17-13-1300_PD_17R0007.docx

VIBB 17-13-1300

3 May 2017

PURCHASE DESCRIPTION FOR THE ACQUISITION OF AN AUTOMATED CLEANING LINE

1.0 SCOPE.

1.1 Scope. The content of this specification describes the minimum requirements for design, manufacture, delivery, installation, and acceptance testing of an Automated Cleaning Line from here on known as the system. This will replace one (1) manual cleaning line in Shop 93112, Building 133, at the Fleet Readiness Center East (FRCE). The equipment shall be used to perform automated cleaning of hot section turbine engine components per Local Process Specification (LPS) CP03-0-FF-9537. This equipment will process various aircraft engine components from H-53, AV-8B, and other military aircraft.

2.0 APPLICABLE DOCUMENTS.

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

2.2 Government Documents.

2.2.1 Specifications, Standards, and Handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract.

STANDARDS – FEDERAL

FED-STD-H28A: Screw Thread Standards for Federal Service (1994 Ed.)

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

29 CFR 1910: General Industry, OSHA Safety and Health Standards (2015 Ed.)

29 CFR 1926: Safety and Health Regulations for Construction

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

Environmental Protection Agency (EPA)

40 CFR 82: Protection of Stratospheric Ozone (2015 Ed.)

40 CFR 761: Polychlorinated Biphenyls (PCBs) Manufacturing, Processing, Distribution in Commerce, and Use Prohibitions (2016 Ed.)

(Application for copies should be addressed to the EPA Ariel Rios Building 1200 Pennsylvania Avenue, N.W. Washington, DC 20460)

DEPARTMENT OF DEFENSE

U.S. NAVY

OPNAV 5100.23G w/change 1: Navy Safety and Occupational Health Program Manual (2011 Ed.)

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

NAVAL FACILITIES ENGINEERING COMMAND

NAV P-307 w/Change 3: Management of Weight Handling Equipment (2012 Rev.)

(Copies available online at https://portal.navfac.navy.mil/portal/page/portal/docs/doc_store_pub/p-307%20december%202009.pdf or from Naval Inventory Control Point, ATTN: NAVICP 03334 Room 3200, 700 Robbins Avenue, Philadelphia, PA 19111-5098)

UNIFIED FACILITIES CODE (UFC)

UFC 1-200-01: General Building Requirements (2015 Rev.)

UFC 3-301-01w/Change 1: Structural Engineering (2014 Ed.)

UFC 3-410-04N: Industrial Ventilation (2004 Ed.)

UNITED FACILITIES GUIDE SPECIFICATIONS (UFGS)

UFGS-23 35 19.00 20: Industrial Ventilation and Exhaust (2010 Ed.)

UFGS-23 08 01.00 20: Testing Industrial Ventilation Systems (2006 Ed.)

(Copies can be acquired at https://assist.daps.dla.mil/quicksearch or Whole Building Design Guide, National Institute of Building Sciences, 1090 Vermont Avenue NW, Suite 700, Washington, DC 20005 or www.wbdg.org)

US ARMY CORPS OF ENGINEERS (USACE)

COE EM 385-1-1: Safety and Health Requirements Manual (2014 Rev.)

(A copy of this instruction can be acquired at http://www.usace.army.mil/publications/eng-manuals/em385-1-1/entire.pdf )

MILITARY STANDARDS

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property (2012 Ed.) Item Unique Identification Marking (IUID)

MIL-STD-1472G: Human Engineering (2012 Ed.)

MIL-STD-1839: DOD Standard Practice for Calibration and Measurement (2010 Ed.)

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

2.2.2 Other Government Documents, Drawings, and Publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract.

LOCAL FACILITY DOCUMENTS

FRCEASTINST 5090.1: Environmental Compliance

Local Process Specification (LPS) CP03-0-FF-9537: Cleaning of Hot Section Turbine Engine Components (Revision D)

(A copy of this manual can be acquired at https://www.neco.navy.mil/necoattach/M0014610T9017M0014610T9017_Attachment_01.pdf )

FRCE Drawing (Attachment A dated 12 December 2016): PE-21626 Equipment Layout and Utilities Locations

(Applications for these documents should be addressed to the contracting officer)

2.3 Non-Government Publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract.

2.3.1 Specifications, Standards, and Handbooks.

American National Standards Institute, Inc. (ANSI)

ANSI B11/STD 11.19: Machines-Performance Criteria for Safeguarding (2010 Ed.)

(Address application for copies to the American National Standards Institute, Dept. 969, 1430 Broadway, New York, NY 10018)

American Society of Civil Engineers (ASCE)

ASCE 7-10: Minimum Design Loads for Building and Other Structures (2013 Rev.)

