and indicating devices on the MPI booth shall be graduated in the inch/pound system. All pressure gauges on piping shall be graduated in PSI, differential pressure gauges for air or other compressible fluid flow shall be graduated in inches of H2O, and temperature gauges shall be graduated in degrees Fahrenheit. All instruments shall be calibrated and remain in calibration for a minimum of six months after installation. A calibration procedure shall be made available to the OO-ALC NDI Program Office, AFMETCAL and local

CAL/CERT personnel and Metrology. These procedures can be COTS Manuals or separate calibration processes and shall include +/- tolerances that can ensure that all required calibration adjustments can be made and verified to an acceptable degree of uncertainty. The contractor shall provide an outline of parameters, value/range, and accuracy for the system, subsystem, support equipment, and calibration standards. Minimum use specifications are the principal parameters required for performance of the calibration, therefore, the test system performance and measurement requirements shall be specified at the test system I/O interface and reflect actual use requirements. (Actual use requirements reflect what parameters are being tested, not just the manufacturer’s specifications). The parameters and tolerances in each line shall be expressed in consistent units of voltage, frequency, power, current, etc., or percentages. The requirements apply to all systems, subsystems, and equipment that require measurements of any type to ensure proper operation.

3.9.1 Required Calibrated Gauges:

• Liquid temperature gauge (Pre-rinse, Post-rinse, and Developer

Stations)

• Water pressure gauge (Pre-rinse and Post-rinse Stations)

• Air Temperature gauge (Dryer)

• Developer tank temperature

3.9.2 Two sets of gauges shall be supplied: an installed set and a spare change-out set. Both sets shall have a Certificate of calibration traceable to the National Institute of

Standards and Technology (NIST). All gauges, shall be calibrated and be industrial grade.

Liquid pressure gauges shall have a full-scale accuracy of 2 percent with minor graduations in 1 psi. Analog pressure gauges are preferred. All temperature gauges shall be calibrated. Temperature gauges shall be industrial grade with 1 percent full-scale accuracy with graduation of 1 degree. Sensors shall be supplied for an input to the PLC.

The sensors attached to the PLC shall have a calibration screen on the HMI to adjust for offsets if the readings differ from the NIST certified gauge at the same/near location.

Sensors and gauges shall be located near each other to read the same conditions.

4. GENERAL REQUIREMENTS

4.1 Ergonomic Layout. All components shall be accessible without removing or disturbing other items, with the exception of wiring and piping connections or minor tubing. All required maintenance and operational activities shall be performed without over reaching or straining.

Gauges and other instruments shall be visible from a normal standing position at or near the operator’s position. All maintenance activities shall be performed without frequently moving positions. Two modes of egress shall be provided from any confined space or area of greater than 100 ft. sq. All equipment shall be removable for repair or replacement without disturbing other equipment in the system, such as conduit and other "utility" items. To include any misc.

items i.e. tubing removal of power or signal wiring on the components, needing to be removed for access to equipment.

4.2 Maintenance Accessibility. All enclosed booths shall have LED White lights installed for aid in maintenance at a minimum 75-foot candles throughout; verified at part height, at each corner of booth. All lights shall be connected to a switch on exterior of booth.

4.3 Safety and Health Requirements. All Fluorescent Penetrant System parts, components, mechanisms, and assemblies furnished on the MPI Line, whether or not specifically required herein, shall comply with all OSHA requirements. Any suspended weight that inspection personnel would be required to be under at any time shall include some safety device to prevent injury to inspection personnel in the event that the main suspension system should fail.

Drip pans shall be provided in the conveyance path to prevent any deposits of chemicals on the floor from normal operation of the equipment.

4.4 Safety Guarding. The safety devices shall not interfere with the operation of the

Fluorescent Penetrant System. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts. Examples of guarding methods are—barrier guards, two-hand tripping devices, electronic safety devices, etc. per OSHA 1910.

4.4.1 Guards must affixed to the MPI system, where possible and secured elsewhere if for any reason attachment to the machine is not possible. The guard shall be such that it does not offer an accident hazard in itself.”

4.4.2 Guards shall be provided to cover all belts, gears, electric motors and any other mechanical moving parts. Safety interlocks, over-travel limit stops and warning devices shall protect the MPI System, controls and operator from damage

4.5 Audible Noise Level. Audible noise emitted by the equipment shall not exceed 80 decibels (dB) from any operator work position or travel area, measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any other point at a distance of three (3) feet from the equipment. Every effort shall be made in the overall MPI design to reduce noise levels to less than 80 dB from any operator work position or travel area.

4.6 Lockout/Tag out. MPI System or equipment shall accept lockout devices for the isolation of energy sources.

4.7 Walking/Working Surfaces. All floor and wall openings/holes within and immediately adjacent to MPI shall be protected and not left uncovered in accordance with 29 CFR 1910

Subpart D.

