SOW_Revision.docx

STATEMENT OF WORK

1. DEFINITIONS

The individual instruments utilized for actual cotton testing located in the classification (classing) lab area. The automation systems shall be able to accommodate up to 6 HVI workstations in the lab.

The conveyor with a section of air duct connected under the frame for the purpose of pulling conditioned air down through cotton samples being transported across the conveyor.

2. BACKGROUND:

The USDA, AMS, Cotton and Tobacco Program (CT) operates High Volume Instruments (HVI) to electronically classify cotton samples (each approximately 8 ounces) that are taken from full bales (500 pounds) at gin locations and transported to designated testing laboratories operated by the CT.

Currently an employee places samples in designated locations on the HVI to test fiber length, strength, uniformity, micronaire, color and trash content. These instruments are solely relied upon by USDA and the domestic and international cotton industries to provide accurate and timely classification data for the marketing stream. The data is transmitted in real time, as samples are tested, to mainframe computers and made available to owners or agents of the cotton all over the world. CT is considered the world’s leader in HVI testing and tests virtually every bale of cotton grown in the U.S. each year (approximately 15-18 million samples on average in a typical year) so speed, accuracy and efficiency are key components of the CT operation in each of its ten testing locations across the Cotton Belt (cotton producing states across the United States).

3. SCOPE:

USDA, AMS, Cotton and Tobacco Program requests bids for conveyance equipment, components, and peripheral devices as described in this document for the Lubbock Cotton Classification Office located at 4316 Ironton Avenue in Lubbock, Texas. This project includes the removal of two of the office’s existing conveyance systems and the installation of a new conveyance and conditioning system.

4. Overall Proposed Process Described

1. Sacks filled with approximately forty (40) cotton samples (each sample weighing one-half pound) will be received in the Lubbock receiving room (north side of building) via a USDA-contracted hauler.

2. Cotton sacks will be delivered into the classing lab via mobilized flexible conveyors or carts (Carts would be provided by USDA).

3. A person will empty each cotton sack onto one of two (2) belt conveyors that shall transport the loose cotton samples to a PA workstation (refer to drawing).

4. A person will prepare the cotton samples. A person will load sub-samples and the main sample into containers that will be distributed to the HVI workstation for processing.

5. A person will scan the bale identification barcode associated with that sample into the RFID system and that 12 digit unique bale number shall be written to the container.

6. A loader workstation shall contain a queue of eighteen (18) containers including the container in the actual load area. Once the container is loaded, the loader will push the container approximately two (2) inches where the container shall be taken away by a conveyor. The conveyance in the area denoted by “load” in the container shall be such that such that a switch can be set to two different settings for operation (on / off) (refer to drawing).

7. The container shall be transferred to the supply conveyor that shall deliver the containers to one of six HVI workstations.

8. Each HVI workstation shall be equipped with an HVI workstation conveyor that shall contain a queue of eighteen (18) containers which includes the container in process.

9. The RCU shall be located at the HVI workstation. The conditioning process will allow the cotton to absorb moisture from the atmosphere in the room.

10. The HVI workstation conveyor shall transfer the containers to the position denoted by an “HVI” in the container as shown in the drawing. The venturi devices shall be installed for the transfer of the sample. This transfer shall not occur until the container has been over the RCU for a minimum of 120 seconds to ensure proper conditioning.

11. Once the container is processed at the HVI workstation, the employee will push the container approximately two (2) inches where the container shall be taken away and transported on the return conveyor. The conveyance in the area denoted by an “HVI” in the container shall be such that a switch can be set to automatic allowing containers to flow through that area if desired (refer to drawing).

12. The return conveyor shall transport the containers from one of the six (6) HVI workstations to one of the three (3) Classer workstations denoted by “class” (refer to drawing).

13. The Classer workstations shall contain a conveyor that can accommodate nine (9) containers including the container in process.

14. Once the cotton in the container at the classer workstation is processed, the classer will push the empty container approximately two (2) inches where the container shall be transported to the main empty return conveyor for the process to start over. The conveyance in the area denoted by “class” in the container shall be such that a switch can be set to three different settings for operation (on / off / automatic) that would determine the container flow through that area (refer to drawing). NOTE: The loose cotton conveyance from this area is the responsibility of USDA and not the contractor.