(American Society of Civil Engineers, 1801 Alexander Bell Drive, Reston, VA 20191 or www.asce.org)

American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE)

ASHRAE 90.1-2016: Energy Standard for Buildings Except Low-Rise Residential Buildings (2016 Ed.)

(American Society of Heating, Refrigerating, and Air-Conditioning Engineers, 1791 Tullie Circle, NE, Atlanta, GA 30329 or www.ashrae.org)

American Society of Mechanical Engineers (ASME)

ASME A13.1: Scheme for the Identification of Piping Systems (2015 Ed.)

ASME B16.3: Malleable Iron Threaded Fittings Classes 150 and 300 (2011 Ed.)

ASME B16.5: Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard (2013 Ed.)

ASME B16.9: Factory-Made Wrought Buttwelding Fittings (2012 Ed.)

ASME B16.11: Forged Fittings, Socket-Welding and Threaded (2011 Ed.)

ASME B31.1: Power Piping Code (2016 Ed.)

ASME B31.9: Building Services Piping (2014 Ed.)

ASME Y14.100-2013: Engineering Drawing Practices (2013 Rev.)

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

American Society for Testing and Materials (ASTM)

ASTM A53/A53M: Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless (2012 Ed.)

ASTM A123: Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products (2015 Ed.)

ASTM A182/A182M REV A: Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service (2016 Ed.)

ASTM A216: Standard Specification for Steel Casings, Carbon, Suitable for Fusion Welding, for High-Temperature Service (2016 Ed.)

ASTM A312 REV A: Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes (2016 Ed.)

ASTM B209: Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate (2014 Ed.)

ASTM C195: Standard Specification for Mineral Fiber Thermal Insulating Cement (2103 Rev.)

ASTM C547: Standard Specification for Mineral Fiber Pipe Insulation (2015 Ed.)

(American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959 or www.astm.org)

International Organization for Standardization (ISO)

ISO 4413: Hydraulic fluid power-General rules and safety requirements for systems and their components (2010 Ed.)

ISO 4414: Pneumatic power-General rules and safety requirements for systems and their components (2010 Ed.)

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

Manufacturer’s Standardization Society of the Valve and Fittings Industry, Inc. (MSS)

MSS SP-58: Pipe Hangers and Supports – Materials, Design, Manufacture, Selection, Application, and Installation (2009 Rev.)

MSS SP-70: Gray Iron Gate Valves, Flanged and Threaded Ends (2011 Ed.)

MSS SP-71: Gray Iron Swing Check Valves, Flanged and Threaded Ends (2013 Rev.)

MSS SP-110: Ball Valves Threaded, Socket-Welding, Solder Joint, Grooved and Flared Ends (2010 Ed.)

(Manufacturers Standardization Society of the Valve and Fittings Industry, Inc., 127 Park Street, NE, Vienna, VA 22180 or www.mss-hq.org)

National Electrical Manufacturers Association (NEMA)

NEMA 250: Enclosures for Electrical Equipment (1000 Volts Maximum) (2014 Ed.)

NEMA ICS 1: Industrial Control and Systems General Requirements (2015 Rev.)

NEMA ICS 6: Industrial Control and Systems: Enclosures (2011 Rev.)

NEMA MG 1: Motors and Generators (2016 Ed.)

NEMA Z535.4: Product Safety Signs and Labels (2011 Ed.)

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

National Fire Protection Association (NFPA)

NFPA 70: National Electrical Code (2017 Ed.)

NFPA 70E: Standard for Electrical Safety in the Workplace (2015 Ed.)

NFPA 79: Electrical Standard for Industrial Machinery (2015 Ed.)

NFPA 704: Standard System for the Identification of the Hazards of Materials for Emergency Response (2017 Ed.)

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

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

3.0 REQUIREMENTS.

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

3.1.1 Measuring and Indicating Device Graduations. All measuring and indicating devices on the system shall be graduated in the inch/pound system.

3.1.2 Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's work station(s).

3.1.3 Safety and Health Requirements. All system parts, components, mechanisms, and assemblies furnished on the system, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910. The contractor shall comply with all requirements of FRCEASTINST 5000.1A while at the FRCE.

3.1.3.1 Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11.19. The safety devices shall not interfere with the operation of the equipment. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

3.1.3.2 Human Engineering. The equipment shall be ergonomically designed in accordance to MIL-STD-1472G, as to reduce/eliminate injury to the operator while operating the equipment. All points of operation shall be easily accessible to the operator from the front of the tanks and tables with minimal motion and there shall be no overextending conditions. The system shall be designed and manufactured to minimize the possibility of human error or injury (i.e. back injury) and to ensure human/machine compatibility. Adequate access to support maintenance functions and personnel shall be provided as part of the design.

