20180531_HX_Production_Facility_Tech_Spec.pdf

DEPARTMENT OF THE ARMY

PINE BLUFF ARSENAL

PINE BLUFF, ARKANSAS 71602-9500

JMPB-TS-2018-ET-01

TECHNICAL SPECIFICATION

FOR

HX PRODUCTION FACILITY

31-630NS

January 2018

SYSTEMS ENGINEERING DIVISION

DIRECTORATE OF ENGINEERING AND TECHNOLOGY

JMPB-TS-2017-xx TECHNICAL SPECIFICATION FOR: HX Mixing Facility 31-630NS

WRITTEN BY: _______________________________

Matt Fritsche Project Engineer

REVIEWED BY: _______________________________

Alan Buckmaster, P.E.

Project Engineer

REVIEWED BY: _________________________________

Justin Selby Mechanical Engineer Public Works

REVIEWED BY: _________________________________

Jada Gray Safety Engineer

CONCUR: ________________________________

Chris Richards Chief, Production Engineering

TABLE OF CONTENTS

1 SCOPE 5

2 APPLICABLE DOCUMENTS 5

2.1 Government Documents 5

2.2 Non-government Documents 5

2.3 Safety Regulations 6

3 TERMS AND DEFINITIONS 6

3.1 Item Definition 6

3.1.1 Item Diagrams 6

3.1.2 Interface Definition 6

3.1.3 Demolition/Construction 6

3.1.4 Major Components 7

3.2 Characteristics 7

3.2.1 Performance Characteristics 7

3.2.1.1 System Operational Sequence 7

3.2.1.2 Installation, Training, and Removal 8

3.2.2 Physical Characteristics 8

3.2.2.1 Service Manuals and Drawings 8

3.2.2.2 Preventative Maintenance Schedule 9

3.2.3 Reliability 9

3.2.4 Maintainability 9

3.2.5 Availability 10

3.2.6 Transportability 10

3.2.7 Environmental Characteristics 10

3.3 Design Demolition, Construction and Major Components 10

3.3.1 Materials, Process, and Parts 10

3.3.1.1 Electrical/General 10

3.3.2 Tooling 12

3.3.3 Identification and Markings 12

3.3.4 Interchangeability 12

3.3.5 Safety 12

3.3.6 Human Performance/Human Engineering 13

3.3.7 Standards of Manufacture 13

3.3.8 Facilities 13

3.3.8.1 Demolition 13

3.3.8.2 Construction 15

3.3.9. Major Component Characteristics

3.3.9.1 HC Bag Opener

3.3.9.2 Attrition Mill

3.3.9.3 100 Ton Watson-Stillman Presses

3.3.9.4 Mandrel Ejector

3.3.9.5 Reamer

3.3.9.6 Crimping Press

3.3.9.7 HC Bag Opener Feed Conveyor

3.3.9.8 HC Attrition Mill to Drum Feed Conveyor

3.3.9.9 Scales

3.3.9.10 Double Cone Mixer

3.3.9.11 Drum Dumper

3.3.9.12 Belt Conveyors

3.4 Quality Of Construction 22

3.4.1 Protective Coatings 22

3.4.2 Accessibility 23

3.4.3 Hardware 23

4 QUALITY ASSURANCE PROVISIONS 23

4.1 General 23

4.1.1 Special Tests and Examinations 23

4.2 Quality Management Program 23

4.3 Quality Conformance 24

5 PERIOD OF PERFORMANCE 24

6 PREPARATION FOR DELIVERY 24

7 CONDITIONS OF WORK 24

7.1 Order and scheduling of Work 24

7.2 Disposal of Excess Removed Material 25

7.3 Emergency First Aid 25

7.4 Safety Requirements 27

APPENDIX I:

CONDUCTIVE FLOORING

APPENDIX II:

DELUGE SYSTEM AND SIGNALING SYSTEM AT

BUILDING 31-630

APPENDIX III:

CONTRACT DATA REQUIREMENTS LIST (CDRL)

1. Preventative Maintenance Schedule

2. Concept Drawings and Vendor Cut-Sheets

3. Operation and Maintenance Manuals

4. As-Built Drawings

5. Drawings

6. System Safety Hazard Analysis Report

7. Time Line Charts

1 SCOPE

This Technical Specification establishes the performance, design, fabrication, testing, installation, acceptance, and training to provide Pine Bluff Arsenal (PBA) with a HX mixing and canister pressing facility.

The work to be performed under this technical specification consists of facility preparation, moving, installing, and restoring to operation the government furnished equipment and furnishing all other materials, equipment, supplies, labor and transportation to complete and make fully operational the production process within the facility. Work required by this contract shall be performed in strict accordance with specifications and drawings. Final acceptance will be based on the systems performance after installation at PBA and shall be evaluated on the acceptance criteria hereafter referenced. Operator and maintenance training shall be provided by the contractor for this system after acceptance.

2 APPLICABLE DOCUMENTS

2.1 GOVERNMENT DOCUMENTS

Drawing Number Title 31-630AR-3000S1 Architectural 31-630 Building Alterations 31-630AR-3000S2 Architectural 31-630 Building Alterations 31-630EL-3000S1 Electrical Service 31-630 480VAC 3 Phase 31-630EL-3000S2 Electrical Service 31-630 480VAC 3 Phase 31-630EL-3001 Conductive Flooring and Grounding 31-630 31-630EL-3002 Fire Alarm System Legend and General Notes 31630-EL-3003 Electrical Classifications 31-630EQ-3000 HX Equipment Layout 31-630 31-630HVC-3000 HVAC Changes 31630 Building Alterations 31630ME-228 Hydraulic Piping for 100 Ton Press 31-630ME-3000 Model RTS-100 Bag Opener W/ Crusher for Hexachloroethane Bags 31-630PP-3000 HX Deluge Piping

2.2 NON-GOVERNMENT DOCUMENTS

Codes, Standards, and other specifications which are called for or referred to herein are considered part of this specification. In the event of discrepancies between this specification and codes or standards, the Government shall be notified.

