C04_Attachment 1 SOW.doc

STATEMENT OF WORK

Automation Conveyance System Corpus Christi Cotton Classification Laboratory Corpus Christi, Texas Issued By: Jarvis G. Franklin, Engineer Agency: Agricultural Marketing Service Program: Cotton and Tobacco Program

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 in the cups of the containers being transported across the conveyor. It is crucial that this section of conveyor be sealed as well as possible to minimize air loss.

PURPOSE:

This Statement of Work establishes the requirements for the design, fabrication, delivery, installation, integration, testing, commissioning, and maintenance of two fully automated cotton sample conveyance systems at the USDA Cotton Classification Office located in Corpus Christi, Texas. The Contractor shall provide a complete turnkey system that is fully operational and compliant with all requirements set forth herein.

Turnkey, as used in this SOW, means the Contractor shall provide all labor, supervision, materials, equipment, engineering design, programming, integration, utilities, commissioning services, documentation, training, and warranty support necessary to deliver a complete and fully functional system without additional cost for any component reasonably inferred to achieve operational performance.

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 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).

SCOPE:

USDA, AMS, Cotton and Tobacco Program requests bids for the removal of the existing conveyance systems in Corpus Christi, TX and the installation of new conveyance systems which are specified below in the Corpus Christi, TX cotton classification office located at the following address:

USDA, AMS, Cotton &Tobacco Program

3545 Twin River Blvd.

Corpus Christi, TX

78410 The work shall include all electrical power distribution, communication cabling, pneumatic systems, controls, structural supports, containers, RFID components, and associated equipment necessary to provide a complete and operational installation.

The Contractor shall be fully responsible for engineering design, fabrication, programming, system integration, database development, and integration with USDA computing systems, including HP Non-Stop computer systems and Ethernet-connected High-Volume Instruments. All programming, middleware, and interface development necessary to ensure seamless communication between conveyor controls and USDA systems shall be included in the Contractor’s responsibility.

The system shall be fully installed, integrated, and commissioned no later than March 31, 2027. The Contractor shall provide monthly written progress reports beginning 1 month from award, including percentage of material acquisition, fabrication status, and schedule updates. The Contractor shall confirm in writing no later than Aug 1, 2026, that all required materials and long-lead components have been procured.

Overall Proposed Process Described

· Sacks filled with approximately forty (40) cotton samples (each sample weighing one-half pound) will be received in the Corpus Christi, TX receiving room via a USDA-contracted hauler.

· Cotton sacks are delivered into the receiving room via mobilized flexible conveyors or carts.

· A person will empty each cotton sack onto one of two (2) conveyors that shall transport the loose cotton samples to two fill workstations on each conveyance system.

· A person will fill containers with loose cotton samples, then scan the sample ID with a Radio Frequency Identification Reader (RFID) which will write that information to a chip that is on the container. The sample will then be transferred to one of four loader workstations.

· Bale Range Check-controls system to send bale ID numbers from RFID tag to USDA software. Wait for USDA software to respond with a with a "go/no-go" response for each sample. Display the results of the response on the user interface. If it a “no-go” the incline conveyor should stop until the bale range is corrected in the non-stop. There shall be a Bale Range Check bypass label at the HMI in case the functionality of this service faults.

· Ethernet Upgrade-Upgrade all Uster testing instrumentation interfaces communicating with the PLC from serial to ethernet.

· A person will prepare two cotton samples that will weigh approximately 8-15 grams, sub-samples obtained from the primary cotton sample. Each sub-sample will be placed on a scale for mass determination prior to its placement into a plastic container. The RFID data shall be transmitted via ethernet to the HVI connected at the loader workstation.

· The container is then transferred to the supply conveyor that delivers the containers filled with cotton to one of six HVI length/strength workstations for further testing. The cotton sub-samples will be transferred into HVI via the ventures. The RFID data shall be transmitted to the HVI via the ethernet connection. The container is then released from the HVI after processing.