3.1.4 Audible Noise Level. Audible noise emitted by the equipment shall not exceed 85 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, in accordance with OPNAVINST 5100.23 at the operator's work position or any point at a distance of three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

3.1.5 Hazardous Material Exclusions. Supplies or materials being provided as part of the equipment shall be free of known hazardous materials. Hazardous materials shall not be brought on site without prior approval of the Government Point of Contract. Hazardous materials not needed for this project are prohibited. Definitions of hazardous materials are specified in accordance with FED-STD-313D. Notwithstanding any other hazardous material usage permitted in this contract, radioactive materials or instruments capable of producing ionizing radiation as well as materials which contain asbestos, mercury, cadmium, lithium, methylene chloride, lead (= or <0.06%), or polychlorinated biphenyls (PCBs) verified containing less than five (5) parts per million (<5 ppm) in accordance with 40 CFR part 761, are prohibited. Nickel Metal Hydride and lithium batteries are permissible for memory backup. Class I Ozone depleting substances, as defined in 40 CFR 82, shall not be used or be provided as part of the equipment. Exceptions to the prohibition of these materials shall be referred to the Contracting Officer in writing, for consideration within thirty (30) business days after contract award and prior to any work being performed. Contractors shall comply with FRCEASTINST 5090.1, before introducing to, or removing any hazardous materials from, FRCE. The contractor shall submit all safety data sheets (SDS) prior to bringing any hazardous materials on site at FRCE. Under the operating, service, transportation, and storage conditions described herein, the system shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

3.1.6 Lubrication. Means shall be provided to ensure adequate lubrication (oil, grease, coolant, etc.) for all moving parts. Recirculating lubrication systems shall include a filter that is cleanable or replaceable. Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low lubrication condition. When a low lubrication condition occurs the machine shall complete the current operation and come to a complete stop. The machine shall indicate that lubrication is required and the operator shall refill the lubrication reservoirs according to machine manuals. All oil holes, grease fittings, and filler caps shall be easily accessible.

3.1.7 Replacement Parts. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, 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.

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

3.2.1 Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

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

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

3.2.4 Materials. Direct contact between dissimilar metals, especially brass, copper, or steel in contact with aluminum or magnesium, shall be avoided. When dissimilar materials are used a dielectric barrier is required preventing the metals from contacting each other.

3.2.5 Painting. The system shall be painted in accordance with the manufacturer’s commercial practice. All paint shall be of the lead free type.

3.2.5.1 Corrosion Control. Ferrous components of equipment subject to corrosion shall be galvanized or similarly treated before painting. Painting is an acceptable corrosion resistant treatment for switchboard panels, distribution cabinets, and similar enclosures.

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

3.3 Components. The system shall contain all stations and ancillary equipment necessary to perform cleaning of hot section turbine engine components per Local Process Specification (LPS) CP03-0-FF-9537. The system shall consist of, at a minimum, the following components:

a. Automated Material Handling System

b. Ten (10) Tank Cleaning Line

c. Control System

3.3.1 Components to be Processed. The cleaning line shall process parts as described below. The parts will have complex shapes with numerous holes, cavities, passages, and recesses with a high potential for liquid puddling. The maximum part size is 72 inches long by 66 inches wide by 60 inches high. The maximum part weight is 600 pounds. The cleaning line shall be capable of processing a minimum of 120 parts in an eight (8) hour period. Parts processed will vary in size and quantity.

3.3.2 Baskets. The contractor shall provide a minimum of ten (10) part baskets. All the baskets shall have the same dimensional and physical characteristics. The baskets shall be made of a strong, light weight, and corrosion resistant material. The baskets shall be made of material resistant to all chemicals used in the cleaning line. The baskets shall be robust in design and fabrication to withstand damage from normal handling in a shop environment that could prevent the basket from operating correctly inside the cleaning line.

3.3.3 Material Handling System. The material handling system shall run the length of the cleaning line to automatically transport baskets to each station as required by the recipe (Paragraph 3.3.6.5.c). The material handling system will be controlled via the Programmable Logic Controller (PLC) and Human Machine Interface (HMI) displays.

