Purchase_Description_REV_1.pdf

PRODUCTION ENGINEERING

PURCHASE DESCRIPTION

BLDG 350 PAINT BOOTHS 59 & 60 EXHAUST FAN UPGRADES

1.0 GENERAL

1.1 Scope: This specification describes the replacement of 4 each exhaust fans on Paint Booths Numbers 59 & 60 (Asset Numbers: S0407, S0405) in Building 350 at Letterkenny Army Depot, Chambersburg, PA. The (4) new replacement fans shall be belt drive duct axial swing-out style fans with new VFD controls. The contractor shall perform the work as described herein in its entirety (turnkey operation), including but not limited to the following: fan and ductwork plan design/drawings, all labor and equipment to remove/demolish the existing fans and related components, installation of the new fans and related components, connections to the provided utilities (i.e. electrical, controls, fire suppression), training, and performance testing.

1.2 General Information:

1.2.1 Place and Performance of Installation: The new exhaust fans shall be installed in Building 350. Due to production downtime limitations, there is a restriction on when contractor work may be performed. The contractor performing work will be permitted access and allotted only 3-5 days per booth (completion of 2 fans) before government acceptance of fully operational systems (maximum of 10 days downtime for both booths). One paint booth shall remain operational at all times, and the contractor shall provide the Government full, unrestricted access to the operational booth. In consideration of above, all work shall be performed between the hours of 6:00 AM and 3:30 PM, Monday thru Thursday, exclusive of Federal Holidays and special depot closures (typically the Monday before or Friday after Fed Holidays that fall on either Tues or Thurs). Other hours, weekend, and holiday work will be considered separately as requested by the contractor and approved by the Contracting Officer. Contractors shall provide bid submittals with proposed work schedules that may be beyond normal working hours (to meet work restrictions above of 3-5 days of booth downtime), for approval through the Contracting Officer.

1.2.2 Security Requirements: The contractor shall be responsible to ensure that all employees and subcontractor employees that will visit the depot shall comply with applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative). The contractor shall also provide all information required for background checks to meet installation access requirements to be accomplished by installation Provost Marshal Office, Director of Emergency Services or Security Office. Contractor workforce shall comply with all personal identity verification requirements as directed by DOD, HQDA and/or local policy. Should the Force Protection Condition (FPCON) change, the Government may require changes in contractor security matters or processes.

1.2.3 Security, Safety and Fire Protection: All work shall comply with LEAD regulation 385-1 and LEAD Pamphlet 385-4.

1.2.4 AT Level I Awareness Training: All contractor employees, to include subcontractor employees, requiring access to Army installations, facilities, and controlled access areas shall complete AT Level I awareness training within 30 calendar days after contract start date or effective date of incorporation of this requirement into the contract, whichever is applicable. The contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee to the COR or to the contracting officer, if a COR is not assigned, within 15 calendar days after completion of training by all employees and subcontractor personnel. AT Level I awareness training is available at the following website: www.lead.army.mil.

1.2.5 iWATCH Training: The contractor and all associated sub-contractors with an area of performance within an Army-controlled installation, facilities or area shall brief all employees on the local iWATCH program. This local developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the TPOC or contracting officer. This training shall be completed within 30 calendar days of contract award and within 30 calendar days of new employees commencing performance. The contractor shall report completion for each affected contractor employee and subcontractor employee, to the TPOC and contracting officer within 15 calendar days after completion of training. iWATCH training is available on the Letterkenny Army Depot homepage – www.lead.army.mil

1.2.6 OPSEC Training: Per AR 530-1, Operations Security. Contractor employees and associated sub-contractor employees shall complete Level I OPSEC training within 30 calendar days of their reporting for duty and annually thereafter. The contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee, to the COR or to the contracting officer if a COR is not assigned, within 15 calendar days after completion of training. Level 1 OPSEC training is available on the Letterkenny Army Depot homepage – www.lead.army.mil

1.2.7 Badges: Identification badges will be issued for admittance of personnel before performing work or service on this contract. The identification badge is the property of the US Government and shall be returned upon termination or demand. The contractor/vendor shall ensure all badges issued to employees are returned to the Badge and Identification Section, Security Division, Letterkenny Army Depot promptly on termination of need or on expiration, which occurs first. The badge room is located in Bldg 2, phone # 717-267-5301. Hours of operation are 7:30 AM to 3:30 PM, Monday thru Thursday, exclusive of Federal Holidays.