Instrumentation, Systems and Automation Society (ISA) ISA-5.1-84 Instrumentation Symbols and Identification

National Electrical Manufacturers Association (NEMA) NEMA ICS-1 General Standards for Industrial Control and Systems

National Fire Protection Association (NFPA) NFPA 70 National Electrical Code (NEC)

Standards of Manufacturing ASME American Society of Mechanical Engineers ASTM American Society for Testing and Materials OSHA Occupational Safety and Health Administration

2.3 SAFETY REGULATIONS

All Contractor personnel performing work within the Pine Bluff Arsenal will adhere to the regulations and supplements listed below.

AR 40-5 Preventive Medicine AR 380-5 DA Info Security Program AR 385-10 Army Safety Program w/AMC Supplement 1 AR 385-64 U.S. Army Explosives Safety Program DA-PAM 385-64 Ammunition and Explosives Safety Standards AMCR 385-100 AMC Safety Manual PBAR 190-3 Installation Employee and Visitor Access Requirements

3 TERMS AND DEFINITONS

3.1 ITEM DEFINITION

a. Contractor is to furnish all materials, labor, equipment and supplies necessary to design and construct equipment to meet the Scope and Intent of this specification. All contractor furnished equipment and material shall be new and unused and of commercial manufacture. The contractor will unload and unpack all equipment. The winning contractor or his/her licensed, bonded agents will accomplish demolition, physical installations and utility tie-ins; the contractor shall perform all adjustments, and is responsible for the installations.

b. Utility services consisting of water, compressed air, and electricity, to the extent available, will be furnished to the contractor without charge, subject to the terms and conditions of the general provisions entitled, "INTERFACE DEFINITION ". Such utility services shall be furnished at building 31-630 where all equipment in this contract is to be installed.

3.1.1 ITEM DIAGRAMS

N/A

3.1.2 INTERFACE DEFINITION

Air - 90 PSIG Plant Air Electric - 240/480 Volts, 3-Phase, AC Electric - 120/240 Volts, Single-Phase, AC Water - Potable Industrial Waste Drain System

3.1.3 DEMOLITION/CONSTRUCTION

1. Electrical Service Renovation

2. Compressed Air Piping to Cubicles and East Bay

3. Partition Wall in East Bay

4. Diverting Existing HVAC Ventilation from South Cubicles to East Bay

5. Extension of Cubicle 6

6. Diverting Existing Dust Collection to Northside Cubicles and East Bay

7. Extending Existing Vacuum system to Northside Cubicles and East Bay

8. Conductive Floors in Cubicles 1-12

9. Fire Suppression System

3.1.4 MAJOR COMPONENTS

A. Government Furnished Equipment

1. Hexachloroethane(HC) Bag Opener

2. Attrition Mill

3. 4 each 100 Ton Watson-Stillman Press with Hydraulic Units

4. Mandrel Ejector

5. Reamer

6. Crimping Press

B. Contractor Furnished Equipment

1. HC Bag Opener Supply Conveyor

2. HC Attrition Mill to Transfer Drum Feed System

3. Scales

4. Double Cone Mixer

5. Drum Dumper

6. 3 Belt Conveyors

3.2 CHARACTERISTICS

The mix manufactured using the new double cone mix will be used in end items that produce white smoke. White smoke mix uses the following chemicals: Tin Oxide, Hexachloroethane (HC) & Aluminum. This mix is known as HX mix. Density of HX mix is about 3.245g/cm3 or 118.5 pounds per cubic foot. All contractor furnished equipment and materials need to be compatible with these materials (See 3.2.7).

3.2.1 PERFORMANCE CHARACTERISTICS

3.2.1.1 SYSTEM OPERATIONAL SEQUENCE

The operator will start the Dust Collection System before any other system can be operated. The contractor shall interlock the other systems to prevent operation without the dust collection and its diverter valve in the right position.

The east room sequence of startup that shall be interlock by the contractor shall be as follows: The operator will place a 30 gallon drum on the scale below the discharge of the Attrition Mill to Transfer Drum Feed System, Attrition Mill, and Bag Opener. The bag opener system starters shall be interlock in the following order: Bag Opener Bag Compactor, Bag Opener Auger, Bag Opener Rotary Screen, Bag Opener Crusher, Bag Opener Cutter No. 1, Bag Opener Cutter No. 2, Bag Opener Infeed Conveyor, and Bag Opener Supply Conveyor. The operator will then load bags of HC on the Bag Opener Supply conveyor. Once the drum is filled to a predetermined weight the operator will stop the system and change the drum and restart the system if necessary. The operator needs to be able to see the fill weight while filling the container and stop the system when the drum is full. Note that the Bag Opener system may continue to run since it will be wired independent of the rest of the system.

Cubicle 8 is the location of the Tin oxide storage. A 30 gallon drum will be placed on scales and filled with Tin Oxide to a desired weight.

Cubicle 9 is the location of the Aluminum storage. A 30 gallon drum will be placed on scales and filled with Aluminum to a desired weight.

Cubicle 11 and 12 will be used for loading the mixer, mixing, and then unloading the mixer. The aluminum, HC, The mix will be unloaded into drums. The unloading of the mix from the mixer should be able to be stopped and the containers changed out when full.

3.2.1.2 INSTALLATION, TRAINING, AND REMOVAL

The Contractor shall be responsible for installation of equipment to include training, setup, and final adjustments as needed. The Contractor shall provide the Contracting Officer (KO) a milestone chart within thirty (30) calendar days after award of contract. Contractor will also provide KO an updated milestone chart for approval prior to start of installation phase. The milestone chart shall be provided in both hard copy and in digital format (CD media) in Microsoft Project® format, and shall contain all phases of fabrication, demolition, installation, training, and start-up. Training at the installation site shall be conducted in a class with six or more people attending. Training shall cover equipment operations, maintenance, and systems trouble-shooting. Upon completion, the entire area shall be cleaned of all debris produced by demolition or installation of equipment.

