PD_W911N2-18-R-0020_FINAL.pdf

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LETTERKENNY ARMY DEPOT

PURCHASE DESCRIPTION

WATER BLAST/ WASH BOOTH - BLDG 350-1

1.0 GENERAL

1.1 SCOPE: This purchase description is for a turnkey operation that shall include fabrication and installation of the following:

• containment booth with lighting, personnel doors, and overhead doors

• ultra-high pressure water blast system (called water blast)

• heated high pressure washing system (called pressure wash)

• three axis platform system for operators

• concrete work for the booth, areas around booth, and sump trenches

• grating for sump trenches and sump pit

• heated ventilation system with fall protection

• water recirculation and filtration

• electronic controls for booth, ventilation, wash system, and blast system

• sprinklers and alarm system

The project shall be located in building 350-1. The ultra-high pressure water blast and the high pressure wash will serve as cleaning preparation for a stand-alone paint booth to be added at a future date. The filtration equipment, ventilation system and blast support equipment shall be located outside the blast booth enclosure. Ventilation plenums shall be located in the blast enclosure.

The components shall comply with all specifications, standards, and requirements listed in this document. The contractor shall provide all labor and materials for installation of a complete and usable system.

1.2 GENERAL INFORMATION

1.2.1 Place and Performance of Installation: The water blast/wash rack booth shall be located inside building 350-1 on the south end as specified in attachment A. The project shall include the enclosure, overhead doors, personnel doors, natural gas heated makeup air and exhaust air for ventilation, filtration system, pressure washer, and all necessary water blast equipment. The work shall include all necessary plumbing, electrical, and controls for a fully operational wash rack – water blast combination booth. All work will be performed between the hours of 6:00 AM and 3:30 PM, Monday through Thursday, exclusive of Federal Holidays and special depot closures (Typically the Monday before or Friday after Federal Holidays that fall on a Saturday, Sunday, Tuesday or Thursday). Other hours, weekend, and holiday work will be considered separately as requested by the contractor and approved by 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

2 4/24/2018 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 pamphlet 385-4. The equipment and the installation shall also meet all the safety criteria set forth in OSHA 1926.501 and ANSI/ASSE Z359.

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.

http://www.lead.army.mil/ http://www.lead.army.mil/ http://www.lead.army.mil/

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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 hours listed in section 1.2.1 above

2.2. Equipment:

2.2.1. Building 350-1 where the booth will be located inside and on the south end of the building.

2.2.2. Electrical and compressed air hookups will be available for tools needed by the contractor during installation.

2.2.3. Water, natural gas, electrical, and compressed air will be available to connect utilities to the all components of the water blast/pressure wash booth and assorted supporting systems.

2.3. Materials/Services:

2.3.1. Provide a single point of connection for power and compressed air within 25 feet of the mixing room. Power will be provided via a fused disconnect switch.

2.3.2. The Government will provide a connection point within 25’ for the interface between the water blast/wash rack containment room sprinklers, strobe, alarm, etc. and the Government’s fire alarm control panel.

2.3.3. Provide electricity and compressed air for vendor hand tools.

2.3.4. Provide space to layout out supplies, tools, etc. needed to complete the project.

3.0 Contractor Responsibilities: The contractor shall be responsible for the following:

3.1. Provide a summary of the required utilities and general layout 60 days prior to the equipment delivery, and the detailed installation requirements (to include installation schematics and installation schedule) 30 days prior to equipment delivery.

3.2. Supply all equipment, parts, labor and materials necessary for off-loading, positioning, installation and operation of the system.

3.3. Supply all materials, parts, and labor for the pouring of the concrete floor and sump area for the system. Provide grating to cover the collection trenches and the sump.

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3.4. Ensure that all welding is performed in accordance with AWS D1.1.

3.5. Ensure that all plumbing follows the applicable codes for ASME B31.3 process piping.

3.6. Ensure that the electrical installation is performed in accordance with the National Electrical Code. All electrical work shall be subject to inspection by LEAD electricians.

3.7. Electrical equipment and devices must meet OSHA requirements for grounding, rating, and listing by a recognized testing laboratory (such as UL), and for conformity to the applicable provisions of the latest edition (at the contract award date) of NEMA ICS 6, and C12.1 and the National Electrical Code.

3.8. Contractor shall make final connection to a government installed disconnect switch located within 25 feet of the Water blast/wash rack control panel.

Supplied voltage will be 480 Volt, 3-phase, 3-wire with a separate equipment grounding conductor. Contractor shall provide any transformation to other required voltages.

3.9. Remove all excess equipment, shipping crates, scrap and consumable materials used by the contractor for shipment and installation of the room.

3.10. The contractor shall supply no fewer than two of each special tool required to service the room and its components.

3.11. The contractor shall be responsible for obtaining site/equipment measurements and dimensions. Any dimensions provided by government personnel shall be considered approximate and shall not be used for design purposes. Failure of the contractor to acquaint himself with conditions attending the work site will not be considered sufficient reason for changing the cost or performance schedule of this project.