1. The containers will be supplied by the USDA, AMS, Cotton and Tobacco Program.

2. The container direction shown in each of the drawings shall be strictly adhered to for proper container location at the individual workstations. The container positions regarding heights and angles where specified shall be strictly adhered to in the design and installation of the system. The container is made of ¼” ABS plastic with a texture on the outside and smooth on the inside.

1. The cotton sample feed conveyors shall consist of a combination of the smooth incline belt conveyor and a smooth horizontal belt conveyor. The smooth horizontal belt conveyor shall be a zone accumulating belt conveyor that consists of eighteen (18) inch zones. The area between the zones shall be one (1) inch and the sensors shall be placed in the one (1) inch area between the belts. The belting material selected is important since it must be resistant to the tagging of cotton. All belting material shall be submitted with samples for approval by USDA.

2. The cotton will be loaded on the incline conveyor by a person at a distance of eight (8) feet from the load end of the accumulating belt conveyor as shown in the drawing.

3. The cotton sample feed conveyor, which incorporates the incline and the zone accumulating smooth belt conveyor, shall be thirty (30) feet in length and (20) inches in overall width (refer to drawing).

4. The incline conveyor shall be installed fifteen (15) eighteen (18) inches above the floor at the load point and shall elevate to a final height of forty two (42) inches.

5. The incline conveyor shall be enclosed on the feed end and the two sides with twelve (12) inch high side rails to keep cotton contained on the conveyor.

6. The smooth belt conveyor shall be equipped with four (4) inch side rails. There shall be no end stop on the smooth belt conveyor (refer to drawing).

7. The cotton sample feed conveyor shall be speed-adjustable with an appropriate controller that shall control the speed from 0 to 1 foot per second.

a) All side rails must be a minimum ten (10) gauge galvanized steel with all edges hemmed where possible.

b) Other areas must be smooth and covered with some type of smooth hard rubber molding.

c) All corners must be rounded to a minimum two (2) inch radius.

5.3 supply conveyors

1. The containers shall be distributed from the main supply conveyor that originates at the loader workstation to one of the six HVI workstations.

2. The conveyor shall be approximately one hundred nine (109) feet in length and shall be approximately twelve (12) eighteen (18) inches in width.

3. The conveyor shall be a zone accumulation conveyor with zones to allow for container separation along the length of the conveyor. The conveyor shall be capable of stopping the containers within each zone with zero points of contact with an adjacent container.

4. The HVI supply conveyor shall be equipped with one (1) inch rails except in areas where the transport mechanisms are located. All rails in transition areas that change the direction of flow for the container shall incorporate arcs and not hard angles for guiding the container. This is to prevent the container from hanging up in areas of transitions.

5. The conveyor system shall be capable of distributing three (3) containers per minute to each HVI workstation and a total of twenty (20) containers per minute for the system.

6. The supply conveyor shall be equipped with a mechanism to transfer the containers from the supply conveyor to the HVI workstation conveyors. (refer to drawing)

5.4 rcu conveyors

1. The HVI workstation conveyor shall incorporate an area for the conditioning of cotton known as the RCU. The intake cfm at each of these workstations is 1100. To obtain the desired conditioning time of 120 seconds and maintain a flow of containers that will not starve the RCU, one conditioning section will be required. The preference is to have a sealed area underneath the entire conveyor area where the RCU is to be located – bottom and both ends. (Refer to drawing for location).

The HVI workstation conveyor shall incorporate an area for the conditioning of cotton known as the RCU. This 5” x 60” area shall consists of five (5) individual duct intake hoods that shall be enclosed under the conveyor frame with a minimum of eighteen (18) gauge sheet metal air duct. Each compartment shall enclose the subsample portion of the container that measures five (5) inches wide by eleven (11) inches in length.

2. Each air intake hood shall connect with a four (4) inch diameter hose to an air plenum. There shall be 5 intakes for the RCU centered and spaced equally lengthwise.

