SNI_Statement_of_Work_(SOW).pdf

Single Note Inspection System Packaging & Cutting

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SECTION C – DESCRIPTION/SPECIFICATIONS/STATEMENT OF WORK

C.1 BACKGROUND

The Bureau of Engraving and Printing (BEP) is seeking to automate its existing Single Note Inspection (SNI) equipment located at the BEP Washington, D.C. Facility (DCF) and the BEP Fort Worth, TX. Facility (WCF). The existing Single Note Inspection (SNI) systems are Giesecke & Devrient (G&D) Banknote Processing Systems (BPS) 2000.

Under this requirement, the contractor shall be responsible for designing, fabricating, assembling, integrating, and installing a packaging system and optional cutting system into the current SNI equipment. Contractor shall also train BEP personnel on the operations of the updated automations of the SNIs equipment.

The packaging system delivered with the current SNIs does not track, verify the product by serial numbers, or package finished products that meet the BEP’s requirements. The BEP must manually package notes from the SNI for shipment to the Federal Reserve. The resulting integrations will automate the packaging operation of notes accepted by the SNI for shipment to the Federal Reserve and enable the BEP to significantly improve accountability and issues with the current product packaging.

C.2 STATEMENT OF WORK

This Statement of Work (SOW) defines the requirements of the Bureau of Engraving and Printing (hereafter referred to as the BEP or Bureau) to automate its existing SNI equipment and integrate a packaging system for the BEP SNI systems at each of the BEP facilities.

The contractor shall provide all labor and materials to integrate their inspection software and hardware into the BEP’s existing machinery. The contractor shall be responsible for the performance of all activities and materials to install and make the system ready for operation.

The contractor shall provide the design, fabrication, assembly, testing, shipment, delivery, startup and acceptance of the system machinery and performance of all services, as well as provide the BEP with information on the status of the work being performed for this requirement herein.

This requirement is being processed to automate (integrate two SNI systems onto one packaging system and cutting system at each BEP facility) all four SNI systems. The automation of the existing SNIs is to be performed in sequence; the contractor will not be allowed to integrate a second SNI system to the packaging and cutting system until the first integration of the first SNI has been fully validated, formally accepted by the BEP, and returned to operation through the Bureau Acceptance Test (BAT).

The contractor shall perform all work to assess the capabilities of the SNI BPS 2000 machines and determine what changes to propose as part of the required modification to integrate a packaging system.

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C.3 DOCUMENTS

C.3.1 NON-DISCLOSURE AGREEMENT

During the course of this contract, the contractor will require sensitive but unclassified information that is proprietary to the United States Government. A Non-Disclosure Agreement (NDA) shall be signed and notarized as part of the submission package for consideration, Attachment 18.

The notarized agreement shall be returned to:

Bureau of Engraving and Printing Office of Acquisitions, Room 705-A 14th and C St, SW Washington, DC 20228 Attn: Millie Cortes, Contract Specialist

C.3.2 REFERENCED DOCUMENTS

Equipment to be delivered under this contract shall meet all current U.S. commercial codes and industrial standards, or equally stringent international standards, for manufacturing of high quality industrial equipment, commercial printing presses and finishing equipment to be utilized within an industry environment. At a minimum, all equipment shall conform to National Electric Code, NEC, standards.

The following is a listing of specific standards that the equipment shall meet:

All applicable sections of American Conference of Government Industrial Hygienists (ACGIH) (www.acgih.org)

All applicable documents related to Energy Policy Act of 1992 with specific reference to Executive Order 13123 (www.omb.gov) or at (https://www.archives.gov/federal-register/executive-orders/1999.html)

All applicable Occupational Safety and Health Administration (OSHA) standards with specific references to OSHA standards 29 CFR 1910 (www.osha.gov)

All applicable codes and standards and environmental permitting of U.S. Environmental Protection Agency (EPA) (www.epa.gov) or at (https://www.epa.gov/laws-regulations/laws-and-executive-orders) and District of Columbia (DC) government (www.doee.dc.gov) and State of Texas (TX) government (www.tceq.texas.gov).

C.3.3 LIST OF ATTACHED DOCUMENTS

The following lists the documents attached to this SOW. NOTE – Attachments identified with an asterisk (*) require a Non-Disclosure Agreement (NDA). All NDA documents provided under this contract shall be considered proprietary and sensitive to the government. NDA documents shall not be copied, scanned or reproduced without written approval by the U.S.

Government, such as a BEP Contracting Officer (CO). All NDA documents shall be returned to the BEP when no longer required or upon request by the CO.