3.12. The contractor shall connect the sprinkler system from the water blast booth to the building sprinkler/alarm system. They shall also connect their strobe light/audible unit and alarm initiating relays to the building emergency system tie in provided by LEAD. The relays shall be alarm initiating and notification /shutdown modules.

3.13. The contractor shall coordinate all wall penetrations with the government representative. No structural members shall be removed or modified to make penetrations. All penetrations shall be sealed with a material acceptable for use in an industrial environment.

3.14. The contractor shall coordinate all roof penetrations with the government representative. Only licensed metal roof installers will be allowed to make and any roof penetration. All penetrations, flashing, etc. need to be coordinated with a government representative before the work takes place.

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4.0 SPECIFICATIONS

4.1. Performance Specifications

4.1.1. Two systems shall be supplied for use within the containment booth.

4.1.1.1. A heated high pressure system shall be supplied that shall be called “pressure wash” or “pressure washer” throughout this spec.

4.1.1.2. A ultra-high pressure water blast system shall be supplied that shall be call “water blast” throughout this spec.

4.1.2. Pressure Wash System

4.1.2.1. The pressure wash system shall be able to wash parts or assets with a supplied hot water pressure washer.

4.1.2.2. The pressure washer shall be capable of handling 4.0 gallons per minute at 3,000 psi or greater.

4.1.3. Water Blast System

4.1.3.1. The water blast system shall also be able to blast utilizing water only or water with various types of blast media.

4.1.3.2. The water blast system shall be able to blast at pressures from 10,000 psi to 40,000 psi. The system shall be capable of 3.5 gallons per minute or greater at 40,000 psi.

4.1.3.3. The water blast system shall be capable of blasting with water only as well as a variety of medias that shall include but not be limited to baking soda, garnet, and star blast.

4.1.4. Concrete Work

4.1.4.1. Concrete work shall include the containment booth area, walk way (one on side of the booth) and the equipment area (on the other side of the booth).

The total area to be covered is 63’ by 38’9” (See attachment A).

4.1.4.2. The wash bay floor shall be formed with a central trench and a transverse trench that feeds the sump. See attachment A.

4.1.4.3. The grade shall be 1/8” per foot in length and ¼” per foot for width for the wash bay to feed the trenches. See attachment B.

4.1.4.4. The grade in the trenches shall be ¼” per foot and feeding to the sump.

See attachment B.

4.1.4.5. The concrete work performed on the wash bay floor and the equipment room sump shall be in accordance with ASTM C39/C 39M.

4.1.4.6. The concrete shall have a minimum compressive strength of 4,000 psi at 28 days.

4.1.4.7. Grating over trenches and the sump formed during concrete work shall have a minimum load bearing status of 10,000 lbs,/sq. ft.

4.1.5. Ventilation

4.1.5.1. The ventilation system shall maintain a minimum of 100 feet per minute across the cross section of the booth to maximize visibility. It shall also maintain a negative pressure in the booth of -.05 inches w.g...

4.1.5.2. The supply air makeup unit shall be heated with natural gas.

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4.1.5.3. Both the supply and exhaust air units shall have fixed ladders and maintenance platforms with ratings that are OSHA compliant for maintenance.

4.1.6. Water Recirculation and Filtration

4.1.6.1. The filtration/ water recirculation system shall be capable of handling water and soap from the pressure washer, blast with water only, or blast with water media.

4.1.6.2. The water for the water blast system shall be a closed loop. Soap from the pressure wash system shall kept out of the closed loop as part of the process design.

4.1.6.3. The water filtration for the closed loop water blast system shall include a centrifuge process, a flocc process, and a bag filtration process to keep process water in optimal condition.

4.1.7. Containment Booth

4.1.7.1. The booth shall have two overhead doors with electric controls and two personnel doors.

4.1.7.2. The booth shall have overhead and personnel door interlocks that will keep the system from running or shut the system down if doors are opened.

4.1.7.3. The booth shall have multiple locations where e-stops can shut down the blasting or pressure washing process.

4.1.7.4. A minimum of four locations for shutdown shall be provided. These shall located two places in the booth and one location outside the booth on each side personnel door.

4.1.7.5. The booth shall have sprinklers and an emergency notification that will be tied into the buildings alarm system. In addition to the wet sprinkler system, a strobe light and audible alarm shall be included.

4.1.8. The system shall have two control panels. A larger more comprehensive control panel shall be located in the equipment area. A smaller panel shall be located in the containment booth for the water blast operation.

4.1.9. Penetrations for roof and for walls

4.1.9.1. Contractor shall take care in sizing ducts and locating openings to avoid steel structural members, including columns, beams, girts, purlins, diagonal bracing, etc.

4.1.9.2. Contractor shall secure the services of a metal building installer to provide framed openings, flashed and trimmed according to the metal building manufacturer's requirements.

4.1.9.3. Contractor shall be responsible for the cost of additional structural framing, should it be a requirement for any of the openings.

4.1.9.4. Ducted roof penetrations shall include a manufacturer's compatible pre-insulated roof curb, square-to-round cover, storm collar flashing and weathertight seal.