3. An air tight hinged access door shall be installed for cleaning and maintenance of the ½ inch expanded metal screen that is located in the air plenum.

4. The samples will be conditioned for a minimum of two (2) minutes as they travel across the Rapid Conditioning Unit. It is imperative that air loss be minimal around the containers, between the containers and between the frame of the conveyors, otherwise airflow through the cups on the container will fall off affecting the conditioning of the subsamples. The RCU open area for suction should be approximately 5” x 55” and have very minimal air loss between the container and top edge of the ductwork.

5. The ductwork shall start one container in from the end of the conveyor as the RCU this 5” x 55” area must always be covered with a container.

5.5 hvi workstation conveyors

1. The HVI workstation shall be capable of holding twelve (12) containers in the queue including the container in process at the HVI.

2. One (1) inch railing shall be installed along the frame in order to control the location of the container on the conveyor.

3. The conveyor shall position the container in process to within a ½ inch tolerance. This tolerance is necessary for the automatic delivery of the cotton subsamples contained in the two (2) small compartments of the container. The container shall be held in position for processing until the delivery of the subsamples to the HVI.

4. The conveyance in the area denoted by “HVI” in the container shall be such that a switch can be set to automatic allowing containers to flow through that area if desired. (Refer to drawing)

5. There shall be two (2) four (4) inch EXAIR Line Vacs, or equivalent, venturi devices connected with 3/8 inch air tubing with a minimum rating of 200 psi at each HVI workstation. The venturi devices shall be connected to two (2) four (4) inch round tubes positioned directly over the subsample portion of the container with a clearance of not to exceed 1/8 inch to ensure a good vacuum for cotton transport. All ducting and tubes for the transport of the cotton samples shall be smooth inside and outside to resist cotton lint tagging. NOTE: The portion of pipe that directly feeds samples to the HVI must be able to be moved out of the way quickly as the top hood on the HVI has to be opened regularly. When the hood is opened, the top corner is at 65” from the floor. When the hood is closed, the openings where samples are conveyed are at 44” height from the floor.

6. The conveyor system shall be capable of receiving an electronic ready signal from the HVI.

7. The conveyor system shall activate the two venturi devices when the HVI ready signal is received and the container is in the proper location.

8. The conveyor system shall deliver a start signal to the HVI within a second of the successful delivery of the cotton samples.

9. After the cotton in each container at a HVI workstation has completed testing, the container will be pushed by the employee approximately two inches where the conveyor shall incline the container for removal from the HVI workstation on the return conveyor from the HVI.

10. The processed container shall be merged onto the return conveyor from the HVI conveyor without collisions (Refer to drawing).

11. The HVI workstation shall have the ability to ensure the conditioning time of 120 seconds for each container utilizing something like the following:

a) A sensor at position 5 of the RCU to ensure full coverage of the RCU portion of the conveyor.

b) Samples shall not transfer to the venturi position until all RCU positions are occupied and 120 seconds have expired.

c) This logic shall only occur when less than 5 samples are on the HVI workstation feed conveyor.

d) The system shall allow a 20 second timeframe during which position 5 can be uncovered before the logic re-engages.

12. Each HVI workstation shall be controlled and operated by its own PLC controller.

13. The workstations shall also contain a switch for activation. This shall allow USDA personnel to enable or disable each workstation, at their discretion, without interrupting the conveyance system.

5.6 Return conveyors

1. The return conveyor shall deliver the HVI-processed containers to one (1) of three (3) load/class workstations.

2. The return conveyor shall be approximately seventy four (74) feet in length and twelve (12) eighteen (18) inches in overall width.

3. The return conveyor shall be located directly over the supply conveyor providing a minimum container clearance of six (6) inches from the top of the container to the bottom of the conveyor.

4. The conveyor shall span the necessary distance to provide delivery from all HVI workstations to all classer workstations.

5. The conveyor shall be a zone accumulation conveyor with zones to allow for container separation along the length of the conveyor. The conveyor shall be capable of stopping the containers within each zone with zero points of contact with an adjacent container.

