COMPETITIVE INITIATIVE POWDER COATING SPRAY SYSTEM MINES TECHNICAL SPECIFICATION The powder coating spray system is designed for the surface preparation and painting of mines of various configurations, including cylindrical, spherical, cubical, and other shapes. In addition, the system is used to refurbish torpedoes and submarine components. The system shall incorporate an iron phosphate cleaning/spraying station, powder paint spray booth, manual spraying equipment, and an infrared drying oven capable of curing mines of the above geometries. Off-the-shelf turnkey equipment is to be used in this system whenever possible. The equipment is designed for simplicity of operation and safety to operating personnel and shall permit easy accessibility to components for normal maintenance and servicing. Mine Design Parameters: The geometry and dimensions of the underwater mines are as follows. Cylindrical Mines: 55 to 132" long x 10 to 23 3/8" diameter; weight from 500-2,400 lb. Spherical Mines: 34 1/4" diameter; 580 lb. Rectangular Mines: 40" long x 29 1/4" wide x 25" high; weight from 800-900 lb. Applicable Documents: Occupational Safety and Health Administration (OSHA) Safety and Health Standard (29 CFR 1910, 1910.1025, 1919) EPA Title 40 CFR, Protection of the Environment NEC Articles 250 and 300 NFPA 33, Fire Protection NFPA 70, Safety Standard NFPA 79, Electrical Standard for Industrial Machinery UL Standard 508 South Coast Air Quality Management District Rules and Regulations System Requirements: The system: 1. shall not generate hazardous waste as defined by EPA Title 40 CFR 2. shall not emit vapors or fumes as defined by EPA Title 40 CFR
3. shall meet all EPA requirements and the South Coast Air Quality Management District Rules and Regulations. Facility Interface Requirements: Space Requirements: Shall fit within a straight line length of approximately 100 feet and use the existing overhead hoist system to hold and manipulate the mines. System Electrical Requirements at Full Load: 120 V, 60 Hz, 20 A, 3 phase; 460 V, 60 Hz, 454 A, 3 phase System Disconnect Size: 525 A Water Requirements: 6 gpm at 40 psi Air Requirements: 53 cfm at 120 psi, maximum dewpoint of 38 F; 77 cfm at 100 psi, maximum dewpoint of 38 F. Minimum Requirements: 0001 Powder Paint Spray Booth The Nordson Versa-Coat Batch Booth is designed for batch, short-run, or special color operations. The booth is a pass-through design, with doors at both ends and silhouettes for part passage. The booth includes items as specified below. Overall Width: 20' Overall Height: 8'6" Working Width: 12' Working Depth: 18' 6" Overall Depth: 18'10" The enclosure frame is constructed of stainless steel, with 18-gauge walls and ceilings. The existing floor of the facility is used. Electrical Requirements: 460 V, 50 A power Air Requirements: 77 cfm at 100 psi, 30 F dewpoint maximum Filtration: The booth includes a cartridge baffle and a set of 18 round primary cartridges and 9 final filters. Primary cartridges shall measure approximately 26 high and 12.75 round. The final filters shall measure approximately 23.375 high and 17.375 wide. Gauges: Three minihelic gauges are included to monitor differential pressure drop and detect filter cartridge binding. Crane Slot: A one-foot-wide, front-to-back material handling slot is positioned longitudinally in the center of the booth ceiling so the (user-supplied) bridge crane/jib crane can hold and manipulate the mine during the painting operation. Lighting: Six fluorescent light fixtures four-tube, 40-W, 120-V, Class I, Division II are included. The fixtures are sealed and gasketed.
Exhaust Blower Unit: Blower capacity is approximately 10,200 cfm @ 1' static pressure. The calculated face velocity is 100 fpm through the empty booth. The exhaust blower unit shall comprise the following: Three exhaust fan sections with belt-driven fan, air foil, 3400 cfm, 5-hp motor, 230/460 VAC, 3 phase, 60 Hz. Three clean air sections with final filter assembly. Nine final filters. Filters are 95% efficient at 0.3 microns. No tools are required to remove these filters. Three powder-coated collector modules of 3,400 cfm with cartridge baffles to prevent powder buildup. 0002 Iron Phosphatizing Spray Booth The iron phosphatizing spray booth shall comprise the enclosure where the iron phosphatizing will be performed, as well as the iron phosphatizing equipment itself. The Aaladin 8430 electric one-stage phosphatizing spray wand unit is designed to apply heated iron phosphate at high pressure through injection into a high-pressure water stream. The design shall not include an open flame. This unit prevents surface rust on underwater mines and applies iron phosphate at approximately 1,000 psi. Overall Dimensions: Features: Length: 58" (maximum) Width: 29" (maximum) Height: 47" (maximum) Weight: Not to exceed 600 lb. (dry), 800 lb. (shipping) Electrical Requirements: 460 V, 1 phase, 60 Hz, 20 A power Water Connection: Standard female end, swivel type Pump: 7.5 hp Flow Rate: 4 gpm Pressure: 1,600 psi (maximum), 800 psi for phosphatizing Safety: Unit shall shut itself off after approximately 5 minutes if unattended. A high-temperature shutoff is included. Hose: 50 feet of wire braided hose with stainless steel couplings. A hose reel is also included. Wand: Stainless, trigger-operated, with automatic shutoff. Used for applying iron phosphate or high-pressure water. Chemical Neutralizing System: The system comprises a metering pump that will dispense the required amount of caustic (alkaline) solution to neutralize acids in the unit. The amount of caustic solution administered will be determined via automatic monitoring of the iron phosphate solution. This system will operate for approximately 2 1/2 hours during an 8-hour workday based on normal operation.
