PWS_Rev2_11July2019.pdf

PERFORMANCE WORK STATEMENT (PWS)

For

CAAA Plating Equipment Procurement and Installation

11 July 2019

Table of Contents

Page

1 General 2

Quality Control System and Workmanship 7

Performance Requirements 7

Process Design Information 8

Equipment, Materials and Services Included 8

Excluded from Scope 30

Appendix 30

Deliverables 31

Meetings 33

Design Schedule 34

Installation Schedule 34

Submittal Packages 34

Security Requirements 35

Contract Manpower Reporting 35

1 GENERAL DESCRIPTION:

1.1 The intent of this specification is to define the minimum requirements to be met in the final design, fabrication, supply and installation of the equipment ordered for the following systems:

1.1.1 Ferrous Line Plating/Coating

1.1.2 Non-Ferrous Line – Anodizing/Chromate Coating

1.1.3 Copper/Brass Brightening/Paint Stripper/Passivation

1.1.4 Ventilation and Scrubber System

1.1.5 Reverse Osmosis System

1.1.6 Waste Water Treatment System

1.1.7 New Utilities Systems – see section 1.9

1.2 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. The existing metal finishing processes at CAAA have become outdated. To improve the operation’s efficiency, quality, and reliability CAAA desires to obtain plating process equipment and installation which conforms to the following specification. CAAA will be here after referred to as the Government in this specification.

1.3 This Specification is for a turn-key installation including finalization and implementation of the design and layout of new plating/metal finishing equipment. The contract shall include procurement and installation of equipment including but not limited to all process tanks, pumps, insulation, filters, manifolds, electric immersion heaters with welded heads, metering and pumping equipment, mixing systems, access platforms, materials, installation services, and erection supervision to deliver and provide the complete installation inside a new building of two (2) new automated metal finishing lines that include zinc and manganese phosphating, chromate conversion coatings, zinc plating, hard coat anodizing; manual systems for copper/brass brightening, stainless steel passivation, and paint stripping; and support systems including a scrubber system, process water reverse osmosis system, and a waste water treatment system. Facility-related utilities, lab and administrative spaces, and structural design is out of scope and will be provided by others, but this design implementation shall comply with any special electrical, water, wastewater drainage, HVAC etc. requirements each piece of equipment requires to operate properly. Source elimination, reduction, recycling, treatment and disposal conservation efforts shall be used, refer to Executive Order 13693. All controllers/computers designed into the system must include stand-alone software (cannot be networked). Final design, procurement and installation of the equipment is included in this scope. The contractor shall furnish all the necessary engineering, labor, technical support, documentation services, and materials to implement a new plating/metal finishing equipment system including all supporting systems and disciplines.

1.4 Plating equipment supplier and building (MILCON) contractor will be required to work together, coordinating work schedules, and testing of building and equipment interface.

Design implementation needs to maximize flexibility to allow different processes to run concurrently and separately.

1.5 The allocated building area for the plating equipment and wastewater treatment room is approximately 46’ wide x 180’ long x 16’ high. Some of this space will be occupied by relocated existing equipment including a Lewis Aqueous Ultrasonic Cleaner and a Vapor Degreaser. A general arrangement is shown in drawing LO-1 (see Appendix 7.4).

The Lewis Aqueous Ultrasonic Cleaner consists of three 50” wide (DOT) x 36” long x 32” deep baths with an access platform and coalescer and is for parts requiring cleaning only.

1.6 Metal Finishing - Related Specifications (available as public information, not included in this Specification)

1.6.1 MIL-STD-171F Department of Defense Manufacturing Process Standard, Finishing of metal and Wood Surfaces

1.6.2 ASTM B633-15 Standard Specification for Electroplated Coatings of Zinc on Iron and Steel

1.6.3 MIL-A-8625 Military Specification: Anodic Coatings for Aluminum and Aluminum Alloys, Type 2 Dyed sulfuric acid anodizing

1.6.4 MIL-A-8625 Military Specification: Anodic Coatings for Aluminum and Aluminum Alloys, Type 3 undyed sulfuric acid anodizing

1.6.5 MIL-DTL-5541 Military Specification: Chemical Conversion Coatings on Aluminum and Aluminum Alloys

1.6.6 MIL-DTL-81706 Chemical Conversion Materials for Coating Aluminum and Aluminum Alloys

1.6.7 ASTM A967 Standard Specification for Chemical Passivation Treatments for Stainless Steel Parts, types Nitric 1, Nitric 2, Nitric 3 and Nitric 4 Stainless Steel Passivation

1.6.8 TT-C-490, Type V Conversion Phosphate Coating

1.6.9 MIL-DTL-16232G Conversion Phosphate Coating/Heavy, Manganese or Zinc Base

1.7 Regulatory Codes, Standards & Regulations

All equipment furnished shall comply with the Occupational Safety and Health Act, including all applicable amendments, and any pertinent federal, state, or local codes, ordinances and regulations. Support shall be provided to the Government in obtaining any approvals or permits required. The design & construction shall also conform to the latest edition or version of the following:

1.7.1 Indiana Building Code: (675-IAC-13 IBC)

1.7.2 2015 International Building Code (IBC) or latest version with Indiana Amendments

