SPEC SHEET.pdf

BULLET SPECIFICATION FOR

30 TON ABRASIVE BLAST & RECOVERY UNIT with STORAGE HOPPER

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JML 4165-3927

OPERATING CONDITION AND SIZE OF EQUIPMENT

Operating Environment - The proposed system will be operated in a heavy-duty marine industrial environment and shall be capable of continuous operation over an extended period of time with minimal maintenance and upkeep. The blasting operation will occur in a remote location from the abrasive blast machine.

Equipment Size - The proposed system shall be used in an industrial manufacturing environment having limited space. Maximum overall dimensions shall be 12’- 0” high x 8'-6" wide x 10’- 9” long (excluding access ladder) and maximum overall weight of 12,000 pounds when empty.

Environmental Conditions - The unit shall be designed to operate in a salt and dust laden outdoor industrial environment, subject to wind driven rain, sleet and snow.

Temperature Range: 32° Fahrenheit to 110 o Fahrenheit

Relative Humidity: Up to 100% Non-Condensing

GENERAL BLAST EQUIPMENT REQUIREMENTS

Blast Media – Steel grit G80, G50, G40 or G25/50 blend and garnet/aluminum oxide shall be used.

Electrical - The equipment as delivered and with all accessory parts shall operate from a single source of primary power, which is 110 VAC (+5%), single-phase. The proposed system shall include all transformers required for individual circuits such as control power, etc.

Compressed air - The unit shall operate from a single source of dry, compressed air which delivers 1200 CFM at 100 PSIG based upon the performance of four (4) 7/16" diameter blast nozzles.

NRTL Listing or NRTL Field Inspection and Approval - The blast and recovery system shall be listed or approved.

Energy Isolating Devices - The equipment shall be provided with energy isolating devices (e.g., power switches, safety switches, circuit breakers, valves, etc.) that protect personnel from the release of hazardous energy. The devices shall be designed and manufactured such that they can be padlocked in the OFF position. This includes both mechanical and electrical devices.

Audible Noise Levels - During normal operation, the unit shall not produce noise levels greater than 84 dB(A) as measured on the “A” scale and 92 dB(C) as measured on the “C” scale, at any point three feet from the unit of a standard sound level meter at slow response (29 CFR 1910.95, Occupational Noise Exposure Standard) .This excludes the noise at the nozzle.

Environmental Protection - The unit shall be designed and constructed so that during operation, service, transportation, and storage conditions described herein, including final disposal, the equipment will comply with all applicable Environmental Protection Agency (EPA) and Occupational Safety and Health Agency (OSHA) and State of Washington Department of Ecology (WDOE) restrictions for materials classified as hazardous to the environment in effect on the date of the contract. The equipment described herein shall not contain or emit material hazardous to the ecological system as prescribed by federal, state, and local statutes in effect at the point of installation.

Hazardous Material Exclusions - Materials being provided as part of the equipment shall be free of known hazardous materials. Definitions of hazardous materials are specified in the latest version, including revisions adopted during the term of the contract, of Federal Standard No. 313. Notwithstanding any

Page 2 of 6 1May23 Rev0 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 (PCB’s) are prohibited.

Painting - Exterior surfaces of all components shall be either hot dip galvanized, stainless steel or blasted and painted with ADI standard color or optional federal standard green (14187). All steel components shall be primed with an inorganic zinc paint and top-coated High Solids Epoxy Coating and painted with 2 part urethane paint with UV inhibitor, having a dry film thickness of 5 to 8 mils. Paints containing lead, cadmium, or hexavalent chromium at 0.01% (dry weight) or more are prohibited.

Safety Signs and Labels - Corrosion resistant “Caution” or “Warning” plates and labels in accordance with ANSI Z535.4 shall be securely attached to the equipment in visible locations, with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the plates.

Identification Plate - An identification plate shall be furnished with the equipment. A nameplate shall be affixed to each major component of the system showing the Contract Number, manufacturer’s name, equipment model, year of manufacture, and any other pertinent information for identifying the part as a unique component of the system.

Bearings - All bearings contained in the equipment and the entire system must be United States (U.S.) or Canadian manufactured. If they are not U.S. or Canadian manufactured bearings, the vendor must provide a list of exact U.S. or Canadian made equivalent bearings that can be used for replacement of each bearing within this equipment or system.

ABRASIVE BLAST UNIT

ASME Section VIII coded tank, certified for a working pressure of 175 PSIG (minimum).

Four (4) – 6.5 cubic foot capacity, single chamber, conical bottom blast vessel.

