Attachment_1_-_Statement_of_Work.pdf

Statement of Work For

Replace Paint and Primer Booths Bldg. 3

DLA Distribution Richmond, VA

Apr 30, 2014

15 Mar 19

Prepared By:

DLA Installation Support for Distribution

DF-FDI; Bldg. 430 430 Mifflin Avenue, Suite 2227

New Cumberland, PA 17070-5008

SP3300-19-Q-5023

ATTACHMENT 1 - STATEMENT OF WORK

TABLE OF CONTENTS

1.0 SCOPE -------------------------------------------------------------------------------- 3

1.1 SITE ----------------------------------------------------------------------------------- 3

1.2 SYSTEM LAYOUT AND FUNCTION ----------------------------------------- 3

1.3 REQUIRED SYSTEM THROUGHPUT ----------------------------------------- 3

1.4 CONTRACT LINE ITEMS -------------------------------------------------------- 4

2.0 APPICABLE SPECIFICATIONS, STANDARDS AND CODES ----------- 5

2.1 GOVERNMENT DOCUMENTS -------------------------------------------------- 5

2.2 STANDARDS AND CODES ------------------------------------------------------ 6

3.0 REQUIREMENTS ------------------------------------------------------------------- 7

3.1 GENERAL REQUIREMENTS ---------------------------------------------------- 7

3.2 EQUIPMENT SPECIFICATIONS ------------------------------------------------ 15

3.3 TRAINING ---------------------------------------------------------------------------- 23

3.4 ELECTRICAL REQUIREMENTS------------------------------------------------- 24

4.0 QUALITY ----------------------------------------------------------------------------- 25

4.1 LAYOUT ------------------------------------------------------------------------------ 25

4.2 SYSTEM MAINTENANCE ------------------------------------------------------- 25

4.3 SYSTEM CHECKOUT ------------------------------------------------------------ 26

4.4 INSPECTION AND TEST --------------------------------------------------------- 26

SECTION 1

1.0 SCOPE

This specification covers the necessary services, labor, material, equipment and control components required to supply and install a primer booth and paint booth in Bldg. 3, located at DLA Distribution Richmond, VA at DLA Aviation Richmond, VA. The systems shall be turnkey systems when complete which include fire protection systems, electrical installation and all utilities work required to make the systems completely operational.

1.1 SITE

The systems shall be installed at DLA Distribution Richmond, VA; 8000 Jefferson Davis Highway, Bldg. 3; Richmond, VA 23297-5900.

1.1.1 SITE DESCRIPTION

Bldg. 3 is a DLA Cylinder Reconditioning Facility with nominal dimension of 201ft. long x 201 ft. wide. The building is a block wall facility with a nominal stacking height of 18 ft.

1.2 SYSTEM LAYOUT AND FUNCTION

The function of Bldg. 3 is to refurbish gas cylinders. The mechanization systems consist of the following: 1) 3 reach machines for halon recovery, 2) A mechanized wheelabrator system with conveyor in-feed and out-feed of gas cylinders for stripping the paint from the cylinders, 3) A mechanized primer booth which is fed by the conveyor coming out of the wheelabrator. 4) Mechanized hydrostatic testing machines to ensure the cylinders are safe for refilling the cylinders and 5) A paint booth for repainting the cylinders after they hydrostatically tested.

Under this statement of work, the existing paint booth and primer booth will be replaced.

1.3 EXISTING SYSTEM THROUGHPUTS

The hours of operation of the system will be M-F 0700-1530. The average daily workload is as follows:

Cylinders Refurbished:

Average daily throughput: 250 Maximum daily throughput: 270

1.4 CONTRACT LINE ITEMS

The offeror shall bid the system with separate prices for each contract line item.

Quantities specified are only estimates and shall be designed and verified by the contractor. The Government shall reserve the right to award each contract line item together or separately in order to match budget allocations with the maximum system capability. If the Government does not award all the contract line items during the initial award, the Government reserves the right to award CLINS 0003 up to 180 days from the initial contract award. CLIN numbers 0001 and 0002 are the base bid. CLINS 0003 and 0004 are optional. The performance period for CLIN 0001 is 180 days, CLIN 0002 is 120 days and CLIN 0003 is 60 days.

1.4.1 CLIN NO. 0001 PAINT BOOTH

QTY DESCRIPTION

1 ea. Paint Booth 1 ea. Breathable Air System

1.4.2 CLIN NO. 0002 PRIMER BOOTH

1 ea. Primer Booth 1 ea Demo existing primer booth

1.4.3 CLIN NO. 0003 OPTIONAL DEMO EXISTING PAINT BOOTH

1 ea Demo existing paint booth

1.4.3 CLIN No 0004 OPTIONAL 1 YEAR MAINTENANCE CONTRACT

1 Yr Preventive and Corrective Maintenance Contract for the Entire

System

SECTION 2

2.0 APPLICABLE SPECIFICATIONS, STANDARDS AND CODES

The following list of specifications, standards and codes shall apply to the work covered within this document. The offeror shall be responsible to ensure that all such applicable regulations are satisfied. Special attention shall be given to federal state and local requirements. The issue in effect of the following documents on the date of the solicitation forms a part of the specification to the extent specified herein:

2.1 GOVERNMENT DOCUMENTS

2.1.1 FEDERAL SPECIFICATIONS

NN-P-71 Pallets, Material Handling, Wood Stringer Construction, 2 way and 4 way (partial)

TT-P-645 Primer, Paint, Zinc Chromate, Alkyd Type TT-E-489 Enamel, Alkyd, Gloss, Low Voc Content Aluminum W-F-408 Fittings for Conduit, Metal, Rigid (thick wall and thin wall (EMT) type