3.3.4 Cleaning Line. The cleaning line shall consist of 10 tanks total. Each tank shall have a minimum useable work area of 72 inches wide (left to right), 66 inches deep (front to back) and 60 inches high. All electrical drive components for each tank shall be mounted at shop floor level and not inside the pit. All tanks requiring recirculating or agitating pumps shall use magnetic drive pumps. All parts of the cleaning line that come in contact with the chemicals shall be SS 316. A NFPA 704 placard shall be affixed to each new tank. Specifics of the tanks are as follows:

3.3.4.1 Hot Water Rinse Tank.

a. The tank shall include heaters to heat rinse water to 180° degrees Fahrenheit.

b. The tank shall include a lowerator system to raise and lower the baskets into and out of the tank. No moving parts, guides, or wear items associated with the lowerator shall be permanently installed inside the tanks.

c. The tank shall include eductor agitation to ensure proper chemical solution mixture.

d. The tanks shall be fully insulated.

e. Appropriate ventilation shall be provided for this station per ventilation requirements stated in Paragraph 3.3.5. Appropriate ventilation shall pull any vapors away from the artisans.

3.3.4.2 Alkaline Tanks. The contractor shall provide two (2) tanks for use with J-84AL alkaline solution:

a. The tank shall include a lowerator system to raise and lower the baskets into and out of the tank. No moving parts, guides, or wear items associated with the lowerator shall be permanently installed inside the tanks.

b. The tank shall include eductor agitation to ensure proper chemical solution mixture.

c. The tanks shall be fully insulated.

d. The tanks shall be cable of heating the solution to 190°-200° degrees Fahrenheit and sustaining that temperature.

e. Appropriate ventilation shall be provided for this station per ventilation requirements stated in Paragraph 3.3.5. Appropriate ventilation shall pull any vapors away from the artisans.

3.3.4.3 Acid Descaler Tanks. The contractor shall provide two (2) tanks for use with J-3 acid descaler.

a. The tank shall include a lowerator system to raise and lower the baskets into and out of the tank. No moving parts, guides, or wear items associated with the lowerator shall be permanently installed inside the tanks.

b. The tank shall include eductor agitation to ensure proper chemical solution mixture.

c. The tanks shall be fully insulated.

d. The tanks shall be cable of heating the solution to 180°-190° degrees Fahrenheit and sustaining that temperature.

e. Appropriate ventilation shall be provided for this station per ventilation requirements stated in Paragraph 3.3.5. Appropriate ventilation shall pull any vapors away from the artisans.

3.3.4.4 Rinse Tanks. The contractor shall supply one (1) rinse tank for the alkaline solution and one (1) rinse tanks for the acid descaler.

a. Each rinse tank shall include a lowerator system to raise and lower the baskets into and out of the tank. No moving parts, guides, or wear items associated with the lowerator shall be permanently installed inside the tanks.

b. Fresh water shall circulate through the tank via eductor agitation to ensure proper removal of all residual chemical.

c. A stainless steel gutter shall collect all any overflow and direct it back into the tank.

3.3.4.5 Permanganate Tanks. The contractor shall provide two (2) tanks for use with J88L permanganate.

a. The tank shall include a lowerator system to raise and lower the baskets into and out of the tank. No moving parts, guides, or wear items associated with the lowerator shall be permanently installed inside the tanks.

b. The tank shall include eductor agitation to ensure proper chemical solution mixture.

c. The tanks shall be fully insulated.

d. The tanks shall be cable of heating the solution to 185°-200° degrees Fahrenheit and sustaining that temperature.

e. Appropriate ventilation shall be provided for this station per ventilation requirements stated in Paragraph 3.3.5. Appropriate ventilation shall pull any vapors away from the artisans.

3.3.4.6 Permanganate Rinse Tank. The contractor shall supply one (1) rinse tank for permanganate.

a. The rinse tank shall include a lowerator system to raise and lower the baskets into and out of the tank. No moving parts, guides, or wear items associated with the lowerator shall be permanently installed inside the tank.

b. The tank shall include eductor agitation to ensure proper removal of all residual chemical.

c. The tank shall be fully insulated.

d. Operator shall be able to select either to rinse with fresh water or with a solution of 0.25-0.5% of Nortex heated to 150°-170° degrees Fahrenheit.

e. A stainless steel gutter shall collect all any overflow and direct it back into the tank.

3.3.4.7 Parts Washer. The contractor shall provide new parts washer for use with Ardrox 6333A or any MIL-PRF-29602 qualified cleaner. The parts washer shall meet the following requirements:

a. 460 Volt, 3 phase, 60 Hz, 67 Amp maximum is available. The contractor shall use the electrical service connected to the existing parts washer.

b. The parts washer’s interior work envelope shall be a minimum of 42 inches in diameter by 42 inches high. The total footprint of the parts washer including all accessories and with the door open shall not exceed 17 foot by 10 foot. The parts washer shall be installed flush with the floor with soap tanks being located below floor level in the pit. Available space and location is show on drawing PE-21626. The contractor shall ensure the parts washer meets all requirements of Paragraph 3.3.8 of this specification.

c. The parts washer’s construction shall be SS304 for all wetted surfaces. Spray nozzles shall be stainless steel as well.