2.0 GOVERNMENT FURNISHED PROPERTY AND MATERIALS: The Government will provide the facilities, equipment, materials and/or services listed below:

2.1 Facilities: The Government will provide clear access to all working areas necessary for the contractor to perform the installation outlined, during the specified hours listed in section 1.2.1 above.

2.2 Equipment: none

2.3 Materials: none

2.4 Services: The Government will provide a sprinkler maintenance contractor (via Government service order) to only cap off existing sprinklers and reinstall sprinkler line similar to existing operation. The contractor shall provide work schedule to Contracting Officer and Government TPOC for coordination with Government provided sprinkler maintenance contractor IAW Section 4.2.2.1 (Section 3.2).

2.5 Utilities: The Government will provide electricity for vendor hand tools.

3.0 CONTRACTOR RESPONSIBILITIES: the contractor shall be responsible for the following:

3.1 Contractor shall obtain Government written design approval, field verify all existing conditions and requirements before purchase, demolition, or installation of related equipment.

3.2 The awarded contractor shall provide LEAD Contracting Officer the following deliverables on a scheduled project timeline:

- Contractor shall field verify site conditions/dimensions and submit design plans to Contracting Officer and LEAD TPOC for an allotment of 30 calendar days for Government written design approval process.

- (1) written proposed work schedule, for each Paint Booth #59 & 60 (Building 350), 30 calendar days in advance for written approval through Contracting Officer, LEAD TPOC, Government Rep for sprinkler maintenance contractor. This approval will be done before any 3-5 day scheduled downtime per booth.

3.3 Contractor shall assure that at least one paint booth (either Paint Booth #59 or 60) is available for full, unrestricted LEAD production use. Any deviations to this plan must be signed and approved in writing through the TPOC coordination.

3.4 Demolition/removal of the existing wiring, controls, ductwork, project interferences, exhaust fans and related components for Paint Booths 59 & 60 in Building 350.

3.5 The contractor shall submit designs through the Contracting Officer for Written design approval process involving the following: LEAD TPOC, LEAD Maintenance Department, LEAD Production, LEAD Fire Department, and LEAD Safety Department.

3.6 Supply all labor and materials, equipment, parts, fabrication necessary for the purchase, off-loading, storage, positioning, installation and proper operation of the (4) new exhaust fan systems in the entirety. The new exhaust fans shall be factory-assembled, and tested with features to meet the specifications listed in section 4.0 of this document.

3.7 Install utility connections to new equipment (i.e. electrical, etc.) from Government provided existing utility connection points (i.e. disconnect switches).

3.8 Provide training for operation, inspection, and maintenance of the new equipment installed.

3.9 Perform baseline testing of equipment to verify equipment meets manufacturer RPM/CFM/pressure performance specifications. Provide hard copy of documented performance results to the TPOC for reporting each new unit condition at project completion.

4.0 SPECIFICATIONS:

4.1 Existing Equipment Removal

4.1.1 The contractor shall remove the (4) existing exhaust fans (Cincinnati Model TAF- 42, 42626, etc.), duct transitions, and related components. As required, all affected items shall be disconnected from utilities (Electrical, controls, prior to demolition/removal.

4.1.2 The contractor shall remove fans and related components to designated areas outside at the time of disassembly with TPOC coordination.

