A21_Attach_0001_PWS_Design_Plating_Shop_Equipment_2016-01-04.docx

Performance Work Statement (PWS) for Design of Plating/Metal Finishing Equipment and Wastewater Treatment System 4 January 2016

1.0 BACKGROUND

Crane Army Ammunition Activity (CAAA) is located in Crane, Indiana. One of CAAA’s missions is producing conventional ammunition and related components to meet contingency requirements in support of the warfighter. Production of ammunition components requires various types of finishing coatings prior to assembly, loading, and packaging.

The finishing processes at CAAA include zinc phosphating, chromate conversion coatings, zinc plating, stainless steel passivation, and hard coat anodizing to provide the munitions its form, fit, and overall function.

To improve the operation’s efficiency, quality, and reliability CAAA desires to obtain a fully developed plating equipment design.

2.0 DESIGN SCOPE

This project’s scope of work includes providing the overall consulting service, design, layout, and detailed cost estimate of new plating/metal finishing equipment including a closed loop wastewater treatment system. Design shall be non-proprietary for use in a future procurement contract. Procurement and installation of the designed equipment is not included in this scope.

The contractor shall furnish all the necessary engineering, labor, technical support, documentation services, and materials to design a new plating/metal finishing equipment system including all supporting systems and disciplines. Facility-related utilities and structural design is out of scope and will be provided by others, but this design shall note any special electrical, water, wastewater drainage, HVAC etc. requirements each piece of equipment requires to operate properly. The contractor shall comply with all the federal and state laws including applicable sections of safety (29 CFR) and environmental (40 CFR) regulations. All controllers/computers designed into the system must include stand-alone software (cannot be networked).

2.1 The contractor shall spatially organize and fully design the plating/metal finishing system to provide an efficient, functional layout for CAAA operations.

Necessary design features (described in more detail below) include aqueous ultrasonic/ vapor degreaser aluminum alloy cleaning and ferrous metal blast booths, alkaline non-cyanide zinc plating (rack, basket, and barrel), zinc and manganese phosphating, chromate conversion coatings, stainless steel passivation, anodizing aluminum finishing, closed loop waste treatment, paint stripper, copper/brass brighteners, laboratory, and Reverse Osmosis (RO)/Deionized Water (DI) system. Design needs to maximize flexibility to allow different processes to run concurrently and separately. Available building area for the plating equipment and wastewater treatment room is approximately 40’ wide x 180’ (not including lab and administrative spaces). Various options for system automation shall be discussed during the initial design phase.

The design package shall provide enough detail for CAAA to procure and install equipment including but not limited to all process tanks, pumps, insulation, filters, manifolds, immersion plate steam coils, metering and pumping equipment, and mixing systems.

2.2 Cleaning Area

· Small aluminum parts require a clean only. Require an aluminum/ferrous metal cleaner system that will not etch, smut, or tarnish the substrate’s surface. Aqueous ultrasonic/Vapor degreaser self-contained unit with cleaning, rinsing, and drying capabilities.

· Abrasive blasting cabinet required to mechanically clean ferrous substrates (steel and stainless steel)

2.3 Alkaline non-cyanide zinc plating (throughput approximately 1,000 ft2/10-hour shift; largest part size 4” diameter, 7-3/4” long):

Alkaline Cleaning

· Immersion or spray alkaline cleaner that removes oils, fats, waxes, and greases that can be run through an oil separator. Electro -cleaning which removes organic contamination and also insoluble and non-saponifiable contamination. Heat will be required 120° – 180°F. [Rinse freely, non-attack or tarnish metal surfaces, no formation of excessive foam, and long lasting and able to utilized with an oil separator.] Rinse Water

· Immersion or spray rinse water make-up with city water, Deionized (DI) or Reverse Osmosis (RO) water with the utilization of multiple rise tanks that will require counter-flow. Closed looped system shall be used to clean/polish contaminated water and return to the finishing system. Water supply will be designed by others, but this design should note equipment locations where water will be required.

Acidic Pickling

· Immersion to remove light surface stains and oxides, while also activating the metal surface. The steel shall be free from the detrimental effects of hydrogen embrittlement after cleaning. [Inhibited, Iron (Fe) ion exchange, Heat (optional), No formation of excessive foam, and long lasting] Alkaline Neutralizer

· Immersion or spray rinse that neutralize the steel surface prior to the alkaline non-cyanide zinc plating process. [Neutralizing rinse (optional)] Alkaline Non-Cyanide Zinc Plating

· Immersion electrolytic alkaline zinc plating process that produces a sacrificial, corrosion protective coating on steel parts that are greater than or equal to 0.2 mils thickness. [Filtration (organic and inorganic), Chiller, Rectifier, Zinc regeneration process, one process tank with multiple racking/barrel area.] Acidic Activator or Brightener

· Immersion process that dissolves off any oxide that may have developed on the zinc plated surface.