Each blast vessel shall be air and watertight with gasketed manway for interior access to each blast vessel.

Each blast vessel piping system shall have the following: one compressed air control valve for blasting, one remote adjustable abrasive media control, one pot pressurization valve, one vessel depressurization/blow down valve, one plunger/pop up media loading valve, and a blast pressure regulator.

All air piping will be 1 ½” pipe minimum

The abrasive media control valve will be remotely controlled not requiring manual adjustment at the media valve to adjust the media flow during blasting.

The abrasive media control valve to automatically fully open during “choking” without requiring adjustment or operation at the media valve.

An inlet plunger/pop up valve shall be installed between the inlet of the blast vessel and the hopper on each blast vessel to control the filling of the vessel. The plunger/pop up will be of a cylinder/diaphragm power up design. Plunger/pop up that uses the pressurization air to close will not be accepted.

Overpressure protection shall be provided by means of a rupture disc assembly to protect the equipment in case of pressures exceeding the working pressure rating of each pressure vessel. The rupture disc shall be easily accessible.

Integrated Control System, which works in conjunction with each blast vessel to provide a fully automatic refill system when the dead-man switch is released/turned off.

The vessels shall depressurize to the filter housing or thru a MERV 15 rated filter

Each outlet (4 outlets) shall include an electric 3 wire trigger "dead-man” remote control with 10 feet of control cord and switch. The trigger switch shall have electric "dead man” controls - an on-off trigger switch - controlling the compressed air with media (blast) or compressed air only (blow down) functions of the blast machine and defaults to “off” when released by the operator. The dead man control shall be

Page 3 of 6 1May23 Rev0 the type that requires continuous pressure for operation and stops and secures the air pressure and abrasive flow to the blast nozzle and depressurizes the vessel automatically in the event the operator drops the blast nozzle or power is lost to the dead-man switch controls.

One (1) 4 inch or larger diameter compressed air manifold, with inlet check valve, providing air to the blast vessels.

The compressed air manifold shall have a ball valve and pressure relief valve provided for draining of collected moisture and relief of air pressure (one valve located at each end of the manifold).

The manifold shall be equipped with 1 ½” air piping to each blast vessel metering/blowdown valve. Ball valves to have locking handles to latch in the closed position.

Each blast vessel will have a separate manual valve to manually close the inlet plunger/popup for access to drain and work on the blast vessel without requiring the storage hopper to be emptied.

STORAGE HOPPER

The hopper shall be designed with 10 gauge steel

A working volume capacity of 30 tons of G50 steel grit blast media. Working volume is the amount of abrasive that can be loaded into the hopper and discharged by gravity, without shoveling or external assistance. Material left in the hopper when fully emptied is not considered part of working volume.

Top access with removable or collapsible (to the outside) OSHA guardrails and external access ladder with swing gate to provide access to the top of the unit.

The hopper shall be air and watertight with gasketed manway with internal ladder for interior access to each blast vessel without the use of tools to access each plunger/popup valve.

A 4” NPT threaded drain with plug to be supplied above each blast pot to empty the hopper.

CLASSIFICATION RECOVERY UNIT

The unit shall include a 5 inch ID interior/inside hose type vacuum hose connection for connection to the external vacuum source.

Vacuum inlet into the classifier shall include one 5 inch ID exterior/outside hose type hose connection.

The classification system shall be sized to recycle abrasive at a minimum of 8 ton/hr.

The inlet to the classification system shall be designed with replaceable rubber lining and wear resistant plate(s).

The classifier shall be a 7 gauge (minimum) carbon steel.

The classification shaker screen system shall eliminate abrasive or waste larger than a number 4 mesh screen (3/16 inch size openings) from the reclaimed abrasive.

Cleanout shall be provided to classification shaker screen.

Heavy trash/debris larger than the classification screen openings shall be collected in a 6 inch (minimum) trash discharge pipe and fitted with an air-tight manual dump valve.

Unclean abrasive and fines shall pass through an air wash system, which shall remove the fines without the use of screws or bucket elevator.

The air shall be filtered through the Vacuum Rated Dust Collector.

The remaining unclean abrasive shall be sent through a rotating magnetic drum separator removing 99% of non-magnetic particles. Magnetic drum will be a minimum 15” diameter x 24” wide.

The debris from the magnetic separator shall be collected in a 4 inch (minimum) trash discharge pipe and fitted with an air-tight manual dump valve.

The recycled abrasive shall dump into a single chamber transfer vessel.

The single chamber transfer vessel volume shall not exceed 3 cubic feet.