4.1.9.5. Top of curbs shall be level with ground and shall include a full-length cricket on the upside of the curb.

4.1.9.6. Side wall openings for duct penetrations shall be sleeved with a sheet metal liner with exposed edges folded back to form hems.

4.1.9.7. Openings shall be made weathertight with the application of an approved sealant around the perimeter of all penetrations.

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4.2. Design Specifications

4.2.1. General

4.2.1.1. The system shall include all required hardware for operation of water blast and pressure washing, a media separation and collection system, and a high solids pump for conveying the water and media.

4.2.1.2. All equipment shall include heavy duty steel frames either with built in fork slots or capable of being moved with a forklift.

4.2.1.3. All equipment shall be painted with durable coatings designed to hold up in a wet environment. The only exception would be stainless steel surfaces that would not receive coatings.

4.2.1.4. The containment booth shall include four compressed air hookups, two hookups on either side of the booth.

4.2.1.5. Drain lines shall be included in the equipment area for sending water from the pressure wash or water blast process to the industrial waste water system. A stub line shall be available for these tie ins.

4.2.1.6. Water Blast System components are:

a. Water blast unit

b. Media injection unit

c. Blast guns for water only blast and for water blast with media

d. Blast hoses for water only blast and for water blast with media

e. Natural gas heated pressure washer

f. Soap injector unit for pressure washer

g. High pressure hose and gun for pressure washer

h. Primary control panel for system

i. Control panel for system in booth

j. Cyclonic separator

k. Media centrifuge

l. Floccing and filter paper workstation

m. Hi-solids sump pump for water blast

n. Hi-solids sump pump for pressure washer.

o. Floor vacuum with HEPA filtration capable of utilizing a waste drum.

p. 50 gallon reserve water tank

q. Natural Gas Heated air makeup with filtration

r. Exhaust air unit with filters and moisture control

4.2.1.7. Pressure Washer System components are:

a. Heated pressure washer unit

b. Soap injection capability

c. High pressure hose and gun

d. Hose reel for inside containment booth

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e. Hard wired remote setup for hose, gun, and soap dispensing in containment booth.

4.2.1.8. The blast system shall be capable of blast pressure from 10,000 psi to 40,000 psi without changing gun tip.

4.2.1.9. The process equipment shall be housed in the equipment area shown in attachment A.

4.2.1.10. The blast unit and filtration system shall be installed in the area outside of the containment room but inside the building. The equipment will be positioned along the containment room wall within the building (See attachment A).

4.2.1.11. The small control panel and operational hardware (hoses, guns, etc.)

shall be installed in the wash rack/blasting area of the booth (see attachment A).

4.2.1.12. The large control panel shall be installed in the equipment storage area shown in attachment A.

4.2.1.13. Installation shall include all mechanical, electrical, plumbing, roof penetrations, etc. Installation shall be considered turnkey so that Letterkenny personnel will be able to begin operation with no additional work.

4.2.1.14. Safety equipment shall be incorporated for servicing any other equipment above four feet in height that requires maintenance. This can be tie off points or rails for attaching safety harnesses where needed.

4.2.1.15. Four complete sets of personal protective gear shall be provided.

These shall be complete protective water blast suits including boot covers, coveralls, jacket, and hard hat with drop down shield. Suits shall be made of ballistic materials capable of protecting and operator utilizing industry safety standards.

4.2.2. Water Blast Main Unit

4.2.2.1. A water blast unit shall be rated at a minimum of 70HP, PLC controlled, and capable of blasting 4.0 gallons/minute of water from one blast gun.

4.2.2.2. The water blast unit shall have a color touch screen monitor capable of adjusting settings at the unit or remotely by the operator using a hard wired remote control panel in the booth. Settings shall include pressure, pump rpm, and pump pressure.

4.2.2.3. The system shall be capable of water blasting in a range of 10k to 40k psi.

4.2.2.4. The blast unit shall have a VFD not a soft starter.

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4.2.2.5. The blast unit shall have a two trigger safety feature so that all pressure will be relieved and blasting ceased immediately upon release of either of the gun triggers.

4.2.2.6. The blast unit shall have a safety interlock feature so that if either of two overhead doors or two man doors open during operation, the blasting system will shut down and all blasting will be ceased immediately.

4.2.2.7. The water line shall have a high pressure rupture disc as a safety feature.

4.2.2.8. The water blast unit shall have a PLC which will monitor output pressure and adjust the drive to compensate for changing conditions or tip wear.

4.2.2.9. The control panel shall monitor water levels and monitor make-up water levels for the system with alarms and shutoffs for low water levels.

4.2.2.10. The water blast system shall have a booster pump of at least 1-1/2hp.

4.2.2.11. The system shall have a minimum of a 50 gallon holding tank or another means of maintaining constant pressure at the water blast gun.