2.1.2 MILITARY SPECIFICATIONS

MIL-C-83286 Polyurethane Paint MIL-P-514 Plates, Identification, Instrumentation, and Marking DOD-P-15328 Pretreatment Primer

2.1.3 FEDERAL STANDARDS

FED-STD-595 Federal Standard 595, A (9), Colors

2.1.4 OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

STANDARDS

29 CFR 1910 Occupational Safety and Health Standards

2.1.5 U. S. ARMY CORPS OF ENGINEERS MANUAL

EM-385-1-1 General Safety Requirements

2.1.6 MILITARY STANDARDS

MIL-PRF-61002 Identification Marking of U.S. Military Property MIL-STD-248 Welding and Brazing Procedures and Performance MIL-STD-1474 Noise Limits for Army Material

2.1.7 DRAWINGS

DF-FDI Drawing No. 19-3-1 Replace Paint and Primer Booths, Bldg.

3, DDRV.

2.2 STANDARDS AND CODES

Standards of the National Electrical Manufacturer’s Association (NEMA) American Welding Society Standards Code of the American Society of Mechanical Engineers Standards of the American Institute of Electrical Engineers American Society for Testing Materials (ASTM) Standards

ASTM 53

ASTM 120

American National Standards Institute (ANSI) B20.1 Safety Standards for Conveyors and Related Equipment B31.8 Gas Transmission and Distribution Piping Systems

National Fire Protection Association (NFPA) Publications National Electrical Code (NEC) Underwriters’ Laboratories, Inc., Publication Standards

ANSI/UL-558 - Standards for Safety for Internal Combustion Engine UL-583 - Standards for Safety Power Operated Industrial Trucks

American Iron and Steel Industrial Standards (AISI) Factory Mutual System (FM) Publications

SECTION 3

3.0 REQUIREMENTS

3.1 GENERAL REQUIREMENTS

The general requirements cited herein shall apply to any system or equipment proposed by the contractor. The final design of the system and the capability of the designed system to meet the firm performance requirements of this contract are the responsibility of the contractor Alternate equipment and system architecture may be proposed by the contractor provided all firm performance requirements specified in Sections 1.3 through 1.4 and 3.1 through 3.4 are satisfied by the proposed design. The contractor shall provide all equipment, material, control components, engineering and labor necessary to provide completely installed systems ready for operation. The system shall be tested by the contractor prior to performance testing by the Government. All equipment (each whole product with its integral software) shall be the manufacturer’s current, commercially designed and available or a commercial product that has been slightly modified to fit the proposed system. The commercial product must have proven, successful field application for at least two years immediately preceding the issue date of this solicitation. The field experience of each specific equipment product shall have been gained by an identical or previous model to the one being offered. The design of the specific equipment product offered must be fully defined. Also, any design changes during the two year period of field experience shall be identified by the offeror. These design changes must be minor and insignificant or be demonstrated reliable through commercial application. Plastic piping for compressed air is prohibited except as a final carrier from solenoid to actuator. Pneumatic controls shall not be permitted.

3.1.1 MATERIALS AND OPERATING CONDITIONS

Unless otherwise specifically stated, all material shall be new and of the most suitable grade for the intended purpose. All parts shall be manufactured to such standards as will permit replacement or adjustment without modification to system components. All system equipment must be capable of operating in an industrial environment with temperatures from 50 to 100 degrees Fahrenheit and from 5 to 95 percent relative humidity (non-condensing). Dust and other airborne particle shall be filtered by a replaceable air filter. Electronic components will be equipped with cooling fan to protect the systems from heat damage.

3.1.2 TREATMENT AND PAINTING

All surfaces not yet painted but suitable for painting, with the exception of plated surfaces, shall be thoroughly cleaned to provide a clean, dry surface, free of all mill scale, oil grease, dirt, rust or other inhibiting material, and shall be painted with paint conforming to Federal Specification TT-E-489H, consisting of one coat of base primer conforming to Federal Specification TT-P-645B and one coat of enamel applied in accordance with standard commercial practices to assure complete coverage and durability of finish. An alternative painting process which will also be acceptable is an on-line metal cleaning process, then a blown dry or baked dry preparation prior to painting. The dry metal material is painted using an electrostatic spray paint process. The pre-wash cleaning process deposits an iron phosphate coating which is then covered with an alkyd baking enamel. The finish coat, when dry, shall be a smooth, even surface, free of runs, sags, drips or other defects. Color of the finish coat shall be the manufacturer’s standard commercial color.

3.1.3 STATE-OF-THE-ART COMPONENTS

The systems supplied by the contractor shall embody features that represent the current commercially available state-of-the-art products. Such features as plug-in electrical or electronic modules, solid state circuitry, trouble detection lights, and electronic diagnostic systems shall be utilized when practical to do so. Automatic or lifetime lubrication shall also be utilized where applicable.

3.1.4 MATERIAL TO BE HANDLED

Material to be handled consists of gas cylinders 70 ins. In length or less, and 9 to 16 inches in diameter and small cylinders 22 to 45 inches high and 4 to 9 inches in diameter.

These item will flow through the primer booth. The paint booth shall be used to paint these type cylinders and also the 1,000 lbs. cylinders.

3.1.5 LUBRICATION AND ADJUSTMENT

All equipment shall be greased, oiled or lubricated and properly adjusted by the contractor when installing equipment to insure satisfactory operation. Lifetime lubrication shall be utilized wherever possible.

3.1.6 DIMENSIONS

Dimensions required to design and install equipment for use in facilities shall not be obtained from drawings, but shall be taken from measurement of the site location.