d. The parts washer shall have a turntable with a minimum diameter of 42 inches. The turn table shall be rated for a minimum of 750 pounds. The load height for the table shall be 36 inches. A turntable jog push button shall be provided.

e. The parts washer shall include one (1) basket. The baskets shall be made of a strong, light weight, and corrosion resistant material. The baskets shall be made of material resistant to all chemicals used in the cleaning line. The baskets shall be robust in design and fabrication to withstand damage from normal handling in a shop environment that could prevent the basket from operating correctly inside the parts washer.

f. The parts washer shall include a regular wash and rinse cycle as well as a hot wash and hot rinse cycle. Operating pressure shall be 60 psi. A full flow filter system shall be provided with pressure sensor and fault indicator to make the operator aware of a clogged filter.

g. The parts washer shall be able to maintain the detergent between 140°-160° degrees Fahrenheit. In addition, the parts washer shall include a seven (7) day programmable timer for heating.

h. The parts washer shall include a manual hand held spray wand for additional touch up fresh water rinse by an artisan.

i. All drain valves shall be manually activated.

j. The parts washer shall include a stainless steel demister for removing all mist from inside the parts washer prior to opening the door.

k. The parts washer shall include a means to lock the door in an open position.

3.3.5 Ventilation. The contractor shall be responsible to determine suitability of existing industrial ventilation systems currently in use for the cleaning line. If the existing exhaust fan is determined to be sized appropriately, then the contractor may re-use the exhaust fan but shall replace the fan sheaves, drive belts and motor controller. If the exhaust fan must be replaced, then the contractor shall determine the mechanical and electrical requirements for a new replacement exhaust fan, furnish and install the new exhaust fan and electrical components as required, including, but not limited to raceways, conductors, starters, disconnects and circuit breakers, all in accordance with the fan manufacturer’s recommendations. The contractor shall install the new fan in the same location and configuration, using existing power source. If the existing ductwork is determined to be sized appropriately, then the contractor may re-use the ductwork. All existing capture hoods shall be demolished and replaced with new capture hoods. If the industrial ventilation ductwork is determined to be in-appropriate or inadequately sized, then the contractor shall be responsible for the demolition of the system, and the contractor shall be responsible for the design, procurement and installation of the new ventilation system. The contractor shall utilize the ACGIH Industrial Ventilation Manual and UFC 3-410-04N to determine required capture velocities, ducting design, hood design, and installation practices. If new ductwork is necessary, the contractor shall re-use existing wall penetrations and modify as necessary for the new ventilation system. All ductwork, either new or modified, shall be fabricated and installed in accordance with SMACNA Accepted Industry Practice for Industrial Duct Construction.

a. Design new industrial ventilation duct systems in accordance with Industrial Ventilation of Recommended Practice by The American Conference of Governmental Industrial Hygienists, Inc. New system shall include new hoods at cleaning tanks (hoods not required at rinse tanks), new ductwork, new fan(s), accessories including means of balancing, controls, and incidental items. Where existing ductwork is suitable for re-use, existing ductwork may be re-used. Where existing ductwork is re-used, provide new duct accessories specified for new ducts. Industrial ventilation ductwork and fan materials shall be fully compatible with effluent. The final completed system shall be designed, built, tested, adjusted, and balanced to accordance with the requirements of ACGIH Ventilation Manual, OSHA 29 CFR 1910, UFGS-23 35 19.00 20, UFGS-23 08 01.00 20, UFC 3-410-04N, ASCE 7-10, and NFPA 13, 70, 79, and 91. Hoods shall be constructed of galvanized steel two gauges heavier than the duct connected to the hood. Hoods shall be free of sharp edges or burrs, and reinforced to provide necessary stiffness. All joints and seams in hoods shall be sealed with fibrous exterior grade mastic. The contractor shall fasten hoods to equipment and provide additional hood support using brackets attached to the floor, wall, or equipment as required.

b. Design new ventilation system to provide a capture velocity of 150 feet per minute at the operator side of cleaning tanks. Provide “push-pull” system if required to achieve capture and contain vapors. Provide “push” fans as required to meet design “push” air volume.

c. Construct industrial ventilation system to the next higher static pressure class than that calculated (i.e. for calculated value of -2 W.G, construct ducts to -3 W.G. pressure class). Construction shall conform to SMACNA Round Industrial Duct Construction Standards. Support ductwork at intervals recommended by SMACNA. Seal all duct joints and seams.

d. The contractor shall properly test, record and submit the capture velocity and hood static pressure of each system to ensure compliance with 29CFR 1910 Subpart G, the ACGIH Ventilation Manual, UFGS-23 08 01.00 20 and this specification. For ventilation acceptance the calculated capture velocity shall match or exceed the measured captured velocity at the artisan workstation site.

e. Test and Balance (TAB) the industrial ventilation system. TAB work shall be performed by an independent contractor not affiliated with the general contractor or subcontractors. Balance system to a tolerance of ±10 % percent. At the completion of TAB work, perform smoke test to verify capture is acceptable. Make final adjustments to balancing that will improve capture where required. Smoke test shall be witnessed by FRCE Facilities Engineering Department and by Industrial Hygiene Department.

f. Ventilation as-built drawings shall be delivered to the Government thirty (30) calendar days after final acceptance.