6. The return conveyor shall be equipped with one (1) inch rails except in areas where the transport mechanisms are located at the HVI workstations.

7. The conveyor system shall be capable of distributing ten (10) containers per minute to each of the two conveyors that supply the classer workstation and a total of twenty (20) containers per minute for the system.

8. The return conveyor shall be equipped with a mechanism to transfer the containers from the conveyor to the classer workstation conveyors. (Refer to drawing.)

5.7 PA Load workstation conveyors

1. The PA Load workstation shall be capable of holding eighteen (18) containers including the container in process. (refer to drawing)

2. One (1) inch railing shall be along the frame in order to control the location of the container on the conveyor.

3. The conveyor shall position the container in process to within a one (1) ½ inch tolerance in the area denoted by “load” in the container at a top of conveyor height of thirty-two (32) inches.(Refer to drawing)

4. Each load station shall be controlled and operated by its own PLC controller.

5. The contractor shall purchase and install RFID tags on the containers supplied by USDA.

6. The contractor shall purchase and install RFID readers/writers for each of the workstations.

7. The loader shall scan the barcode tag and the PLC shall write the unique 12 digit bale identification number to the RFID tag on the container via the RFID writer. The PLC shall also verify the data written to the RFID tag by reading the tag and verifying the data that was written.

8. After the cotton in the container has been loaded, the completed container will be pushed by the PA approximately two (2) inches to a conveyor that will transport the container to the supply conveyor.

9. The load workstations shall also contain a switch for activation. This shall allow USDA personnel to enable or disable each workstation, at their discretion, without interrupting the conveyance system.

5.8 classer workstation conveyors

1. The Classer workstation shall be capable of holding nine (9) containers including the container in process at the classer area. (Refer to drawing).

2. One (1) inch railing shall be along the frame in order to control the location of the container on the conveyor.

3. The conveyor shall position the container in process to within a one (1) inch tolerance. The conveyance in the area denoted by “class” in the container shall be such that a switch can be set to automatic allowing containers to flow through that area if desired.

(refer to drawing)

4. The container in the processing position shall be at an angle such that the top of conveyor facing the classer is at a height of thirty six (36) inches from the floor.

5. After the cotton in the container has been classed, the completed container will be pushed by the classer approximately two (2) inches to a conveyor that will transport the container to the PA load workstation empty container conveyor.

5.9 empty container conveyor

1. The empty container conveyor shall deliver the empty containers to one (1) of three (3) load workstations.

2. The empty container conveyor shall be approximately forty three (43) feet in length and twelve (12) inches eighteen (18) in width.

3. The empty container conveyor shall be located directly under the supply conveyor providing a minimum container clearance of six (6) inches from the top of the container to the bottom of the conveyor.

4. The conveyor shall span the necessary distance to provide delivery from all classer workstations to all loader workstations.

5. The conveyor shall be a zone accumulation conveyor with zones to allow for container separation along the length of the conveyor. The conveyor shall be capable of stopping the containers within each zone with zero points of contact with an adjacent container.

6. The conveyor shall be equipped with one (1) inch rails except in areas where the transport mechanisms are located at the classer workstations.

7. The empty container conveyor system shall be capable of distributing ten (10) containers per minute to each loader workstation and a total of twenty (20) containers per minute for the system.

8. The empty container conveyor shall be equipped with a mechanism to transfer the containers from the conveyor to the load workstation conveyors. (Refer to drawing.)

9. The conveyor shall contain six (6) inch side rails. The cotton samples shall fall off the discharge end of the loose conveyor into an underground conveyor.

5.10 Conveyor Distribution

The containers will contain an RFID tag that identifies specific containers. There will be twenty five (25) containers that will be placed on the conveyor every two (2) hours that will require special distribution handling. Each of these containers will contain two (2) specific digits of ninety (90) at the beginning of their identification number. These containers should be routed so that all five (5) HVI workstations each receive five (5) containers.

5.11 Sack Conveyor

1. Two motorized (2) flex conveyors shall be provided that will convey cotton sacks loaded with cotton weighing approximately 40 pounds. The loaded sacks are approximately three (3) feet in length and eighteen (18) inches in diameter.

