Whirl Wind Tower

Description: ****ATTENTION****ALL FORMAL COMMUNICATIONS RELATED TO THIS ACQUISTITION MUST BE DIRECTED TO LAURIE A. HEWITT, CONTRACTING OFFICER, CCAM-DPD, VIA email: contact@example.gov, or fax number +1 (555) 000-0000. No telephone requests will be accepted. For additional information on the below synopsis, please see the following POC: Alma Studer, Mechanical Engineer, contact@example.gov. The U.S. Army, Corpus Christi Army Depot (CCAD), Test Equipment Engineering Branch is seeking an Expression of Interest (EOI) and Rough Order Magnitude (ROM) cost estimate from prospective contractors, experienced in designing and installing whirl towers, who may be interested in providing input into a business case analysis of two alternatives for providing sustainment of main rotor blade balancing (whirling) capability at CCAD. The two alternatives are to upgrade both existing whirl towers or to upgrade tower #1 and replace tower #2. All work would require phasing to allow one tower to remain in operation at all times during the project. At the end of the project, each tower would have capability to balance both UH-60 main rotor blades and CH-47 Forward and Aft rotor blades to the respective Original Equipment Manufacturer's (OEM) and/or military work requirements. OPTION 1: UPGRADE BOTH TOWERS A. Tower 2 1. Containment cage: NOTE - This work may get completed prior to initiation of the proposed tower upgrade. Please include containment cage work as an option. Renovate upright support concrete footers as required; grit blast uprights to bare metal; prime and apply protective coating system designed for salt water splash, heat and the south Texas coastal climate. Install new hot dip galvanized tie bars and hot dip galvanized fabric. 2. Superstructure: Demo existing structural steel superstructure (excluding cone) and replace with HD galvanized structure after fabrication (bolted construction). Demo existing personnel elevator, stairs and related structures between building and cone. Demo existing unused superstructure (abandoned from previous features). Grit blast, prime and recoat cone with coating system designed for salt water splash, heat and the south Texas coastal climate. Seal cone to prevent moisture intrusion. 3. Drive train: Overhaul existing gearbox, bearings and shafting. Replace existing 2500 horsepower (hp) drive motors with new 3000 hp motors. New motors to be AC totally enclosed fan cooled motors designed for vector drive, harsh weather and 1.2 or better service factor, continuous rating. Retain existing Sikorsky Aircraft Simulated Flight Hardware (rotor head) but design system, including rotor head and adapters for use with multiple blades (H60, CH47) and bi-directional whirling. Design & manufacture blade adapters for CH-47 Fwd and Aft blades. 4. Elevator: Upgrade elevator to include capability to carry passengers. 5. Tracking: Provide new set of existing model blade tracking system; existing system to be saved as spares. 6. Data Acquisition: retain existing system. 7. Controls: Modernize all controls to allow everything to be energized from inside the control room and all computers and monitors are able to fit with a clean, ergonomic operator interface. Replace existing Toshiba motor drive system with new drive controls designed for constant torque application. Replace existing GE Model 9030 PLC with new Allen Bradley PLC. Provide a new, climate controlled equipment enclosure to house the high voltage equipment, drive controls and an engineering support / critical spares area (approx. 300 square feet (sf)). 8. Lubrication system: replace with new temperature controlled system including tank, piping and instrumentation. B. Tower 1: 1. Containment cage: Remove containment fabric, blast structure to bare metal, prime and paint using coating system designed for salt water splash, heat and the south Texas coastal climate. 2. Superstructure: Strip superstructure of all attachments, blast to bare metal, prime and paint using coating system designed for salt water splash, heat and the south Texas coastal climate. 3. Drive train: Replace gearbox with one designed for 4000 hp, 400 RPM output and a clutch controlled inching motor. Gearbox to fit exact footprint of existing gearbox. Replace lube oil system with a packaged system designed for the gearbox that utilizes an air-cooled chiller for cooling instead of a cooling tower. Provide clutch controlled inching motor system that will allow operators to use it to index rotor head during blade installation and removal. Replace drive motor with a 4000 hp AC vector drive unit designed for severe weather and VFD usage; install new equipment enclosure adjacent to tower to house motor starters, electrical distribution system and 300 sf critical spares storage / engineering support area; Relocate control cabinets from existing control room to the new enclosure. Enclosure to be fully lighted and provided with temperature and humidity controls as well as fire protection. 