3.2.2 PHYSICAL CHARACTERISTICS

a. The contractor shall be responsible for checking the work site and accuracy of drawings, dimensions, and field conditions. Questions should be provided in writing to the attention of the KO for resolution.

b. The configuration/s of the process equipment shall be chosen by the contractor but such equipment must be approved by the KO in the Design Review Process.

c. The system must also provide sufficient access for maintenance. The equipment will be located in a building cubicle or cubicles separated by 12-14 inches thick reinforced concrete blast walls refer to drawing 31-630-AR-3000.

d. The interior of all cubicles and 10ft distance from the outside of the walls of the cubicles including the mezzanine area of building 31-630 shall be a Class II Div I Groups E, F, & G environment.

e. The west and east bays shall be not rated but all wiring shall be done to dust tight standards.

3.2.2.1 SERVICE MANUALS AND DRAWINGS

Concept drawings and available manufacturer's literature shall be furnished to the KO five (5) business days prior to design review. Drawings and material submittals shall be provided to the KO at the 90% completion of detail design point. One set of shop drawings will be maintained on site and all changes shall be red lined and approved by KO prior to any changes during installation. Shop drawings shall be kept current and correct at all times during the project. For both of the Concept drawings and 90% Completion documents, the contractor shall furnish a hardcopy no larger than “D” (22" X 34") in size and a digital format (CD media) in MicroStation (*.dgn) or AutoCAD (*.dwg) or SolidWorks. Drawings will be clearly identified with a contractor supplied number and a title that describes the contents of the drawing. Electronic drawings will include the number and the title as the title in order to make finding drawings easier. Upon completion of installation one copy of Maintenance and Operation manual with all drawings shall be submitted to the KO for approval. The contractor shall correct or revise the final drawing to comply with as-built conditions. All manuals and drawings shall be supplied and approved before training and final run-off. The contractor shall furnish two (2) maintenance and operating manuals for all equipment installed under this contract, and one copy in digital format (CD media) in Microsoft Word and as a pdf. These manuals shall be indexed and tabbed, with a hard cover binder and label, to include a list of all replacement parts. Parts list shall include all information required to purchase the components from the manufacturer or a representative vendor and shall include the list price at the time of purchase. A complete reproducible set of drawings and one copy of those drawings in digital form (CD media) must be in MicroStation (*.dgn) or AutoCAD (*.dwg) formats or SolidWorks. Drawings and Schematics will include Assembly and Schematics of the control room equipment and as built drawings showing Equipment Layout, Piping, Electrical, etc., shall be furnished before acceptance is complete. No drawing shall be larger than "D" (22" X 34") in size unless the government supplied drawings are a larger format (i.e., E, F). The Government will stamp, tag or otherwise identify showing status of all drawings and submittals furnished to the KO within 15 working days of receipt to be returned to the contractor.

Any and all manufacturer’s literature and manuals that is submitted via hard copy shall have all model and size clearly identified. This includes but not limited to being highlighted or marked to indicate what has been used for this project. If color is being used to highlight then all copies must be in color.

3.2.2.2 PREVENTIVE MAINTENANCE SCHEDULES

The contractor shall furnish separate from the maintenance and operating manuals, two (2) copies of preventive maintenance schedules and one copy in digital format (CD media). The schedule will be broken down into daily, weekly, monthly, semi-annual and annual checks or services that should be performed on the control equipment, along with any other frequency that is required. Also to be included is a schedule for replacing wear type items on the process equipment. Also to be included shall be a recommended spare parts list with recommended stocking levels, sufficient to properly maintain the equipment.

3.2.3 RELIABILITY

An estimate of the proposed product's reliability expressed in terms of Mean Time between Failures (MTBF) shall be required for contractor furnished equipment. This estimate shall be based upon actual experience with equipment produced by the prospective supplier and must be supported by raw data.

(NOTE: MTBF is simply the total operating time for a piece of equipment, excluding downtime, divided by the total number of corrective maintenance actions.) The reliability of the system shall be 0.998 (99.8%) with a 90% confidence level.

3.2.4 MAINTAINABILITY

a. Unit downtime for preventive maintenance (PM), routine scheduled and non-scheduled service, repairs and adjustments shall not exceed 1% of normal operating time.

b. Rates for frequency of PM shall not exceed one service day per quarter. Man-hour expenditures per service must not exceed 1% of normal operating time.

c. Maintenance complexity shall not require more than two journeyman grade millwrights or more than standard hand tools for each service.

d. Bidders shall submit as a part of their bid an estimate of their proposed product's maintainability expressed in terms of Mean Time to Repair (MTTR). The prospective supplier shall base this estimate upon actual experience with this type of equipment. NOTE: MTTR is simply the total machine downtime due to failure divided by the total number of corrective maintenance actions.)

3.2.5 AVAILABILITY

Availability is defined as the probability that the equipment will operate satisfactorily at any given time and is expressed as a function of the MTBF and MTTR discussed above.

A = MTBF The desired availability for this unit is established at .9975

MTBF + MTTR

3.2.6 TRANSPORTABILITY

The equipment shall be capable of being transported and located into position by a fork truck and fit though 8’H X 8’W doorway for the bay area and 7’H X 5’W for the cubicles. The Contractor will be responsible for the transporting of all equipment to Pine Bluff Arsenal, be responsible for receiving, unloading, unpacking, and provide all equipment and operators for such equipment for example: fork trucks, pallet jacks, hoists, dollies/hand trucks and etc., for such purposes.