· The return conveyor shall transport the containers from one of the six HVI length/strength workstations to one of the three Classer workstations.

· Once the cotton in the container at the classer workstation is processed and the cotton has been removed by the classer, the container returns to the empty return conveyor. The empty container is transported back to the fill workstations where the process resumes.

· The conveyance system shall have the ability to route several samples (e.g. 30 cassettes) with given PBIs (e.g. 709980000001) distributed equally in number to each HVI workstation (e.g. Load station(s), each HVI workstation on that conveyor receives equal amounts of cassettes to each workstation. The priority is that each individual HVI receives the first designation of samples and then the next HVI receives the next designated number of samples until all workstations have received the equally designated number of samples.

· Zebra Printers-Supply and install printers in the classer workstation area to print missing bale ID tags through the thin client interface. One (1) printer (plus 1 spare) will be provided per conveyor leg. Each conveyor leg is comprised of 3 classer workstations. Load the printer with the bale ID obtained from the RFID scan.

· The conveyance system shall also be capable of lane changing defined as the capability of transferring containers across to the adjacent spine of the adjacent conveyance system. The system shall transfer containers from one system to the other side if the containers have backed up to a designated position on the system. The system shall have this capability between each of the major workstations identified as the fill, loader, HVI and classer. If any one of the areas become backed up to the designated location, the system will divert containers across to the adjacent system where the containers can be processed.

SPECIFICATIONS / REQUIREMENTS

Containers

1. The containers will be supplied by the contractor, but with USDA guidance for design.

a. 18 x 11 x 5 (inches) overall outside dimensions (with exception to top around 4-inches holes)

b. Two (2) adjacent, 4-inches diameter openings

c. These openings must be completely sealed where no air is allowed except through the holes in the bottom.

d. Each 4-inches opening must contain approximately Thirty-seven (37) in total, 3/8-inch holes

e. Each of these holes must not have a sharp edge as cotton will tag on it. The top and bottom of the holes must be beveled or rounded smooth.

f. Material must be 1/4-inch ABS plastic.

g. All inside corners must be reinforced with triangular blocks or similar. 18 on the long side must NOT be glued but bent to increase strength along each of those sides.

h. The containers must be capable of enduring considerable pushing motion from the side and ends 24 hours per day, seven days a week.

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 where specified shall be strictly adhered to in the design and installation of the system.

Horizontal Fill Station Belt CONVEYOR (1 per conveyor system)

1. A conveyor should be installed to provide cotton samples from a sack into the loading area.

2. It shall be approximately 144 inches in total length, 30 inches in width and shall be height adjustable utilizing manual cylinders from 24 to 34 inches from top of conveyor to the floor.

3. It shall contain 8-inch side rails around the entire perimeter except for where samples are being removed at the end.

4. It shall be a low-profile conveyor with sensors to stop it when samples reach the end of the conveyor at the top.

5. This conveyor shall be on locking casters and portable.

fill workstation conveyors (1 per conveyor system)

1. The empty containers shall be distributed from the main return conveyor that originates at the three classer workstations and end up at only one sample FILL workstation.

2. The conveyor shall be a zone accumulation conveyor. The conveyor shall be capable of stopping the containers within each zone with zero points of contact with an adjacent container.

3. There shall be two filling zones. One zone shall be on a timer which can be adjustable through the HMI interface. The other zone shall be controlled by an RFID writer where the container moves once the bale identification card is scanned.

4. The conveyor system shall be capable of distributing containers at a rate of (30) per minute to the supply trunk that is transporting filled containers to the four (4) load workstations.

5. The end transfers next to the sample fill zones must be covered so cotton won’t drop into the transfers.

6. Prior to the first loader workstation, the trunk conveyor shall be equipped with a mechanism to transfer the containers to any Load workstation conveyor from the adjacent conveyor system.

