Attachment 2 Scope of Work.doc

Performance Work Statement (PWS) Project: Replace Existing Grain Scale with Automation Phase A in Building 3 at the CGAHR Grain Pilot Headhouse at 1515 College Avenue, Manhattan, Kansas, 66502 1.0 Performance Work Statement: Remove the existing grain scale and Replace with new grain scale for 2500 bushels of wheat per hour, hydraulic gate operators, load cells, in the Grain Elevator, and automation controls in Grain Elevator Scale House.

2.0 Background: Existing Scale is 50 years old, is no longer accurately measuring grain, and needs replacement for automatic operation. Existing Grain Elevator is an operational Elevator and will be operated in the spring, before this project is started. Building will be occupied in other areas and other processes will be ongoing during the site visit and construction, but not in the immediate work area.

3.0 Technical Requirements/Tasks:

A. Phase A: Replace Scale and Install Automatic Controls.

1. Remove existing scale.

2. Remove existing cleaner from the system and slide it to the north, leaving it on the cleaner floor.

3. Cut hole in Scale Floor directly under both legs and install a new 2,500 bph scale directly south of legs.

4. New Scale may need to be custom built to be conducive to the install door entrance limitations.

a. Scale to be Rice Lake Scale, customized if needed, or equal.

b. Upper garner shall be built as to be assembled on the Scale floor in pieces to be fit through the exterior door. Hopper to be built from 11ga carbon steel and flanges to be bolted with 3/8” bolts.

c. Scale hopper to be built in sections to facilitate the entrance to south outside door on the Scale floor. Hopper to be built from 11ga carbon steel and all bolted flange connections to bolted with 3/8” bolts.

d. Bottom garner shall be built in sections as well to facilitate entrance of the Scale floor door opening. Flange bolts shall be 3/8”.

e. Scale frame, upper, and lower garner frame shall be constructed from rectangular carbon steel tubing. All of the structure shall be of shop welded and field bolted.

f. A shop coat of white paint shall be applied.

g. A rubber booted connection shall be supplied between the scale and garner bins.

h. A vent tube connection shall be supplied for customer connected dust system.

i. Provide adequate hangers and brackets for scale load cells.

j. Provide (1) bindicator for the top garner to proof a (full) status.

k. Provide proximity switch for proof of empty on bottom garner.

5. Provide hydraulic unit to operate gates and test weights.

a. Provide (1) Mark Hydraulic- hydraulic power unit, reservoir gallon size to be determined by Contractor.

b. Provide 3 phase explosion proof motor to power pump.

c. Provide Nachi or equivalent closed center hydraulic pump, with internal pressure and flow compensator.

d. Provide suction strainer and return filtering back to tank.

e. Provide 3-DO3 series all ports closed valve body, 2 position 4-way, for valving to scale cylinder.

f. Motor horsepower, pump gallons per minute, and psi of hydraulics to be determined.

g. Hoses to scale, to be provided by Contractor.

h. Hydraulic fluid to be provided by Contractor.

i. Install hydraulic unit in electrical room to keep it clean and free of dirt and to not have in a classified environment.

j. Provide cylinders, hoses, and rigging for test weights.

2. Scale read out equipment.

a. Load cells and scale equipment to be Rice lake weighing systems equipment, or equal.

b. The indicator head shall be Rice Lake 480, or equal.

c. The load cells are Rice Lake RL-2001, or equal.

d. The summing box is a JB4-ss, or equal.

e. The scale weights are 3-500 #Rice Lake, or equal.

f. The scale equipment is to be tested and certified by WH Scale Co from Topeka KS, or equal.

g. The assumption of 2500 bu/hr. is the rate to achieve.

3. Control Platform. Control Platform shall have the capability to control or be expanded to control the items in Phase A and Phase B, for automation of the whole mill within 5 years.

a. The control platform shall be Allen-Bradley PLC based operation. The platform model number determined by the integrator.

b. The remote I/O section of the PLC shall be mounted in a cabinet in the scale skid.

c. A panel view touchscreen shall be located in the scale house as well for control of all scale functions.

d. All communications shall be Ethernet between scale controller and scale house.

e. Provide one (1) emergency stop for the scale equipment in the scale house.

f. Programming shall be designed to load all data, (draft weight) to a USDA provided desktop windows Excel program

g. An Ethernet switch shall be provided to facilitate communication to scale, PLC, desktop and remote I/O.

h. All programing and shake down included in the scope for the PLC, and the excel data push.

i. Scale set-up and test check by WH Scale- Topeka, Kansas, or equal.

j. All operation of the scale functions shall be controlled by the PLC.