4.2.2.12. A water pressure unloader valve is required.

4.2.2.13. The inlet water manifold shall have a pulsation damper.

4.2.2.14. Unit drive technology shall utilize in line, direct drive motor coupling and guard.

4.2.2.15. The system utility requirements shall operate on 480 volt, 60 hertz, and 3 phase.

4.2.3. Water Blast Hose and Gun

4.2.3.1. A rotary gun shall be supplied with a safety shroud for water blasting.

4.2.3.2. An abrasive fan gun shall be supplied with a safety shroud for water blasting with media.

4.2.3.3. A combination ultra-high pressure water hose, air hose, and control cord assembly shall be supplied for blasting with water only.

4.2.3.4. A combination ultra-high pressure (UHP) water hose, air hose, media hose, and control cord assembly shall be supplied for blasting with water and media.

4.2.3.5. The UHP hose for water shall be capable of handling over 100k PSI burst pressure.

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4.2.3.6. The rated operating pressure of the UHP hose shall be 40k psi, with test pressure of 60k psi for 30 seconds, and rated at a flow of 4 gallons/minute.

4.2.3.7. The hoses shall come with 3/8” UHP male ends and couplings.

4.2.3.8. The UHP hose shall be reinforced high pressure hose with abrasion covering.

4.2.3.9. The airline shall be 1/2” line rated at 300PSI with male and female quick disconnects.

4.2.3.10. The control cord shall be 16/3 insulated power cord with twist lock male and female plug ends.

4.2.3.11. The media hose shall be 50 feet long, ½” x 2 ply blast hose rated for 150 PSI with a 2 prong coupler on each end. The hose shall be compatible with a large variety of media grades and types.

4.2.4. Water Blast Media Injection System

4.2.4.1. System shall be capable of blasting with water and media or with water only.

4.2.4.2. System shall be capable of blasting with a variety of medias including but not limited to baking soda, glass, garnet, sand, aluminum oxide, etc.

4.2.4.3. The system shall have an air pressure gage for incoming supply air.

4.2.4.4. Pressure pot shall be at least 3.5 cubic foot ASME coded pot. The pot shall have a differential pressure gage, a method to pressurize for optimal media flow, and a reliable means of depressurizing the pot as needed.

4.2.4.5. Abrasive flow rate shall be adjustable and capable of flow rates between

0.5 and 5.0 pounds per minute.

4.2.4.6. Media feed system shall be capable of feeding abrasive up to 200 feet vertically and 300 feet horizontally.

4.2.4.7. System shall be capable of providing multiple and adjustable spray patterns (i.e. wider or narrower fan pattern for spray).

4.2.4.8. System shall be capable of injecting a rust inhibitor while spraying water with media or water without media.

4.2.4.9. System shall have a bleed air regulator to allow for a media purge to avoid water mixing with media.

4.2.4.10. System shall have the capability of spraying the media in a fan pattern with variability of media/spray utilizing the gun’s trigger.

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4.2.4.11. Media injection head shall be designed utilizing metals with special alloys and (or) special hardening procedures to insure optimal operational lifetime.

4.2.5. Water Treatment/Media Recovery – For Water Blast

4.2.5.1. Three stage filtration shall be required with a primary filter at 10 micron, a secondary filter at 2 micron, and a 2 micron final pump filter.

4.2.5.2. A filter paper final stage filtration unit shall treat the water with floc agent and clean all remaining solids.

4.2.5.3. The water blast sump pump for filtration shall be rated for 10HP, severe service, high-efficiency motor with VFD and solid state motor starter.

4.2.5.4. The pressure wash sump pump for filtration shall be rated for 5 HP, severe service, high-efficiency motor with VFD and solid state motor starter.

4.2.5.5. The sump system shall have two strainers. One is a strainer basket that shall be located on the top of the sump pit. The second is a strainer shall be located in the output line going to the floor wash.

a. Strainer basket has 3/16” square openings.

b. Second strainer has standard screen perforations of 1/32”.

c. The second strainer shall have an inlet and outlet that are twice the diameter of the hose (1-1/2” minimum hose with 3” minimum openings)

4.2.5.6. Both sump pumps shall have the following safety features

a. Low pump inlet water pressure lamp and shutdown.

b. Low reserve water tank level lamp and shutdown.

c. Dirty water filter lamp and shutdown

d. Low pump crankcase oil level lamp and shutdown

e. High pump crankcase oil level lamp and shutdown

f. Incoming power fault lamp and shutdown

g. Soft starter fault lamp and shutdown.

4.2.5.7. Both sump pumps shall be capable of passing solids up to 3/4”.

4.2.5.8. The pressure washer sump pump shall have the following specifications.

a. 230v 3phase 60Hz

b. Minimum 5HP rating

c. Minimum 3450RPM rating

d. NEMA 4X rating

e. Aluminum alloy (356T6 or comparable)

f. Silicon carbide seals

g. 17-4 PH heat treated, Vortex type impeller

h. Hardened cast iron volute

i. 17-4 PH heat treated agitator

j. 416 SS rotator shaft

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4.2.5.9. The water blast sump pump shall have the following specifications.

a. 230v 3phase 60Hz

b. Minimum 10HP rating

c. Minimum 3450RPM rating

d. NEMA 4X rating

e. Aluminum alloy (356T6 or comparable)

f. Silicon carbide seals

g. 17-4 PH heat treated, Vortex type impeller

h. Hardened cast iron volute

4.2.5.10. Pumps shall be a piston design and not belt driven.

4.2.5.11. Pump design shall be maintenance friendly to allow for each cylinder to be an independent setup capable of being serviced without taking apart the entire pump.