4.7.1 During equipment installation/removal, warning signs and rigid barricades shall be promptly placed when covers of manholes, hand holes, or when floor openings/holes exist.

4.7.2 Warning/Caution Labels: Prominent and legible warnings, shall be posted in the area or on the equipment and, where feasible, areas demarcated to indicate the contractors work area.

4.8 Asbestos Restriction. Asbestos and materials containing asbestos, shall not be used on or in the MPI Line.

4.9 Lead. Lead and materials containing lead, shall not be used on or in the MPI Line.

4.10 Use of Polychlorinated Biphenyl (PCB). The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited.

4.11 Environmental protection. Under the operating, service, transportation, and storage conditions described herein, the MPI Line shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

4.12 Lubrication. A means to ensure adequate lubrication for all moving parts. Recirculating lubrication systems shall include a filter that can be cleaned and or replaced. In the case that a low oil condition would occur, the PMI System shall enter an emergency stop condition upon completion of the current operation. Oil holes, grease fittings, and filler caps shall be accessible without removal of machine panels. Lockout of machines and invasion of guarded areas is acceptable. Lubrication shall meet high quality industry standards. All grease fittings shall be easily accessible or plumbed to an accessible location, if at all possible.

4.13 Contractor Responsibility. The contractor shall not utilize U.S. Government personnel, equipment, or consumable materials. The contractor can use government furnished water and power; however, the contractor is responsible for all connection materials and related design carrier.

5. CONTRACT SCHEDULE.

5.1 Government anticipated project schedule, shall follow outlined below. The contractor shall provide an Integrated Master Schedule, which includes critical path and major milestones with their proposal. The contractor shall ensure adequate allowance is in place to complete the contract on time. Special attention shall be given to the installation period (reference section 13 of Specification) at Hill Air Force Base such that no delays shall occur in this period, as delays shall directly affect weapon system sustainment activities. (CDRL A001)

Government Anticipated Project Schedule

Activity Time

Award to Critical Manufacturing Review 170 days

Critical Manufacturing Review Period 20 days

Critical Manufacturing Review to Delivery 30 days

Delivery to Beneficial Acceptance 50 days

Beneficial Acceptance Period 7 days

Technical Performance Assurance Period 35 days

Final Acceptance 2 days

Total 314 Days

5.1 Preconstruction Conference. A Preconstruction Conference (PreCon) shall be conducted virtually or by phone within 15 calendar days after award. Representative(s) from the contractor’s plant who are familiar with both the equipment to be furnished and the requirements of the specification shall attend the PreCon. During or within 15 days of the

PreCon the contractor shall submit an updated Integrated Master Schedule (IMS) for the period of the contract. The IMS shall include interim design review and final design review with the

Government Program Manager. There may be more than one interim design review. It is critical that the design meets the requirements of this specification and that no interference occurs to other operations in the facility. The IMS shall also show when the safety plan shall be submitted.

Other items in the contract, and all requirements regarding regulatory compliance, equipment, layout, delivery, demolition, installation, disposal, training, and warranty. (CDRL A001)

5.2 Bi-Weekly Meeting. Meetings shall be held periodically during the contract. The government project manager shall establish meeting forum, schedule, attendees, and frequency as needed. The contractor or contractor superintendent shall participate. Initially a status meeting shall be held monthly on conference call. As on-site work begins meeting frequency is expected to be weekly. Additional informal and formal meetings may be scheduled by the government project manager or the contractor to resolve issues in a timely manner. The purpose of each meeting shall be to coordinate and review implementation schedules, implementation issues, overall project status and any other issues. The contractor shall ensure subcontractors and appropriate personnel are invited as required. Meetings are to be held in an

MXSG provided conference room in building 843 or other locations approved by the government project manager.

6 GOVERNMENT FURNISHED PROPERTY (GFP)

6.1 There will be no GFP for this acquisition.

7 BASE ACCESS

7.1 The contractor respective employees shall be required to obtain government identification, security badges, and controlled area badges to gain access to Hill AFB and building

507 prior to performing any work on site. Building 507 is in a controlled area. This process can take as much as 120 days to accomplish. See General Requirements Section 01 00 00, para. 1.15, Appendix E.

7.2 Normal hours of operation: The contractor shall have access to the facility during normal hours of operation: Monday through Friday from 6 A.M. to 6 P.M. MST with the exception of the recognized holidays listed below. After hour access may be granted at Governments’ discretion.

Authorization to work any times or days shall be requested to the Government Program

Manager at least two weeks in advance. Production activities in the building vary according to changing workloads.