3.1.7 NOISE LEVELS

No single item of equipment shall produce an operating noise level in excess of 70 decibels within 4 feet of the equipment and no combination of operating elements of equipment shall exceed an 8 hour time weighted average sound level of 84 decibels measured on the A scale, when measured in accordance with section 1910.95 (“Occupational Noise Exposure”) of 29 CFR 1910 (OSHA Safety and Health Standards).

Noise levels shall also be in compliance with MIL-STD-1472.

3.1.8 ELECTRICAL POWER SOURCE

All electrical equipment shall be taken from the main electrical panel in Room 117 which is 480 volt, 3 phase, 60 Hz. All conduit, wire, electrical power distribution equipment, including transformers, and other electrical hardware, and labor necessary to provide power to the contractor installed equipment shall be contractor furnished and installed in accordance with the National Electrical Code (NEC), National Fire Protection Association (NFPA), and other applicable state and local codes. All wiring runs shall be enclosed in heavy walled rigid conduit or thin-wall electrical Metallic Tubing (EMT) with threaded fittings. Conduit runs shall not obstruct personnel, vehicle, or other material flow patterns. All electrical work shall be in accordance with the NEC.

3.1.9 SWITCHES AND CONTROLS

All start buttons, switches, selection buttons, and other control devices shall be marked with a permanent identifying label. All wires used in control circuits shall be identified at each junction or end with a wire number which corresponds to the number used in the contractor’s electrical control drawings specified in CDRL A002) of this document.

Wiring terminal strips shall be used to the maximum extent practicable.

3.1.10 STANDARDIZATION OF COMPONENTS

Corresponding units and replaceable assemblies, subassemblies and parts in this specification shall be physically and functionally interchangeable as complete items without modification thereof or of other articles with which items are used. Where dimensions, ratings and characteristics are not specified herein, the manufacturer’s published design limits shall be used to determine compliance with the foregoing.

3.1.11 FASTENERS

Unless otherwise specified, all threaded fasteners, washers and cotter pins required to fabricate the components of the system (except those designed to be in contact with oil in reservoirs) shall be plated to resist corrosion. All fasteners for similar applications shall be identical. If torch cutting or welding is required permits must be obtained per paragraph 3.1.16.1.7.

3.1.12 METAL FABRICATIONS

Metals used in the fabrication of components shall provide original quality surface finish and shall be free from kinks and hard bends. Metals having corroded or pitted surfaces are not acceptable. Metal straightening or forming shall be done by methods that will not cause weakening or injury to the material. Burrs and sharp edges in holes and on sheets, plates and members shall be removed sufficiently to assure correct fits and to prevent loosening of fasteners and damage to components. Flame cutting with a tip suitable for the thickness of metal may be employed instead of shearing or sawing. Splatter and slag shall be removed and exposed cuts ground smooth. Heated metals shall be allowed to cool slowly, except in the performance of designed heat treatment and overheating shall be avoided in accordance with the recommendations of the metal manufacturer. All bends of a major character and all modular assembly fabrication shall be made with controlled means to ensure uniformity of size and shape.

3.1.12.1 WELDS

Welded joints shall be sound, thoroughly fused to the base metal, smooth, free from cracks, pits, holes, fissures, under cuts, rough projecting edges and sized to provide strength necessary to suit the intended purpose. All welds shall be smooth, continuous, with complete heat penetration and shall transmit stress without permanent deformation or failure when the equipment supplied is subjected to normal service and the testing in Section 4 of this statement of work. The contractor’s welders, welding operators and welding procedures shall be qualified to meet the requirements of MIL-STD-248, the American Welding Society (AWS) Standards or American Society of Mechanical Engineers (ASME).

3.1.12.2 BOLTED AND RIVETED CONNECTIONS

Holes in the sizes recommended in standard practice shall be accurately punched, drilled or formed and shall have burrs removed. Bolts, studs and cap screws shall be provided with washers or lock washers. Self-locking nuts are acceptable in lieu of standard nuts and lock washers. All fasteners shall be correctly tightened and shall have full engagement. Rivet heads shall be full, neatly made, concentric with rivet holes and in full contact with the surface of the member. Excessive upsetting of rivets to fill holes is not acceptable.

3.1.12.3 CASTINGS AND FORGINGS

Castings and forgings shall be of the best quality normally used in commercial practice and not produce any deleterious effects for the intended purpose.

3.1.12.4 MACHINE WORK

All parts shall be manufactured to gage through the use of correct jigs, fixtures, tape controlled machines or combination thereof.

3.1.13 FLOOR MOUNTING OF EQUIPMENT

All equipment shall be floor supported, except non-load bearing system components such as conduit, and shall be securely bolted to the concrete floor in accordance with Table 1.

Type Schedule Number of Bolts Required Diameter Length

IT hardware, tables, Electrical equipment and other components requiring light

Not less than one per support leg

5/16” 2”

Table 1

3.1.14 IDENTIFICATION MARKING

All equipment and major components shall have identification plates permanently attached. The information contained on the plates shall be as indicated herein and as specified in MIL-STD-130. Identification data shall include, as a minimum, contract number, manufacturer, serial number, model number and date of manufacture.

3.1.14.1 CONTROL IDENTIFICATION

Major items of electrical equipment and major components shall be permanently marked with an identification nameplate to identify the equipment by type or function and specific unit number as shown on the drawings and as required by NEC. All start buttons, selection buttons, switches and control devices shall each be marked with a permanent identification label. Hand lettering or marking is not acceptable.

3.1.15 SPECIAL PROVISIONS

3.1.15.1 INTERRUPTION OF WAREHOUSE OPERATIONS

The installation shall be phased to minimize downtime the warehouse operations shall not be curtailed nor suspended except as absolutely essential. Any required curtailment or suspension shall be coordinated with at least 5 days notice to the Government through the Contracting Officer’s Representative.