4.2.5.12. Discharge valves shall be accessible without removing/taking apart the entire head.

4.2.5.13. Pump maintenance to cylinders, discharge valves, etc. shall be compartmentalized so that service can be performed without requiring lifting or supporting devices.

4.2.5.14. All piping connecting pumps, tanks, etc. shall be schedule 80 PVC or better.

4.2.6. Pressure Washer System

4.2.6.1. The pressure washer (pw) shall utilize natural gas for heat.

4.2.6.2. The pw shall be able to achieve 4gpm at 3,000psi.

4.2.6.3. The pw shall include controls on the unit which will be hosed in the equipment area as well as controls for in the wash bay area.

4.2.6.4. The pw setup in the wash bay shall include a hose reel and remote controls for washing with or without soap.

4.2.6.5. The pressure washer shall include a high pressure gun/wand with insulated grip and quick disconnects. This shall be setup for operation in the wash bay.

4.2.6.6. The pressure washer shall include a high pressure hose of at least 50 feet in length also with quick disconnects.

4.2.6.7. The pressure washer shall include an adjustable thermostat, safety pressure relief valve, and hour meter.

4.2.6.8. The unit shall include a soap solenoid with controls for adding soap during operation along with controls for soap on the unit and also in the containment booth.

4.2.6.9. The pressure washer sump pump shall have the following specifications.

a. 230v 3phase 60Hz

b. Minimum 5HP rating

c. Minimum 3450RPM rating

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d. NEMA 4X rating

e. Aluminum alloy (356T6 or comparable)

f. Silicon carbide seals

g. 17-4 PH heat treated, Vortex type impeller

h. Hardened cast iron volute

4.2.7. Electronic Controls

4.2.7.1. There shall be at least three control panels that run and/or assist in running the system.

a. The main control panel shall be located outside the containment booth and shall be capable of interfacing with all components of the system.

b. The hard wired remote control panel shall be located inside the containment booth and capable of operating the blast equipment.

c. The water blast unit shall have a control touch screen capable of operating the blast system and high pressure pump.

4.2.7.2. The electrical panel shall have 125 amp circuit breaker and remote E- Stop capable of stopping the entire booth system as well as the water blaster.

4.2.7.3. The main control panel shall have a main control panel, utilizing one or more PLC’s, with graphic display and minimum 10” touch screen displaying key processes, controlling blasting, fluid process flow, filtration, ventilation, and lighting. Listed below are some of the primary functions. Further control panel functions may be necessary to insure system performance and efficiency:

a. Process flow for entire system

b. Ventilation flow for entire system

c. Blast operation settings, start, and stop controls.

d. Tank levels (sump pit, dirty tank, clean tank, and holding tank)

e. Booth lights

f. Heated makeup fan operation/status

g. Exhaust fan operation/status

h. Monitor static pressure with regard to supplied air and exhaust air

i. Pump operation/status (HP pump, transfer pump, floor feed pump, and booster pump)

j. Loop filter restrictions

k. Digitally displayed gages for high pressure filter differential, air supply, and water level.

l. Programmable maintenance mode.

m. Machine hours

n. Number of HP pump motor starts

o. Pressure sensors and open door sensor status.

p. Water and air processing system overviews/status.

q. All system faults

r. Interactive system fault troubleshooting

s. Password protection

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4.2.7.4. The booth shall have a hard wired remote control panel tied to the main PLC control panel, as well as running the blast unit from the wash bay without the need to access the main panel.

4.2.7.5. The hard wired remote control shall be a graphic display with a touch screen panel capable of showing the status or controlling the following:

a. Pumps and pressure sensors

b. Open door sensors

c. Tank levels

d. Exhaust levels

e. Booth lights

f. Status and control of heat air make-up air unit

g. Alarms for pressure levels, water levels, ventilation

h. On and off control for the system and components

4.2.7.6. The system booster pump shall utilize a soft motor starter and voltage transformer.

4.2.7.7. A fault banner shall be used to display system anomalies. Internet updates and diagnostics from a remote sight shall be capabilities of the main control panel.

4.2.7.8. The system shall allow the fault banner to be highlighted/activated so that the fault action requirements are displayed along with repair actions, parts, etc.

4.2.7.9. Separate circuit breakers for safety and control circuits shall be utilized.

4.2.7.10. The system shall be capable of handling a waste water treatment and recirculation option at a later date.

4.2.7.11. The system shall be capable of an automatic system shutdown for system overflow. The system shall have the capability of programming additional auto shutdowns based on customer requirements utilizing existing system sensors or pressure gages.

4.2.7.12. The system shall have four interlocks tied to 2 overhead doors and 2 man doors such that if any door opens during operation, all blasting will cease immediately.