American Concrete Institute (ACI) 318-11 Building Code Requirements for

Structural Concrete

ACI 301-10 Specifications for Structural Concrete

American Institute of Steel Construction (AISC) 360-10 Specification for

Structural Steel Buildings 14th Edition

AISC 303-10 Code of Standard Practice for Steel Buildings and Bridges

AISC 360-10 Specification for Structural Steel Buildings 14th Edition

Research Council on Structural Connections (RCSC) Specifications for

Structural Joints Using High-Strength Bolts December 31st 2009

American Society of Civil Engineers (ASCE) 7-10 Minimum Design Loads for

Buildings and Other Structures

1.7.3 Safety: Occupational Safety and Health Administration (OSHA) 29 CFR 1910

Chromium (VI): OSHA 29 CFR Safety 1910.1026 OSHA

1.7.4 Safety and Health Requirements: The equipment shall be fitted with safety devices or coverings for any parts which present safety hazards. All equipment furnished under this installation must comply with applicable OSHA and NFPA standards. The equipment shall include provisions to isolate and lock out all sources of hazardous energy, either input to the machine or generated by the machine, to ensure safety of operation and maintenance personnel. Electrical lockout devices for electrical or any other type of hazardous energy (mechanical, hydraulic, pneumatic, chemical, thermal, or other) shall be designed to allow full operational compliance with the requirements of OSHA Standard 29 CFR 1910. All system and operation standards shall comply with OSHA standards on Human Factors Engineering (Ergonomics).

1.7.5 Environmental: Environmental Protection Agency (EPA) 40 CFR Environmental

1.7.6 Environmental Permits

EPA Tile V of the Clean Air Act

Indiana Department Environmental Management

Local Environmental Permits

National Pollutant Discharge Elimination System (NPDES)

Resource Conservation and Recovery Act (RCRA)

1.7.7 Pressure Vessels: American Society of Mechanical Engineers (ASME) Section VIII, Division 1

1.7.8 National Electrical Code (NEC)

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

ANSI Z9.2-2018, Fundamentals Governing the Design and Operation of Local Exhaust Ventilation Systems

NFPA 34-2018, Standard for Dip Tanks Containing Flammable or Combustible Liquids

ACGIH's Industrial Ventilation: A Manual of Recommended Practice, 29th Edition (Section 13.70 Open Surface Tanks, Section 13.72 Push-Pull Ventilation

ANSI Z9.1-2016, Ventilation and Control of Airborne Contaminants During Open-Surface Tank Operations

1.7.10 Fire Protection – National Fire Protection (NFPA)

1.7.11 Structural Welding: American Welding Society (AWS) D1.1

1.8 Available Site Utilities – The following utilities will be provided in the new facility through connections to the existing site distribution systems. Vendor tie-in locations to the existing utilities may be assumed to be within 50 feet of the new installation. The proposal shall indicate the utilities required and estimated usage.

1.8.1 Electrical Power - 480 V AC, 3 phase, 60 Hertz

1.8.2 Natural Gas – 5 psig

1.8.3 City Water - Supply: 60°F @ 40 psi

1.8.4 Instrument Air - Supply: 100–120 psi, dry (less than -20⁰F dew point) and oil free

1.8.5 Mechanical: Building make-up air and roof/wall openings for equipment ductwork will be by others

1.9 New Utilities – The following utility systems shall be provided as part of the scope of work for this project:

1.9.1 RO Water system

1.9.2 Chilled water system(s)

1.9.3 Low pressure air (ventilation)

1.9.4 Waste Water Treatment

1.9.5 Vent scrubbers and exhaust fans for plating line exhausts

1.10 Site Data – Crane, Indiana

Elevation 602 ft., 38.98 °N, 86.91 °W

Basic Wind Speed:105 mph (3-sec peak gust)

Ground Snow Load: Pg = 20 psf

Seismic Conditions:

ASCE 7 2005 & IBC 2015

S1 = 0.122*g; Ss = 0.285*g

Site Class = B; Occupancy Category = II SDS = 0.299*g; SD1 = 0.189*g; Design Category = B

1.11 Interior conditions - The metal finishing equipment room will be air conditioned. Temperatures will be controlled within the range of 65°- 80°F.

1.11.1 Electrical / flammable classifications – The chemicals used for metal plating are nonflammable based on the information known at the time this specification was developed. The area should be considered unclassified.

1.11.2 Corrosivity / toxicity / other hazards – Many of the chemicals used are either very alkaline or acidic and/or pose health concerns. These chemicals need to be contained, ventilated and treated prior to discharge

1.12 Shop Painting

1.12.1 Where shop painting is necessary to adequately protect or finish the equipment and materials supplied, apply such paint in accordance with the best practices utilizing industrial quality paint products. All structural steel shall be coated/protected from chemical corrosion due to a wet, chemical environment. The final top-coat shall be white.

1.12.2 Surfaces to be painted shall be sandblasted or otherwise thoroughly cleaned, and then given multiple coats of rust inhibitive primer and other paints, as required.

1.13 Equipment Noise Level - The sound level for any item furnished shall not exceed 85 dBA measured at three feet per OSHA 1910.95.

1.14 Shipping and Material Handling

1.14.1 All material and equipment, together with instruction books, packing list and special site instructions, shall be adequately protected for shipment and storage at the site to preclude the possibility of damage to the equipment. All openings in equipment must be sealed and weatherproofed. All materials for platforms, walkways, stairs, and ladders shall be supported and blocked during handling and shipment to ensure that no piece will be bent, twisted, or otherwise damaged.

1.14.2 All surfaces subject to corrosion shall be coated with rust preventing compound before shipment.

1.14.3 Equipment which may be damaged by water, high humidity or dust shall be encased in watertight and/or airtight plastic covering.