3.3.6 Operator Control System. The control system shall be designed per NFPA 70 and NFPA 79. The machine control shall be implemented using an Allen-Bradley Controllogix PAC with Ethernet I/P network connectivity with separate networks for I/O. The machine shall also use Allen-Bradley PowerFlex series motor drives. Human Machine Interface shall be accomplished using five industrial touch screens with FactoryTalk View software. One shall be located at the load station, three shall be located across the front of the line and one shall be located at the end of the line. All HMIs shall be identical in look and function. All alarms shall be handled in such a way so that alarms will appear on all terminals in the exact same manner simultaneously. The act of resetting, acknowledging, or suppressing an alarm on one terminal shall execute that same function on the other terminals. Alarm logs on all terminals shall remain synchronized at all times to provide a sense of singular control and organization. All development of machine software and part recipes shall be the responsibility of the contractor, with input from appropriate production and engineering personnel. The PLC ladder logic and Graphical User Interface project files shall be provided to the awarded contractor with the understanding that it may be used as a basis for the development of the final software package.

3.3.6.1 Automation Programming and Visualization Computer Hardware. The contractor shall supply a new Precision M4800 Mobile Workstation PC with the following hardware requirements. The workstation shall have connectivity and visibility of the entire automation system.

a. Processor: Intel® Core™ i7-4810MQ Processor (Quad Core 2.80GHz, 3.80GHz Turbo, 6MB 47W, w/HD Graphics 4600)

b. Memory: 8GB (2x4GB) 1600MHz DDR3L

c. Video Card: AMD FirePro M5100 w/2GB GDDR5

d. Keyboard: Internal English Dual Pointing Keyboard

e. Hard Drive: 500GB 2.5" 7200rpm Hard Drive

f. Optical Drive: 8X DVD+/-RW Drive Slot Load

g. Media Card Reader: 9 in 1 Media Card Reader

h. Display: 15.6" UltraSharp FHD(1920x1080) Wide View Anti-Glare LED-backlit with Premium Panel Guarantee

3.3.6.2 Automation Programming and Visualization Computer Software. The workstation PC shall have the following software packages installed and activated.

a. Windows 7 Professional SP1 64-bit or latest SP

b. Adobe Reader latest version

c. FactoryTalk View Studio latest version

d. FactoryTalk View ME Station (Runtime) (included with FactoryTalk View Studio)

e. FactoryTalk Services Platform (included with FactoryTalk View Studio)

f. RSLinx Enterprise latest version (included with RSLogix5K)

g. RSLinx Classic latest version (included with RSLogix5K)

h. RSLogix 5000 Professional latest version

3.3.6.3 Automation Programming and Visualization Computer Software Licenses. All software installed on the workstation shall be licensed and activated. All Rockwell Software licenses shall be transferred to customer and placed under their current TechConnect contract. The information to transfer all licenses shall be forwarded to the customers receiving department.

3.3.6.4 Program Control Console. The control system shall have the ability to perform the following functions:

3.3.6.4.1 General HMI functions.

a. There shall be an overview screen, which shall provide the operator with status of each basket on the line as well as the general mode of each tank. The tanks shall indicate when a basket is present, when there is a caution/alarm, and when there is a fault associated with the tank.

b. Navigation to any screen on the system shall be a single click from the overview screen.

c. There shall be user security on the HMI to limit access to recipes and specific maintenance functions.

d. Each sensor connected to the control system shall have indication on the HMI and shall have alarms associated with it to identify problems.

e. There shall be a system-reset function to clear out the system after an event such as complete power loss.

f. Each output device (motors and valves) shall have the following:

1. Touch animation, which will pop-up a display that will identify the device number, provide a device description, display on/off/or faulted, and provide the ability to select Manual-Off-Auto modes for the device.

2. In addition, motors with VFDs will display their motor current and provide the ability to adjust the motor speed while in Manual mode.

3. The ability to clear motor faults.

g. The device shall also have color animation to indicate the following states: Off / Faulted / On / Manual-Off / Manual-On.