Some documents will only be made available in redacted versions. Request to have copies of the original versions must be made to the Contracting Officer (CO) with information on why the information is required.

http://www.acgih.org/ http://www.omb.gov/ https://www.archives.gov/federal-register/executive-orders/1999.html https://www.archives.gov/federal-register/executive-orders/1999.html http://www.osha.gov/ http://www.epa.gov/ https://www.epa.gov/laws-regulations/laws-and-executive-orders https://www.epa.gov/laws-regulations/laws-and-executive-orders

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Identifier Title/Description Attachment 1 Paper Strap Specification Attachment 2 Shrink-wrap Film Specification Attachment 3 Drawing 30084 r1 Cash Pak Shipping Label Attachment 3A Drawing 30085 Cash Pak Eagle Label Attachment 4 Drawing 30101 Bundle of 1000 Notes Attachment 5 Drawing 30102 Brick of 4000 Notes Attachment 6 Drawing 30083 Cash-pak of 16000 Notes Attachment 7 Cash-pak Drop Test Requirements Attachment 8 BEP-FRB Currency Skid Attachment 9 Currency Skid Stacking Drawing – Skid of 640000 Notes Attachment 10 Site Drawing Attachment 11 Federal Information Processing Standards Attachment 11A NIST Special Publication 800-53 Attachment 11B US Government Security Baseline (USGCB) Attachment 11C Department of Justice Reference Attachment 12 75.00-ENV-005-FW: EH&S Boilerplate Requirements for Construction and

Service Contractors Attachment 12A 75D-07.0-04 EHS Contractor Requirements Attachment 13 SNI Automated Packaging Preliminary Test Plan Attachment 14 Prohibited Materials 75D-07.0-07 Restricted Materials at DCF

Attachment 15 Certificate Regarding Lobbying (Disclosure of Lobbying Activities)Standard Form LLL (SF LLL)

Attachment 16 Past Performance Questionnaire Attachment 17 Standard Form SF1019A – Subcontracting Plan Attachment 18 Non-Disclosure Agreement (NDA)

C. 4 REQUIREMENTS

Under this contract, the contractor shall accomplish at a minimum the following:

A. DATABASE

(1) Amend SNI (BPS 2000) data output to provide the serial numbers of the top note of each strap for tracking through the packaging operation

(2) Integrate data from packaging system with SNI database of Serial Numbers of acceptable notes within each unique Bundle and Cash-Pak. Each bundle and Cash-Pak shall have a unique identifier in the form of a “3 of 9” bar code.

B. PACKAGING SYSTEM

(1) Modify the existing SNI (BPS 2000) machines so that the current output (½ bundles) works with the packaging system to produce packages meeting the BEP requirements and utilizing BEP materials. Packages shall be identical to those presently produced by the BEP Large Examining Printing Equipment (LEPE) and

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Currency Overprinting Processing Equipment (COPE) machines. Specifications for current packages are included in this document as text or Attachments.

(2) Remove the existing bundle packaging system.

(3) Fabricate, install, integrate, startup, test and turn-over an automated packaging system to produce Bundles, Bricks, Cash-Paks and Skids similar to those produced by KBA-Notasys’ LEPE press; that uses BEP materials and resulting product that matches the appearance and performance of existing packages produced by the BEP. The packaging system must have an integrated serial number tracking system to verify the packaging of the product and ensure that the serial numbers of the notes being packaged are known and are recorded.

The packaging system shall accept notes from one (1) or two (2) SNI machines. The contractor shall integrate the packaging system onto one (1) SNI and demonstrate compliance with the Government’s site specification, Attachment 10. After acceptance by the BEP, the contractor shall integrate the second SNI with the packaging system and demonstrate the complete system for final acceptance. When running at full capacity, there are two (2) SNI machines running simultaneously with both machines outputting product into the single packaging system.

However, the packaging system shall be capable of packaging notes with just one SNI running as well. Either SNI machine shall be capable of running in single SNI operation. This flexibility is intended to provide the ability to still maintain production when maintenance is being performed on an SNI machine. The system shall be able to track the serial numbers of all notes whether one

(1) SNI is running or both.

C.4.1 TASK 1 – SNI DATA REQUIREMENT

The contractor shall perform all software code generation, testing and debugging to perform the following:

A. Amend SNI (BPS 2000) data output to provide the serial numbers of the top note of each strap for tracking thru the packaging operation.

The data shall be digitally outputted with the physical output of the ½ bundles from the SNI machine for packaging. System shall verify receipt of the data transfer to the packaging system prior to proceeding.

B. Integrate data from packaging system with SNI database of Serial Numbers of acceptable notes within each unique Bundle, Brick, Cash-pak and Skid.

Data is to be uploaded into the BEP database. System shall verify receipts of data transfer and redundantly maintain backup copies of the data to ensure against loss. Refer to section C.4.5.D (1).

C. Data integrity is to be maintained at all times and all stages of the process. Data integrity shall be such that the BEP can maintain product tracking as described on Section C.4.5 (B).

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C.4.2 TASK 2 – PACKAGING SYSTEM REQUIREMENT

The contractor shall:

A. Modify the existing SNI (BPS 2000) machines so that the current output (½ bundles) works with the packaging system to produce packages meeting the BEP requirements utilizing BEP materials.

B. Remove the existing bundle packaging system.

C. Fabricate, install, integrate, startup, test and turn-over an automated packaging system to produce Bundles, Bricks, Cash-Paks and Skids similar to those produced by KBA- Notasys’ LEPE press. Resulting product shall match the appearance and performance of existing packages produced by the BEP. The packaging system must have an integrated serial number tracking system to verify the packaging of the product and ensure that the serial numbers of the notes being packaged are known and recorded.

C. 4.3 MATERIALS REQUIREMENT

The system shall utilize the following materials.

A. SKIDS

The system shall use the BEP’s skids for the stacking of the finished product for shipment. The drawing of the skids and lids are at Attachment 9.

B. SNI STRAPS

The system shall accept the straps produced by the SNI . A strap is 100 notes, bound together face up, and held together with a paper band. The paper band around the straps and positioning on the strap shall remain the same.