4. Control platform shall have three modes.

a. 1 Automatic mode

b. 2 Manual mode

c. 3 Calibration mode

5. Remove and replace gates B1 and B2 Rack and Pinion (R&P) gates with Central Metal Fabricators (CMF) 9” square 480V/3ph, Class II-G electric R&P gates on the Scale Floor.

6. Remove B3 because it will no longer be needed.

7. Re-run 9” square spouting to allow grain from both legs thru the sampler into new scale or to bypass the sampler and scale to go to the East Distributor or to the Pilot Plant on Scale Floor.

8. Install new B3 - CMF 3-way R&P gate to allow grain to go to West Distributor, East Distributor or to the Pilot Plant on the Cleaner Floor.

9. Remove gates B4, B5, B6, B7 because they will no longer be needed.

10. Items to be fully automated and controlled from a computer in the office using customized Programmable Logic Controller (PLC) program:

a. Receiving Hopper Belt Conveyor (Turn ON/OFF)

b. North Leg (Turn ON/OFF)

c. South Leg (Turn ON/OFF)

d. Gate B1 (OPEN/CLOSE)

e. Gate B2 (OPEN/CLOSE)

f. 2500 BPH Scale (ON/OFF, actual weights, recorded weights)

g. Gate B3 (OPEN/CLOSE)

h. Gate F19 (OPEN/CLOSE)

i. Gate F22 (OPEN/CLOSE)

j. Gate F23 (OPEN/CLOSE)

k. Belt Conveyor #2 from pilot plant (Turn ON/OFF)

l. Belt Conveyor #3 (Turn ON/OFF)

m. Screw Conveyor #4 (Turn ON/OFF)

n. Rolfes Hazardous Communication Program (Show Alarms, Speeds, RPM), or equal and compatible.

B. Phase B. Additional Automation for the Remainder of the Grain Conveying System. Includes additional connections and programming to be controlled by Control Platform from Phase A.

1. Remove and replace 6-Hole full round Distributor 3 (Manual) with a Custom Metal Fabricators, Inc., CMF, TH Series Distributor. A new 110V/1ph, Class II-G, Power Select electric positioning system on the Distributor Floor.

2. Remove and replace F1, F2, F3, F4, F5, F6 R&P gates with CMF 12” square 480V/3ph, Class II-G electric R&P gates on the Working Floor.

3. On Receiving Floor - remove and replace F7, F8, F9, F10, F11, F12, F13, F14, F15, F16, F17, F18, F20, F21 R&P gates with CMF 9” square 480V/3ph, Class G electric R&P gates.

4. Remove and replace B14, B15, B16, B17, B18, B19, B20, B21, B22 with CMF 9” square 2-way diverter valve with 110V/1ph, Class II-G Andco actuator drive on the Receiving Floor.

5. In the Basement Floor, remove and replace B25, B26 with CMF 9” square 60 degree Y-Type diverter valve with 110V/1ph, Class II-G Andco actuator drive.

6. Remove and replace B23 with CMF 14” x 10” rectangle Y-type diverter valve with 110V/1ph, Class II-G Andco actuator drive.

7. Remove and replace B24 with CMF14” x 10” rectangle dropout diverter valve with 110V/1ph, Class II-G Andco actuator drive.

8. Items to be fully automated and controlled from a computer in the office using customized Programmable Logic Controller (PLC) program:

9. Gates B14 - B26 (OPEN/CLOSE)

10. Gates F1- F18, F20, F21 (OPEN/CLOSE) 4.0 Government Furnished: Reference Material as follows from historical information and recent assessments.

A. Manhattan KS Grain Elevator Upgrades – Full Assessment REVISED20200122.pdf B. Existing Grain Elevator Layout Updated Jan 2020.pdf C. Proposed Grain Elevator Layout on Jan 2020.pdf D. Grain Elevator Elevations from 1969 20200124.pdf E. Lower Sections of Grain Elevator from 1969 20200124.pdf

5.0 Deliverables / Schedule:

6.0 Travel: Not applicable 7.0 Contractor’s Key Personnel:

A. On site Superintendent’s name.

B. Operator’s certification or license on equipment that operates over buildings or personnel.

8.0 Security Requirements: All personnel shall have a U.S. photo ID, such as U.S. Driver’s License, or U.S. passport.

9.0 Data Rights: Not Applicable.

10.0 Section 508 – Electronic and Information Technology Standards: As-Built Drawings in Adobe file format.

Attachment: See referenced drawing file “Existing Grain Elevator Layout Updated Jan 2020.pdf”; “Proposed Grain Elevator Layout on Jan 2020.pdf”; “Grain Elevator Elevations from 1969 20200124.pdf”; “Lower Sections of Grain Elevator from 1969 20200124.pdf”. See referenced Assessment “Manhattan KS Grain Elevator Upgrades – Full Assessment REVISED20200122.pdf”.