3.1.15.2 INSTALLATION SEQUENCE

Installation of the conveyor systems shall be in the following order. Demo of existing paint booth shall not occur until new paint booth is completely operational and has passed the final operating test.

a. Demo existing primer booth.

b. Install new primer booth.

c. Install new paint booth.

d. Demo existing paint booth.

3.1.15.3 WORKING HOURS

Normal working hours are 0700 through 1530 Monday through Friday excluding federal holidays. The contractor may be allowed, under extenuating circumstances, to perform work outside of regular hours. Where work is desired to be performed other than during regular hours, the contractor shall request permission from the Contracting Officer’s Representative (COR) at least 24 hours in advance to allow for the necessary arrangements to be made.

3.1.15.4 REMOVAL OF WASTE AND DEBRIS

All on-site waste and debris, old conveyor, and conduit generated in performing this contract shall be disposed of off-site at contractor arrangement and expense. The contractor shall comply with FAR 52.236-7. The contractor shall maintain the work site and premises in a clean and neat condition during the installation.

3.1.15.5 PENETRATION OF FIREWALLS

Firewalls may be penetrated for installation of electrical and communications cables and air lines pending inspection and approval by the DLA Aviation Richmond, VA Fire Department. Cables shall be enclosed in rigid conduit completely through the wall. The opening around the conduit/pipe shall be sealed with builder’s mortar and finished to original appearance.

3.1.15.6 WALL OPENINGS

The walls will be carefully cut to prevent undue damage. All permanent new openings shall be protected with masonry lintels and angle iron frames with steel jams. Head and sill members shall be not less than 2 inches by 2 inches by 5/16 inch angles and steel plate material shall be not less than ¼ inch in thickness. Openings shall be finished in a neat, quality workmanship like manner and any damage resulting to the walls or floors or any part of the warehouse shall be repaired with material of a kind, texture and quality to match existing materials. The contractor is required to obtain approval from the Contracting Officer’s Representative prior to making any permanent or temporary firewall or exterior wall openings other than those identified in this specification. The contractor is required to provide and install fire protection for all temporary or permanent openings made in the firewalls of the warehouses, including removal of fire doors. All fire protection equipment planned for or used will be installed in accordance with NFPA codes. All contractor installed fire protection equipment shall be tested in accordance with the procedure found in paragraph 4.5.

3.1.16 SAFETY REQUIREMENTS

3.1.16.1 GENERAL REQUIREMENTS

3.1.16.1.1 These safety provisions are only general in nature and are not intended to be all inclusive. The contractor shall follow and will not be excused from following the safety requirements of EM 385-1-1, appropriate safety standards or other requirements established by DLA, National Electric Code, OSHA, National Fire Code or other established safety requirements.

3.1.16.1.2 It is the responsibility of the contractor to be aware of the safety requirements for personnel, equipment, buildings and materials. All protective coverings, shields, protective barriers, barricades, warning signs, etc., will be furnished and installed in accordance with ANSI and OSHA Standards by the contractor where a hazard or potential hazard exists. Twenty-four (24) hours prior to the planned installation of protective barriers and barricades, the contractor will coordinate with the COR for concurrence and approval. The removal of barricades and barriers will be accomplished by the contractor at the completion of the work in the area.

3.1.16.1.3 All personal protective equipment (PPE) must be in accordance with OSHA Standards and must be worn by all contractor personnel throughout the system installation.

Failure to wear PPE shall be considered an OSHA violation. Safety Personnel from both the DLA Aviation, DDRV and the COR will make random inspections to ensure compliance by contractor personnel.

3.1.16.1.4 The contractor must comply with all OSHA standards for the storage, handling and application of flammable paints and liquids, combustibles and other hazardous materials. This includes the use of ventilation, personal protective equipment, respiratory protection, monitoring for air contaminants and requirements to convey to workers the hazards associated with the operation.

3.1.16.1.5 The contractor shall submit current material safety data sheets for all materials to be used on the project. This includes new materials selected and substitute materials.

3.1.16.1.6 The equipment and the controls, including any modifications and installation of same, shall conform to the requirements of ANSI/ASME B20.1-1984, Safety Standards for Conveyors and Related Equipment.

3.1.16.1.7 No torch cutting or welding work of any description shall be permitted within the installation boundaries until the site of the proposed work has been inspected by the base fire department, and a permit has been issued. Permits must be obtained on a daily basis by contractor personnel coordinating the request through Mr. David Hughes,

(757) 449-8145 and the Norfolk Naval Shipyard Fire Department and identifying the location and type of work to be done.

3.1.16.1.8 All edges shall be beveled, ground smooth, or otherwise shaped to preclude sharp edges. Protruding parts will be designed to eliminate any hazards that could cause personal injury and will be installed only after approval by the contracting officer or his designated representative. The equipment and the controls, including any modifications and installation of same, shall conform to the requirements of ANSI/ASME B20.1-1984, Safety Standards for Conveyors and Related Equipment.

3.1.16.1.9 MISHAP REPORTING

A copy of the report on each job connected injury, property damage, or motor vehicle mishap will be submitted to the COR and the safety and health office. This report may be made on either a contractor’s report form, a DLA Form 1591, mishap report, or SY 91a (motor vehicle). The estimated absence in days, if any, by employee due to injury and/or cost of property or vehicle damages shall be included.

3.1.16.2 INSTALLATION SAFETY PRACTICES

3.1.16.2.1 Personal protective equipment such as hard hats, safety glasses, safety shoes, etc., shall be worn in all areas and on all jobs as required by the safety and health office. All hard hat areas shall be indicated by contractor furnished signs. Safety and health office personnel may inspect the work site at any time for compliance.

3.1.16.2.2 All contractor material shall be stored in a neat and stable manner so as to preclude leaning or falling stacks. Housekeeping will be maintained at a high level at all times.