C. BAND SPOOLS (Bundle) The system shall use the BEP’s spools of paper bands for application around the 10 straps to produce a Bundle. Bundle bands are plain unprinted bands. The specifications for the paper bands are Attachment 1.

D. PACKAGING FILMS (Bundle, Brick, Cash-pak and Skids) The system shall use the BEP’s Bundle, Brick and Cash-pak shrink-wrap films for the packaging of the notes. The Bundle film is linear low-density polyethylene ( LLD-PE) material. The Brick film is a polyvinyl chloride (PVC) material. The Cash-pak film is a LLD-PE material that has been printed and laminated. The specifications for the stretch-wrap film are Attachment 2.

The system shall use the BEP’s stretch-wrap film for the wrapping of the skids of cash-paks after palletizing. The BEP’s stretch-wrap film specification is included in Attachment 2.

E. LABELS (Bundle and Cash-pak) The system shall use the BEP’s Labels for the Bundles and Cash-paks. One (1) label is applied to each bundle that contains bar-coded information applied over the face of the bundle. Each Cash-pak has two (2) labels applied, a shipping label that contains bar-coded information applied over the face and a BEP-Federal Reserve Board (FRB) label that covers the window on the back of the Cash-pak. The specifications and drawings of the labels are Attachment 3 and

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Attachment 3A.

F. CONTRACTOR FURNISHED MATERIALS

Any other materials required for successful utilization of the system shall be specified and an initial batch of the materials shall be provided by the contractor for BEP review and approval.

The specification shall be complete to allow the BEP to competitively procure the materials in the future. An initial batch shall be sufficient for one year (240 working days) at three (3) shifts per day, eight (8) hours operation per day. The initial batch shall be in addition to that supplied by the contractor for startup and testing of the system prior to final acceptance.

Any contractor supplied materials shall have a shelf life of not less than one (1) year. Materials with specific storage requirements to maintain their shelf life shall be identified or shall be furnished in batches to minimize the time in stock.

An initial batch of material(s) shall be supplied prior to the performance of the Bureau Acceptance Test (BAT) by the contractor. The remaining supply of material(s) shall be scheduled in accordance with the anticipated usage rate of the system with the final material(s) being supplied no later than 9 months after completion of the BAT.

A specification and Safety Data Sheet (SDS) shall be provided for each contractor proposed material no later than 90 days prior to Bureau Acceptance Test (BAT). Materials shall be reviewed and approved by the BEP Office of Environmental, Health and Safety prior to the contractor bringing the material on site. Materials not approved shall not be brought on to the site and consequently not used on the system. In this case, alternative materials shall be proposed.

C.4.4 PRODUCT REQUIREMENTS

Product from the system shall meet the following requirements.

A. BUNDLES

A bundle is 10 straps, one thousand (1000) notes, bound together face up, held together with a paper band, shrink-wrapped and labeled. All straps within a bundle shall be face up with every other strap rotated 180°. A bundle with paper band is shown in the attached drawing, Attachment 4. The paper band shall be tight enough to hold the straps together. Position of the band on the bundle shall be within ± 4 mm of the location set by the operator.

The bundle shall be shrink-wrapped as a total enclosure package with plastic film and have a unique label applied to the top. The film shall be shrink-wrapped tight around the bundle without wrinkles. All edges of the film shall be sealed together. The package shall be tamper evident and have no holes other than holes within the film to allow air removal during the wrapping process. Air escape holes shall be no larger than 6.35 mm (¼”) diameter. The appearance, strength and durability of the bundles produced on the system shall be identical to the existing bundles produced by the BEP.

The wrapped package shall be labeled with a unique label designating the bundle. The labels shall be applied over the top note. The label font shall be “Impact” and the bar code shall be code 39.

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B. BRICKS

A brick is four (4) bundles, four thousand (4000) notes, shrink-wrapped together. A brick is shown in the attached drawing, Attachment 5. Only the two (2) ends of the film need be heat sealed, the overlap of the film does not require sealing.

The package shall have no holes other than holes within the film to allow air removal during the wrapping process. Air escape holes shall be no larger than 6.35 mm (¼”) diameter. All bundles shall be face up within the brick. The brick wrapping film over the bundle label shall not prevent scanning of the bar code on the bundle label or reading of the information printed on the label.

The brick film shall not fuse to the bundle film. The appearance, strength and durability of the bricks produced on the system shall be identical to the existing bricks produced by the BEP.

C. CASH-PAK

A cash-pak is four (4) bricks, sixteen thousand (16,000) notes, shrink-wrapped together using a polyethylene laminated film as a total enclosure package. The attached drawings show the cash-pak, including placement of the labels, Attachment 6. The system shall have the ability to handle up to 24 ½” long cash-paks.

All edges of the film shall be heat sealed together. The film shall be shrink-wrapped around the cash-pak tight without wrinkles. The package shall be tamper evident and have no holes other than holes within the film to allow air removal during the wrapping process. Air escape holes shall be no larger than 6.35 mm (¼”) diameter. The clear windows along the top and bottom of the cash-pak shall allow counting of the straps’ paper bands contained within the cash-pak.

Labels shall be placed over the clear windows at both ends of the package covering the currency within. The cash-pak film shall not fuse to the brick film nor cause the brick film to fuse to the bundle film. The appearance, strength and durability of the cash-paks produced on the system shall be identical to the existing cash-paks produced by the BEP. The performance requirement for cash-paks, drop test, is Attachment 7.