7. This part of the trunk conveyor shall be capable of transferring containers from one conveyor system to the other to maintain a balance of containers referring to item #6 of “Fill workstation conveyors”.

8. The software code controlling the transfer of the container once a successful RFID scan is completed shall activate the following 4 zones to transfer the container away from the fill workstation. If the RFID scan is not performed successfully, the following 4 zones will not be active so an individual will not be able to push the container past the load zone. A 10-inch display shall be installed in the workstation, so the operator is aware of the status of the container. The following are potential errors that could occur such as bale out of range, improper scan, bad RFID tag, bad RFID read/write head, etc.

load workstation conveyors (4 per conveyor system)

1. Hardware shall be provided for the mounting of two loading areas for the two cotton sub-samples. Both loading areas shall be equipped with an electronic scale/transducer that can measure within 0 to 20 grams with resolution to within one-tenth of a gram. It should be capable of communicating with a PLC device. Cotton weight scale holder will need to be designed with the guidance of the USDA.

2. PLC programming of the controller shall be as follows.

· The container is detected in the LOAD position.

· The current barcode identification number is read from the container in the LOAD position, and the identification number is provided to the HVI color/trash (C/T) workstation for sample identification prior to testing.

· The loader places cotton into the two loading areas. A scale/transducer is utilized to measure the amount of cotton in each loading area. Each of the two loading areas will act independently in the following manner. If the scale contains a weight less than the adjustable lower gram parameter setting, usually 8-9 grams, a yellow light is illuminated to indicate low weight. If the scale contains a weight higher than the adjustable upper gram parameter setting, usually 14-15 grams, a red light is illuminated to indicate a high weight. If both scales contain a weight between adjustable low/upper parameter settings, a green light is illuminated for each loading area, and a push button start switch is then active and illuminated.

· The lower and upper weight parameters shall be adjustable on the Human Machine Interface (HMI) screen. The parameters require password protection to limit access to these adjustments.

· The loader places the primary sample back in the container after color and trash testing.

· The button is then pushed by an operator, and the container leaves the LOAD position.

· The next container enters the LOAD position and the process repeats.

· The scales shall have automatic taring after every sample.

supply conveyors (Horizontal/incline)

1. The supply conveyors shall consist of a combination of two horizontal and one incline conveyor. As containers meet the inclination, there must be a smooth transition ensuring no hang up of containers. The inline conveyor must have less than a twenty-five (25) degree angle and be capable of transporting the containers with no slipping.

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

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 conveyor system shall be capable of distributing three (3) containers per minute to each HVI workstation and a total of twenty (30) containers per minute for the system. Software programming should be such that no HVI machine is starved of cotton when containers are leaving the loader workstations at the rate of 30 containers per minute and each HVI workstation is taking containers at a rate of 3 containers per minute.

5. An RFID read/write head shall be located at each “LOAD” and “HVI” workstation transfer or just prior to those workstations to control the distribution of certain containers with a unique PBI number. Programming should be such that containers may be directed to those workstations based on information coming back from the USDA HP non-stop computer system.

6. The supply conveyor shall be equipped with a mechanism to transfer the containers from the supply conveyor to the HVI workstation conveyors with no hanging up of containers.

7. The supply conveyor shall be equipped with a mechanism to transfer the containers to any HVI workstation conveyor from the adjoining conveyor systems.

8. The supply conveyor shall be capable of transferring containers from one conveyor system to the other to maintain a balance of containers referring to item #7 of “Supply conveyors”.

rcu conveyors (incorporated in the hvi workstation conveyors)

1. The HVI workstation conveyor shall incorporate an area for the conditioning of cotton known as the RCU. This 55” long area by width of conveyor shall enclose this section of conveyor on the ends and bottom allowing minimal air loss. Five containers must be in direct contact with the adjacent container in this area and be sealed along the guard rails with some type of durable seal to minimize the air leakage around the containers. The RCU must be constructed of 18-gauge steel minimum and match the color of the conveyor. There must be two intakes located on the bottom spaced equally from each other or approximately 18 inches from each other with two centered under the cups of the container and the other two spaced 18 inches on each side of the RCU. Four caps must also be included as only two of the intakes will be used depending on the layout scenario.