1.14.4 Equipment with moving or loose parts shall have such parts securely anchored or packed and be shipped in separate crates or cartons. Relays, instruments and other delicate equipment shall have their moving parts rigidly secured, or be shockproof, or be packed and shipped separately in shockproof cartons.

1.14.5 Equipment shall be broken down into individual sections of the maximum size that can be conveniently handled or moved into restricted spaces at the site. The building will include a 12’ minimum wide x 14’ minimum high equipment door. All heavy and crated equipment shall be provided with suitable lifting devices to facilitate unloading without removing equipment from crating.

1.14.6 Packing list and any special site unloading, handling and/or storage instructions shall be encased in watertight enclosures and securely fastened to the outside of each shipping enclosure.

1.14.7 Each separate package of material (and each component within package), item of equipment, fixture, box, crate or other shipping enclosure shall be marked and tagged with the following information:

1.14.7.1 Government's Contract or purchase order number.

1.14.7.2 Equipment item number received from the Government

1.14.7.3 Vendor's job and item reference number.

1.14.8 Marking shall be by means of block letters stenciled to the box, crate or package with black paint in an easily read location. When stenciling is not possible, the information shall be marked on a durable metal tag which shall be securely wired to the box, crate, or package.

1.14.9 Each component within the box, crate or package shall be tagged for identification to show Government's or Vendor's item number in the case of instruments, electrical devices, specialties or other items of equipment, and such other identification as deemed necessary to relate the item to the equipment and system assemblies.

1.15 Nameplates – Equipment items shall each be identified by permanent imprinting or a nameplate shall be permanently attached. Instrumentation and valves shall be provided with tags that include only item numbers identifying the unit on drawings.

2 QUALITY CONTROL SYSTEM AND WORKMANSHIP

2.1 Quality control system: A Quality Control System is required.

2.2 Workmanship: The equipment and installed system shall be constructed in a thoroughly workmanlike manner and in accordance with quality requirements herein and in accordance with the quality control system. Attention shall be given to neatness and thoroughness of marking of parts, welding and brazing, painting, machining, and freedom from corrosion, burrs, or sharp edges. Structural welds shall be per AWSD1.1

2.3 Interchangeability and replaceability: All parts having the same part number shall be directly and completely interchangeable with each other with respect to installation and performance.

3 PERFORMANCE REQUIREMENTS

3.1 The required design capacity of each metal finishing line for a given part is shown in Appendix

7.1 Parts Information Table, both in terms of number of parts to be processed per day and number of loads per day based on assumed barrel and rack sizes. Note: production is based on 10 hours per day, 5 days per week.

Note - the Parts Information Table does not indicate any parts requiring Anodizing. The information supplied for chromate conversion of Part #13 will be used as a basis for Anodizing albeit at a reduced number of parts.

The Parts Information Table is based on the output of a line dedicated to a given part, but the production from each line is independent. Therefore, based on this table, the lines should be capable of finishing a count of 671 of part #4 on the zinc plating line while also phosphating a count of 500 of part #9, chromate coating, 700 of part#13 and anodizing 170 part #13. The daily design capacity of the zinc plating line will be limited to a count of 671 of part #4.

3.2 Sizing shown in the Parts Information Table was done based on the following method: The number of loads was based on assumptions of barrel and rack size and capacity. The number of parts processed per barrel was based on the minimum value of the following:

o 60% the volume of an 18” Diameter x 42” barrel, 300 pounds of weight or 500 parts.

The number of parts per rack was based on the minimum value of the following:

o 50% of the total area of a 48”x48” double-sided rack or 100 parts.

3.3 The number of loads that can be processed in a day will be limited by the required cycle time for each line. The Tank Schedule in Appendix 7.1 provides an estimated process time for each step which with allowances for dwell, hoist lift & transit times can be used to estimate a cycle time. Contractor shall verify their design is capable of achieving the estimated required loads per shift based on the expected cycle time

3.4 Size all ancillary utilities within the identified scope of supply, rectifiers, chillers, heating requirements, scrubber components, and waste water treatment components based upon the capacity of the plating lines

3.5 Design shall include required clearances around equipment for maintenance and operation.

Industry standards required for safety egress shall be adhered to.

3.6 Lifting Devices: All equipment or production parts weighing fifty pounds or more shall be provided with lifting rings, lugs, or other equally suitable means to facilitate movement or positioning of equipment or production parts. Each process will require a lifting device.

3.7 The equipment should be of a type previously placed in successful operation and it should embody proven principles of design. Standalone computer system cannot be networked to Army system.

4 Process Design Information

4.1 The following Suggested Process Flow Diagrams are included in the Appendix 7.2

4.1.1 PFD-1A Ferrous Line Plating/Coating Equipment

4.1.2 PFD-3 Non-ferrous Line Anodizing/Chemical Conversion Coating Equipment

4.1.3 PFD-6 Copper/Brass Brightening/Paint Stripper/Passivation

4.1.4 PFD-7 Scrubber System

4.1.5 PFD-8 Reverse Osmosis System

4.1.6 PFD-9A Waste Water Treatment System

4.2 The Parts Information Table is included in Appendix 7.1 which describes the parts and their respective metal treating processes.

4.3 A Suggested/Sample Tank Schedule is included in Appendix 7.3 which provides the requirements for each station. It should be noted that the tank size information included in the Tank Schedule is based on preliminary sizing. Size the equipment in accordance with calculations based on the performance requirements listed in Section 3.