Chromate Treatment

· Immersion process used to protect the zinc plating from corrosion, yet it does not completely prevent zinc corrosion it will only slow the corrosion rate down considerably. [Filtration, Chemical Feed] Alkaline non-cyanide zinc plating process needs to be on a straight line process with no intervening steps. Minimize handling of machined parts and finished parts accounting for enhanced operator ergonomics. The alkaline non-cyanide zinc plating process needs to be able to run both racks and barrels. The plating will be run on amps per square feet and an initial ramping of the voltage is required.

2.4 Conversion Phosphate Coating (throughput approximately 1923 ft2/10-hour shift; largest part size 5” diameter, 15” long):

Alkaline Cleaning

· As previously stated.

Rinse Water

· As previously stated.

Acidic Pickling

· As previously stated.

Alkaline Neutralizer

· Immersion or spray rinse that neutralize the steel surface prior to the abrasive blasting process.

Zinc/Manganese Phosphating

· For a paint base that will reduce and retard corrosion formation under paint or dry film lubrication.

· For corrosion retardation with the assistance of an oil or wax final finishes. Coverts the iron substrate into a crystalline of zinc or manganese phosphate which serves as an absorptive base for an organic coating (oils or paints/dry film lubrication).

Chromium Sealing

· To obtain the maximum corrosion protection, the zinc or manganese phosphate coating is followed by a sealing rinse.

2.5 Anodize (throughput approximately 200 ft2/10-hour shift; new process to acquire, no specific part size) and Chromate Conversion Coatings (throughput approximately 825 ft2/10-hour shift; largest part size 5” diameter, 4-1/4” long) Good agitation is required in all of the tanks within the anodizing and chromate conversion coating systems.

Alkaline Cleaning (Degrease)

· As previously stated.

Rinse Water

· As previously stated.

De-smutting or Deoxidizing

· Immersion to remove oxides and smuts generated from the alkaline etch process. Non-chromium and able to work with all aluminum alloys especially 2000 and 7000 alloy series and will not reduce brightness.

Anodized Coating

· Immersion anodic coating per MIL-A-8625 Type 2 and Type 3 that are dyed and undyed sulfuric acid anodizing. The equipment shall be such as to produce a coating which will meet the military requirements of MIL-A-8625. It is required to provide some means of keeping the temperature of the anodizing bath constant by suitable cooling.

Chromate Conversion Coating

· Immersion chromate coating for maximum protection against corrosion painted or unpainted. The equipment shall be approved for use with chromic acid and in accordance with the qualification requirements of MIL-DTL-81706. [Filtration, Chemical Feed] Dye (2 tanks – Black and Blue)

· Immersion organic dye after a high quality anodized rinse should be done immediately to avoid streaks and discolorations. Must be supplied with means of maintain a constant temperature of 150°F (140° – 160°F) and equipped with some form of agitation. Work must be dyed immediately then followed by thorough rinsing.

Sealing (2 tanks (Nickel Acetate and Hot Water))

· 194° – 212°F immersion sealing process for resistance of staining and corrosion while improving durability of colors.

2.6 Passivation of Stainless Steel The equipment shall be able to perform ASTM A967 types Nitric 1, Nitric 2, Nitric 3 and Nitric 4. With a minimum tank size of 36” wide 48” long and 36” deep.

Alkaline Cleaning

· As previously stated.

Rinse Water

· As previously stated.

Passivation

· Immersion of stainless steel parts within a solution of nitric acid that dissolves imbedded iron and gives the part’s surface a corrosion/chemical resistant oxide film. Must be supplied with means of maintain a constant temperature of 130°F (120° – 140°F) and equipped with some form of agitation. The equipment shall be approved for use with nitric acid and chromic acid.

2.7 Waste Treatment

· Closed loop process that will meet or exceed all state and federal environmental regulations for effluent and dispose of any sludge or solids resulting from the finishing processes. Methods for preventing or minimizing waste at the finishing source is expected. Preliminary treatment processes (equalization, screening, and pH adjustment), physical-chemical treatment process (coagulation, flocculation, and sedimentation), pressure and gravity filters (membrane filters), physical treatment process (air stripping and carbon adsorption), and processes for treatment of finish metal waste streams (zinc, chromium, manganese, copper, lead, iron, aluminum, and nickel).