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The single chamber transfer vessel shall automatically transfer the abrasive to the hopper through a 2 inch diameter static dissipating blast hose into the grit storage hopper for reuse.

VACUUM RATED DUST COLLECTOR

All exhaust airflow from the abrasive system shall be filtered through the dust collector. The dust collector filters shall be of the cylindrical (round) cartridge style rated at 2000 CFM (minimum) with an air to cloth ratio of 2.5 or greater cloth area. Filter element efficiency (i.e. dust weight arrestance) to be a MERV 15 rating or higher. Filter efficiency shall meet the ASHRAE 52.2 minimum requirements and shall be verified by independent laboratory test results. Test results are required to be submitted with the Offeror’s proposal.

Minimum of 2000 CFM capacity for the dust collector.

The dust collector shall include automatic, adjustable, solid state filter cleaning controls. Solenoid operated diaphragm valves shall sequentially introduce compressed air pulses into each filter or filter bank. Cleaning air manifold(s), diaphragm valves, and pulse cleaning nozzle piping shall be factory assembled. The cleaning system shall operate with 100-125 PSIG compressed air.

An external aneroid (i.e. magnehelic) gage with a 0-10” range shall be provided for monitoring differential pressure across filter elements (not to be mounted in the control panel).

An inline filter shall be installed on the dirty side of the aneroid gage tubing to protect the gage from dust.

The dust collector shall operate under the negative pressure condition of 29 inches HG.

The hopper discharge shall be fitted with an air-tight, gear operated-hand wheel butterfly dump valve for emptying accumulated dust and debris into standard 55 gallon drums (slide gates are not acceptable).

MAIN DISCONNECT PANEL (120 V, SINGLE PHASE)

A NEMA 4X stainless steel, heavy duty, safety switch (visible blade type) panel shall be included to allow the power to the main control panel to be isolated. Safety switch will have external operator to disconnect power to main control panel without opening the safety switch panel. A circuit breaker type safety switch with external operator is acceptable. Safety switch must have provision for lock out/tag out.

Install a stainless-steel cover over the main disconnect panel lip or cover panel with machine components to eliminate snow or rainwater from accumulating on top and entering the panel.

MAIN CONTROL PANEL (12/24 VDC)

NEMA 4X stainless steel enclosure, with a fused main disconnect switch or circuit breaker for single point electrical disconnect to the entire system.

A lockable hinged stainless steel window kit to cover switches/buttons on the exterior of the panel, excluding the emergency stop button.

Install a stainless-steel cover over the main control panel lip or cover with machine components to eliminate snow or rainwater from accumulating on top and entering the panel.

Control panel shall include the following controls, buttons, switches, or gages to operate the system:

a. Screen classifier on/off switch and indicator light, which will shut down the external vacuum, via auxiliary relay connection, when light is off.

b. Magnetic separator on/off switch and indicator light, which will shut down the external vacuum, via auxiliary relay connection, when light is off.

c. Switch to reverse direction of the magnetic separator to allow blasting and reclaim with nonmagnetic media.

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d. Dust collector air pulse on/off switch, which will shut down the external vacuum, via auxiliary relay connection, when switch is not in the on position.

e. Hour meter for the classifier.

f. High level failure light for each of the screen trash, magnet trash, and magnet grit, which will shut down the external vacuum, via auxiliary connection, when light is on.

g. Emergency stop button to stop all abrasive reclaim and blasting operation when activated.

h. Power “on” light to indicate there is control power going to the panel.

i. On/off switch with indicator light for dead-man switch for each (4 total) blast vessel.

j. Three-way switch for each (4 total) blast vessel to change from blowdown, blast, and choke.

k. Remote vessel media valve adjustment for each (4 total) without going into panel.

l. Adjustable blow down delay timer for each (4 total) blast vessel to eliminate accidental trigger flutter.

m. Hour meter for each (4 total) blast vessel.

n. Control regulator with gage on the exterior of the panel to adjust and indicate the blast pressure for each (4 total) blast vessel.

o. Pressure gage indicating the manifold pressure to the system.

p. Panel control pressure gage.

q. Individual resettable circuit breaker for each blast vessel trigger.

An auxiliary relay inside the panel to allow for an external vacuum to be interlocked with the unit to shut down the vacuum if a failure occurs. The auxiliary relay shall be wired to an interlock plug (Hubbel plug 2411SW or equal).

Motor starters, overload protection devices, remote control circuits for solenoid operated valves, and all necessary controls for the skid system.

Control panel shall include a timer circuit for automatic cleaning of the dust collector filters.