4.4 The following conceptual design drawings are included in the Appendix 7.4 & 7.5

4.4.1 LO-01 Line Layout – Plating Process

4.4.2 P-EL-01 Line Layout Elevation

5 Equipment, Materials and Services Included

Furnish a turn-key installation that includes equipment, materials, installation services, and erection supervision to deliver and provide the complete installation inside a new building: two

(2) new automated metal finishing lines that include zinc plating, zinc and manganese phosphating, chemical conversion coatings and hard coat anodizing; manual stations for stainless steel passivation, copper and brass brightening, and paint stripping; a ventilation system including scrubbers, process water reverse osmosis system, and a waste water treatment system.

5.1 Automated Lines

The automated lines will be divided into a Ferrous line and a Nonferrous line. The Ferrous line is shown on PDF-1A in Appendix 7.2.1. The Ferrous line includes zinc plating, zinc and manganese phosphating, The Non-Ferrous line is shown on PDF-3 in Appendix 7.2.2. The Nonferrous Line includes chemical conversion coatings and Type II and Type III (hard coat) anodizing.

5.1.1 The design shall provide flexibility to allow different processes to run concurrently and separately to achieve required capacities.

5.1.2 The design capacity of the metal finishing lines for a given part is shown in the Parts Information Table. Required capacities are stated in terms of square feet of surface area per 10-hour shift. The design capacity and part size information shall be used as the basis for sizing lines and racks.

5.1.3 The design shall show the proposed equipment configuration and shall include access platforms and structures for normal operation, service, and maintenance with fall protection guarding and service hoists as required. The overall design shall accommodate access to all tanks for process monitoring and preventive maintenance with emphasis on operator and maintenance personnel safe ease of access.

5.1.4 Rack/Barrels:

Design of the racks and barrel system will be based on characteristics of the customer parts and drawings. Detailed information will not be made available prior to Contract award.

Spray Through rinse systems employing only a single rinse station, with water conservation and pollution control shall be considered before other rinsing options. These systems provide efficiency with the minimum floor space available.

5.1.4.1 Racks: Racks are not required as a part of this solicitation, however flight bars are required.

• Include a minimum of four (4) flight bar adapters for using racks with hoist flight bars.

• Spray rinsing system tank shall be designed for cooperation with racks.

5.1.4.2 Barrels: Contractor shall work with Manufacturing Engineer to determine best barrel design giving special attention to customer specific parts.

• Minimum of Four (4) barrels shall be included. (Approximate size 20” Diameter x 42”)

• Variable frequency drives (VFD’s) shall be used to allow for slower barrel rotation (4-8 revolutions/min)

• Barrel construction shall be of Ultra High Molecular Weight

(UHMW) plastic with dovetail fusion joints.

• Contractor shall supply Barrels with a self-contained latch system capable of unlocking by means of one actuator (one hand operation)

• Barrel construction shall include ability to rinse, limiting water consumption/waste.

5.1.5 Automatic Material Transport System (Hoist): A contractor-provided automatic material transport (Hoist and track) system shall be integrated with, and controlled by, the process control system in paragraph No. 5.13. The material transporter system shall pick up the flight bars and move them through the proper plating line steps under the control of the process control system. The system shall allow for the movement of a flight bar loaded with rack/part/barrel. The width will be limited by the tank width provided and including buss bars, sensors and heating devices.

5.1.5.1 Four automated hoists shall be included. Two hoists shall be provided for the Ferrous line, and two hoists shall be provided for the Non-Ferrous line.

5.1.5.2 The material transporter system shall not be attached to the overhead structure of the building. The system shall be supported by the floor structural steel/concrete.

5.1.5.3 The material transporter system shall be certifiable weight lifting equipment and have a minimum load rating of 1,000 pounds. The hoist shall be weight tested after final assembly and before acceptance testing by local NAVFAC weight handling/test technician. Hoist(s) shall be weight tested to 200% capacity.

5.1.5.4 The material transporter system and its support structure shall be designed to operate in a Plating Shop environment with minimal maintenance required. (i.e., designed to withstand and operate in a wet chemical environment.)

5.1.5.5 The material transporter system shall have appropriate limit switches and hard stops to eliminate the chance the transporter mechanism can run off the tracks. Industry standard safety sensors shall be included to prevent the possibility of personnel or equipment injury or damage.

5.1.5.6 The material transporter system shall have the capability of being manually controlled for maintenance purposes or to unload the process tanks during an automatic control system failure.

5.1.5.7 The material transporter system shall have a positive positioning system to provide an absolute position for precise positioning of the load.

5.1.5.8 The system shall incorporate multiple emergency stop stations and emergency pull cords.

5.1.5.9 Additional hoists for staging manual lines and stations required such that no load over 50 Lbs. will be required to be lifted by means of man power alone.

5.1.5.10 Hoist shall have capability of powering barrels for final rinse spin upon lifting from process tanks to minimize drag out.

Additional hoists may be required due to layout, scheduling and staging needs. The type of hoist, overhead vs. sidearm may be subject to weight and/or space limitation;

for example, a sidearm hoist requires less space but cannot handle as heavy a load.

5.1.6 Flight bars: The Contractor shall provide flight bars fitted with pick-up lifts and set downs. The Contractor shall also provide and install racking stations to include saddles for the flight bars at the beginning of the process lines. A means of cleaning the flight bars shall be provided (without any additional tanks).

5.1.7 Load/Unload Stations will be provided for loading & unloading racks and barrels onto carts for the automated lines. Design shall include a safe method for loading and unloading racks and barrels manually without stopping the entire line. Ten (10) carts for staging the racks and barrels will be required.