2. The flex conveyors shall be capable of conveying sacks from sixteen (16) feet extending to approximately forty eight (48) feet and shall be 30 inches in width.

3. The flex conveyors shall be mobile with heavy duty lockable casters.

4. The flex conveyor must be 120V with reversing capability.

5.12 CONVEYOR SYSTEM DESIGN REQUIREMENTS/CONSTRAINTS

1. There is currently 110/230/460V power available in the Lubbock Classing Office for this project. There is also an existing electrical panel currently being used for a zero-pressure conveyance system. The panel is located on the wall separating the two rooms shown in the drawings (Classing Lab and Receiving Room).

2. The Lubbock office also has available compressed air at 100 PSI. This compressed air source has limited capacity and therefore the contractor must attain USDA approval of any designed components using compressed air prior to acquisition of equipment or installation.

3. All electric motors shall be rated and equipped for a high lint and dust environment and suitable for an area designated as potentially flammable.

4. All belt conveyors shall be comparable to a slick rubber finish that will be resistant to cotton tagging.

5. All roller conveyors shall be equipped with rollers that are sealed and contain pre-lubricated ball bearings.

6. Each HVI workstation will be a height of 32 inches.

7. The height of each classer station shall be 36 inches.

8. The height of each PA Load Workstation shall be 32 inches.

9. The height of the horizontal sample feed conveyor shall be 42 inches.

5.13 SUPPORT REQUIREMENTS

1. All conveyor equipment shall be equipped with polytier supports with cross pipes and U-brackets with plates for support where needed to span the 48 inch trench or elsewhere As an option to this over the trench, a cross beam approximately 60 inches in length can be used and conveyor legs attached to it. This beam must be of appropriate size to handle the weight of the conveyor systems.

2. The conveyor equipment shall utilize splice plates, as needed, for all unsupported bed sections.

3. The support legs shall be galvanized or painted (See “Finish Section” for paint specifications).

4. All support adjustment increments shall be one (1) inch or less.

5.14 ELECTRICAL CONTROLS

General Requirements for system:

1. There shall be a monitor located in an easy accessible location coordinated with USDA personnel for each conveyor system. This monitor screen should be a minimum of 17”. Two tablets shall also be provided as a remote device accessible to the data presented by the monitor. The following items need to be programmed and shown on the monitor:

· Each HVI, classer, and loader output.

· To quickly troubleshoot problems, a light tree shall be installed at each HVI, classer and load workstation showing problem conditions along with those problems being shown on the monitor.

· External downloading of data via USB and internet. This data at minimum shall include all HVI, classer and loader outputs.

2. There shall be three (3) Start/Stop Buttons for the system - Activation shall control all conveyors of the conveyor system.

3. All Emergency Pull Cords and e-stops shall be located for accessibility from all workstations. Pull cords shall consist of a red cable or wire insulated to 3/16 inch diameter. Activation shall stop all conveyors in the conveyor system. Emergency pull cords must be designed to be manually reset before the conveyor can be restarted.

4. There shall be one (1) primary disconnect for the system to disable all conveyors.

5. Each motor shall have its own disconnect, located adjacent to the motor’s location.

6. Each motor shall be equipped with phase protection.

7. The main control panel shall include a Start/Stop button.

8. All disconnects shall be located in an easily accessible area and provide lockout capabilities.

9. Startup of conveyors shall be delayed 5 to 10 seconds and sound an alarm during the delay. Alarm intensity shall be at 100 decibels.

10. The location of the main control panel is shown in the drawing. The contractor shall furnish a complete electrical schematic of the conveyor controls, switches, etc. as well as clearly labeling all breakers, controls, switches, etc. at their designated locations.

11. PLC Features

a. The system shall integrate Allen Bradley CompactLogix L43 Processors or equivalent, with 2.0Mbyte Memory and Ethernet communications. The PLC documentation shall include the electronic ladder listing along with the annotations and cross-references. The PLCs shall control all motor control equipment, sensors and field electrical devices. The PLCs shall be linked via Ethernet to a system compatible with BACNET.