Scrap material, such as empty cartons, wood crates, etc., will be removed by the contractor at the end of each work day.

3.1.16.2.3 Smoking is prohibited except in designated areas.

3.1.16.2.4 Gasoline operated equipment used in the building will be kept to a minimum to preclude the build-up of carbon monoxide and other hazardous fumes. For welding, electric motor driven arc welders are preferred. If gasoline or diesel engine welders are used, the welder will be kept outside the building with welding cables run inside, or the engine exhaust will be ducted to outside the building subject to the safety and health manager’s approval.

3.1.16.2.5 Only a one (1) day supply of flammable, combustible, corrosive and other hazardous materials is to be kept at the job site. All other stock of hazardous materials shall be stored in accordance with applicable OSHA Standards at a location remote from the job site and approved by the Government.

3.1.16.2.6 Safety markings shall be in accordance with 29 CFR 1910.144 and 145. Location of safety equipment shall be designated by alternating green and white stripes on the floor.

3.1.16.3 FIRE PREVENTION

The use of all fire hydrants will be controlled by this center’s fire department. No unauthorized use of fire hydrants will be permitted. Fifteen feet clearance is required around all fire hydrants at all times. Fire aisles, building entrances and building exits will be kept clear of obstructions at all times. A 24-inch clearance will be maintained at firewalls at all times.

3.1.16.4 FLAME CUTTING AND WELDING PROCESSES

3.1.16.4.1 Welding, cutting or use of flame devices require prior approval of the Fire Chief and shall be performed in accordance with ANSI Z49.1 (1975). A welding screen shall be used whenever welding is being done. The contractor shall have on duty at such times and as required by the DLA Aviation Richmond Fire Department Fire Chief when welding, cutting or using open flame devices, a fire watcher who shall be a qualified fire fighter with not less than three years consecutive experience.

3.1.16.4.2 “Hot tapping” or other cutting or welding on a flammable gas or liquid transmission or distribution utility pipeline shall be performed by a crew qualified to make hot taps.

For a gas pipeline, see 841-28 in “Gas Transmission and Distribution Piping Systems,”

ANSI B31.8 (1968).

3.1.16.4.3 At no time will contractor use or block installed fire equipment, valve houses, or post indicator valve unless authorized by the fire department.

3.1.17 CONTRACT DATA REQUIREMENTS

The contractor shall furnish contract data as required in DD Form 1423, Contract Data Requirements List, included with this specification. Contract data, outlined in Table 2, shall be prepared in accordance with this specification or data item descriptions attached thereto, and submitted in the quantities and at the times specified for approval.

Sequence Title DID ID. Number

A001 Installation Schedule DI-S-SAT1

A002 Installation Drawings DI-E-SAT9

A003 As-Built Drawings DI-S-30575

A004 Operating Manual DI-E-SAT3

A005 Maintenance Manual DI-E-SAT3

A006 Technical Representative List DI-E-SAT11

A007 Training Material DI-E-SAT

Sequence Title DID ID. Number

A008 Power Requirements DI-P-SAT1

A009 Design Data and Calculations DI-E-2440A

A010 Real Property Materials Test Reports DI-T-30718

A011 Real Properties Facilities Fire Protection, Eng. Drawings, Associated Descriptive Data and Calc.

DI-E-SAT10

A012 Certificate of Compliance DI-E-SAT14

A013 System Test and Verification Plan DI-T-SAT1

Table 2

3.2 PAINT BOOTH AND PRIMER BOOTH

3.2.1. GENERAL. The Contractor shall furnish all services, materials, supplies, plant, labor, equipment, and superintendence as required in connection with the execution of the services identified within this SOW.

3.2.2. SERVICES. Services under this SOW consist of providing labor and material to remove and replace a paint booth and primer booth in Bldg. 03 at DLA Distribution Richmond, VA.

Specific services will include:

3.2.2.1 DEMOLITION - Remove/disconnect fire protection sprinkler system piping, compressed air, breathing air system, supply air/exhaust air duct, make-up air unit on the roof, exhaust fan on the roof, and electrical service from to the booths as necessary to facilitate the demolition and removal of the paint booth and the primer booth. The breathing air systems for the primer and paint booths are to be salvaged for reuse on the new paint booths to be installed. All demolished equipment, material, and debris shall be disposed of by the contractor off Government property. All roof penetrations shall be completely covered and sealed if they are not used. The contractor shall use the roofing material as the original installation.

3.2.2.2 PAINT BOOTH AND PRIMER BOOTH - Provide and install 1 new pressurized, dry filter crossflow paint spray booth beside the existing paint booth and provide one water wash primer booth. The primer and paint booths shall be installed in accordance with the manufacturer's shop drawings and installation instructions.

3.2.2.3 FIRE PROTECTION SYSTEMS Install a fire sprinkler system inside each of the new paint and primer booths. The systems shall be designed and installed in accordance with NFPA 33, Chapter 9, extra hazard, Group II. Sprinkler piping is to be feed from the existing wet pipe system. The only fire alarm system in this building is a signal from the existing dry pipe valve to the local Fire Station. Control of fans is to be in accordance with recommendations as indicated in NFPA 33.

3.2.2.4 COMPRESSED AIR OUTLETS Using the existing compressed air system, install three (3) compressed air outlets along each wall of each paint booth. Each outlet is to be furnished with shut off valve and filter/regulator.

3.2.2.5 BREATHABLE AIR SYSTEM OUTLETS The contractor shall install two breathable air out-lets for the new paint booth and one breathable air outlet for the new primer booth from the existing breathable air compressor system in behind the existing paint booth. All piping, labor and materials to ensure a complete and safe breathable air system for the new paint booth shall be performed by the contractor. The operators shall use their existing hoods/respirators from the old paint/primer booths. All new piping shall be type L or K copper.