4.2.8. Ventilation System

4.2.8.1. Minimum of 100 CFM across cross section of booth area as per ACGIH, VS-80-01 for cross draft abrasive blasting booth.

4.2.8.2. Heated air makeup

a. Heating system shall be direct fired natural gas heat

b. Heating unit and fan operations shall be tied into the main control panel.

c. Makeup air shall have wire mesh filtration in booth.

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d. Control shall be tied to main electronic control panel.

4.2.8.3. Exhaust system

a. Exhaust system shall have a system component to remove water vapor prior to exhausting outside.

b. Exhaust fan unit operation shall be tied into the main control panel.

c. Wire mesh filtration shall be required in the booth.

d. Control shall be tied to main electronic control panel.

e. Three stage moisture elimination shall be part of the exhaust system.

1. Stage one is the wire mesh filtration.

2. Stage two is PVC drift eliminators.

3. Stage three is moisture eliminating baffles.

4.2.9. Vacuum System

4.2.9.1. A wet/dry heavy duty vacuum unit shall be supplied for media cleanup in the bay outside of the sump.

4.2.9.2. The vacuum unit shall have the following specifications:

a. HEPA filtration

b. Air inlet hose size of ¾” NPT

c. Minimum compressor size of 15 HP

d. Incoming airline pressure of 100psig

e. Utilizing a 55 gallon drum of waste collector.

f. Unit shall come with a wheeled dolly with heavy duty plastic wheels for mobility.

4.2.10. Containment Room Specifications

4.2.10.1 Sound deadening foam shall be used on the containment room walls and ceiling

4.2.10.2 20 GA stainless steel shall be used on the bottom 6’ of the inside containment walls in the blasting area.

4.2.10.3 3” of sound deadening foam center with aluminum sides for walls and 6” of sound deadening foam center with aluminum sides shall be the minimum amount utilized on the enclosure.

4.2.10.4 With the exception of the stainless steel on the inside containment area, all aluminum on the walls shall be painted white with a water resistant coating.

4.2.10.5 Booth size shall not exceed 26’wide x 59’long x 20’high for outside dimensions, including the support structure.

4.2.10.6 Booth inside dimensions shall be a minimum of 23’6” wide x 54’6” long (inside the plenums) x 18’ high (to the top of the sprinkler heads).

4.2.10.7 8 foot - 2 bulb wet location florescent light fixtures shall be used on the ceilings and walls for lamination. A minimum of 30 fixtures shall be used for lighting in the booth.

4.2.10.8 The booth shall be drive through with two roll up overhead doors on both ends and two personnel doors, one on each side.

4.2.10.9 One E-stop will be located next to each personnel door.

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4.2.10.10 Roll up overhead doors are to be a minimum of 14’ wide x 14’ high openings with automatic doors.

4.2.10.11 Painted tubular steel for overhead doors and fan supports.

4.2.10.12 Personnel doors shall be aluminum painted with glass panels.

4.2.10.13 Supply and exhaust filter frames shall be of galvanized steel.

4.2.10.14 Shall have a safety railing on top for maintenance fall protection.

4.2.11. Three Axis Lift Specifications

4.2.11.1 Shall utilize pneumatic power source operating at 100psi (80SCFM).

4.2.11.2 Shall have an operator platform with a safety railing.

4.2.11.3 Shall have operation controls on the front of the platform.

4.2.11.4 The standing platform shall be 21” deep by 40” wide with a 500lb capacity.

4.2.11.5 Unit shall be designed for and used in heavy industrial environments.

4.2.11.6 Unit shall be designed for ease of maintenance utilizing self-lube bushing and a minimum of grease points.

4.2.11.7 Unit shall be equipped with in line filter, regulator, and lubricator with moisture separator to insure long life on pneumatic components.

4.2.11.8 Standard compressed air plug in location for operator use.

4.2.11.9 Lift shall ride on a floor mounted and wall mounted rail.

4.2.11.10 Installation of rails and three axis lifts shall be included.

4.2.11.11 Wall mounted rail shall be an I-beam rail with cam followers for tracking the lift along the wall.

4.2.11.12 The wall mounted rail shall serve as support for the festooned pneumatic hoses which will move in a roller trolley system.

4.2.11.13 The lift shall run on two aluminum wheels that will run along the floor mounted rail (length of booth: x axis)

4.2.11.14 Rate of travel shall be variable up to 40FPM or better.

4.2.11.15 Rate of travel shall be controlled with a variable flow foot valve for hands free operation.

4.2.11.16 Unit shall be able to travel across the booth (width of booth: y axis)

4.2.11.17 Unit shall be able to travel up to 79” or more in the y axis.

4.2.11.18 Unit shall be able to travel at 15FPM or more in the y axis.

4.2.11.19 Unit shall be driven by a sealed linear actuator that can be quickly replaced for ease of maintenance.

4.2.11.20 Platform shall be able to go from 2’ to 12’ in height (height: z axis)

4.2.11.21 Rate of vertical travel shall be 15FPM or more in the z axis.

4.2.11.22 Z axis driveline shall be a positive displacement system utilizing a rotary ball screw driven through a self locking worm drive gear reducer for safety and precise control.