· Temporary storage tanks to hold concentrated wastes (acidic and alkaline) which then can be bled into the stream of other wastes during normal operations.

· Dumping of spent concentrated baths should be minimized and every effort into making each finishing chemical process tank last by ion exchange, filtration, or other means of purifying.

· Preferred design is no discharge and minimal Indiana Department of Environmental Management (IDEM) permitting.

2.8 Reverse Osmosis Water and Deionized Water Generation System

· Ultra-Pure water generation system that will produce water that has no ionic or organic contamination to be used within all rinse tanks (fill, recirculate, and spray hose).

· Storage containers to ensure enough clean water for one full day of production with overflows not to exceed 3 gallons per minute.

2.9 Paint Stripper

· Immersion long lasting, non-hazardous, and fast acting paint (alkyd, acrylic, enamel, epoxy, and polyurethane) removal at low temperatures for ferrous and non-ferrous substrates. Paint stripper must provide cleaning to the bare metal surface. Heat, circulation, filtration, ventilation, and sludge collection capabilities.

Rinse Water

· As previously stated.

Drying

· Parts are required to be dried quickly as to show no signs of blush rust formation.

2.10 Copper/Brass Brighteners

Alkaline Cleaning

· As previously stated.

Rinse Water

· As previously stated.

Acidic Pickling

· Immersion to remove light surface stains and oxides, while also activating the metal surface. The copper/brass shall be free from the detrimental effects of hydrogen embrittlement after cleaning. [Inhibited, Copper (Cu) ion exchange, Heat (optional), No formation of excessive foam, and long lasting].

Brightener

· Immersion acidic brightener solutions that will require agitation (No formation of excessive foam), heat (80° to 150°F), filtration, and long lasting. Brighten the copper or brass surface and retard tarnishing.

3.0 DESIGN DETAIL

The equipment design shall be non-proprietary in nature in order to promote procurement competition. It shall incorporate all features and information necessary for the government to procure and install the complete system without additional design effort, including but not limited to:

3.1 Tanks: Design in drawing all chemical process tanks (Insulated), pumps, manifolds, heating process, rinse counter flow, ion exchange units, and agitation process. The following information shall be shown on the drawings:

· General Arrangement of the steam piping

· Valve locations

· Valve clearances to permit proper valve operation in confined spaces

· Floor stand, valve chain wheel operators where required

· Expansion joints

· Steam condensate trap locations

· Schematic of drain and condensate return systems

· Schematic of process and raw water lines, including hose bibs

· Foundation description and ladder/catwalk plan

· Safety features

· The maintenance features and requirements of the equipment

· Material handling design description

· List of motors and horsepower

· List of pumps

· List of parts and components

4.0 MEETINGS AND DELIVERABLES

4.1 Site Visits/Meetings

· Organization of and attendance at the following meetings shall be required at a minimum:

4.1..1 Design kickoff and existing plating facility visit (requirements gathering meeting): One day meeting attended by government personnel and all contractor team members responsible for design 4.1..2 Design submittal 50% review meeting: 1/2 day meeting attended by government personnel and contractor project manager at a minimum 4.1..3 Pre-final design 100% review meeting: 1/2 day meeting attended by government personnel and contractor project manager at a minimum

· Requirements for each meeting listed above:

4.1..1 Contractor shall provide meeting minutes including “living” action item list. Provide one (1) copy of the meeting minutes to each Attendee within five working days of the meeting date. Electronic distribution is preferred.

4.1..2 At each design review meeting contractor shall provide (10) hard copies of government review comments with contractor responses incorporated. This document will serve as the meeting agenda.

4.2 Design Schedule: The following is the initial draft for the design schedule. All items for each stage of project development must be submitted concurrently.

(CALENDAR DAYS)

TOTAL DURATION (CALENDAR DAYS)

4.3 Submittal Packages

· Plating process layout and other design features shall be saved in AutoCAD format

· Electronic design deliverables: Full set of design drawings and a detailed equipment cost estimate shall be provided in .pdf for interim submissions and .pdf and native format for final submission to the address below:

Crane Army Ammunition Activity Attn: Bryan Peterson 300 Highway 361, B-3373 Crane IN, 47522