3.2.2.6 NEW BREATHABLE AIR SYSTEM FOR NEW PAINT BOOTH IF CLIN

0003 IS NOT EXCERCISED The contractor shall supply a new breathable air system for the new paint booth because the existing breathable air system only has the capacity to power three outlets. There is one outlet in the existing primer booth and two outlets in the existing paint booth. Operations in the existing paint booth must be maintained until the new paint booth is completely operational. Therefore, an additional breathable air system must be supplied to maintain concurrent operations. The specifications are as follows:

Air Compressor: (Sullair Model 1100e S-Energy Encapsulated Rotary Screw Air Compressor or equivalent):

a) Must be a rotary screw compressor.

b) Shall deliver 60 acfm at 125 psig, air cooled, oil lubricated.

c) 15 HP TEFC drive motor, 460/3/80 power, NEMA 4 controls

d) Sound attenuating enclosure, heavy duty filters

e) Capable of operating as low as 66dBA

f) WS microprocessor controller with sequencing

g) 8000 hour lubricant for initial fill.

h) System must be vented to the outside for air intake.

Air Dryer: (Sullair Model RN-50 or equivalent refrigerated air dryer)

a) Designed to provide 33-39 F pressure dew point.

b) 115/1/60 power required, electric timed drain valve

c) Includes SCF 125 in-line prefilter and SCH125 in-line coalescer

d) In-line filters and automatic drains shipped loose for field installation by the supplier.

e) Refrigerant: R-134A

Receiver: (Steel Fab Model A10053 or equivalent) 240 Gallon Vertical Air Receiver)

a) Industrial design, welded steel skirt support

b) Standard FNPT tank openings.

c) Tank trim accessories shall include the following: Safety relief valve, pressure gauge and gauge cock, manual tank drain valve, timer controlled condensate drain (115V).

All tank fittings, bushings, plugs, pipe, etc shall be supplied by the contractor.

Condensate Treatment: (BEKO Quik-Pure 100 or equivalent gravity type oil water separator)

a) Shall include multi-inlet adapter for connection of condensate drains.

b) Oil removal element shall typically last for one year.

Respiratory Protection: (MST Model RP050BMST-S1 or equivalent 50 SCFM System)

a) 5700 Series CO Monitor with digital readout of CO Level.

b) Shall include two-stage inlet filter and catalyst for CO removal.

c) Panel mounted system shall include AC adapter and remote alarm.

d) 5700 Monitor shall be approved for Class1, Div 1, Grps A,B, C and D using 9V batteries.

e) Shall handle three users of full face-continuous flow hoods (contractor supplied)

f) Approximate length from paint booth to air compressor room is 170 ft.

g) Approximate length from primer booth to air compressor room is 150 ft.

h) The primer and paint booth shall be piped so that two hoods can be hooked up to the air supply outlets (contractor supplied) in the paint booth and one outlet adjacent to the primer booth.

3.2.3 PAINT BOOTH SPECIFICATION - Pressurized, Dry Filter Cross-flow Paint Spray Booth

3.2.3.1 GENERAL DESCRIPTION: Provide pressurized cross-draft type vehicle paint booths for use in painting large vehicles. Booth air shall be supplied through the use of a makeup unit. Bridge type air intake chamber straddling the vehicle doorway shall supply the booth with the necessary airflow for painting operations. Air shall be filtered at the intake chamber and drawn horizontally across the vehicle and through a filtered exhaust bridge type chamber at the rear of the booth. The air shall then be drawn from the exhaust chamber and exhausted from the system and facility by means of ductwork and plenums.

3.2.3.2 CAPACITIES AND DIMENSIONS:

a) Exterior dimensions:

i) Width: 25 feet.

ii) Length: 30 feet.

iii) Height: 16 feet.

b) Vehicle doors:

i) Type: Electrically operated flat slat canister style roll-up door, two per booth.

ii) Size opening:

(1) Width: 12 feet, 0 inches.

(2) Height: 14 feet 0 inches.

c) Personnel doors:

i) Type: Man access doors with panic locks and 18 by 24 inch observation windows, two each.

ii) Quantity: 2.

iii) Size opening:

(1) Width: 36 inches.

(2) Height: 7 feet 0 inches

d) Airflow rate: 100 FPM average over cross sectional area of empty booth.

e) Exhaust system:

i) Exhaust capacity: 32,000 CFM, external static pressure as recommended by the paint booth manufacturer, with tube axial in-line fan designed per AMCA 210 Standards.

Bearings shall have L10 life of 40,000 hrs. min.

ii) Motor: 7.5 HP with variable pitch drive sheave.

iii) Noise level: 85 dBA, maximum.

iv) Fan diameter: 48 inches.

f) Heated air makeup system:

i) Volume capacity: 32,000 CFM, external static pressure as recommended by paint booth manufacturer.

ii) Heat output: 70 degrees F maximum temperature rise.

iii) Motor: 20 HP, High Efficiency EPACT.

iv) Noise level: 85 dBA, maximum.

v) Type of heater: Natural Gas

g) Lighting fixtures:

i) Illumination level: 70 ft. candles

ii) Type: 48 inch fluorescent four tube NFP A and OSHA code approved, 32 watt,120 V AC, Class 1, Division II, ETL approved fixtures with T-8 ballast and clear tempered glass.

iii) Lamps: 48 inch color correct fluorescent tubes, four per fixture.