5.1.8 See Section 5.5 and the Tank Schedule in Appendix 7.3 for information concerning requirements for the tanks and accessories

5.1.9 Space allocated for each automated line is approximately 10’ wide by 91’-3” long (DOT) by 16’ high (see LO-01 in Appendix 7.4).

5.2 Manual Lines:

5.2.1 Paint stripping, stainless steel passivating and brass & copper brightening will be manual operations. This equipment is shown on PFD 6 in Appendix 7.2.3. The throughput for these operations is intermittent. Equipment size is based on part sizes and should be as listed in the Tank Schedule. Manual hoists shall be provided and used to lift baskets into the chemical and rinse tanks.

5.2.2 The Paint Stripper will be an immersion system for the removal of various paints (alkyd, acrylic, enamel, epoxy, and polyurethane) (at approx. temps of 180 deg F) from ferrous and non-ferrous substrates. The paint stripper must provide cleaning to the bare metal surface with heating, circulation, filtration, ventilation, and sludge collection capabilities. For the purpose of this specification, the paint stripper chemicals are non-flammable.

5.2.3 Space allocated for each manual line is as follows (see LO-01 in Appendix 7.4):

Stainless Steel Passivation: 4.5’ wide x 16’ long (DOT)

Brass & Copper Brightening: 8.5’ wide x 16’ long (DOT)

Stripping: 4.5’ wide x 12’ long (DOT)

Lewis Aqueous Cleaning: 6.5’ wide x 12.5’ long (DOT) with platform.

5.3 Purified Water Generation

5.3.1 A reverse osmosis unit shall be used to treat Crane municipal water to supply pure make-up water for the metal finishing operations. A conceptual process flow diagram is included in Appendix 7.2.5.

5.3.2 The pure water generation system will produce 10 to 20 gpm water that has little ionic or organic contamination (<10 µS/cm) to be used within all rinse tanks (fill, recirculate, and spray hose).

5.3.3 The water supply is from Crane Water Treatment Facility which draws surface water from Lake Greenwood. A water quality report is included in Appendix 7.6.

5.3.4 Supply any pretreatment steps such as water softening, multi-media filter and/or activated carbon filter if required.

5.3.5 The system will be automated with control panel and include product conductivity and flow rate, product conductivity alarm, reject flow, tank level control, low supply pressure and high membrane pressure interlocks.

5.3.6 A 6,000-gallon storage tank is required to ensure enough clean water for one full day of production. The maximum height of this tank is 16’.

5.3.7 Space allocated for the RO skid is 4’ wide x 11’-4” long x 16’ high (not including the tank)

5.4 Waste Water Treatment System

5.4.1 The design shall minimize wastewater discharge and require no environmental permitting. Provide information on applicable permitting requirements for air, water, and hazardous materials based on their equipment design.

5.4.2 Solutions for alkaline cleaning, acid pickling and zinc plating have relatively long service lives before being drummed and treated as hazardous waste. 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

Design will minimize loss through drag-out and extend the life of chemical solutions.

Treating the spent finishing materials will not be a requirement for the waste treatment system; however, an option to do so is desirable.

5.4.3 Countercurrent rinse tanks with conductivity control shall be provided to minimize generation of water requiring treatment.

Each conductivity control system shall include an analyzer, a conductivity sensor, and a solenoid valve. The design is to include an electrodeless design sensor for ease of operation and maintenance due to less frequent cleaning.

5.4.4 Waste water from rinse stations will be segregated into low TDS (Total Dissolved Solids) and high TDS streams which will be sent to waste water treatment. Low TDS rinses will be sent to an ion exchange system to remove contaminants. The treated water will be reused.

5.4.5 High TDS rinse waters and effluent from ion exchange regeneration will be treated with a batch reactor to remove heavy metals. This will include a step to convert the hexavalent chrome to trivalent chrome depending on the concentration. Precipitates from the reactor will be sent to an automated filter press. Clarified water from the reactor will go to a pH adjust/monitoring tank.

5.4.6 The effluent from the pH adjust/monitoring tank will be discharged to local waste treatment or go to an evaporator (see options, Section 5.4.10).

5.4.7 The existing wastewater treatment plant 3064 (Navy operated) is regulated by an NPDES permit. A zinc treatment system processes water from zinc plating and zinc phosphating. The system is composed of oil/water separator, holding tank (tank 5), pH adjustment system, two carbon adsorbers and final pH adjustment. The pH adjustment system adjusts the pH before each carbon adsorber when caustic is used (for zinc phosphate wastewater). When zinc- plating wastewater is treated only a single acid addition is used. The treatment technology is based on granular activated carbon.

Parameter Design Influent Condition Effluent Limits

Flow Rate 15 gpm pH 2-6 7-9

Total Suspended Solids

90 mg/L <10 mg/L

Zinc 3.9 mg/L 2.61/1.48 mg/L*

*Daily Maximum/Monthly Average

Additional requirements are included in Appendix 7.7

Average daily flow 4300 gal/shift or 8 gpm.

Influent pH = 11.7; zinc concentration 22 ppm operator test of grab sample at oil/water separator life of carbon in filter vessel – about 4 weeks

Replacement of the carbon in the filter vessel requires 600 pounds. This generates 4 drums of hazardous waste. Cadmium in trace amounts from racks, parts or cleaning solution makes the carbon hazardous waste. Replacement of the carbon takes 8 hours.

5.4.8 The design shall be based on the new metal finishing system generating 20 to 30 gpm of rinse water continuously with similar level of contaminants as from the existing system. The effluent discharged from the water treatment system shall be no more than 15 gpm with contaminant levels within the effluent limits and additional requirements listed above for the existing wastewater treatment system.