The neutralizing system will adjust the ph to 7 to enable the iron phosphate solution to be disposed of normally through the drain system. The system shall be designed to prevent siphoning of chemicals when not in operation. The Spray Booth Systems, Inc. spray enclosure includes a containment tank, pump, and floor grating. Additionally, it will contain the following features: Nominal Dimensions: Overall Width: 11' 8" Overall Height: 10 6 Working Depth: 18' 5" Overall Depth: 18 9 Electrical Requirements: 460V, 125A power Water Requirements: 6 gpm at 40 psi minimum Air Requirements: 53 cfm at 120 psi, dewpoint 38 F or less Crane Slot: A full-length material handling slot is positioned longitudinally in the center of the booth ceiling so the (user-supplied) bridge crane/jib crane can hold and manipulate the mine during the painting operation. Ventilation: The enclosure shall replace the entire volume of air within no more than a three-minute interval. Dual exhaust fans shall be included. Lighting: Six fluorescent light fixtures four-tube, 40-W, 120-V, Class I, Division II will be included. Tank: The tank in the floor of the wash booth will have a capacity of approximately 700 gallons. The tank floor will be sloped to the drain. The tank is filled with a pneumatic diaphragm pump. The iron phosphate solution is piped to various points in the pan and recirculated to ensure complete neutralization before discharge. Drains: The enclosure is installed, and the liquid is pumped to the drain. Piping from the pump discharge valve is supplied by the using activity. Manual Blowoff Station: The manual blowoff station consists of a hose that supplies compressed air located inside the booth at the exit opening.
0003 Manual Powder Paint Spray Equipment The Nordson Versa-Spray II IPS Three Gauge Control Unit manual electrostatic powder coating application system includes a stand and interconnecting hoses and fittings. It is as specified below. Electrical Requirements: 110 V, single phase Compressed Air Requirements: 90 psi, 15 cfm Features: Nordson Versa-Spray II IPS Manual Powder Spray Gun: The handle is grounded. Pattern size adjustment is located on the rear of the gun. A two-stage trigger allows the voltage output to the gun to be manipulated. The gun weight shall not exceed approximately 23 oz., the height shall not exceed 7", and the length shall not exceed 12". Hopper: A manual system fluidized feed hopper assembly constructed of stainless steel and with a minimum 50 lb. capacity. The hopper includes a powder feed pump. Hoses: Attached with quick disconnects. The equipment is designed specifically for the use of polyester triglycidal isocyanurate (TGIC) or polyester urethane powder paint. NOTE: Since this is a manual system, fire protection is not required per NFPA 33. 0004 Infrared Curing Oven The Infratech custom oven includes doors at each end and a material handling slot that runs the entire length. The curing oven will be designed to be operated manually (with the operator responsible for the time and temperature of the cure) or automatically (setpoint for temperature, timer controls curing time). Overall Width: 10 6 5/8 Overall Length: 14 11 Overall Height: 6 11 Heated Width (Adjustable): 15" to 36" minimum (Zone A) Heated Height: 30" minimum (Zone B) Heated Length: 13' 4" minimum (Zone C) Extraction Stubs: One of 12 diameter Total Air Recirculation: 1,600 cfm Temperature Range: 350 F to 400 F (part temperature); 800 F to 900 F (heating temperature)
Electrical Requirements: 460 V, 350 A power Operation: In order to position the oven around the mines, actuators move the oven sides in and out. To cure spherical mines, the two end zones are manually positioned to angle. Once the mine is positioned inside the oven, the operator will press the start button, turn on the required zones, and set the target temperature ranges for each zone. Once the oven reaches the target temperature, it will automatically cycle. When the maximum curing time is exceeded, the oven will automatically turn off if the operator has not already turned it off. Control Panel: The infrared oven is semiautomatic, with controls designed to bring the mines up to and maintain the desired temperature range for the specified cycle time, or until the operator manually turns off the oven. All supplied controls are UL-listed. The oven will incorporate a control panel with the following features: a. Master on/off switch b. Module selector switch c. Emitter indicator light d. Full power selector switch e. Control connector loom a. Fused main disconnect b. Individual zone selector switches c. Pilot lights for operation of individual zones d. PID devices (3) with digital temperature readout (one per zone) e. Solid-state relays for switching heat load f. Contact strip for connection to remote interlocks g. Off delay timer for maximum cycle time. Target Area: 30" minimum radius Air Circulation: Reverse convection type Recirculating Air System: Each oven section will have a separate blower that draws air in through damped inlets located below the top heat panel and discharges it through a dampened plenum located above the bottom heat panel. Exhaust System: The entire oven is built on a skirted platform with damped openings in the center of the oven target area to control airflow. Bypass dampers on one side of the plenum allow static pressure in the oven to be regulated. One 12 tube axial fan will exhaust air from one fixed position. Width Adjustment: Width adjustment for the enclosure is accomplished by actuators. Construction: The oven is constructed of tubular steel with industrial panels. The tubing is completely primed and painted with an industrial polyethylene finish.