3.3.6.4.2 Alarming.

a. There shall be a common alarm banner on the top of each HMI screen, which shall display the most current alarm as well as provide access to the alarm history.

b. The alarm history screen shall show the active alarms as well as archived alarms.

c. Most recent motor fault codes shall be displayed on the HMI.

3.3.6.4.3 Recipes.

a. There shall be thirty (30) recipes available, these shall have the ability to have a unique name associated with them.

b. The recipe screen shall be security protected.

c. Each tank dip time and dwell time shall be adjustable per recipe.

d. Which tanks a basket gets dipped into shall be selectable per recipe.

3.3.6.4.4 Tanks.

a. The tanks, which have temperature control, shall have the ability to adjust the temperature set point. A graphic display of the temperature control loops and devices shall be provided.

b. The temperature sensors shall have the ability to be calibrated from the HMI screen

3.3.6.4.5 Fully Automatic Mode.

a. The recipes (3.3.6.4.3) shall control the process functions of each basket of parts as it is automatically processed.

b. The operator shall select a recipe for a given basket and initiate it to start processing. The basket shall then go through each process tank required for that recipe.

c. Each Tank on the system shall interact with the material handling system to transfer baskets between tanks as required by the recipe.

3.3.6.4.6 Manual Mode.

a. In addition to the automatic processing of parts, the control system shall provide operators with the ability to manually operate the motors and valves on the system.

b. When a device is placed in manual mode the HMI system shall provide indication on an overview screen and on the specific device itself.

3.3.6.4.7 Trends. Trends shall be included on the HMI system to track temperatures.

3.3.6.4.8 Light Curtains.

a. Light curtains shall be provided to protect against the automatic movement of the tank lifts and the trolley system.

b. Light curtains shall be SIL Level 3, Category 4.

3.3.6.4.9 Sensors.

a. Proximity sensors shall be provided to detect lift positions and trolley positions. These sensors shall be IP69K rated.

b. Temperature sensors shall be provided for each heating loop and shall be IP69K rated.

3.3.7 Electrical System. The system shall conform to NFPA 79. The existing source power available at the facility is 460 Volt, 3-phase, 60 Hertz (Hz). The system’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete, including 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 system with means of lockout in the off position only. Graphic symbols for logic diagrams shall be in accordance with applicable requirements of NEMA ICS1. All installed wiring shall be properly sized stranded copper wire. Each circuit shall have an equipment grounding conductor installed. An installed conduit run shall not be considered to meet the requirement for an equipment grounding conductor. Each 120 or 240 Volt circuit shall have a separate grounded conductor (neutral). No shared neutral conductors shall be permitted under any circumstances. All switches, receptacles and other wiring devices shall be commercial grade or better.

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

3.3.7.1.1 Arc Flash Protection. The system enclosures shall be marked for arc flash in accordance with NFPA 79 Paragraph 16.2.3 “Safety Signs for Electrical Enclosures” for arc flash safety.

3.3.7.2 Motors. Motors shall be rated for continuous duty. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG-1. Each motor shall have an identification plate in accordance with paragraph 3.7 to identify manufacturer, model number, serial number, voltage, amperage, horsepower, phase, frequency, and frame number. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

3.3.7.3 Fail-Safe Operation. All electrical systems shall be designed for fail-safe operation and shall be insulated, isolated, shielded, and grounded for operating safely.

3.3.7.4 Emergency Stop. The equipment shall include a minimum of eight (8) emergency stop buttons throughout the system, within the reach of the operator to remove all energy sources in a safe manner for the termination of the operation, per NFPA 79. After an emergency stop has been activated the operator shall have to re-start the system via the HMI. The emergency stop buttons shall be SIL Level 3, Category 4.

3.3.7.5 Lockout/Tagout. A single point disconnect for lockout/tagout shall be provided for the equipment per 29 CFR 1910.147. A written procedure including pictures of the actual location where each lock and tag is intended to be placed for locking out all energy sources shall be provided in accordance with Paragraph 3.6.5.

3.3.8 Hydraulic System. Where the design of the system requires any hydraulic components, the hydraulics system shall conform to ISO 4413, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

3.3.9 Pneumatic System. Where the design of the system requires any pneumatic components, the pneumatics system shall conform to ISO 4414, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

3.3.10 Operating Conditions. The equipment shall be capable of 16 hours of continuous, efficient and safe operation in a factory environment of 80° Fahrenheit ±20° degrees, atmospheric pressures between 25.5 and 30.5 inches of mercury, and relative humidity of 95% or less without exceeding the designed operating limits of any of its components.