4. Elevator: Update the elevator mechanical room with new pumps, tank, and control system. Install new cage around the lift perimeter with limit switches on all entrances. 5. Tracking: Provide new set of existing model blade tracking system; existing system to be saved as spares. 6. Data Acquisition: retain existing system. 7. Controls: Modernize all controls to allow everything to be energized from inside the control room and all computers and monitors are able to fit in and it all looks clean. Also reposition the console to allow accessibility from behind. All drawings must be provided. 8. Cooling tower: demo cooling tower, pits, pumps and pipes; backfill holes from pits & resurface. 9. High Voltage: Provide a new climate controlled equipment enclosure adjacent to the tower, with floor approximately 5 inches above grade and relocate all high voltage and circuit breakers into that location. Provide new infinitely variable speed drive designed for constant torque control. 10. Replace all conduit, wiring and piping with new. OPTION B: UPGRADE TOWER 1 / REPLACE TOWER 2 TOWER 1 1. Containment cage: Remove containment fabric, blast structure to bare metal, prime and paint using coating system designed for salt water splash, heat and the south Texas coastal climate. 2. Superstructure: Strip superstructure of all attachments, blast to bare metal, prime and paint using coating system designed for salt water splash, heat and the south Texas coastal climate. 3. Drive train: Replace gearbox with one designed for 4000 hp, 400 RPM output and a clutch controlled inching motor. Gearbox to fit exact footprint of existing gearbox. Replace lube oil system with a packaged system designed for the gearbox that utilizes an air-cooled chiller for cooling instead of a cooling tower. Provide clutch controlled inching motor system that will allow operators to use it to index rotor head during blade installation and removal. Replace drive motor with a 4000 hp AC vector drive unit designed for severe weather and VFD usage; install new equipment enclosure adjacent to tower to house motor starters, electrical distribution system and 300 sf critical spares storage / engineering support area; Relocate control cabinets from existing control room to the new enclosure. Enclosure to be fully lighted and provided with temperature and humidity controls as well as fire protection. 4. Elevator: Update the elevator mechanical room with new pumps, tank, and control system. Install new cage around the lift perimeter with limit switches on all entrances. 5. Tracking: Provide new set of existing model blade tracking system; existing system to be saved as spares. 6. Data Acquisition: retain existing system. 7. Controls: Modernize all controls to allow everything to be energized from inside the control room and all computers and monitors are able to fit in and it all looks clean. Also reposition the console to allow accessibility from behind. All drawings must be provided. 8. Cooling tower: demo cooling tower, pits, pumps and pipes; backfill holes from pits & resurface. 9. High Voltage: Provide a new climate controlled equipment enclosure adjacent to the tower, with floor approximately 5 inches above grade and relocate all high voltage and circuit breakers into that location. Provide new infinitely variable speed drive designed for constant torque control. 10. Replace all conduit, wiring and piping with new. Provide new DAQ system to match that provided for tower 2. TOWER 2 New tower capable of balancing UH/SH-60, CH-47D Fwd & Aft, CH-53 main rotor blades to existing Original Equipment Manufacturer (OEM) Acceptance Test Procedures and military Depot Maintenance Work Requirements (DMWRs, Technical Orders, NAVAIR requirements) 1. May reuse existing foundation for building, equipment pad and containment cage footings. 2. Containment cage: Design, fabricate and install new containment cage to protect equipment and personnel in case of blade failure. Cage diameter to be sufficient for whirling CH53 rotor blades. Structural supports to minimize joints and pockets where water and solids would accumulate and foster corrosion; consider the use of rectangular tubing instead of H-beams. Materials to be selected to provide minimum 50 year lifetime in the existing humid salt air environment. Consider hot dip galvanized after fabrication. Fabric installation to be designed for ease of replacement. 3. Superstructure: Demo the existing cone and build a new steel reinforced concrete structure that puts the plane of blade rotation 20-40 feet above grade and adequately supports and protects the new drive train system. The existing foundation for the gearbox and motors may be re-used. The structure must be enclosed, properly sealed when doors are closed and temperature and humidity controlled. 