4.2.11.23 Unit shall be equipped with safety systems to keep the unit from an uncontrolled descent in the unlikely event of loss of air pressure or mechanical driveline failure.

4.2.11.24 Unit shall be equipped with an E-down system so the operator can lower the platform if air supply fails.

4.2.11.25 Unit shall be able to be raised or lowered from the ground in the event an operator becomes disabled or maintenance needs to perform work from the ground.

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4.3 Safety System Specifications

4.3.1 E-Stops shall be provided at both personnel doors, at the main control panel, and at the water blast unit.

4.3.2 A strobe light and audible alarm shall be included inside the booth and tied into the alarm system.

4.3.3 A wet sprinkler system shall be included inside the booth.

4.3.4 Two relays shall be provided to tie into the sprinkler system and the building alarm system.

4.3.5 A tie in to the building alarm system location shall be provided by Letterkenny within 25 feet of the booth and/or booth equipment.

4.3.6 A shutdown of the water blast and all ventilation shall be incorporated in the system design if the alarm is tripped.

4.3.7 Fall protection shall be included where maintenance is required on system components.

4.3.7.1. Fixed ladders with cages shall be provided for both exhaust fans and for the heated air makeup unit.

4.3.7.2. Platforms with railings shall be provided for the three units covered above.

4.3.7.3. Tie off points or tie on rails shall be incorporated for any locations that require maintenance above 4 feet that are not covered in a & b above.

4.4. Floor/Concrete Specifications for Wash Bay Floor

4.4.1. Area to be covered with concrete is 63’ by 38’9”.

4.4.2. Three areas shall be covered. First area is 4’ by 63’ for east walkway.

Second area is 63’ by 26’ which will be the area of the containment booth and support structure for booth. The third area is 8’9” x 63’ which is for the system equipment and the sump area.

4.4.3. Tie in to the existing concrete floor will be needed.

4.4.4. A stub line to the industrial waste water treatment plant will be provided.

All required floor drainage will be connected to this for the equipment area.

4.4.5. Slope of wash bay floor shall be 1/8” per foot sloping to the center wash bay trench. See attachment A.

4.4.6. Slope of the trench shall be ¼” per foot. North –South wash bay trench shall slope to the center of the booth where the wash bay trench connects with the transverse trench. The transverse trench shall slope to the sump. See attachment A.

4.4.7. Demo and removal of unfinished floor in wash bay to be converted.

4.4.8. Work bay will slope to center of bay as shown in attachment B.

4.4.9. Slope of the bay shall be set up from the north and south ends of the bay towards the center of the bay as shown in attachment A.

4.4.10. A sump pit will be installed in the equipment area. See attachment A for location.

4.4.11. Piping from the sump pump to the equipment room will need to be cut into the floor going to the recirculation system.

4.4.12. Any other plumbing required for the recirculation and filtration system can be under the wash bay floor or mounted on the wash bay walls, ceiling, etc.

as long as they don’t hamper movement of the three axis lifts.

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4.4.13. Ramps leading into/out of the north and south end of the wash bay shall provide a smooth transition out of the wash bay to the pavement outside the bay.

4.4.14. Concrete requirements:

4.4.14.1. Concrete shall have a minimum compressive strength of 4,000 psi at 28 days unless otherwise indicated.

4.4.14.2. The air content shall be between 4.5 and 6.5 percent with a slump between 2 and 4 inches.

4.4.14.3. The maximum water cement ratio shall be 0.45.

4.4.14.4. Exposed concrete surfaces shall have a light broom finish.

4.4.14.5. Curing to prevent premature drying of concrete shall begin after placement and continue for at least 7 days.

4.4.14.6. A curing/sealing compound complying with ASTM C 309, Type 1, Class A and B, and ASTM C1315, Type 1, Class A shall be applied in accordance with the manufacturer’s instructions and recommendations.

4.4.14.7. During curing concrete shall be protected from extremes in temperature, freezing, and mechanical damage. If forms are removed prior to the end of the required curing period, the contractor shall ensure that the formed surfaces are properly cured for the remainder of the curing period.

4.4.14.8. Compressive strength testing shall be performed on concrete used to construct the concrete slab on grade in accordance with ASTM C 39/C 39M.

4.4.14.9. Samples for strength tests shall be taken not less than once each shift in which concrete is produced. A minimum of six specimens shall be made in accordance with ASTM C 31/C 31M; two shall be tested 7 days for information and two shall be tested at 28 days for acceptance. The extra two specimens shall be tested if the 28-day test is unsatisfactory. The strength of the concrete will be considered satisfactory if the average strength of the two specimens tested at 28 days is equal to or exceeds the specified compressive strength requirement and no individual specimen tested falls below the required compressive strength by more the 500 psi.

4.4.14.10. Prior to installing new concrete on top of existing concrete surfaces, the existing surfaces shall be roughened or milled to facilitate adhesion.