3.2.7 ENVIRONMENT CHARACTERISTICS

The equipment shall be placed at Building 31-630. The equipment will be exposed to dust from the chemicals. The building is also submitted to environmental conditions such as pollen, mold, dirt, dust, moisture in the atmosphere, daily cleaning with water.

Hexachloroethane (HC) is a hazardous chemical. It is corrosive. All bare metal or wear parts must be stainless steel, aluminum, or brass. Bearings must be sealed and Stainless Steel where possible. HC, in the air as a dust or a vapor from the HC subliming, creates a health hazards. All processes transferring HC need to be enclosed and well ventilated using the dust collection system. HC also tends to bridge easily.

Hoppers with HC may need agitators to help the material flow out of the hopper.

3.3 DESIGN, DEMOLITION, CONSTRUCTION, AND MAJOR COMPONENTS

Emphasis shall be placed on simplicity of operation, efficient utilization of allowable area and a minimum of components. Ease of cleaning/wash-down and access for such purposes are necessary design parameters, added credence is given to designs that include them. Frame structure shall be of all welded steel plate or square and rectangular steel tubing with welded end caps. Welded joints shall be sound, smooth, and free from pits, holes, fissures and rough projecting edges and shall be thoroughly fused to the base metal. Frameworks and tooling mounts shall be designed and fabricated to provide smooth, vibration free machine movements. All machine fasteners shall be in Standard English or metric units. English and metric fasteners will not be mixed. Contractor shall employ use of quick release fasteners for non-structural guards, inspection and maintenance access covers. The equipment shall be clean, well made, and free from any and all product defects, which may affect appearance or serviceability. All metal surfaces (other than stainless steel, brass, or aluminum) shall be primed and painted with the manufacturer’s standard color and finish. All parts subjected to severe wear shall be hardened where required.

3.3.1 MATERIALS, PROCESS AND PARTS

Special component features for the machines are as follows:

3.3.1.1 ELECTRICAL/GENERAL

a. All electrical work shall meet the requirements of the latest revision of the National Electric Code (NEC), and Part 1910, title 29 of the Code of Federal Register (OSHA).

b. Conduit shall be 3/4" diameter minimum, galvanized heavy wall rigid steel. RMC shall be installed per NEC article 344.

c. Conduit system shall be routed parallel and perpendicular to building walls, ceiling, etc., with proper offsets to all junctions and terminals.

d. The contractor is responsible for determining the presence of hazardous (classified) location beyond what is laid out in drawing 31630-EE-3003 as defined within the NFPA and NEC and is responsible for providing electrical systems that meet all the requirements for such locations (explosion proof or intrinsically safe).

e. Wiring shall be stranded copper with THHN insulation for AWG No. 16 and larger. Full size ground wire will be pulled with each circuit (conduit shall not be used as a ground; see also section g. below).

f. Control circuit wiring shall be stranded copper, AWG No. 18 minimum, with type THHN insulation.

g. Terminal strips shall be used in the panels for all wire entering or exiting the panel. Also all wires shall be labeled at both ends of termination and the terminal strips shall be labeled. Where possible the address of the PLC I/O point shall be used as the wire number, otherwise the contractor shall assign a wire number using a wiring scheme developed by the contractor and approved by the KO. The contractor shall use wiring ducts and wire ties in panels where required in order to maintain an organized panel.

h. Mount all surface mounted electrical equipment on suitable channel (1 5/8" x 1 5/8" minimum), i.e., disconnects, panels, etc. All channels shall have a Perm-Green finish. Provide proper support and attachment for all items.

i. As minimum, Meyers (or equal) watertight hubs for all rigid steel conduit entrance to panels, disconnects, junction boxes and all other enclosures not provided with sealed and threaded conduit entrance.

j. All starters are to be full voltage, thermal overload protected and sized for the equipment according to the NEC.

k. All motor control circuits are to be single-phase 110V nominal.

l. All push button and selector switches are to be full size NEMA 4 or 4X as a minimum.

m. Control panel or box shall have a NEMA 4 or 4X rating as a minimum.

n. All necessary step down transformers required for operation of single-phase controls and equipment shall be rated at a minimum of 150 percent of full load current.

o. Contractor shall supply a three phase locking disconnect for each branch circuit in accordance with the NEC.

p. For long runs of conduit (20 feet or more), power wiring to devices shall not be run in the same conduit with the control wiring (limit switch contacts). Power wiring for more than one device can be run in a common conduit as can control wiring for more than one device.

q. Solid copper wire shall be used to ground each piece of equipment to provide safe grounding. All components shall be bonded together for an effective and safe grounding system. Final grounding- shall be bonded to the building grounding system or approved grounding. Each system shall be completely grounded in accordance with Article 250 of NEC.

r. Auxiliary contacts of starter shall be taken back to the PLC and used for running indication. PLC outputs are not to be used as indication of an energized starter.

s. Electrically driven equipment requiring repeated starting and stopping shall be controlled by clutch-brake.

t. All electric motors shall be TEFC (total enclosed fan cooled). All 3-phase motors shall be multi-voltage 240/480vac.

u. All PCs, VFDs, and HMI shall be manufactured by Allen Bradley. If another band is used, then all additional software needed to program such devices from an externally connected computer must be supplied with all licenses needed to use such software. Also any interconnect cables must also be provided.

3.3.2 TOOLING

All machine fasteners shall be in Standard English or metric units. English and metric fasteners shall not be mixed. Contractor shall employ use of quick release fasteners for non-structural guards, inspection and maintenance access covers. Special tools shall not be required to service the machine.