5.4.9 The largest tank containing classified hazardous materials must not exceed 2000 gallons and be less than 16 feet high due to containment restrictions. This includes the spent alkaline tank, spent acid tank, Low TDS Rinse Tank, High TDS Rinse Tank and the batch reactor. Double wall construction should be used for these tanks.

5.4.10 Space allocated for rinse waste treatment is 21’ wide x 35’ long x 16’ high

5.4.11 Rinse Water Treatment Options

Include the following options for water treatment

Continuous treatment of the high TDS rinse water as an option to the batch treatment base case

Adding the capability to treat the spent chemical solutions

Including an Evaporator to increase water recovery and/or reduce waste discharge

5.5 Metal Finishing Tanks and Accessories: refer to the Tank Schedule in Appendix 7.3

REQUIRED: Spray Through rinse systems employing only a single rinse station with water conservation and pollution control shall be utilized. These systems also provide space efficiency with the minimum floor space available. Spray Rinse shall be provided within barrel for barrel applications, and within specially designed Spray rinse tanks for racking systems. Rinse tanks designed for racked parts shall include enough space for future work load and not be a limiting factor of part size (tank shall be capable meeting same requirements of process tanks). Conductivity Sensor/Rinse Water Control: The rinse stations shall be provided with conductivity control systems to minimize wastewater treatment costs and to conserve water. Each conductivity control system shall include an analyzer, a conductivity sensor, and a solenoid valve; all interfaced with PLC controls. The design is to include an electrodeless design sensor for ease of operation and maintenance due to less frequent cleaning.

5.5.1 Tanks shall be made of suitable materials for the specific application as indicated in the Tank Schedule found in Appendix 7.3. Materials listed include reinforced polypropylene; 304 stainless steel or 316 stainless steel. Mild steel lined, with alkaline resistant rubber shall NOT be used. The tanks will have common depths and lengths; widths (direction of travel) will vary. Note: the tank sizes shown in the Tank Schedule are approximate. Size the tanks based on the required design capacities indicated in section 3. Each tank bottom will be sloped to a 2” drain. Poly tanks shall have material thickness of 1” MINIMUM, and shall be double seam welded MINIMUM. Insulated tanks shall include at a minimum: Manganese phosphate, zinc phosphate, Electro-clean, Soak clean, and Type III anodizing.

Flanged plumbing outlets/inlets shall be provided. Threaded full couplings and ball valves shall be used. Equipment access shall be provided such that all equipment is easily accessible to perform maintenance related tasks on process tanks and pumps. All heat exchangers, pumps, feeder pumps, tank fittings, etc., shall have the same interchangeable parts/fittings.

5.5.2 Process tank mounting insulators: A sheet of ¼-inch thick (minimum thickness) PVC or equivalent load bearing insulation material shall be placed between *ALL* tanks and the tank-supporting structural steel. This material is also necessary to protect the structural steel from corrosion.

5.5.3 Tanks shall include Power supply for barrel drives, Variable frequency drives (VFD’s) shall be used to allow for slower barrel rotation (4-8 revolutions/min)

5.5.4 Chemical control system: The Contractor shall provide process tank pH, automatic titration, level, and conductivity sensors for chemistry level monitoring and /or auto make-up water fill in required tanks. The design is to include electrodeless design sensors for ease of operation and maintenance due to less frequent cleaning.

5.5.5 Agitation will be by pump & eductor systems for the process tanks (with 10x turnover/hour).

5.5.6 Types of Pumps: High temperature plastics such as CPVC, Ryton, or PVDF shall be used for hot solutions. Pumps with conventional seals and magnetic seal-less type pumps with ceramic shafts and bushings and thrust washers which are likely to experience electroless plating of the seals shall NOT be used. Centrifugal pumps for use with electroless plating shall be either vertical, bearing free, for use in-tank or out of tank, or horizontal with double water-flushed mechanical seals.

5.5.7 Tank Filtration: The Contractor shall provide process tank filtration systems with pumps, properly designed and sized for a minimum of three (3) tank solution volume turnovers per hour. The filtration system shall be easily maintained by the Operators.

A pressure switch shall be included to prevent deadheading pump if filter pressure issues. Self-contained automatic permanent media style systems shall be used.

Automatic microprocessor controlled backwash filters shall be used. Filtration units for electroless plating should be built of materials that limit the tendency of electroless solutions to plate out on surfaces. The filtration system shall be sized to provide high turnover rates and the design should facilitate quick cleanout and reuse of the filter media. Filters shall not be sized to require retaining large volumes of solids, but shall operate with minimum of differential pressure, to maximize the flow rates.

5.5.8 Cartridge filters will be provided for tanks as specified in the Tank Schedule.

Minimum of Eight (8) cartridge filters are required for the ferrous line, seven (7) for the nonferrous line, and five (5) are required for the manual equipment. The ferrous line will also require a fabric roll type filter for periodic sludge removal from the Phosphate Conversion tank.

5.5.9 Heavy sediment shall be removed from the Soak cleaner tank by a coarse cartridge filter or automatic gravity filter. Oils shall be effectively removed off line by feeding from overflow weir to unheated side tank. Cooled cleaner shall be skimmed, prefiltered and coalesced. Self-contained automatic permanent media style systems shall be used. Zinc Phosphate sludge removal is required.