a. The rapid conditioning units shall have end seals containing 1/16-inch neoprene rubber.

b. The units shall also be modified with side seals of 1/16 inch neoprene rubber.

c. The railing shall be approximately 2 inches tall and the void area between the rail and the conveyor frame shall be filled with rubber seal material that is attached to the conveyor frame.

d. Connect two intakes with five (5) inch diameter hose to USDA piping. Each intake must have at least a 2-inch lip for hose attachment.

e. The plenum shall begin at the start of the second zone from the trunk.

f. The software code shall not advance the containers in the RCU zones (2-6) until the first zone is occupied by a container while operating in Automatic mode. The only exception would be if the workstation were in Manual mode, all zones would clear the workstation upon processing through the HVI.

g. A single pressure differential sensor located in one of the plenums for the detection of air flow in the RCU. If there is no air flow, the system should shut down. There should also be a RCU airflow senor bypass label placed on both HMI, in case the senor faults.

h. An error indication shall be displayed on the HMI to alert employees of the lack of air flow.

2. The samples will be conditioned for a minimum of two (2) minutes as they travel across the Rapid Conditioning Unit. The conditioning clock does not start until all containers are occupying the RCU zones of 2-6.

hvi (L/S) workstation conveyors (6 per conveyor system)

1. 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 (cups) of the container. The container shall be held in position for processing until the delivery of the subsamples to HVI.

2. An HVI workstation shall contain a queue of containers that accumulate containers up to the actual HVI area which is denoted by “HVI” next to container in the drawing. Conveyance in the area denoted by “HVI” shall be such that a switch can be set to three settings for operation (off/manual/automatic).

· Manual operation – No containers will be transferred off the main supply trunkline. After the last container on the workstation has been on the RCU for the required 2 minutes, containers are allowed to be processed at the HVI zone. Once the container is processed at the HVI workstation (Both samples in cups have been transferred to the HVI machine and the RFID tag scanned successfully), the HVI machine will send a signal to the conveyance system signaling that the sample has been completed and the HVI operator will activate a push button device signaling the conveyor system that the sample is back in the container. Once those three processes are complete (HVI sample transfer, HVI signal complete, HVI operator process complete), the container can then move to the next zone to be merged onto the return conveyor.

· Automatic operation – Containers are diverted from the trunkline to the HVI workstation. Once the container is processed at the HVI workstation (Both samples in cups have been transferred to the HVI machine and the RFID tag scanned successfully), the HVI machine will send a signal to the conveyance system signaling that the sample has been completed and the employee will push the container approximately two (2) inches where the container shall be taken away and transported on the return conveyor. Once those three processes are complete (HVI sample transfer, HVI signal complete, HVI operator process complete), the container can then move to the next zone to be merged onto the return conveyor. Note, the last container on the RCU must stay in place unless there is a container in the zone prior. The RCU must be always covered.

· Off –This shall allow USDA personnel to disable each workstation, at their discretion, without interrupting the conveyance system.

3. 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 ventures 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 1/4 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. Air flow shall be adjustable to each Line Vac.

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

5. The conveyor system shall lift the container to a loading position for the delivery of the cotton samples from the container to the HVI.

6. The conveyor system shall activate the two ventures when the HVI ready signal is received, and the container is in the proper location.

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

8. Once the sample is delivered and the RFID information is transferred to the HVI via ethernet, the container shall move out of the “HVI” workstation and back to the return conveyors.

9. The processed container shall be merged onto the return conveyor from the HVI conveyor without collisions. Prior to merging, programming should be such that an adjustable time delay can be entered for each HVI workstation on the HMI.