3.3.3 IDENTIFICATION AND MARKING

All push buttons, indicators, control points, etc. shall be identified with commercially printed legend plates. All disconnect enclosures, junction boxes, panel boards and all other enclosures shall be permanently marked with 1/2-inch high letters showing function, voltage and phase. The letters shall be marked in accordance with OSHA standards and readable at a distance of 15 feet minimum. All motor starters and contactors shall be marked with 1/4 inch high letters showing function (meaning the name of what it is controlling), voltage, phase, and size or HP rating. All tubing and wiring shall be labeled at both ends of termination along with the terminal strips with a label designed to hold up in a harsh environment. Contractor is responsible for Arc flash labeling and shall comply with the most current NFPA 70, NFPA 70E, NEC, current arc flash labeling requirements, as well as best practices for creating and maintaining such labels.

3.3.4 INTERCHANGEABILITY

Like component parts, such as limit switches, proximity switches, starters, etc., shall be interchangeable to provide ease in maintenance and reduce spare parts requirements.

3.3.5 SAFETY

The system shall be designed to conform to the established safety rules and regulations as outlined in OSHA, NFPA, NEC, AMCR 385-100, DA Pam 385-64 and AR 385-64. Each piece of equipment shall be grounded utilizing solid copper wire. All components shall be bonded together for an effective and safe grounding system (2 OHM max reading). Final grounding shall be bonded to the building grounding system or approved alternate. The design for each system shall also include all of the protection devices, safety shields, and indicating and audible signals required for complete personnel safety. The contractor is required to perform a system hazard analysis on this contract in accordance with OSHA, 29 CFR 1910.119. MIL-STD-882D may be used as guidance to perform this analysis. The contractor may submit questions to the KO in writing about the system hazard analysis.

3.3.6 HUMAN PERFORMANCE/HUMAN ENGINEERING

Equipment will be installed to provide access to all points where maintenance is required.

3.3.7 STANDARDS OF MANUFACTURE

All equipment provided by the contractor such as tanks, vessels, valves, etc. shall be designed to meet or exceed ASME, ASTM, and OSHA requirements.

3.3.8 FACILITIES

Prior to submission of bids, the bidders should visit the site to check the scope of demolition, construction, and modifications to the building and existing equipment.

3.3.8.1 DEMOLITION

a. After any demolition then the cubicle walls shall be smooth, any item formed into the walls shall be cutoff flush with the wall, and all unused holes in the walls shall be filled completely with grout then painted to match existing wall color. Remove all abandon lines to the source unless otherwise noted.

b. Holes in the walls of the building will be need to cut for several tasks below. These include but are not limited to the duct work for HVAC, dust collection system, vacuum system, fire system, compressed air lines, conveyors in the cubicle, drum dumper chute, and various lines needed to install equipment.

c. The three phase electrical panel mounted on the side wall in front of cubicle 12 and the conduit run to a junction box on the wall between cubicles 9 and 10 and all the wiring from that panel to the vault at the edge of the building shall be removed. The three phase electrical panel mounted on the side wall in front of cubicle 10 shall be removed and replaced as shown on drawing 31- 630EL-3000. The 3φ 240VAC transformer bank will also be removed and replaced as shown on drawing 31-630EL 3000.

Remove this panel, associated smaller conduit, and 3 ½’ conduit back to junction box shown in the lower picture.

Also remove junction box.

Cut conduit back and retread to route to new panelboard.

d. The single phase electrical panel mounted on the side wall in front of cubicle 9 shall be removed and replaced as shown on drawing 31-630EL-3000.

3.3.8.2 CONSTRUCTION

a. Grounding: There shall be a single point of connection to the building grounding system (this is different than the electrical ground). All metal equipment shall be connected such that all items are grounded. All grounding wire is to be #6 bare copper conductor. All grounding wire and connectors shall remain unpainted. Anchor copper conductor to existing masonry with ¼” expansion shield anchors and copper loop straps. Copper loop straps to be ½” wide .032" thick copper with ¼” drilled holes to receive anchors equal to Robbins Cat. No. 82. The grounding system as specified above is the minimum requirement for this project. All equipment installed shall be grounded to the building grounding system using #6 bare copper conductor.

b. Class II Div. 1 Groups E, F, & G: All conduit, electrical enclosures, fittings, and lighting in Class II Div. 1 Groups E, F, & G areas called out in drawing 31630-EL-3003 that do not meet the standard must be removed and replaced with a system that is properly rated. New Class II Div. 1 group E, F & G lights with appropriate rated conduit and fittings will be installed in cubicle 1-12, under the Northside mezzanine, west bay in cubical area where conveyor located, and the enclosed portion of

Replace this 3 phase panelboard with a 600VAC Main Lug Panelboard in new location as shown on

DWG 31630-EL-3000

Remove both wiring trough and panelboard.

New panelboard and conduit shown on Dwg

31630-EL-3000

Fire disconnect may need to be relocated and conduit to new location

Conduit shall be rerouted to new panelboard location the east bay such that a minimum of 50 foot candles can be measured at any point in the cubicle three foot above floor level. Consideration shall be given to the location of the lights as not to interfere with maintenance and operation of the equipment.

c. Transformer: Three new 100 KVA transformers will be installed on the pole where the 3φ 240VAC transformer bank was located. The new transformers configuration will be a 95 KV BIL, 4 hole spade lug secondary, class OA, and have two - 2 1/2% taps above and below neutral. The transformers will be wired delta-wye 480VAC, primary side is 13,200-7600. The primary fuses will be sized. 350 kcmil Cu will be used from the new transformer bank to the new panel board and conduit will be sized and replaced from the vault box on the north side of the building to the transformers. The panelboard will be a I-line or equal rated for 600VAC, 600 amp frame, 45" breaker space, NEMA 3R and 3S, and supplied with main lugs. Refer to drawing 31-630EL-3000 for more details. Contractor will fill out table on drawing 31-630EL-3000 sheet 2.