5.5.10 A total of three (3) coalescers will be required for the Alkaline Cleaning Stations.

5.5.11 Drip shields will be provided between tanks to minimize drag-out. Sloped lids will be provided for tanks to return chemical solution drainages to their original tanks as specified in the Tank Schedule. Gaps between tanks are to be minimized and drip shields shall not obstruct work flow.

5.5.12 Cooling coils will be mounted inside the Zinc Generator Tank, Type II and Type III Anodizing Tanks to provide indirect cooling.

5.5.13 As per the Ref. Tank Schedule in Appendix 7.3, Minimum of nine (9) immersion heaters will be required for the ferrous line, Minimum of eight (8) immersion heaters will be required for the nonferrous line and a Minimum of five (5) immersion heaters will be required for the manual equipment.

5.5.14 Automated temperature control is required to ensure solution remains within the operating range. Electric Immersion heat exchangers/heaters made from titanium, or stainless steel, PTFE or equivalent coated, shall be used. Zinc Phosphate tank shall have two tank heaters which are PTFE coated. Magnesium Phosphate tank shall have two PTFE coated tank heaters. Tank size shall be appropriately considered for allowance of two tank heaters per Zinc/Mag Phosphate tank.

5.5.15 Heat exchangers: The Contractor shall provide internal/external RTD temperature sensor-controlled heat exchangers to the specified tanks. The Contractor shall include recirculation pumps to maintain adequate heating/cooling of the tanks’ contents. Air-free agitation using pumps and eductors shall be used to eliminate air sparger problems (minimum 4 turnovers/hour).

5.5.16 Heating Coils: The Contractor shall provide electric heating coils to heated tanks, properly sized to reach operating temperatures within four (4) hours of start heating.

This includes the anodize tanks that are also chilled. The temperature control shall be via RTD temperature sensors and PLC.

5.5.17 Overflow weirs shall be used where space permits for tank heaters and pumps.

5.5.18 Heated tanks and rinse tanks (see Tank Schedule) will include rim sprays equipped with a flow control valve and solenoid valve for automatic operation.

5.5.19 Push/pull ventilation shall be provided for tanks requiring ventilation. This will be done using a PVC updraft hood and an air knife. Tank ventilation hoods shall be placed in front of pumps and heaters such that ventilation does not pull tank moisture/chemistry towards equipment.

5.5.20 Air knives shall be used for part drying following heated final rinse/spray.

5.5.21 Chemical Replenishment Pumps – Ten (10) Chemical Replenishment Pumps will be provided to maintain chemical concentrations in the process tanks for chemicals supplied in liquid form. Tank level will be maintained by addition of RO water. The chemical concentration within the tanks will need to be periodically analyzed and adjusted. After lab data is entered, the replenishment pumps will transfer liquid from the bulk containers located in the chemical storage room to the process tanks.

5.5.22 Zinc Generator Tank: A Zinc Generator Tank will be required for the zinc plating process as a means to generate zinc ions and reactivate the zinc ion source. Zinc Generator tank shall contain cooling coils and agitated using eductors and pump.

Filter chamber and by-pass activated carbon filter shall be supplied in line from the return line of the zinc generating tank. All components shall be constructed for use with high alkaline solutions. Zinc generator tank shall be constructed of Polyethylene or polypropylene and include a lifting adapter for Zinc cartridge removal to prevent overdose of zinc.

5.6 Structures

5.6.1 Provide all access platforms required for operation and maintenance of provided equipment including an operator walkway between the 2 automated lines

5.6.2 Provide required concrete housekeeping pads and anchor bolts for interior equipment and site pads and anchor bolts for exterior equipment

5.6.3 Contractor shall supply corrosion resistant supports that bear on the concrete subfloor, not grating. IF the equipment requires cutting of the grating for the equipment supports to transition through to bear on the concrete subfloor, the contractor shall be responsible for strengthening the grating around the cuts to maintain the floorings original load capacity and integrity. Structural members/beams supporting may not be altered when placing equipment. Any changes to the flooring systems shall be such that the integrity of the flooring system is maintained.

5.7 Piping and Ducting

5.7.1 Process piping shall be suitable for the solutions processed. Due to the alkaline or acidic nature of many of the chemicals, PVC piping will be appropriate. Refer to the PVC pipe specification included in Appendix 7.8.1. Plastic tubing may be more appropriate for some applications such as the chemical replenishment pumps.

5.7.2 Ventilation ducting shall be Type 1 gray extruded PVC for 4” to 14” diameter. For sizes 16” diameter and greater, rolled Type II gray PVC should be used

5.7.3 Stainless steel piping may be used for the purified and treated rinse water. Refer to the socket welded Stainless Steel pipe specification included in Appendix 7.8.2.

5.7.4 Chilled glycol piping, and instrument air shall be carbon steel. Refer to the socket welded Carbon Steel pipe specification included in Appendix 7.8.3.

5.7.5 Ventilation ductwork shall be PVC. Refer to the PVC pipe specification included in the Appendix 7.8.1.

5.7.6 Piping and Ducting Installation –Provide all material and labor for the installation of interconnecting process and utility piping. Include all material and labor for the connections to the existing site utility systems.

5.8 Insulation:

Provide and install all heat conservation, personnel protection, and cold conservation insulation.

Use 1-1/2” fiberglass insulation with a PVC jacket where insulation is necessary. Refer to the cold and hot insulation specification included in Appendix 7.9.1 and Appendix 7.9.2.