4.4.14.11. Prior to installation, deformed steel dowels shall be installed in the existing floor surface. Dowels shall be drilled and epoxied into existing concrete surfaces to a depth of approximately 6 inches below top of floor. Dowels shall conform to ASTM A 675/A 675M, Grade 80.

4.4.14.12. Epoxy coating shall comply with the requirements of AASHTO M 254, Type B.

4.4.14.13. Dowels shall be spaced on a grid at a distance of approximately 6 feet along the length and width of the surface to receive new concrete.

4.4.14.14. A mat of 6 x 6 x 6 welded wire fabric shall be installed at a depth of not less than 2 inches below the finished surface of the new concrete.

4.4.14.15. Concrete joint sealant shall be rubberized joint sealing material complying with ASTM D 6690, Type I or Type II.

5.0 NAMEPLATE: A corrosion resistant metal nameplate shall be securely attached to the paint kitchen/mixing room. The nameplate shall contain the following information:

- Nomenclature

- Manufacturer’s name

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- Manufacturer’s model designation

- Manufacturer’s serial number

- Input voltage, current, phase, and Hertz

- Date of manufacture

6.0 DRAWINGS AND MANUALS: Two sets of the manufacturer’s design drawings shall be submitted for approval within 4 weeks of award. Approval shall be provided within 10 days after receipt by LEAD engineering personnel. Three sets of operator instruction manuals, maintenance service manuals and parts listing manuals shall be provided for the unit. These manuals shall be written in the English language and also provided in electronic version.

7.0 HAZARDOUS MATERIALS: Two sets listing all lubricants, seals, and/or any other hazardous material necessary for preventive and corrective maintenance along with their respective Material Safety Data Sheets (MSDS) shall be submitted for approval within 4 weeks of award. These lists and MSDS shall be written in the English language.

8.0 WARRANTY: A standard commercial warranty or a one year commercial warranty, whichever is larger, shall be furnished with the water blast/ wash rack system and booth in its entirety. The warranty shall cover the system and all components. The warranty period begins when the LEAD Contracting Officer provides official confirmation that the system has satisfied all operational provisions of the contract.

9.0 STANDARD PRODUCTS:

9.1. The equipment must be new and regularly advertised products in order to provide a constant source of replacement parts and technical assistance.

9.2. The equipment must be the manufacturer’s standard product that is marketed, sold, and used for applications that are similar in all essential ways to how LEAD will be using it.

9.3. The firm is using a production (non-prototype) unit in a manner and purpose that is essentially similar to how LEAD will be using the unit.

9.4. The unit operates effectively when operated and maintained in accordance with the written instructions.

10.0 PRESERVATION, PACKAGING AND DELIVERY: The contractor shall utilize standard commercial methods for preservation and packaging appropriate for the return air systems components 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.

11.0 INSPECTION AND ACCEPTANCE

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11.1. The water blast/wash rack booth and 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.

11.2. The contractor shall be responsible for developing test procedures to demonstrate compliance with the requirements of this specification. All test procedures shall be submitted to and approved be Depot Technical Point of Contact (TPOC) prior to the start of testing. To support the testing procedures, LEAD will provide a supply of material for use during the performance tests and training

12.0 INSTRUCTION: The contractor shall conduct no less than 2 hours of operator training for up to 6 personnel that are already familiar with the operation of LEAD’s existing water blast and pressure wash operations, and shall conduct no less than 4 hours of maintenance training for up to 6 personnel familiar with the maintenance of LEAD’s existing water blast and pressure wash.

13.0 APPLICABLE DOCUMENTS: The latest edition of the following documents form a part of this specification:

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

29 CFR 1910.94 Ventilation Copies may be obtained at http://www.osha.gov

AMERICAN CONFERENCE OF GOVERNMENTAL INDUSTRIAL HYGIENISTS

(ACGIH) - Industrial Ventilation Guide Copies may be obtained at http://www.acgih.org

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI Z9.4 - Ventilation and Safe Practices of Abrasive Blasting Operations Copies may be obtained at http://www.ansi.org

AMERICAN WELDING SOCIETY (AWS) - AWS D1.1/D1.1M Structural Welding Code Copies may be obtained at http://www.aws.org

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 6 - Enclosures for Industrial Controls and Systems

NEMA 12.1 - American National Standard for Electric Meters Code for Electricity Metering Copies may be obtained at http://www.nema.org

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 54 – National Fuel Gas Code NFPA 70 - National Electrical Code NFPA 91 - Exhaust Systems for Air Conveying of Vapors, Gas, Mists, & Part.

Solids Copies may be obtained at http://www.nfpa.org

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SHEET METAL AND AIR CONDITIONING CONTRACTOR'S NATIONAL

ASSOCIATION (SMACNA) - Industrial Duct Construction Standards Copies may be obtained at http://www.smacna.org

LETTERKENNY ARMY DEPOT (LEAD) Reg. LEAD 385-1 Safety and Occupational Health Program Copies may be obtained from LEAD Directorate of Contracting