D. SKIDS

A skid is forty (40) cash-paks, six hundred forty thousand (640,000) notes, stacked and stretch-wrapped on a BEP provided currency skid. The cash-paks shall be stacked as shown in the attached drawing, Attachment 8. The appearance, strength and durability of the skids produced on the system shall be identical to the existing skids produced by the BEP.

C.4.5 FUNCTIONAL REQUIREMENTS

The system shall perform the following functions utilizing the materials specified in Section C.4.3 and producing product meeting the requirements in Section C.4.4.

A. MACHINE STAGES

1. Accept data from each SNI (Serial Number of top note of each strap in each bundle)

2. Remove product from each SNI (Either straps or ½ bundles)

3. Separate product into straps

4. Verify serial number of each strap by means of optical character recognition (OCR) to verify order matches with data output from SNI

5. Re-assemble straps to produce bundle per product requirements (rotating every other strap)

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6. Track assembly of straps into bundles

7. Apply paper band around bundle

8. Verify quantity of notes in bundle (1000 note counter). For further details, refer to

Section C.4.4.A .

9. Shrink-wrap bundle

10. Print and apply bundle label

11. Verify label and OCR top note

12. Track bundles into bricks (Bricks may contain bundles from either SNI machine)

13. Accumulate bundles to produce bricks per product requirements

14. Shrink-wrap bundles into brick

15. Track bricks into cash-paks

16. Accumulate bricks to produce cash-paks per product requirements

17. Shrink-wrap bricks into cash-paks

18. Apply BEP-FRB Eagle label

19. Print and apply Shipping Label

20. Verify Labels

21. Track cash-paks onto skid

22. Palletize onto skid per product requirements

23. Offload full skids, hold up to four (4) finished skids while continuing operation

24. Allow Operator to

a. Manually remove skid from offload conveyor

b. Stretch-wrap Skid

25. Merge data with SNI system – Serial Numbers of notes in each of the straps Bundles, Bricks, Cash-pak and Skid

B. OTHER FUNCTIONAL REQUIREMENTS

(1) PRODUCT TRACKING

The system shall track the movement of product (straps, bundle, bricks and cash-paks) through the production process and ensure that no product is missing or out of order. At strategic locations, the system shall verify the product order (via optical character recognition (OCR)) of the top serial number of straps and bundles. A strategic location is where the cameras will have a clear view of the serial numbers of the straps and bundles. If the system detects that any product is missing or out of order, the system shall stop and signal the operator for corrective action and not allow continued operation until corrective action is complete.

Product tracking shall be redundant, robust and shall account for all possible jams or errors that could impact the product movement or potential loss of product tracking information. The system shall know at all times the serial numbers of the straps being packaged into Bundles and Cash-paks.

(2) FAULT RECOVERY

The system shall have detection components to detect whenever a fault, i.e. jam or error, occurs that would result in a disruption to the sequence of the finished product, cause damage to the

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The system shall have provision to recover from all faults. No faults shall negatively impact the sequence of the notes within the straps, bundles, bricks, cash-paks or skids; create a hazard to operational or maintenance personnel; or cause the system to lose tracking of the product so that the straps within a package would be unknown.

If the operator determines that the product was damaged or unacceptable for further processing from an error/jam, the operator shall be able to remove product from the system and OCR enter by the top note of straps removed.

The contractor shall provide detailed plans on each operator station detailing the step-by-step activities for the corrective actions required to correct the fault condition and return to production.

(3) REPACKAGING OF PRODUCT

If the operator determines that any package does not meet the quality level for shipment, the system shall allow for the operator to manually remove the product, re-package the product, and return the product to its correct position within the system. Repackaging shall be able to be performed without emptying the system. Repackaged product will be counted as spoilage from the system.

(4) SINGLE SNI OPERATION

The system shall be able to operate with only one (1) SNI in operation. This is to allow for continued operation when issues/maintenance is being performed on an SNI or if special testing is being performed on an SNI to minimize the impact on operation.

(5) BUNDLE COUNTER

The packaging system shall redundantly verify the count of all bundles produced. If the first counter fails to obtain a correct count, the count shall be re-verified by a second counter on the opposite corner of the bundle.

If both counters fail to verify that the bundle contains 1000 notes, the bundle shall be diverted for operator intervention. An audible and visual signal shall alert the operators to the diverted bundle. The operator shall have a separate counter for manual verification of the bundle count.

The manual counter shall be the same make and model as the counters utilized to count every bundle in the automated system. Manual counting of a bundle shall not cause the packaging system to lose the continuous numerical sequence of the product. After verifying the count, the operator shall place the bundle in a staging area for automatic re-insertion back into the production process in compliance with the product sequence. If the operator takes longer than the system allows to verify the bundle count, the system shall stop and wait on the placement of the bundle in the re-insertion position.

If after manual counting, the operator still fails to verify that the bundle contains 1000 notes, the

S N I P a c k a g i n g S O W P a g e 10 | of 40 bundle shall be removed. The straps shall be removed and assuming the notes are not damaged, will be reprocessed by SNI. The system shall account for the removal of any product, and shall not cause the packing system to lose tracking of the final product so that the straps within a package would be unknown. The contractor shall provide detailed plans on each operator station detailing the step-by-step activities the corrective actions required to correct the fault condition and return to production.