d. Compressed Air Lines: Compressed airlines shall be installed to each cubicle and into the east and west ends of the building. The main line will be a 2” airline which will run the full length of the corridor and will be tied into the existing 2 inch airline that is after the air dryer and terminates in the corridor. The airlines shall be rigid pipe and shall be a minimum diameter 1” pipe. The airlines shall enter the cubicle at the back left corner of the cubicle as you walk into the cubicle and come down to a height of 6 foot of the floor where a ball valve shall be installed as a shutoff valve. The equipment lines shall be installed from the shutoff valve through a contractor provided FRL system (Filter, Regulator, & Lubricator) with an integrated shut-off valve with Quick exhaust and soft start capability and lockout capability.

e. Partition Wall in East Bay: The wall shall extend from the floor to the slope roof. The new wall shall use two by six construction on 16” centers with blocking, with R-19 insulation in the wall and with ½” A/B plywood covering on both sides. The contractor shall supply and install double door in the wall that is 6’W X 8’H. The wall will be painted white with an interior latex gloss white paint.

Also the wall shall be connected to the building trusses as needed to provide for stability. Refer to drawing 31630-AR-3000 sheet 1 for details on wall construction and location.

f. Diverting Existing HVAC Ductwork from South Cubicles to East Bay: The HVAC needs a diverter and ductwork installed to redirect air from the south side cubicles to the enclosed portion to the east bay according to dwg 31630-HVC-3000. A temperature sensor shall be installed in the east bay. Controls should ensure the humidity system is off and the temperature sensor installed in the east bay is used when the air is being directed to the east bay area.

g. Extension of Cubicle 6: Cubicle 6 will be extended approximately 7 foot from the existing front of the cubicle similar to the layout and construction of cubicles 1 and 2 on the south side of the building. The extension will have a 6" high and 8"wide footer around the outside edge except where door openings are. The footer will be constructed using 3000 PSI concrete with two 1/2" rebars located 1 1/2" above the existing slab and the same distance from either edge of the footer. Also every 2' O.C. an anchor bolt shall be used to attached the footer to the existing slab. The extension wall shall be constructed using 2x6 lumber on 16" centers with the bottom plate being pressure treated. The walls of the extension shall be covered with fiberglass reinforced with expanded metal or polycarbonate panels with a minimum thickness of 0.56 inch. The fasteners shall be stainless steel self-tapping screws with a stainless steel and neoprene bonded sealing washers. The panels shall be installed on the inside of the 2x6 frame. Steel doors will be installed in the front of the cubicle of the same width as other cubicles but shall be as tall as will fit under balcony. All doors shall be of commercial manufacture and have steel frames, strike plates, door closures, push-pull plates, hasp for door locks, sweeps, weather stripping, and will be bonded to the grounding system. The old header and footer shall be removed and the old header replaced with 4”x8” tubing to support the upper wall. The floor in the enlarged cubicle will be prepared as necessary such that the floor is smooth and slopes towards the front of the cubicle.

h. Diverting Existing Dust Collection to Northside Cubicles and East Bay: The contractor will modify the existing dust collection piping on the south side of the building with a remotely operated diverting valve and run a new trunk line to the north side of the building as shown on drawing 31630-EQ-3000. The new trunk line will be the same size as the existing trunk line and will be routed above the door openings on the mezzanine. All transitions will be radiuses to minimize loss of air velocity and minimize mix build-up. Clean-outs will be provided at all major transitions of the ductwork. Contractor will make recommendations as to location of the clean-outs. If the equipment does not have a clear location for connection to the dust collector, then the pipe shall be run into the cubicle on the left side of the cubicle as you walk in for about 6 feet and then turned down to a height of 8 feet above the finished floor. There shall be a shutoff valve just prior to the end of each drop. All dust collection lines shall be stainless steel of and all welding will be done by a welder that is certified to weld stainless steel.

i. Extending Existing Vacuum System to Northside Cubicles and East Bay: The contractor will tie into the main trunk of the vacuum line from the bag house on the south side of the building and with an equivalent size line and run it to the north side of the building, as shown on drawing 31-630-EQ- 3000. The main trunk on the north side will routed above door openings on the mezzanine. Drops shall be run to the outside of the cubicles as shown on drawing 31630-EQ-3000 and will terminate at 4 foot off of the finished floor with a self-closing flap on each line. The vacuum line drops shall be 2” in diameter. All vacuum line shall be stainless steel of and all welding will be done by a welder that is certified to weld stainless steel.

j. Conductive Floors in Cubicles 1-12: Install new grounding system and integrate into new conductive flooring (Note: Equipment that is grouted in place need to be installed before the conductive floors are complete). Reference drawing number 31-630EL-300 Conductive Flooring and Grounding 31-630. All grounding wire to be #6 bare copper conductor. All copper grounding plates to be a minimum 8" x 8" 20 oz. copper sheets. Each connection of conductor to copper plate shall be a minimum 2" long brazed connection (both sides of conductor wire brazed). Chip out existing flooring as required (note that each cubicle has places for the plates relived in the concrete) so that the top of the conductor will be no higher than the bottom of the new conductive flooring. Anchor conductor to existing flooring at a maximum of 5'-O" on center. Anchor copper conductor vertically to existing masonry with 1/4' expansion shield anchors and copper loop straps. Copper loop straps to be 1/2" wide .032" thick copper with 1/4" drilled holes to receive anchors equal to Robbins Cat. No.

