PD_W911N218R0022.pdf

LETTERKENNY ARMY DEPOT

PURCHASE DESCRIPTION

FLAME SPRAY BOOTH

1.0 GENERAL

1.1. SCOPE: This purchase description is for a turnkey sound proofed booth and ventilation system for the flame spray operation in building 350’s metal finishing annex at Letterkenny Army Depot. The project shall include fabrication and installation of an enclosure, soundproofing, and a ventilation system with dust collectors. The ventilation system shall include natural gas heated makeup air, all ductwork, electrical controls, and associated equipment. All necessary equipment, labor, and materials required to design, fabricate, and install this system will be included. All specifications, standards, and requirements listed below shall be complied with. This booth, ventilation system, acoustic tiles, sprinklers, controls, etc. shall be called the flame spray booth throughout this purchase description.

1.2. GENERAL INFORMATION

1.2.1. The booth and ventilation system shall be located in the bldg. 350 metal finishing annex in the northwest corner as shown on appendix A. The project shall include the enclosure, one overhead door, personnel doors, natural gas heated makeup air, exhaust air, a dust collector, and an electrical control panel.

The work shall include all necessary plumbing, electrical, and controls for a fully operational 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 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.

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. Located inside the new 350 metal finishing annex in the northwest corner of the building. See attachment A.

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 all components of the flame spray booth and assorted supporting systems.

2.2.4. Sprinkler connection will be available for piping into the building’s fire suppression system.

2.3. Materials/Services:

2.3.1. Provide a single point of connection for power within 25 feet of the flame spray booth. 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 flame spray booth, sprinklers, strobe, alarm, etc. and the Government’s fire alarm control panel.

2.3.3. Provide access to natural gas for the makeup air heating unit within 25 feet of the booth.

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

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

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

3.5. 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.

3.6. 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.

3.7. Contractor shall make final connection to a government installed disconnect switch located within 25 feet of the booth. 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.

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

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

3.10. 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.

3.11. The contractor shall provide relays for connection to the booth’s sprinklers and alarm system.

3.12. The emergency system relays shall be alarm initiating, notification, and shutdown modules. They shall connect their strobe light/audible unit and alarm initiating relays to a building emergency system tie in location provided by LEAD.

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.

4.0 SPECIFICATIONS

4.1. Performance Specifications

4.1.1. Noise levels outside the booth shall not exceed 85 decibels (dB).

4.1.2. Maintain light levels of 70 foot candles or greater throughout the booth area.

4.1.3. Differential pressure shall be maintained at -.05 inches of water (w.g.) by making adjustments between the supply and exhaust air to maintain this pressure.

4.1.4. The minimum volume flow of both the downdraft and makeup air systems shall be 60,000 cubic feet per minute (cfm).

4.1.5. Minimum duct flow rates shall be 3,500 feet per minute (fpm).

4.1.6. Makeup air shall be returned to the booth at a velocity not to exceed 700 fpm.

4.1.7. Air flow shall provide between 2.3 to 5.0 air turns per minute or 60,000 cfm minimum.

4.1.8. NFPA hazard classification for the booth shall be Class II, Div I

4.2. Design Specifications

4.2.1. General

4.2.1.1. The booth enclosure shall be an acoustical design including wall tiles, air inlet silencers, and duct baffles to reduce the noise level outside the booth.

4.2.1.2. Slot plenums for the booths floor slots shall be outside of work area

4.2.1.3. The existing outside overhead door will be incorporated into booth. This overhead door is 20’ wide by 20’ high. The rollup enclosure will remain outside the booth on the roof and shall be able to receive PM’s and repairs from the roof of the booth.

4.2.1.4. Ductwork from plenums to dust collector must go through side walls not roof.

4.2.1.5. The Booth footprint shall be irregular in shape due to building restrictions. This is to maximize work area given the location within the building.

A proposed design is included in attachment A.

4.2.1.6. Booth height inside is 20ft but exiting ductwork is allowed to reduce this if needed. Note: Height to top of building duct is 22'8". However, At least a 19’ clear interior working space shall be maintained to allow for exhaust or supply ductwork.

4.2.1.7. All components, other than galvanized ductwork, located exterior to the building shall be designed, primed, and painted for outside service.

4.2.1.8. All blowers/motors shall be 480 volt, 3 phase, totally enclosed fan cooled (TEFC), weather proof, and spark resistant. A motor starter shall be provided for each fan.

4.2.1.9. The minimum clear interior working space inside (not including plenums) shall be 26’ wide by 50’ long x 20’ high for interior dimensions.

4.2.1.10. The maximum available outside footprint shall be 34’ wide by 52’ long x 22’ high. This area shall include space for plenums, enclosure walls, support structure, etc.

4.2.1.11. Two floor/downdraft plenums shall be provided. One system shall be on each side of the flame spray drive through booth (see attached sketch). The support structure, ductwork, and hardware shall be fabricated from materials which will withstand wear/corrosion from the materials and processes used in the flame spray operation.

4.2.1.12. All bus box disconnects, conduit, control boxes, starters, and associated electrical components necessary to make the equipment operational shall be included.

4.2.2. Safety

4.2.2.1. Sprinklers shall be included with the booth and tied to the buildings alarm system.

4.2.2.2. Strobe light and an audible alarm shall be included with the booth and tied to the alarm system.

4.2.2.3. All electrical connections inside booth shall be Class II Div I hazard zone wiring for explosive dust. This shall also apply outside the booth in relation to booth openings.