3.2.3.3 FEATURES AND CONSTRUCTION:

a) Construction: Paint booths shall be constructed of minimum I8- gauge galvanized sheet steel and rigidly supported with structural steel at regular intervals for rigidity and integrity. Panels are to be pre-punched, companion flanged,and have exterior flanges to provide a smooth interior surface. Booth shall be mounted directly to the concrete slab.

b) Intake/exhaust system: A fully filtered intake and exhaust air system shall be adequate for specified airflow rate and static pressures, complete with exhaust fan and TEFC motor assembly. Provide exhaust stacks, ductwork, weather caps, roof curbs, automatic dampers, flashings, and hardware necessary for a complete and operable installation.

i) Intake filters: Two-ply resilient polyester fibers with a better tackifier capable of extracting 100 percent of visible dust and removing 90 percent of micron particles.

Internal welded steel frame with self-sealing gasket. Internal wire support and heat-sealed seams. Provide adequate quantity to permit one complete filter change. Provide draft gauge for intake chamber to monitor filter restriction.

ii) Exhaust filters: .Continuous filament glass fibers with open weave pattern. UL Class 2 approved. Provide adequate quantity to permit one complete filter change. Provide draft gauge for exhaust chamber to monitor filter restriction.

c) Heated air makeup system: Provide a weatherproof, natural gas heated

d) Air makeup unit suitable for installation on the building roof to provide tempered air as required for comfortable working conditions and efficient paint drying when outside air is cool or damp. Unit shall be factory assembled, pre-wired for automatic operation, and complete as a packaged assembly. Inlet or outlet accessories shall be provided unmounted for on-site installation.

i) Heater housing: Unit shall be enclosed in a completely galvanized sheet steel enclosure with reinforcing members and lifting lugs.

ii) Natural Gas Coil: The natural gas coil shall be sized to provide a 70 degrees Fahrenheit temperature rise with 100% replacement air at the stated CFM. Discharge temperature shall be controlled with modulating valve.

iii) Fans and drivers: Unit shall be equipped with dynamically balanced centrifugal blower and motor assembly with V-belt drive.

iv) Air intake and discharge: Unit shall be configured for horizontal air intake and downward discharge.

v) Control panel: Unit shall be complete with an UL listed electrical control panel containing necessary disconnect switches, starter, relays, fuse blocks, and primary flame guard with alarm contacts, automatic pilot valve, electronic modulating control system and interlock system with booth exhaust air fan.

vi) Miscellaneous: Unit shall include motorized discharge damper, roof support curb, filter section, dirty filter indicating system, intake hood, bird screen, ducting, transitions, and other hardware and incidentals necessary for complete and operable installation.

e) Lighting fixtures: Lighting assembly shall be four tube, NFPA and OSHA code approved explosion proof fixtures with clear tempered glass windows that accept 48 inch fluorescent natural light and color correct tubes. Cool-white or warm-white tubes are not acceptable. A minimum of 75 foot candles of illumination shall be provided to all work areas within the booth.

f) Emergency lighting: Emergency lighting equipped with battery packs shall be provided and located adjacent to vehicle and personnel doors.

3.2.3.4 CONTROLS:

Provide a NEMA 12 UL listed enclosure complete with main disconnect switch, variable frequency drive, auto-balance system, remote breathable air/filter condition trouble/failure alarms, push-button station, control transformer, air make-up selector switch, indicator lights, safety interlock systems, fuses, disconnects, and other electrical control devices. All switching and controls shall meet applicable National Electrical Code requirements.

3.2.3.5 ACCESSORIES:

Accessories shall be provided as follows:

a) Remote control thermostat: Provide a remote thermostat and control station, complete with high temperature override switch for the makeup air unit, at convenient location at the paint booth, to permit operator to vary temperature in paint booth as needed for specific conditions.

b) Automatic safety shut-down system: Provide a safety shut down system with audible alarm that automatically turns off compressed air to spray booth paint gun supply line when paint accumulation in exhaust air filters reaches an adjustable preset load point and whenever exhaust fan stops running to prevent buildup of fumes to hazardous levels.

c) Limit switches: Provide an ON/OFF limit switch with timed delay to de-energize exhaust fan and spray gun air supply when any booth door is opened.

3.2.3.6 UTILITIES AVAILABLE:

a) Electrical:

i) Exhaust system: 460 V AC, 3 phase.

iii) Heated air makeup system: 460 V AC, 3 phase

iii) Lighting fixtures: 120 V AC, 1 phase, 7680 W.

b Natural gas.

3.2.3.7 FINISH:

Prepare interior galvanized surfaces as required, prime and paint with a semi gloss white enamel finish. Exterior galvanized surfaces shall be left unfinished.

3.2.3.8 INSTALLATION:

a) Perform work under direct supervision of Project Manager.

b) Install equipment in accordance with approved shop drawings.

i) Positioning: Place equipment adjacent to existing drying chamber level, plumb and at right angles to existing structures.

ii) Fitting: Where field cutting or trimming is necessary, perform in a neat, accurate, professional manner without damaging equipment or adjacent work.

iii) Anchorage: Attach equipment securely to floor to prevent damage resulting from inadequate fastening. Installation fasteners shall be installed to avoid scratching or damaging adjacent surfaces.

iv) Roof penetrations: The contractor shall be responsible for making all roof penetrations required for the ventilation system. All penetrations shall have flashing and shall be completely sealed to prevent water infiltration to the roof decking or inside the warehouse. All roof penetrations left from the previous booth that will not be reutilized will be completely covered and sealed to protect roof decking and protect the interior of the building from water infiltration.

v) Upon completion of work, finished surfaces shall be free of tool marks, scratches, blemishes, and stains.

3.2.3.9 CLEANUP:

a) Touch-up damage to painted finishes.

b) Wipe and clean equipment of any oil, grease, or solvents to make ready for use.

c) Clean area around equipment installation and remove packing or installation debris from job site.