4.2 Design and Installation

4.2.1 The contractor shall supply and submit all designs for approval including, but not limited to the following: fan manufacturer drawings and specifications, new installation layout elevation drawings, and updates to electrical/wiring/control schematics.

Contractor shall verify in advance that all new and existing equipment connection requirements are compatible with available utilities.

4.2.2 The contractor shall provide exhaust fans and related components that are designed, fabricated, and installed in compliance with NFPA 33 & 91.

4.2.2.1 The contractor shall coordinate with TPOC and Government sprinkler maintenance contractor to spot location, cut opening in ductwork, and reseal opening after reinstallation of fire suppression piping by Government sprinkler maintenance contractor (Section 2.4)

4.2.3 The contractor shall provide and install four (4) new exhaust fans (Hartzell model A46-446DA-STFCO3 or equal) with the following features:

- Fan type: belt drive duct axial, airfoil design, 6 blades

- Fan size: 44" diameter (or size to match existing ductwork)

- Fan construction rating: AMCA B construction (one piece construction cast of 319 aluminum alloy for shaft/propeller meeting ASTM B26, rub ring, flanged and gasket bearing cover, Teflon seal, aluminum cover plate)

- Fan configuration: 12 gauge rolled carbon steel housing with continuous weldment in compliance with AWS D1.1, swing-out style (left hand/right hand configuration shall be determined from LEAD design approval process), flanges with slotted mounting holes

- Fan accessories: (4) vibration isolators/expansion joints on outlet side of each fan housing

- Fan bearings: heavy duty, cast iron pillow block housing, self-aligning, neoprene shaft seal, rated to minimum L10 bearing life of 50,000 hours, extended lube lines for continuous service

- Fan belts: "v" type, heat, oil, and static resistant, rated for continuous service

- Fan sheaves: compatible with "v" type belts

- Fan motor rating: 15 HP, TEFC inverter duty motor, voltage/phases rating to match disconnect switch available power supply, belt guard, adjustable

- Fan performance rating: 24,000 CFM @ 1.5" w.c.

- Fan assembly shall be dynamically balanced at fan manufacturer factory prior to shipping. Fan factory balancing shall be in compliance with standard ANSI S2.19-1989, Grade G6.3. Fan performance testing shall be in compliance with AMCA standard 210 and 300 to bear AMCA Certified Air Performance Rating Seal.

4.2.4 The contractor shall design, fabricate, and install (8) duct transitions from 14 gauge galvanized steel and angle flanges on the inlet and outlet sides of the (4) new exhaust fan housings to match existing ductwork. The smooth duct transitions shall have a transition angle that shall not exceed 15 degrees, and contractor shall submit design drawings indicating the angle measurement for LEAD approval.

4.2.5 The contractor shall verify and install ductwork supports (for existing/new ductwork) separate of new exhaust fans, as required. The contractor shall note on design submittal drawings that the new swing out style fan is not designed to support ductwork above (swing out style fan has a center of gravity that changes when it is swung open). Ductwork below new exhaust fans shall have adequate support for the new exhaust fan weight and design. The contractor shall design, fabricate, and install new support steel for swing-out style door to support the new fan assembly offset weight and prevent any excessive stress on fan housing or bowing/stress/loading to vertical ductwork or ceiling of paint booth.

4.2.6 The (4) new fans shall be provided with a swing-out style of 180 degrees of rotation with hinges (from "operating position" to "maintenance position") away from the front of the paint booth (2 left hand, 2 right hand). To achieve the "maintenance position" with the swing-out door fully open, the contractor shall provide design provisions for LEAD Maintenance personnel to safely access door latches and internal parts from a continuous working height above the paint booth ceiling without any additional ground equipment (i.e. scissor lift, fork lift, etc.). The LEAD design approval process for contractor submitted designs shall provide any comments/changes for the contractor to adhere to be in compliance with LEAD and OSHA regulations for fall protection requirements (Section 3.5).