5.8.1 Insulation shall be provided on heated and chilled lines/piping.

5.9 Ventilation

5.9.1 An exhaust ventilation system with hood, scrubber, and ductwork is required to accommodate all acidic and alkaline tanks. The air quality within the work area shall not exceed the Threshold Limit Value (TLV) for any air contaminants as established by the American Council of Governmental Industrial Hygienists (ACGIH). The design shall minimize the exhaust air requirements. The existing system design separates acidic vapor from caustic vapors. Vapors from the chromium tanks pose health and environmental concerns. Tank ventilation shall be push-pull.

5.9.2 The exhaust ventilation system will connect to the PVC updraft hoods of the tanks and direct the vapor to either scrubbers or general exhaust fans. PFD- 7 in Appendix

7.2.4 shows the Ventilation System. Updraft hoods and ductwork shall not be located directly over tank pumps, heaters, or other equipment which may be damaged by fall out. Contaminated air being pulled over process equipment is not acceptable.

5.9.3 Scrubbers shall be provided for those vents containing contaminants of concern, one scrubber for the Ferrous line and one for the Nonferrous line. The scrubbers will include a fan, demister, recirculation tank and pump with pH control system.

These will be located on 8’ x 20’ concrete pads outside the building (see LO-01 in Appendix 7.4) and will require weather protection. The scrubber discharge will be sent to waste water treatment high TDS rinse tank.

5.9.4 Contractor shall supply general exhaust fans for each automated line for ventilated process tanks which do not require scrubbing. Contractor shall supply the in-line fans located inside the building with roof vents.

5.9.5 Contractor shall coordinate required make-up air requirement for process exhaust systems with the Building Contractor. Provide process exhaust control sequence of operation and related make-up air flow quantities. Provide interlock wiring from process exhaust controls to points of connection at EMCS panels. Coordinate number and form of contact, voltage and signal format with Building Contractor. Commission process exhaust system in conjunction with commissioning of building makeup air unit.

5.9.6 In general, ambient rinse tanks will not be ventilated

5.10 Heating and Cooling

5.10.1 Glycol chiller(s) shall be provided to cool the zinc plating and anodizing stations.

Due to the different operating temperatures between zinc plating and Type III anodizing, using separate chillers may be warranted for these operations. These will be located on 6’ x 6’ concrete pads outside the building (see LO-01 in Appendix 7.4) and shall include weather protection. The contractor shall provide complete, energy star efficient chiller systems and support hardware.

5.10.2 Electric immersion coils shall be provided for tanks requiring heating as noted in Section 5.5.

5.10.3 The chillers shall sufficiently chill the coolant down in order to properly bring the baths to operating temperature within a maximum of four hours.

5.10.4 Chiller system for Type I anodizing at 76-84 deg F: Provide one air-cooled packaged chiller system, designed/sized to handle the heat load from associated rectifier for the tank. The chiller system shall include the coolant recirculation tank, compressor, fuses, tank sight glass, automatic hot gas bypass valve, and system pump. Coils and exterior shall be Adsil-coated by the factory.

5.10.5 Chiller system for Type II/III anodizing at 65-75degF/ 32-35degF: Provide one or two air-cooled packaged chiller systems, designed/sized to handle the heat load from rectifier supplied for the tank. The chiller system shall include the coolant recirculation tank, compressor, fuses, tank sight glass, automatic hot gas bypass valve, and system pump. The maximum time to switch between 32degF and 70degF shall be 4 hours. Coils and exterior shall be Adsil-coated by the factory.

5.10.6 Provide the required number of 55 Gal. drums of Propylene Glycol or proper coolant as required per OEM necessary for the initial coolant system charges. The coolant mixture shall be the same in all chiller systems, mixed to protect against -20degF ambient conditions. All chiller systems shall be clearly marked at their fill points with the proper coolant mixture specifications.

5.10.7 Mount, level, and align the new packaged chiller systems on the new chiller housekeeping pads located on the south exterior building site. Provide organized and systematic, insulated, interconnecting piping between all new chiller system components and anodize/zinc line immersion heat exchangers. Connect water supply, provide electrical power connections with disconnect from existing facility power/distribution panel. Control wiring shall be connected to the Motor Control Console (MCC) of the new plating lines. All new chiller piping is to be insulated. Install backflow preventers as necessary to prevent coolant from draining from systems during power outages.

5.10.8 The chiller’s status messages shall be interfaced with the control system via the PLC.

5.11 Rectifiers

Rectifiers supplied shall have electronics which are PLC compatible, shall have rectifier alarms and timers, shall have customizable controls with rectifier Switch Mode or SCR, (switch-mode style shall have less than 5% ripple over the entire voltage and amperage range), and shall be protected from the corrosive environment by means of stainless or poly constructed exteriors.

The contractor shall also ensure the rectifiers are properly bussed to their respective process tanks.

Bussing to the tanks shall be performed in such a manner as to ensure the supply of current is distributed uniformly across the anode/cathode header bars (the buss cables shall enter the tanks from both ends of the header/cathode bars).

5.11.1 There are 4 existing rectifiers that can be potentially reused. Three of the existing rectifiers are currently used for zinc plating and the remaining rectifier is used in the alkaline cleaning/electro-cleaning station. Assume that these can be reused for the three electro-cleaning stations with one as a spare. Ferrous line electro-cleaning must be compatible with PLC operation to be re-used. Information for these units are as follows:

Clinton Power Model SC750/12 SVCE, AC Input 298 V, 38 Amps, 3 Phase, 60 cycles with DC output 0-12 V, 750 Amps, 9 KW, continuous duty, 5% ripple.

The dimensions of the rectifiers are 54” high x 26” square with a 9” box on one side…