Bundle counters shall have a false acceptance rate of not greater than 1 out of 10,000 and a false rejection rate of not greater than 1 out of 2,500.

C. SAFETY REQUIREMENTS (MANDATORY ELEMENT)

All equipment delivered to the BEP shall be designed to minimize all risks of injury to BEP employees. All equipment shall be in full compliance with government and commercial safety and health regulations and requirements. The following are specific safety and environmental requirements for major production machinery for the BEP.

(1) General safety Equipment shall be designed to prevent injury to operation and maintenance personnel at all times. It shall be equipped with service access equipment; such as, catwalks, access platforms, access ladders, lifts, and other equipment for operation and maintenance. Fixed stairs shall be provided in compliance with OSHA 29 CFR 1910.24, Fixed Industrial Stairs. All catwalks, access platforms, access ladders, lifts, hoists, and any other equipment that are furnished, shall be built and tested to comply with American National Standards Institute (ANSI) and the Occupational Safety and Health Administration (OSHA) standards. All press and service access equipment shall be guarded as required by applicable portions of OSHA Regulations.

(2) Noise Level The maximum noise produced by the operation of the equipment at full production rate shall not exceed 85 decibels A-weighted sound level (85 dBA) when measured at 914 mm (3 feet) distance along the plan view of the equipment and at an elevation of 1,524 mm (5 feet).

(3) Machine Guarding All covers and safety guards shall be interlocked with the equipment’s controls to prevent its operation while any cover or guard is open or absent. Covers and guards shall be manufactured for easy removal by Bureau personnel to facilitate removing mechanical and electrical parts for repair. All rotating and reciprocating parts shall be guarded as specified by OSHA regulation 29 CFR 1910.212. All equipment and service access panels shall be guarded as required by applicable portions of OSHA Regulations.

(4) Mechanical Entrapment Response Procedures The manufacturer shall provide mechanical entrapment response procedures for the emergency release of persons trapped in machinery. Training on the procedures shall also be provided. This requirement applies to equipment that has any potential entrapment point(s) where hands, fingers or any other body parts could become caught between moving parts.

(5) Sharp Edges All sharp edges and corners, which present personnel hazards, shall be guarded or padded.

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(6) Heated Surfaces Equipment shall be designed to prevent heated surfaces from causing burns to personnel during operation.

(7) Prohibited Materials Some materials shall not be used in the equipment. These materials are noted in 75D-07.0-07 Restricted Materials at DCF.

(8) Hazardous Emissions Operation of the equipment shall not result in worker exposure to airborne contaminations exceeding current maximum allowable concentrations established by (OSHA) and the American Conference of Governmental Industrial Hygienists (ACGIH) standards. When the standards differ, the most stringent shall apply.

(9) Interlocks An electrical interlock shall be provided to prevent accidental starting with the mechanical lock engaged.

(10) Hazard Communication Safety Data Sheets (SDS) for all supplied and specified chemicals that are part of the process shall be supplied by the contractor to the COR. The SDS shall comply with OSHA, as listed in standard 29 CFR 1910.1200, with particular emphasis on paragraphs (g) and (i). All MSDS and package labeling must be in English.

(11) Overload Protection Equipment shall be provided with overload protection and power factor correction devices to prevent damage to components and operating personnel.

(12) Safe Ready All control stations shall include a "safe-ready" collar. Upon turning the collar to the safe position, it shall be impossible to start the system from any other station. Console shall indicate that the particular interlock including emergency stop buttons causes the system to start or not.

(13) Emergency Stop Emergency stop buttons shall be provided at strategic locations to minimize the time required to reach them. Emergency stop buttons shall stop the system within one (1) second so as to reduce damage to the system and injury to personnel. Emergency stop buttons shall be of the pronounced mushroom type, red in color. Emergency stop buttons shall remain activated with a blinking red light once depressed until manually reset.

(14) Inching Interlock Whenever an inching of the equipment occurs, only the control station from where the inch was performed shall be able to cause the equipment to move until the safe-ready is activated and deactivated. The equipment shall be designed such that the use of “cheaters” to override the interlock function is not necessary.

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(15) Energy Isolation Disconnect or lockout devices shall be provided and identified with signage for all sources of energy on the equipment; this includes electrical, hydraulic, pneumatic, and kinetic sources of energy. All isolating devices (levers, breakers, valves, etc.) for all associated energy sources (electrical, hydraulics, pneumatics, gravity, etc.) shall be identified by a color coded tag which indicates the type of energy source, the magnitude of the energy and an ID number. All isolating devices shall be capable of being locked out with a standard locking device and/or padlock.

Stored sources of energy such as, pneumatic and hydraulic forces shall be automatically bled and returned to a zero energy state when an interlocked device (i.e. a guard or a door) is opened.

(16) UV Curing/Exposing Equipment All equipment with ultraviolet radiation systems shall be designed such that no operator is exposed at or above permissible threshold levels established by the ACGIH.

(17) Hydraulic & Pneumatic Systems All hydraulic and/or pneumatic systems shall have functional isolation, i.e., when part of a system is operating, no other part of the system shall be adversely affected by pressure drop, flow transients, etc. All hydraulic and pneumatic equipment employed in the system shall conform to the Joint Industrial Council (JIC) standards. Hydraulic and pneumatic pumps shall be energy efficient.