SKID AND FRAME

For portability, the entire unit shall be mounted on a single heavy-duty skid base.

The skid shall provide adequate bracing and support to permit placing the entire assembly on uneven surfaces without causing equipment damage, distortion or overstress. The base and associated framework shall be gusseted and cross-braced as necessary to withstand the stresses, vibration and shock associated with rough handling and transport of the unit by overhead crane or flatbed truck over rough surfaces.

Forklift pockets - The base shall also have fully enclosed forklift slots for handling with a forklift truck. The forklift slots shall be 12 inches wide by 6 inches high rectangular tube (+/- 1/2-inch) and spaced 52” to 72” apart (measured from outside edge to outside edge of each forklift slot) on the length of the skid.

The skid shall have OSHA handrails and access ladder with swing gate.

Lifting Attachments - The skid shall be equipped with four gross weight lifting pads correctly spaced for even and level lifting by a single crane hook without spreader bar(s). The lifting pads and attaching structure shall provide a 3 to 1 (minimum) safety factor based on material yield strength, or 5 to 1 (minimum) based on ultimate strength, and calculated as though the actual weight were loaded on two pads.

o The lifting attachments are required to withstand a load test of 200% +5%-0% of the Working Load

Limit (WLL) for 2 minutes. Acceptance criteria shall be: No bending, cracking, or permanent deformation of the lifting attachments or associated structure. The contractor’s certified representative will perform the load test and inspection requirements of American Welding Society

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(AWS) D1.1 and submit documentation of the satisfactory results of all the various tests. The lifting attachments shall be labeled with the WLL and the test date.

o All calculations required for the design of the lift points shall be performed by a Structural Engineer and/or certified by a Professional Engineer and shall be provided for review at the time of the submittal of the equipment design.

o In certain cases, with prior concurrence of the cognizant technical Code at Puget Sound Naval Shipyard & Intermediate Maintenance Facility, the load test may be waived and a magnetic particle test (MT) of the attachment weld substituted, meeting the acceptance criteria of MIL-STD-2035, Class 3 or equivalent standard as approved by the Government, provided the testing is performed by a certified third party and documentation of the satisfactory results are provided with the receipt of the equipment. Each lifting attachments shall be stamped with the WLL and the wording "MT" and the date certified.

TECHNICAL DATA TO BE PROVIDED

Operator / Maintenance Manuals - The equipment shall be furnished with four (4) copies of the manufacturer’s standard Operation, Maintenance, and Repair Manual(s) and one copy on CD-ROM disk for each order placed. The manuals shall include all mechanical and electrical schematics showing discrete components/block diagrams/wiring diagrams with inputs and outputs identified/system electrical interface documents and drawings for the specific model of all machine equipment/drives/controls supplied.

Lifting Attachment Certification - Concurrent with equipment delivery, the contractor shall provide with the manufacturer’s certification document.

Air Operating Permit Information –The contractor shall provide the Government with the following information within 30 days after the effective date of the contract so the equipment can be locally permitted for use:

- Specify the manufacturer and model number of the blast machine. Serial numbers are not acceptable.

- Specify the flow rate in actual cubic feet per minute (acfm).

- Specify the type and quantity of filters that will be installed in the blast machine.

- Specify the filter fabric material that will be installed in the blast machine.

- Specify the air to cloth ratio of the filters that will be installed in the blast machine.

- Specify the filter cleaning method of the filters that will be installed in the blast machine.

Filter Efficiency Certification – Filter efficiency shall meet the requirements of the specification and shall be verified by an independent testing laboratory. A copy of the filter efficiency certification shall be provided with the Offeror’s proposal.

NRTL Listing or NRTL Field Inspection and Approval Compliance Statement - The contractor shall provide signed, written certification of compliance to the requirements NRTL field inspection and approval.

PCB Certification - The Contractor shall provide written certification from the manufacturer that the equipment contains no detectable PCBs (less than two (2) part-per-million (ppm)). The certification shall be on manufacturer’s letterhead and signed by a company official who is empowered to provide same. It is acceptable that this list is included in each of the operator/Maintenance/Repair manuals.

Warranty - Supplies and services furnished shall be covered by 1 (one) year warranty from date of shipment from defects in design, materials and workmanship. Acceptance of the manufacturer’s standard commercial warranty shall not minimize the rights of the government under clauses in the contract, and in any conflict that arises between the terms and conditions of the contract and manufacturer’s warranty, the terms and conditions of the contract shall take precedence. The warranty period shall commence when final acceptance has been achieved as determined when all contract line item numbers have been processed.