12. Control Cabinet

a. NEMA12 rated control cabinet(s) each with a 460VAC, 3 Phase, 125 amp disconnect shall be furnished. The motor starters shall be IEC manufacture. Field wiring entering the control cabinet shall tie to a terminal strip. The control cabinet shall be UL listed.

b. Note: There is an existing control panel located in the receiving room on the wall adjacent to the classing lab. The control panel provides power to the existing conveyor system and can be utilized as shown in the drawing.

13. Each HVI workstation shall have a minimum of 5 I/O ports. Classer and PA workstations shall have a minimum of 5 I/O ports. The HVI workstation ports must be capable of receiving a ready signal from the container location and the HVI before activation of a sample delivery from the container to the HVI and subsequent activation of the HVI. All workstations are required to track the number of containers processed.

14. At each HVI workstation, a switch must be installed at the point of removal of the sample (Refer to drawing where container has “HVI” in it). This switch must send an output signal of on/off which will be used with each USDA HVI machine.

15. At each classer, and HVI workstations, a switch must be installed that will activate/deactivate conveyance at the point where the sample in a container is processed. (Refer to drawing).

6. EXISTING CONVEYOR DEMOLITION AND REMOVAL

The scope of work includes all demolition and removal of the two existing conveyance systems. The contractor shall be responsible for any damage created in the process of demolition and equipment removal.

7. INSTALLATION / TESTING

This project is to be "turnkey" from start to finish. All electrical and mechanical work including plumbing required to make the conveyor system fully operational will be the responsibility of the contractor. All required moving equipment, tools, etc. shall be furnished by the contractor. The contractor should be aware that the area of installation will contain several testing instruments, classing tables, and ductwork protruding from the floor which will require care during installation to prevent damage. Each conveyor location will be designated by USDA and must be approved by the USDA prior to installation. Test runs and adjustments to assure proper operation shall be performed by the contractor. All work must be of a standard that is considered satisfactory by USDA, AMS, Cotton and Tobacco Program.

8. FINISH

1. The conveyor frame, supports, and guard rails shall be galvanized or painted.

2. Powder coat hybrid epoxy or baked enamel paint is required.

3. The selection of color must be submitted and approved by USDA prior to production.

4. Paint finish must be highly chip and abrasion resistant.

9. DURABILITY

These conveyors will transport large amounts of cotton, some of which will leave the containers in the form of lint and larger masses of cotton fiber and come in contact with the rollers and drive systems. All conveyor drives, rollers, and drive pressure systems must be able to withstand this environment without frequent maintenance to alleviate the difficulties that may arise due to the presence of cotton lint. Further, the conveyor must be able to endure a work schedule of 24 hours per day, seven days per week, year round.

10. REPAIR SERVICE

The manufacturer or distributor of the conveyor systems must have the capability to provide repair service and spare parts to this facility within 24 hours of notification of malfunction.

11. INSTALLATION AND MAINTENANCE MANUAL

A visually and verbally explicit operators' manual shall be provided to the USDA, AMS, Cotton and Tobacco Program. This manual shall fully detail any instructions regarding the installation, operation, and maintenance of the conveyor system.

12. ACCEPTANCE:

The Contractor shall only tender for acceptance those items that conform to the requirements of this contract. The Government reserves the right to inspect or test any supplies or services that have been tendered for acceptance. The Government may require repair or replacement of nonconforming supplies or reperformance of nonconforming services at no increase in contract price. If repair/replacement or reperformance will not correct the defects or is not possible, the Government may seek an equitable price reduction or adequate consideration for acceptance of nonconforming supplies or services. The Government must exercise its post-acceptance rights (1) within a reasonable time after the defect was discovered or should have been discovered; and (2) before any substantial change occurs in the condition of the item, unless the change is due to the defect in the item.

13. COMPLIANCE WITH APPLICABLE LAWS:

The Contractor shall comply with all applicable Federal, State, and local laws, rules, regulations, ordinances, and directives, and all provisions required for this Contract.

15. Delivery Date:

USDA wants delivery, installation, testing and acceptance completed by September 1, 2017.