(18) Laser Systems All equipment with laser systems shall comply with the latest version of the Laser Institute of America’s ANSI-Z136.1 standard, American National Standard for Safe Use of Lasers, and 21 CFR 1040 and shall be designed such that no operator is exposed at or above permissible threshold levels established by the ACGIH.

(19) Illumination Large equipment (such as printing presses) with covered work stations such as impression cylinder, wiping roller, inking-in areas, etc., shall be illuminated to 20 foot-candles of luminance by the equipment manufacturer, in accordance with the latest version of ANSI RP-7.

(20) Industrial Ventilation Equipment which emits airborne contaminants which exceed permissible exposure concentrations as established by OSHA, ACGIH and National Institute of Occupational Safety and Health (NIOSH) shall be equipped with local exhaust ventilation (LEV). LEV shall be designed in accordance with the ACGIH Industrial Ventilation: A Manual of Recommended Practice for Design, (latest edition). All industrial ventilation system parameters and design shall comply with the OSHA Ventilation Standard, 29 CFR 1910.94.

(21) Material Handling Assistance The equipment shall include ergonomic lifting aids for any lifting of more than 32 pounds by the operators.

D. ENVIRONMENTAL PROTECTION REQUIREMENTS (MANDATORY

ELEMENT)

All equipment, materials, and processes must meet or exceed standards in the regulations and

S N I P a c k a g i n g S O W P a g e 13 | of 40 executive orders listed below. Other environmental regulations, executive orders and guidance may also be applicable. The environmental protection requirements focus on emissions, discharges, and waste products impacting air, water, and land. The equipment installed at the Bureau shall comply with the following regulations:

(1) References Federal Regulation: Environmental Protection Agency, EPA Clean Air Act, Clean Air

Act Amendments of 1990, Section 112-Air Toxics (http://www.epa.gov/air/oaq_caa.html)

40 CFR 403 - General Pretreatment Regulations for Existing and New Sources of Pollution(http://www.epa.gov/docs/epacfr40/chapt-I.info/subch-N.htm);

40 CFR 433 – Metal Finishing Point Source Category (https://www.epa.gov/eg/metal-finishing-effluent-guidelines);

40 CFR 261 – Identification and Listing of Hazardous Waste

(https://www.epa.gov/rcra/resource-conservation-and-recovery-act-rcra-regulations);

District of Columbia Municipal Regulations (DCMR), Title 20, Subtitle A, Air Quality Regulations (http://www.dcregs.dc.gov/Gateway/TitleHome.aspx?TitleNumber=20);

District of Columbia Municipal Regulations (DCMR), Title 20, Subtitle E, Hazardous Waste Regulations (http://www.dcregs.dc.gov/Gateway/TitleHome.aspx?TitleNumber=20);

District of Columbia Municipal Regulations (DCMR), Title 21, Water and Sanitation, Chapter 15, Discharges to Wastewater System Regulations (http://www.dcregs.dc.gov/Gateway/TitleHome.aspx?TitleNumber=21);

P.L. 102-486, Energy Policy Act of 1992, October 24, 1992 (http://www.afdc.energy.gov/pdfs/2527.pdf);

40 CFR Part 247, Comprehensive Guideline for Procurement of Products Containing Recovered Materials, May 1, 1996 (https://www.federalregister.gov/documents/2001/08/28/01-21567/comprehensive-guideline-for-procurement-of-products-containing-recovered-materials);

Executive Order 13693 - Planning for Federal Sustainability in the Next Decade,” March 19, 2015 (https://www.epa.gov/greeningepa/executive-order-13693-planning-federal-sustainability-next-decade);

30 TAC (Texas Administrative Code) - Chapters 101, 115, and 116 for Air Quality Rules and air permitting (https://www.tceq.texas.gov/permitting/air/rules/state);

City of Fort Worth Code – Chapter 12.5 for Industrial Wastewater (https://www.epa.gov/sites/production/files/2015-12/documents/nps-ordinanceuments-fort-worth-sw.pdf);

30 TAC – Chapter 335 for Industrial Solid Waste and Municipal Hazardous Waste (https://www.tceq.texas.gov/permitting/waste_permits/ihw_permits/IHW_Rules.html).

http://www.epa.gov/air/oaq_caa.html http://www.epa.gov/docs/epacfr40/chapt-I.info/subch-N.htm https://www.epa.gov/eg/metal-finishing-effluent-guidelines https://www.epa.gov/eg/metal-finishing-effluent-guidelines https://www.epa.gov/rcra/resource-conservation-and-recovery-act-rcra-regulations http://www.dcregs.dc.gov/Gateway/TitleHome.aspx?TitleNumber=20 http://www.dcregs.dc.gov/Gateway/TitleHome.aspx?TitleNumber=20 http://www.dcregs.dc.gov/Gateway/TitleHome.aspx?TitleNumber=21 http://www.afdc.energy.gov/pdfs/2527.pdf https://www.federalregister.gov/documents/2001/08/28/01-21567/comprehensive-guideline-for-procurement-of-products-containing-recovered-materials https://www.federalregister.gov/documents/2001/08/28/01-21567/comprehensive-guideline-for-procurement-of-products-containing-recovered-materials https://www.epa.gov/greeningepa/executive-order-13693-planning-federal-sustainability-next-decade https://www.epa.gov/greeningepa/executive-order-13693-planning-federal-sustainability-next-decade https://www.tceq.texas.gov/permitting/air/rules/state https://www.epa.gov/sites/production/files/2015-12/documents/nps-ordinanceuments-fort-worth-sw.pdf https://www.epa.gov/sites/production/files/2015-12/documents/nps-ordinanceuments-fort-worth-sw.pdf https://www.tceq.texas.gov/permitting/waste_permits/ihw_permits/IHW_Rules.html