82. Locate masonry anchors at 6" above existing floor, 4" below top of masonry, and halfway between at each column. Drill and tap steel columns at connection points and bolt copper conductor to column with a minimum 1/4" diameter x 1/2" long bronze machine screw. Remove any point or other material down to bare metal on column at grounding connection. Crimp edges of copper plate to facilitate embedment into conductive flooring. Each conductor (or fragment thereof if broken at plate) that crosses a grounding plate must be brazed to the plate as specified above. Anchor each conductor to the floor at 6" from the edge of the plate. Conductors shall be anchored to the existing floor with the same expansion anchor bolt and loop straps as specified above. The grounding system as specified above is the minimum requirement for this project. If additional work is required to properly ground the new conductive flooring so that it meets the specified performance requirements in this specification, the contractor shall provide the additional work including all labor materials, equipment, etc. needed for complete installation at no additional cost to the Government. If the grounding system specified herein impairs the performance of the conductive flooring in any way, the contractor must notify the Government immediately in writing with description of conflicts with the grounding system. Such conflicts must be supported with written documentation from the manufacturer. Any changes to the specified grounding system must be submitted and approved by the Government. Then conductive flooring will be applied to all 12 cubicle floors as specified in Appendix I. Suggested materials for conductive flooring: Dex-0-Tex Conductive Neotex -367;

Crossfield Products or General Polymer 3524 epoxy conductive primer sealer, and top coat 3525E static control epoxy coating.

k. Fire Suppression System: The existing fire suppression system piping shall be modified to include cubicle 6. Modifications include extending the fire header into the corridor from the west bay to cubicle 6. Refer to drawings 31-630-EL-3002, 31-630-PP-3000 and Appendix II- “SCOPE OF

WORK FOR DESIGN AND INSTALLATION OF DELUGE SYSTEM AND SIGNALING

SYSTEM AT BUILDING 31-630.” Piping, deluge heads, UV/IR sensors, manual pull station, heat detectors and a new fire control panel, and all interconnecting hardware necessary to make an operational system are required. The system shall also require heat detectors in each of the other cubicles and the bays with pull stations for each. Refer to drawing 31-630-GL-3000 for general locations. Location of the deluge heads, and UV/IR sensors must be approved by the PBA Fire Department.

3.3.9 MAJOR COMPONENT CHARACTERISTICS

For all Government Furnished Equipment: the contractor will be responsible for cleaning all preservatives off of the government furnish equipment and providing and applying lubrication as necessary for operation. The contractor will Meg and ohm the motor windings on all motors and check the bearings on the motors, rebuilding motors as necessary. The contractor will be responsible for replacing all of the pneumatic controls to include but not limited to the control panel and everything in it, all tubing, limit switches, valves and palm buttons. The contractor shall rebuild all hydraulic cylinders and hydraulic pumps and replace all hydraulic piping, filters, regulators, gages and valves. The contractor shall replace the drive coupler on all hydraulic units.

3.3.9.1 HC BAG OPENER (Government Furnished)

EQUIPMENT:

Manufactured by TAUNTON ENGINEERING CO. INC Model RTS-100 Bar Code: 35599

INSTALLTION REQUIREMENTS: The HC bag opener shall be refurbished, installed and made operational. It shall be installed in the east bay at roughly the location shown in Dwg 33630-EQ-3000.

The bag opener shall be leveled and anchored in position prior to operation. The bag opener will be connected to the dust collection system through the ports on the equipment. Additional modifications may need to be taken to keep the bag opener from allowing HC dust into its surroundings. The Bag opener shall have a feed conveyor installed (see drawing 33630-ME-3000).

Refurbish: As a minimum the contractor will do the following to refurbish the equipment:

1. The contractor will clean all preservative off of the equipment and lubricate as required.

2. The contractor will Meg & Ohm the motor windings on all motors, and rebuild the motors if necessary.

3.3.9.2 ATTRITION MILL (Government Furnished)

Manufactured by SPROUT-BAUER INC a subsidiary of COMBUSTION ENGINEERING INC.

Model DM24-ATTM Serial number 87-2267

INSTALLTION REQUIREMENTS: The attrition mill shall be refurbished, installed and made operational. A frame to support Mill shall be built out of structural square tubing. The mill shall be leveled and anchored to the floor through the frame. The mill shall be as close as possibility to discharge of the bag opener with a contractor provided dust proof flexible transition between the bag opener and the mill. The mill will discharge into HC Attrition Mill to Transfer Drum Feed System (see 3.3.9.8).

Refurbish: As a minimum the contractor will do the following to refurbish the equipment:

1. The contractor will clean all preservative off of the equipment and lubricate as required.

2. The contractor will be responsible replacing the bearings on the attrition mill.

3. The contractor will Meg & Ohm the motor windings on all motors, and rebuild the motor if necessary.

3.3.9.3 100 TON WATSON-STILLMAN PRESSES – 4 Each (Government Furnished)

Manufactured by: Watson-Stillman Bar Code: 40407, 40409, 40410, & 40411 Volts 220/440 Amps 63/31.5

INSTALLTION REQUIREMENTS: Four 100-Ton presses shall be refurbished, installed, and made operational. The presses must be placed, leveled and grouted into the floor. The 4 presses will consist of 2 left and 2 right sided presses. The hydraulic units will need to be installed in the corridor. Presses will be installed in cubicles as shown on drawing 31630-ME-3000 and drawing 31630 –ME-228.

Refurbish: As a minimum the contractor will do the following to refurbish the equipment:

3. The contractor will clean all preservative off of the equipment and lubricate as required.

4. The contractor will be responsible replacing all pneumatic controls, limit switches, push buttons, palm buttons and tubing.

5. The contractor will rebuild all hydraulic cylinders and pumps and replace all hydraulic piping, regulators, filters, gages and valves.

6. The contractor will fill all hydraulic units with oil.

7. The contractor will Meg & Ohm the motor windings on all motors, check and replace bearings as necessary and rebuild the motor if necessary.

8. The contractor will replace the drive couplings between the motors and hydraulic pumps.

3.3.9.4 MANDREL EJECTOR (Government Furnished)

Manufactured by: PBA Bar Code: 43871 Pneumatically Controlled and Powered

INSTALLTION REQUIREMENTS: The mandrel ejector shall be refurbished, installed, and made operational. The ejector must be placed, leveled and anchored into the floor.