3.2.4 WATER WASH PRIMER SPRAY BOOTH

Water wash pump-type spray booth is designed and constructred to handle high volume paint spraying operations. The high volume, low velocity water curtain design includes non-clog nozzles on a large water manifold to assure trouble-free performance. The design floods the internal wash curtains with water for more effective overspray pick-up. Moisture eliminator plates displace paint-laden moisture by changing airflow directions. This equipment has no filter pads to replace, paint overspray is trapped in recirculating water allowing longer period between major clean-ups.

3.2.4.1 BOOTH STRUCTURE

The booth is made of minimum 18 gauge galvanized sheet steel, double welded tank chamber for extended life. The booth shall be shipped in two modular sections with all flood sheets and eliminators assembled from the factory. The chambers are constructed of 12 gauge galvanized sheet steel with double welded seams. The moisture eliminators are constructed of 14 gauge galvanized sheet steel. Access doors are designed for maintenance.

The booth features are as follows:

a) An upper and lower wash chamber

b) Large capacity collecting pan

c) Slotted water intake pipe to ensure sediment free water

d) Circulating water to maintain a constant flushed system

e) Removable manifold for easy maintenance

f) Hinged water curtain to allow easy access to the rear of the collecting pan

g) Access door located just below the fan for easy maintenance

h) External float box with level control

i) Two conveyor opening: 30 ins. wide x 2 ft. high.

3.2.4.2 BOOTH SPECIFICATIONS

The booth specifications shall be as follows:

a) Working width: 12’-0”

b) Working depth: 8’-0”

c) Overall Height: 10’-2”

d) Overall depth: 13’-2”

e) Airflow SCFM at 1.3” SP: 12,000

f) Exhaust duct dimeter: 30”

g) Exhaust Motor: HP: 7.5 HP

h) Pump GPM: 396

i) Pump HP: 7.5

j) Light Fixtures: 2 - per paragraph 3.2.3.3, paragraph H (must be explosion proof)

3.2.4.3 SITE PREP, DEMO OF EXISTING BOOTH AND INSTALLATION

The contractor shall be responsible to do all roof penetrations for the ventilation systems and shall seal all existing penetrations if the existing penetrations cannot be reused. The preference is to reutilize the roof penetrations to the maximum extent possible. All penetrations shall have flashing and shall be completely sealed to prevent water infiltration to the roof decking or inside the warehouse. Also all electrical work shall be performed by the contractor to make the system a complete and useable system. The contractor shall demo the existing booth and dispose of the existing booth. The existing booth has one sprinkler head which will be capped off during demo and a new sprinkler head installed with the new booth in accordance with paragraph 3.2.2.3. In addition all plumbing demo/installation and hook-up shall be performed by the contractor to make the system a complete and useable system. If the conveyor system has to be dismantled to to demo or build the new primer booth, the contractor shall be responsible for reinstallation of the conveyor system configured identical to before the existing booth was demoed.

3.3 TRAINING

Training shall be provided in the operation and maintenance of all equipment provided by the contractor. All training media such as visual aids, diagrams and drawings shall be furnished as required per sequence A007. All training shall be conducted by individuals well qualified in training matters, and the operation and maintenance of the contractor furnished equipment.

3.3.1 OPERATOR TRAINING

Two classes, two hours each on-site training shall be conducted by the contractor in the operation of contractor supplied system components. Government personnel shall generally be experienced in warehouse operations. Operator training shall be conducted on a scheduled basis with class size not to exceed ten persons each. Operator training shall be completed prior to performance testing (paragraph 4.4.4). Operational training shall provide employees a complete knowledge of operation of the system and shall include a handout booklet containing pertinent information regarding equipment operation. Specific areas of operator training shall include, but are not limited to:

a. Familiarization with the system capacity, operating characteristics and performance parameters, including operation of manual controls.

b. Familiarization with location, purpose and function of all controls.

c. Hands-on training under expected operating conditions including simulation of emergency/error situations.

3.3.2 ONSITE MAINTENANCE TRAINING

Two classes, eight hours each, onsite maintenance training shall be conducted by the contractor in the maintenance of the installed system provided by the contractor.

Maintenance training shall be conducted on a scheduled basis with class size not to exceed 10 persons each. Onsite training shall provide a working knowledge of preventive maintenance, troubleshooting, diagnostics, and correction of malfunctions including repair, adjustment, disassembly, inspection, and overhaul and reassembly of system components. Specific areas of training shall include, but are not limited to, the following:

a. An overview of manufacturing processes and techniques employed in constructing the systems components.

b. Diagnostic techniques required to isolate defective components using test equipment that is listed by the contractor as necessary to equipment furnished by the contractor.

c. Hands-on training in the repair, adjustment, disassembly, inspection, overhaul, and reassembly of system components to circuit board component level.

d. Preventative maintenance.

3.4 ELECTRICAL REQUIREMENTS

All electrical construction, controls and equipment shall be manufactured and installed in accordance with NFPA 70 (National Electrical Code).

3.4.1 ELECTRICAL INSTALLATION

All electrical equipment shall be taken from the electrical panel in Bay M-5 (east side of the Bldg.), Room 117, (Electrical Room). Power source shall be 480 volt, 3 phase, 60 Hz. All conduit, wire, electrical power distribution equipment, including transformers, distribution panels, subpanels and other electrical hardware, and labor necessary to provide power to the contractor installed equipment shall be contractor furnished and installed in accordance with the National Electrical Code (NEC), National Fire Protection Association (NFPA), and other applicable state and local codes. All wiring runs shall be enclosed in heavy walled rigid conduit or thin-wall electrical Metallic Tubing (EMT) with threaded fittings. Conduit runs shall not obstruct personnel, vehicle, or other material flow patterns.