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(2) Air Pollution Control The DCF is in a non-attainment area for Volatile Organic Compounds and 2.5 Particulate Matter (PM 2.5). Any equipment to be installed in either the DCF or the WCF must meet Lowest Achievable Emissions Rate (LAER) standards in accordance with EPA and District of Columbia regulations. Maximum Achievable Control Technology (MACT) standards may also be applicable to control the emissions of any Hazardous Air Pollutants that result due to the installation of new equipment or change in the method of operations of existing equipment.

The Contractor shall identify potential source locations of air pollutant emissions from the equipment. Equipment must be designed so that pollutants can be captured and ventilated to air pollution control devices. If emission capture and control are required, the Contractor may be required to propose and provide a design and equipment for capture and control of the pollutant in question

(a) Third Party Performance Test A compliance test which demonstrates that the equipment and/or air pollution control device (APCD) meets the applicable EPA or DC performance requirements may be required. If required, the compliance test must be performed according to a test plan that uses approved EPA methods and be submitted to the Office of Environment, Health and Safety (OEHS) for approval prior to the test

(b) Construction Permits The DC Air Quality Division is required to review all equipment that may reasonably be expected to emit air pollutants prior to installation. The contractor must provide sufficient information to the Bureau so that the OEHS can prepare an application to install the equipment and APCD. This requirement applies to equipment to be installed at the WCF as well.

Equipment and the associated control devices may not be installed until the District of Columbia issues a Construction Permit to do so. Note that it takes a minimum of 6 months from the time of submission of the permit application to receive a permit to construct.

(c) Interlocks and Standby Mode All APCDs will be interlocked with the operating equipment to prevent operation without emission capture. The Contractor is responsible for coordinating with Bureau representatives, including OEHS to establish the parameters that warrant a shutdown of equipment. Standby Modes shall be established for periods when equipment is not operating. The Contractor shall document the parameters established and include this information in the operation and maintenance manuals.

(3) Energy, Water and Materials Usage Programs The Contractor shall make every effort to provide the most energy and water efficient equipment to the Bureau. The contractor shall furnish all information to document the energy and water usages for the system including all calculations. The Contractor shall comply with:

P.L. 102-486, Energy Policy Act of 1992, October 24, 1992 (http://www.afdc.energy.gov/pdfs/2527.pdf);

http://www.afdc.energy.gov/pdfs/2527.pdf

S N I P a c k a g i n g S O W P a g e 15 | of 40

Executive Order 13693 - Planning for Federal Sustainability in the Next Decade,” March 19, 2015 (https://www.epa.gov/greeningepa/executive-order-13693-planning-federal-sustainability-next-decade);

40 CFR Part 247, Comprehensive Guideline for Procurement of Products Containing Recovered Materials, May 1, 1996 (https://www.federalregister.gov/documents/2001/08/28/01-21567/comprehensive-guideline-for-procurement-of-products-containing-recovered-materials).

(4) Fluorescent Bulbs All lamping shall be suitable for low mercury in addition to having low energy consumption.

E. CONTROL STATIONS

Control stations shall be provided at all strategic locations to maximize safe and efficient operation. All controls shall be clearly and permanently marked in English. Each control station shall include emergency stop, stop-and-lock, and inch buttons.

An audible warning device shall sound for at least three (3) seconds prior to the operation of the machine in both “inch” and “run” modes.

F. CENTRAL OPERATION STATION (COS)

The contractor shall provide a free standing Central Operation Station (COS) to the government.

The station design shall be approved by the government before the contractor provides the station. The COS shall be equipped with a computerized graphical operational interface, which will display all machine status and operational information, and allow adjustment of all parameters and settings for the machine operation. The interface shall utilize windows and drop-down menus. Additional displays shall be strategically located to facilitate operation of the equipment and to minimize the time required for operators to determine the cause of a stoppage and take corrective actions.

When not in use with one of the subsystems, the COS shall display the: Total number of sheets processed during the shift, Total number of sheets remaining to be processed within a batch (decreasing), Total number of sheets processed within a batch “Process”, Time, Date, Process number being processed, Denomination being processed, and any active error or fault codes.

The COS shall include a bar code reader(s) and standard computer 101 key keyboard to input data. The bar code reader shall read BEP operator and maintenance personnel badges, order number, job suffix load number, and seal numbers. Up to four (4) operating personnel and two

(2) maintenance personnel shall be able to be logged onto the machine simultaneously.

The bar code readers shall be capable of reading a character string of up to fifteen (15) digits printed in a medium density “3 of 9” code (10 characters/inch). This may include ID card sets, which will have a “3 of 9” bar code heat encapsulated in a polyester pouch or between PVC sheets. Card thickness will be between 0.030 and 0.035 inch (0.75 - 0.90 mm).