Refurbish: As a minimum the contractor will do the following to refurbish the equipment:

1. The contractor will clean all preservative off of the equipment and lubricate as required.

2. The contractor will be responsible replacing all pneumatic controls, limit switches, push buttons, palm buttons and tubing.

3. The contractor shall replace the pneumatic cylinder on the machine.

3.3.9.5 REAMER (Government Furnished)

Manufactured by PBA Bar Code:

Volts 230/460 Amps 8.6/4.3

INSTALLTION REQUIREMENTS: The reamer shall be refurbished, installed, and made operational.

The reamer must be placed, leveled and anchored into the floor. The reamer bit needs to be resized to fit the 155mm canister.

Refurbish: As a minimum the contractor will do the following to refurbish the equipment:

1. The contractor will clean all preservative off of the equipment and lubricate as required.

2. The contractor will be responsible replacing all pneumatic controls, limit switches, push buttons, palm buttons and tubing.

3. The contractor will Meg & Ohm the motor windings on all motors, check and replace bearings as

4. The contractor will replace the drive couplings between the motors and hydraulic pumps.

3.3.9.6 CRIMPING PRESS (Government Furnished)

Manufactured by PBA Model number 40418 Pneumatically Controlled and Powered

INSTALLTION REQUIREMENTS: The press shall be refurbished, installed, and made operational.

The press shall be placed, leveled and grouted to the floor.

Refurbish: As a minimum the contractor will do the following to refurbish the equipment:

1. The contractor will clean all preservative off of the equipment and lubricate as required.

2. The contractor will be responsible replacing all pneumatic controls, limit switches, push buttons, palm buttons and tubing.

3. The contractor will rebuild all hydraulic cylinders and pumps and replace all hydraulic piping, regulators, filters, gages and valves.

4. The contractor will fill all hydraulic units with oil.

5. The contractor will Meg & Ohm the motor windings on all motors, check and replace bearings as

6. The contractor will replace the drive couplings between the motors and hydraulic pumps.

3.3.9.7 HC BAG OPENER FEED CONVEYOR (Contractor Furnished)

REQUIREMENTS: A feed conveyor shall be provided and installed to move bags coming off a pallet to the bag opener according to drawing 31630-ME-3000. The conveyor shall be 24” wide and have a cleated belt.

3.3.9.8 HC ATTRITION MILL TO TRANSFER DRUM FEED SYSTEM (Contractor Furnished)

REQUIREMENTS: A feed system shall be provided and installed to transfer the HC from the discharge of the attrition mill to the transfer drum. The feed system shall be enclosed and must be designed to prevent HC dust from escaping into the surrounding environment. The feed system shall use an enclosed cleated belt or bucket conveyor.

3.3.9.9 SCALES (Contractor Furnished)

REQUIREMENTS: Three scales for aluminum, HC, and Tin Oxide weighing shall be bought and placed in the location shown in drawing 31630-EQ-3000. The scales shall be 120V AC, rated Class II Division I Groups E, F, & G, and wash-down safe. Weighing surfaces of the scales shall be 316 stainless steel. The contractor shall provide a means to roll the 30 gallon drums on and off of the scales. The scales shall have a 4-20mA analog output with an I/O barrier.

The scale for the aluminum shall have a 75 lb. capacity minimum with a resolution of 0.01 lbs.

minimum. It shall be a floor drum scale able to weigh a 30 gallon drum.

The scale for the HC shall have a 500 lb. capacity minimum with a resolution of 0.1 lbs. minimum. It shall be a floor drum scale able to weigh a 30 gallon drum.

The scale for the Tin Oxide shall have a 500 lb. capacity minimum with a resolution of 0.1 lbs.

minimum. It shall be a floor drum scale able to weigh a 30 gallon drum.

3.3.9.10 DOUBLE CONE MIXER (Contractor Furnished)

Manufactured by GEMCO Part Number: GBL05HSASC240 or equivalent.

VESSEL CAPACITIES:

5 cubic foot working capacity 56 percent fill level

8.9 cubic foot total volume

MATERIAL DENSITY: Blender designed to handle materials weighing up to 240 pounds per cubic foot.

VESSEL MATERIAL: Vessel contact material shall be constructed of 316 Stainless Steel. Trunnion and support pads shall be 304 stainless steel. All bearing shafts shall be 304 stainless steel.

INTERNAL FINISH: Shall be a #4 finish, all fabrication & handling marks removed. The entire surface shall be buffed to a uniform, appearance finish. Overall surface rating of 40 ra maximum. All butt welds ground flush & smooth. All fillet welds ground smooth not flush. All discoloration and weld splatter removed.

EXTERNAL FINISH: Standard cold rolled mill sheet finish:

fabrication and handling marks remain. All fillet welds shall be ground smooth not flush. All butt-welds ground flush & smooth. All discoloration and weld splatter removed. The welds will be striped.

ACCESS COVER: 1 – 16” diameter quick opening removable vented cover is provided with stainless steel low profile clamps with aluminum tightening knob and white neoprene "O"-ring gasket seal. The vented cover option helps to dissipate heat and pressure build up during the agitation process. The material inside the vented cover shall be conductive.

AGITATOR SYSTEM: The mixer shall be equipped with an "Agitator" milling bar inside the blender. It will be able to de-lump, size and densify powder like a milling process. The blades shall be flat faced, providing constant and repeated contact with the product. The "Agitator, shall be made of 316 stainless steel. The special agitator housing area shall contain pre-lubricated sealed ball bearings that are protected by multi stage lip seals.

These seals shall be designed for high speed bars in an abrasive atmosphere. The lip seals shall completely seal the powders path to the bearing, and should be easily cleaned. Multiple agitator discs shall be provided.

DISCHARGE VALVE: A 6” Butterfly Valve shall be provided as part of…