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

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

Return conveyors

1. The return conveyor shall deliver the HVI-processed containers to one (1) of three (3) classer workstations at a rate of thirty (30) containers per minute. Delivery to each classer should be at a rate of ten (10) containers per minute.

2. The return conveyor shall be located directly over the supply conveyor providing a minimum container clearance of five (5) inches from the top of the container to the bottom of the conveyor.

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

4. 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.

5. An RFID read/write head shall be located at each classer workstation transfer or just prior. Programming should be such that containers may be directed to those workstations based on information coming back from the USDA HP non-stop computer system. A sample identified as a RETEST shall be rerouted to the nearest loader workstation. All other samples shall be distributed to the Classer workstation. A sample that has been retested more than 2 times shall be distributed to the classer workstation.

6. The return conveyor shall be equipped with a mechanism to transfer the containers to any classer workstation conveyor from the adjoining conveyor systems.

7. The return conveyor shall be capable of transferring containers from one conveyor system to the other to maintain a balance of containers referring to item #5 of “Return conveyors”.

CLASSER WORKSTATION conveyors (3 workstations per conveyor system)

1. The Classer workstation shall be capable of accumulating containers including the container in process in the classer area.

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

3. An RFID reader shall be located at the top of each decline conveyor supplying processed HVI containers. The RFID reader shall communicate with our HP Non-Stop computer system to determine its classification status.

· If the RFID reader gets a green light, the container moves down the conveyor to the “class” zone on the drawing.

· If the RFID reader gets a red light, the container moves down the conveyor to the nearest load workstation for retesting.

· There will be another RFID reader communicating with our HP Non-Stop computer at the “class” zone which will read the RFID chip and capable to display that information on the classer’s monitor.

4. After the cotton in the container located in the “class” zone has been taken out of the container, the empty container is automatically transported to the empty container conveyor and back to the “fill” workstation.

5. The RFID tag shall contain all zeros when it leaves the Classer workstation.

6. The container in the “class” position shall have a top of conveyor height of thirty-four (34) inches from the floor.

7. Hardware mounts for USDA classing devices (monitor, keyboard, scanner, cotton disposal and card disposal) shall be responsibility of the contractor but with USDA guidance for design.

empty container conveyor

1. The empty container conveyor shall deliver the empty containers to the fill workstation at rate of thirty (30) containers per minute.

2. The empty container conveyor shall be located directly under the supply conveyor providing a minimum container clearance of five (5) inches from the top of the container to the bottom of the conveyor.

3. The conveyor shall span the necessary distance to provide delivery from all Classer workstations to the fill workstation.

4. 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.

5. The empty container conveyor shall be equipped with a mechanism to transfer the containers from the conveyor to any fill workstation conveyor.

6. The empty container conveyor shall be capable of transferring containers from one conveyor system to the other to maintain a balance of containers referring to item #5 of “Empty container conveyors”.

retest return conveyor

1. The retest return conveyor shall be a return conveyor between the last classer workstation and the first loader workstation as shown in drawing.

2. This conveyor will deliver any USDA samples that are “retests” back to the first loader workstation based on RFID information coming from the RFID reader located at each return conveyor classer transfer. The system should monitor the number of attempts and limit the retest loop to a maximum of 2 times. The display shall report the number of bales and their attempts and the capability to reset the bales and their counters.

Loose Cotton Collection from Length Strength Instruments and Classer Station In collaboration with USDA, the Contractor shall design, develop, and implement an automated air-slide gate collection system to capture loose cotton from each Length Strength Instrument (LSI) and Classer workstation. The system shall transport collected cotton to a centralized baler for consolidation and packaging.

a. Install a proximity or optical sensor on side gate(s) to detect cotton ejection from the Automic, located on the right side of the drum. Sensors must accurately detect cotton presence without false triggers. Upon detection of cotton ejection, the sensor shall send a signal to the gate actuator to open the side gate automatically. After cotton passes through the gate successfully, the sensor shall trigger the gate to close automatically. Gate operation must occur within seconds of detection to maintain process flow. Implement fail-safe logic to prevent gate malfunction during operation.