7.3 Recognized Holidays New Year’s Day, Martin Luther King Day, Presidents Day, Memorial

Day, Independence Day, Labor Day, Columbus Day, Veterans Day, Thanksgiving Day and

Christmas Day. If the holiday falls on Saturday, it is observed on Friday. If the holiday falls on a

Sunday, it is observed on Monday.

7.2 Overhead Cranes are off from 4:00 P.M. until 5:00 A.M. Government will authorize

Contractor to use the Cranes to remove and install equipment when the overhead crane is off between the hours of 4:00 P.M to 5:00 A.M. MST Monday through Friday excluding Government recognized holidays. The overhead crane system rated at 1 ton; anything over this weight shall require additional support. In order to utilize the crane system, the contractor shall attend an on-site training by Government personnel for the safe operation of the crane.

7.3 With prior approval from the Government Facility Engineer, the steam system can be turned off from 4:00 pm until 5:00 am. The contractor shall not be authorized to shut down the steam pipes unless it has been approved by the Facility Engineer.

8 TOOLS, MATERIALS, AND EQUIPMENT CONTROL.

8.1 The contractor shall establish a dedicated and secure Contractor Work Zone to separate the Contractor Work Zones from the production areas. All staging areas, material storage, and work areas shall be confined to the area inside the Contractor Work Zone. The size and location of the Contractor Work Zone shall be coordinated with CMXG (building production organizations) to minimize the amount of disturbance to depot production activities. The contractor shall maintain all tools, materials, equipment, and perform all work (as much as possible) within the Contractor Work Zone.

8.2 The Contractor shall submit a safety plan a minimum of 60 days prior to performing work at Hill Air Force Base in accordance with Appendix C. (CDRL A003)

9 CONSTRUCTION.

9.1 The MPI Line 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 MPI Line to its maximum rating and capacity without distortion. Structure shall be made of suitable material and/or properly coated to withstand the environment in which it is installed for the life of the equipment. The current system is elevated over a containment area, so a support structure, shall be designed under the new MPI system to properly support the system at appropriate working height on the process floor. Contractor shall verify existing support structure can support. The new process equipment shall modify the design accordingly. New footings may be required. The floor in the containment area is a minimum of 6" deep concrete and located approximately 9 feet below the process floor. Any new concrete shall be epoxy coated to match the existing floor. This is required for protection from chemicals and for ease of wash down.

9.2 Painting. The MPI Line shall be painted or finished in accordance with the manufacturer’s commercial practice and prepared and primed per the instructions of the coating manufacturer. Coatings shall be applied to withstand the environment in which the MPI

Line is ultimately installed. Painting on equipment shall be completed prior to installation, not at the installation facility.

9.2.1 Contractor shall paint all new and modified steel structure. This includes but is not limited to new steel work and areas where the existing steel work finish coating is damaged during this project. All painting shall be scheduled and accomplished when the facility not occupied or minimally occupied as approved by government project manager. All facility structural, painting, shall be prepared thoroughly removing scale, rust, and debris from surfaces.

9.2.2 Contractor shall paint the structural steel with the following: Primer: Zinc-Rich

Epoxy Primer Coat Epoxy polyamide, MIL-DTL- 24441/19 (Formula 159, Type III).

Intermediate coat: Epoxy polyamide, MIL-DTL-24441/31 (Formula 152, Type IV, White

(Tinted)). Tint to approximately FED-STD- 595 color number 27778 parchment using pigment dispersions prepared for epoxy paint tinting. Polyurethane topcoat:

Polyurethane coating topcoat of MIL-PRF- 85285, Type II. The tint shall match existing structure paint color.

9.3 Workmanship. Workmanship of the MPI Line 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.

9.4 Drawings. Contract drawing and/or specifications are required per Section 01 00 00

General requirements. (CDRL A005)

10 REMOVAL DEMO Steel structure, walls, ceiling, grading, sump pit, piping, electrical, curtain

10.1 If any utilities are required to be shut down for any production time, The Government requires a minimum 21 day notice for approval prior to any action taken.

10.2 All open holes, shall be guarded, per OSHA regulations during the entire construction period.

11 INSTALLATION.

11.1 The south MPI Line shall be capable of being used while the new north booth is under construction. Installation of new system shall not obstruct or impede existing operations to include the existing overhead crane system from running parts throughout the facility. Other methods of minimizing impact to production shall be submitted, and may be approved by the

Contracting Officer after review by the government project engineer. During installation, a representative from the prime contractor shall be present.

11.2 The contractor shall be responsible for the complete installation of the Magnetic particle booth. This shall include, but is not limited to, any required demolition and removal of equipment/materials no longer needed as well as any modification of system support structure, installation of all components and systems, filtration, and lubrication. All removed equipment and materials shall be moved to the East side of the building to designated location approved by

Government Program…