4.2.7 The contractor shall provide new circuitry/wiring with appropriate electrical capacity for the upgraded 15 HP motors. The contractor shall relocate existing disconnect switches to avoid full swing-out rotation of fan ("maintenance mode").

4.2.8 The contractor shall provide and install (4) Allen-Bradley Powerflex 400 AC VFDs (variable frequency drives) or equal and (2) vented enclosures (2 VFDs per enclosure).

The contractor shall provide startup performance testing for proper operation and training on operation of new VFDs/controls.

4.2.9 The contractor shall return the system in its entirety to a fully functioning condition equal to existing capability or greater for new circuitry/wiring/controls/VFDs/exhaust fans, as required. The contractor shall verify working condition, and reinstall existing pressure switches or other existing components that are functioning properly.

4.3 Utility Connections

4.3.1 Contractor shall provide all necessary conduit, labeling, adaptors, transitions, flexible connectors and/or unions to connect to building utilities where required.

4.3.5 Contractor shall provide and install electrical wiring and connections from electrical disconnect switch to new units within 25 feet of equipment location in accordance with NFPA 70 NEC. Contractor shall provide properly sized fuses per manufacturer’s recommendations.

5.0 DRAWINGS AND MANUALS: Contractor shall provide 1 each manufacturer’s operation manual and registration paperwork for each unit. One electronic and one printed manual for each unit shall be provided.

6.0 WARRANTY: A one year minimum warranty shall be furnished with the equipment.

The warranty period begins when the LEAD Contracting Officer provides official confirmation that the equipment provided has satisfied all operational provisions of the contract.

7.0. PRESERVATION, PACKAGING AND DELIVERY: The contractor shall utilize standard commercial methods for preservation and packaging appropriate for the equipment and acceptable to commercial carriers. As a minimum, all areas susceptible to damage from exposure to the elements shall be preserved and/or packed to prevent damage. The contractor shall be responsible for ensuring the equipment is delivered to LEAD in good condition.

8.0 INSPECTION AND ACCEPTANCE: The equipment shall be examined for design, construction, materials, components, and workmanship to determine compliance with the contract and this specification. Any deviation from these requirements shall be cause for rejection.

9.0 APPLICABLE DOCUMENTS: The following documents form a part of this specification and may be obtained from the sources listed.

National Fire Protection Association (NFPA) NFPA 33 - Spray Application Using Flammable or Combustible Materials NFPA 91 - Standard for Exhaust Systems for Air Conveying of Vapors, Gases, Mists, and Particulate Solids NFPA 70 - National Electric Code (NEC) (copies may be obtained at www.nfpa.org)

American Society for Testing and Materials (ASTM) B26 - Aluminum-Alloy Sand Castings (copies may be obtained at www.astm.org)

American Welding Society (AWS) D1.1 - Structural Welding Steel (copies may be obtained at www.aws.org)

American National Standards Institute S2.19-1989 - Balance Quality of Rotating Rigid Bodies (copies may be obtained at www.ansi.org)

Air Movement and Control Association (AMCA) 210 - Laboratory Methods of Testing Fans for Certified Aerodynamic Performance 300 - Reverberant Room Method for Sound Testing of Fans (copies may be obtained from www.amca.org)

OSHA Regulations (standards - 29 CFR) Part 1910 Occupational Safety and Health Standards and Part 1926 Safety and Health Regulations for Construction (copies may be obtained from www.osha.gov)

American Conference of Governmental Industrial Hygienists (ACGIH) Industrial Ventilation – A Manual of Recommended Practice for Design (copies may be obtained from www.acgih.org)

LETTERKENNY ARMY DEPOT (LEAD)

LEAD Regulation 385-1 - LEAD Safety and Occupational Health Program LEAD Pamphlet 385-4 - Safety Requirements for Security, Safety, and Fire Prevention for contractors performing work on LEAD (copies may be obtained from LEAD directorate of Contracting, Bldg 2)