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

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

3.4.1 Lubrication Plate. A lubrication plate shall be permanently and securely attached to each machine. The plate shall contain the following information:

a. Points of Lubricant Application

b. Servicing Interval

c. Type of Lubricant

d. Viscosity

e. Military or Federal Specification for Each Lubricant (If available)

f. Size and Type of Each Lubricant Filter

3.4.2 Nameplate. A nameplate shall be permanently and securely attached to each system component as required. The nameplate shall contain the information listed below. If the system is a special model, the model designation shall include the model number of the basic standard system and a suffix identified in the manufacturer's permanent records.

a. Nomenclature

b. Manufacturer's Name

c. Manufacturer's Model Designation

d. Manufacturer's Serial Number

e. Power Input (Volts, Total Amps, Phase, Frequency)

f. Contract Number

g. Date of Manufacture

3.4.3 Identification Marking of Military Property. An Item Unique Identification Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with System Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text. At a minimum this tag shall contain the information listed in paragraph 3.4.2 Nameplate.

3.5 Post Award Conference. The Post Award Conference (PAC) shall be held at customer facility no later than 30 days after contract 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 PAC. During the PAC a Plan of Action and Milestone (POA&M) (see Sect 3.6.6) shall be submitted to the Government in hard copy and electronic format. During the PAC, the contract and all requirements regarding regulatory compliance, equipment, layout, delivery, demolition, installation, disposal, training, and warranty shall be discussed.

3.6 Technical Data. Technical data shall contain technical information, specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language.

3.6.1 Software. An electronic copy of all software files for both HMI PCs and the ControlLogix PLC shall be provided by the Contractor to the Government before final acceptance testing. The RSLogix project file shall include tag names and other troubleshooting aids.

3.6.2 Data Rights. The Government shall have unlimited rights to all technical data and drawings. These unlimited rights will allow it to maintain and upgrade the items throughout the planned lifecycle. In addition, the Government’s license to the technical data rights, license, and drawings if the Government chooses to do so, will allow future competitive procurement of replacements and upgrades. When an upgrade or re-procurement is contemplated, the Government shall have the right to provide drawings and technical data to vendors. These data rights shall pertain to all documentation and drawings pertaining to the system to be acquired through this procurement and shall be delivered not later than the initiation of final acceptance testing.

3.6.3 Manuals. Two (2) complete printed sets and one (1) electronic copy (CD-ROM) of the Operation, Software, and Maintenance manuals shall be provided with delivery of the equipment. Documentation shall include at a minimum, operations, installation, maintenance, routine service schedule, calibration, preventive maintenance, lockout/tagout procedures, illustrated parts break down, recommended spare parts list including part numbers, vendor’s literature, mechanical design drawings, pneumatic schematics, and electrical/electronic schematics. All original software manuals and registration keys/codes shall be provided, along with original software installation disks. The maintenance procedures section of the technical manuals shall address procedures required for the corrections of faults occurring with each piece of equipment. The manuals shall contain diagnostic procedures for isolating faults, correcting the faults, and replacing parts. The technical manuals shall provide an engineering approach to the determination of preventive maintenance tasks. Preventive maintenance tasks shall be clearly outlined, with specified periods/cycles for performance of tasks. Technical data packages shall be provided for all special fixtures, tooling, gauges, and master setting equipment. All technical data, drawings, and prints furnished shall be written in the English language. Review by the Government of all technical data and manuals furnished will be accomplished during the preliminary acceptance testing at the contractor's facility. Final manuals are due at completion of installation of the equipment.

3.6.4 Site Preparation and Installation Plan. The contractor shall provide a clear and concise site preparation and installation plan. The plan shall include a detailed description of all installation work, a detailed site layout, general equipment specifications (i.e. size, weight, etc.), any required structural modification or additions, utility requirements and location, pertinent electrical details, and any other details required for site preparation and layout. As part of the site preparation and installation plan the contractor shall include facilities preparation instructions, including detailed information concerning any equipment that applies a load to a facility structure, wall, or roof. The site preparation plan shall be submitted at least 60 days prior to installation for review and comments. The contractor shall have ten days to officially respond in writing to the comments. All Government comments shall be reviewed and answered by the contractor in an acceptable manner before any work begins.

3.6.5 Control of Hazardous Energy (Lock-out/Tag-out). A written procedure for locking out all energy sources shall be provided by the contractor in accordance with 29 CFR 1910.147. The contractor shall submit draft copies to the Government in accordance with the contractor submitted and Government approved Plan of Action and Milestones (Section 3.6.7) and final copies are due at start of equipment installation. The contractor shall provide an electronic copy of the procedure in Microsoft Word to the Government as well as include the procedure in the technical manuals.

3.6.6 Instrument and Calibration Procedures. Calibration procedures and/or tooling requiring operator verification or recalibration as part of a production run or on a daily or periodic basis shall be provided to the Government. These requirements shall be in accordance with MIL-STD-1839.