4.2.2.4. All system components shall be electrically grounded.

4.2.2.5. A safety control package for interlocking the thermal spray process equipment with the booth safety interlocks shall be included.

4.2.2.6. At least two emergency stops inside the booth and two emergency stops outside the booth shall be included.

4.2.3. Ventilation

4.2.3.1. Heated air makeup shall be a natural gas unit.

4.2.3.2. Supply and exhaust air must have variable frequency drives (VFD)

4.2.3.3. All ventilation system components shall be tested for leakage and any leaks shall be repaired.

4.2.3.4. Safety interlocks shall be designed between supply and exhaust air such that if one goes down, the other will shut off.

4.2.3.5. All ductwork shall be designed, fabricated, reinforced, and supported as per SMACNA standards.

4.2.3.6. The downdraft ventilation shall be designed in such a manner as to create downdraft airflow spread evenly across the entire work area. The plenums shall be designed to capture and convey the air to the dust collectors.

4.2.4. Booth Enclosure

4.2.4.1. The booth shall include one overhead door and two personnel doors and share one overhead door with the existing building.

4.2.4.2. The booth shall come with explosion proof light fixtures that open to the inside of the booth so lights can be changed.

4.2.4.3. Interior overhead door motor must be rated for Class II Div I

4.2.4.4. Interior overhead door must be insulated and sound proofed

4.2.4.5. Personnel doors must be insulated, sound proofed, and include a viewing window.

4.2.4.6. Booth walls and ceiling shall include sound proofing to achieve required sound level outside the booth when in operation.

4.2.4.7. Labor required for roof and wall penetrations shall be the responsibility of the contractors.

4.2.5. Dust Collector

4.2.5.1. Dust collectors shall be located on the outside of the west wall (see attachment A).

4.2.5.2. Ductwork to the collector will have to travel up from the plenums, over the booth and out through the wall.

4.2.5.3. The dust collector units shall be down flow cartridge type collectors with a minimum air to cloth ratio for each collector of no more than 2.5:1. The units shall be sized such that the minimum system flow rate of 60,000 cfm (30,000 cfm/collector) will be maintained.

4.2.5.4. Dust shall be discharged into pyramidal shaped hoppers that shall incorporate a slide gate at the discharge end.

4.2.5.5. The cartridges shall be easily accessible from side mounted panels.

4.2.5.6. Each dust collector shall be equipped with explosion vents with rain covers.

4.2.5.7. The dust collector units shall have automatic pulse cleaning for the filters. The pulse controller for both dust collectors shall have adjustable pulse timing and adjustable pulse interval timing.

4.2.5.8. Both collectors shall be provided with ladders and platforms to access filter cartridges.

4.2.5.9. The filtration systems shall incorporate high efficiency (99.999% @ .5 micron particle size) filters followed by a safety filter.

4.2.5.10. Magnehelic differential pressure gauges, mounted next to the control panel, shall be installed across both the cartridge filters and safety filters. The safety filter magnehelic shall be tied to a visual alarm system located at the control panel.

4.2.5.11. The collectors shall be designed to accommodate dust collection in stainless steel box containers. Each unit shall incorporate a steel box kit to include the necessary lids, hose, and clamps.

4.2.6. Heated Forced Air Makeup Unit

4.2.6.1. Makeup air shall come through the west wall and into the booth from the ceiling area and will be directed downward through mixing boxes and diffusers.

4.2.6.2. Overall downdraft design should be based on a minimum volume flow rate of 60,000 cfm and a maximum air velocity of 700 fpm.

4.2.6.3. The heated makeup air unit/units (no more than 2) shall be natural gas fired and shall be located at ground level near the dust collector outside the building.

4.2.6.4. The makeup air unit/units shall incorporate an automatic damper system to ensure that a negative pressure is maintained within the flame spray booth at all times.

4.2.6.5. 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

4.2.7. Control Panel

4.2.7.1. The booth shall be equipped with a single power control panel that incorporates the fan motor starter controls, dust collector controls, warning lights, audible alarms, magnehelic gauges and the requisite NFPA/OSHA mandated interlocks.

4.2.7.2. Dust collectors and makeup air unit shall each have an individual start/stop buttons with a red light indicating the fan is running.

4.2.7.3. The panel shall be in a national electrical manufacturers association (NEMA) 12 or better enclosure and all booth electrical requirements will be derived from this panel.

4.2.7.4. A relay shall be provided to connect to the building emergency system.

In the event the building fire alarm goes off, the ventilation system shall automatically shut down.

4.2.7.5. The panel shall be located inside the booth on the east side near the outside overhead door.

4.2.7.6. When an emergency or fire occurs within the booth, the exhaust and makeup units shall have manual shutdown capabilities and be wired into the fire system notification. In the event that the ventilation system shuts down an audible alarm and strobe light shall be activated to let the operator know that the ventilation system has shut down. There shall be two strobe lights, one on each side of the booth and one audible alarm.

5.0 NAMEPLATE: A corrosion resistant metal nameplate shall be securely attached to the flame spray booth. The nameplate shall contain the following information:

- Nomenclature

- Manufacturer’s name

- 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 after 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 after 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 flame spray booth system 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 equipment provided 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

11.1. The flame spray 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 flame spray booth and 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 flame spray booth.

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 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 70 - National Electrical Code NFPA 33 - Standard for Spray Application Using Flammable and Combustible Materials. Copies may be obtained at http://www.nfpa.org

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

29 CFR 1910.107 Spray Finishing Using Flammable And Combustible Materials.

Copies may be obtained at http://www.osha.gov

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