Access to the system, all set points, settings, and data shall be performed through the interface.

Levels of password protection shall provide protection to critical information and settings, and for different job classifications and work to be performed. The operators shall have the ability to save the configuration settings and set points, by file name. The system shall enable the operators to recall previously saved settings to minimize the time to set up the system to process https://www.epa.gov/greeningepa/executive-order-13693-planning-federal-sustainability-next-decade https://www.epa.gov/greeningepa/executive-order-13693-planning-federal-sustainability-next-decade https://www.federalregister.gov/documents/2001/08/28/01-21567/comprehensive-guideline-for-procurement-of-products-containing-recovered-materials https://www.federalregister.gov/documents/2001/08/28/01-21567/comprehensive-guideline-for-procurement-of-products-containing-recovered-materials

S N I P a c k a g i n g S O W P a g e 16 | of 40 similar work.

Controls for the palletizer are desired to be connected into the COS but may be separate. If separate, the palletizer control system shall provide detailed descriptions for corrective actions and meet the other requirements for control stations. If separate, the COS shall display the status (idle, busy or error) and error code information of the palletizer.

G. DATA COLLECTION SYSTEM (DCS)

The equipment shall have an automated Data Collection System (DCS) with the following subsystems. All DCS database records shall be captured at the date and time of any changes within a given record.

(1) ACCOUNTABILITY SUBSYSTEM

The DCS shall include a subsystem to record and track all products passing through the equipment. Electronic files of all counters, exchanges and all other accountability data shall be recorded.

(2) ERROR CODE SUBSYSTEM

The DCS shall include a subsystem, which will be capable of storing error codes, machine status conditions and associated data. It is required that fault analysis be extended to all components that are monitored by the machine controller.

The system shall include the time and date of each error occurrence.

(3) OPERATOR'S DAILY LOG SUBSYSTEM

The DCS shall include a subsystem that allows for the entry of operational information by the operators. The equipment shall have provisions for manual entry of data for purposes of allocation of labor to various downtime conditions. The BEP currently maintains a log of downtime labor by manually recording the date, time, duration, and description for each occurrence. To facilitate record keeping, numerical codes have been assigned for the more frequent conditions. One approach is to establish "look up tables", in which the more frequent downtime conditions could be entered into on screen menus. Operating personnel could then quickly log the occurrence without entering a written description. The precise format will be determined during the course of the design review meetings.

Shift Log visibility from Managers desks will require equipment data to be replicated to an existing replication database in the BEP infrastructure. The contractor will need to configure the replication.

(4) MACHINERY DATA LOGGING SUBSYSTEM

The DCS shall include a performance monitoring subsystem which will provide a display of current values and conditions and the ability to electronically record those values according to a variable, operator selected scheme. The subsystem shall monitor all specified values and conditions whenever the equipment is running.

The DCS display shall be able to present all electro-mechanical variables, such as sensor inputs that are captured by the logfiles that the controller regulates or monitors. Any operating parameter, which may result in a fault trip or error code condition, shall be included. Each

S N I P a c k a g i n g S O W P a g e 17 | of 40 display value shall be appended with its set point, alarm and trip limits, and its units of measurement. Values displayed shall be current with the control system logic.

Any variable machinery information available on the DCS shall be recordable. Each data element shall be tagged with its units of measurement, year, month, day, shift, and time.

(5) MANAGEMENT INFORMATION SYSTEM (MIS)

The DCS shall include the ability for the BEP to connect to the system to retrieve all data temporarily stored on the DCS. The configuration, layout, and data type shall be specified as where the access points to the data will be located.

The system shall have provisions for authorized BEP personnel to override any or all capabilities/systems. When the override function is exercised by authorized personnel, the badge number, time, date, system number, and all current counters shall be recorded. When reconnection occurs, the system shall record the time, data, machine number, and current counters, and prompt for entry as to why the system was disconnected.

(6) BEP DATABASE INTERFACE SUBSYSTEM (DIS)

The contractor shall configure the BEP provided hardware and software infrastructure necessary for interconnecting the equipment’s control system to the BEP's database. The BEP will use a database as the primary information storage layer between machine control system and other BEP information systems. The database will also serve specialized and localized information processing needs, such as maintenance management and historical process data retrieval.

The DIS will perform the actual exchange of digital information between the machine control system and the BEP's database. The information exchanged will take many forms, including temperature, distance, time, load size, etc.. This specification identifies the control system data that will serve as the BEP’s default configuration.

DIS should deliver “Bi-Directional Ready” data with the existing equipment event telegraphs and infrastructure. The BEP anticipates additional event telegraphs over the life cycle of the system.

The contractor is required to provide the DIS so that the control system can be designed to accommodate information exchange with a database, and so that contractor engineers, most familiar with the specific control system used on the equipment, can provide the best communications devices between the control system and the DIS computer.

To meet the BEP's changing information demands, the contractor shall design a fully open system using commercial-off-the-shelf (COTS) U.S. software products, which maximize BEP configuration. The DIS shall be designed such that a programmer familiar with common programming languages and with the machine control system will be able to make operationally needed configuration changes without the assistance of the contractor; for example, add storage capacity to the database.

The DIS and the control system shall be designed with reasonably sufficient expansion capability to meet the BEP's communication needs over the life of the equipment.

The contractor must provide and support a bi-directional flow solution which…