4. Drive train: 6000 hp AC variable speed, constant torque, up to 400 rpm output with constant torque drives that will be supported for 20 years plus. Provide a separate climate controlled enclosure to house the high voltage and the drives. Design to use existing Sikorsky Aircraft Simulated Flight Hardware (rotor head) and design/fabricate/provide adapters for whirling CH 47 forward and aft rotor blades as well as all H60 blades. 5. Elevator: lift design that will take up all three blades at one time. Also design a cart that is compatible with this design. 6. Tracking: May reuse existing 7. Data Acquisition: Provide data acquisition system to monitor and control all tower operation controls as well as blade balance controls, providing health monitoring of major equipment; all source code, modification software with any required interface hardware items and unlimited usage licenses to be provided to the government. 8. Controls: Modernize all controls to allow everything to be energized from inside the control room and all computers and monitors are able to fit in and it all looks clean. All drawings must be provided. 9. Provide new control room adjacent to tower. COMMON TO BOTH ALTERNATIVES: Contractor to replace existing 12,470:4160 volt transformers with new, weather resistant transformers sized for the final configuration of the towers. Contractor to dispose of all materials of demolition offsite. Mechanical torque limiting devices to protect both ends of the power train to be installed Any new Motor Control Centers to be arc flash resistant type Provide with arc flash resistant remotely actuated medium voltage disconnects upstream of motor drive cabinets, with ability to isolate the drives and still retain 480 and 120 volt supplies to other equipment. SALIENT CHARACTERISTICS: a. Able to balance UH60 blades in accordance with Depot Maintenance Work Requirement (DMWR) 1-1615- 281 section 4.5 Dynamic Balancing of Main Rotor Blades and CH47 Forward and Aft Blades to Boeing document 114-RW-008-1, Procedure and Specifications for Teetering and Tracking of CH-47 Fiberglass Rotor Blades. b. All designs and installations in accordance with applicable standards and codes, e.g., OSHA, AGMA, ASME, NFPA, ASTM, ISO, IEEE, etc. c. Maximize use of Commercial Off The Shelf (COTS) items d. All components selected as proven products for their applications; no "serial number 001" devices e. All structural modifications and/or new structures to be designed to 100 year windstorm resistance f. Corrosion resistant superstructures g. Designed for ease of maintenance h. Drivetrains, data acquisition and controls that are supportable for the next 50 years i. Inverter drive 4160 volt AC motors, totally enclosed Fan Cooled, rated for severe duty; 1.15 service factor or higher j. Infinitely variable speed control with minimal hysteresis during either increase or decrease in set point, vector drive, constant torque, bidirectional rotation capability, with dynamic braking. Consider ABB Direct Torque Control presently used in offshore drilling. Must be capable of ramping up or ramping down and stopping at any rpm setting (versus only ramping up to pre-set speeds) k. Minimize volume of lubricants required for operation (example: 700 gallon reservoir at BBS #2) l. Proven blade tracking technology m. New technology that reduces environmental impact n. Safe, ergonomic design for blade transport, handling and installation o. All programming performed by US citizens living in the US p. All documentation and programming notes in the English language q. All custom software must be provided with unlimited rights assigned to the government. r. Full manufacturing-level, construction and installation drawings and operation, maintenance, calibration procedures to be included in a technical data package to be provided with unlimited rights to the government. All drawings must be provided in AutoCAD. ACC-Redstone intends to schedule an "industry day" in which qualified contractors may perform a coordinated site visit to see details of the existing installed towers and ask group questions. Prospective contractors are requested to submit an EOI that (1) identifies the prospective contractor (business name, business size (large, small, 8a, etc), point of contact including e-mail address and telephone number; (2) describes the prospective contractor's capabilities, relevant experience and corporate resources to perform a contract of the size and complexity of that which is the subject of this procurement and (3) Rough Order Magnitude budgetary cost data for a turn-key design-build project for the contractor to complete a project based on the data contained herein. Any response to this announcement by a contractor in no way obligates or commits the government to pursue this matter any further, nor does it prohibit the contractor from bidding on the project if it does proceed to eventual procurement. For any additional information, please see the following POC: Alma Studer, Mechanical Engineer, contact@example.gov 23 July 2015 _________________________________ ___________________ Contracting Officer Date