Current HVI Slide Gates Setup

b. Incorporate a disposal alley into the Classer station table design for immediate cotton sample discard. The alley shall connect to the cotton transport system that moves cotton directly to the baler. The disposal alley must be positioned within arm’s length of the Classer to minimize movement and maintain productivity. Placement should comply with ergonomic standards to reduce strain and fatigue. Ensure smooth cotton flows from the alley to the baler without clogging or delays. System must operate automatically once cotton is placed in the alley, requiring no additional manual handling.

Current Classer Table Setup

CONVEYOR SYSTEM GENERAL DESIGN REQUIREMENTS/CONSTRAINTS

1. There is currently 110/230/460V power available in the Corpus Christi Classing Office for this project. It will be the responsibility of the contractor to provide all the necessary power to the conveyor system and controls.

2. The Corpus Christi office also has available compressed air at 120 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 should be rated and equipped for a high lint and dust environment and suitable for an area designated as potentially flammable.

4. Any conveyor belt used 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 and be covered with a urethane cover.

6. The height of the conveyor frame at all workstations at HVI, loader, classer, and fill areas shall be at 34-inch top of conveyor height.

7. Refer to drawing for approximate lengths of conveyors. Widths of conveyors shall be as narrow as possible but wide enough to ensure proper conveyance of containers.

8. All conveyor shells are equipped with a minimum of 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. Note: Guardrail height must be high enough from the top of the frame where rollers can be easily changed out.

a. All points of transition from the spine to the workstations shall use a flare configuration to allow for funneling of the container into the workstation area. The flare shall be a minimum of two inches past the edge of conveyor frame to two inches past the opposite edge of conveyor frame for container entry into the workstation areas. This applies to all workstation entry points to minimize the hanging of container.

9. Conveyor frame and supports

a. All conveyor support shall span any conveyor trenches if there is one shown on the drawing and it be constructed of 80/20 or equivalent structural hardware.

b. All conveyor frames must be powder-coated black.

10. RFID

a. 29 RFID read/write total heads per conveyor system

i. Read/write head to be mounted at “fill” workstation will write PBI (permanent bale identification) to the RFID chip on the container.

ii. Read/write heads at each of the 4 loader workstation supply transfers shall read the PBI number on the container and equally distribute it among the loader stations ensuring that they receive an equal number of containers.

iii. Read/write heads at each of the 4 loader workstations at one position prior to the “LOADER” location shall transmit PBI from RFID chip to the C/T HVI machine via ethernet.

iv. Read/write heads at each of the 6 HVI workstation supply transfers shall read the PBI number on the container and equally distribute it among the 6 HVI workstations ensuring that they receive an equal number of containers.

v. Read/write heads at each of the 6 HVI workstations at “HVI” location shall transmit PBI from RFID chip to the HVI machine via ethernet after the ready signal is received from the HVI machine.

vi. Read/write heads at each of the 3-classer workstation return transfers shall communicate with the USDA non-stop for distribution of containers based on USDA HP non-stop computer information.

vii. Read/write heads at each of the 3 Classer workstations at “CLASSER” location shall transmit PBI from RFID chip to the HP non-stop computer.

b. 1000 RFID tags shall be purchased by contractor which are Turck comparable to the current RFID tags USDA has now and contractor is to mount at specified location on top of each container between the cups.

11. When cotton samples are to be finished for the day, currently sample containers are removed before the filling workstation. Therefore, there needs to be a run mode that allows all cotton to be graded that is in containers without having to take off empty containers. This means that empty containers must be allowed to run through the fill workstation and other workstations.

12. There needs to be a mode for startup as well when the conveyor system is full of empty containers so that containers will move back to the filling workstation without any other personnel needed other than the person filling the containers. Once the full containers of cotton samples reach the loaders, those would stop there ready to be processed.

a. Decoupled mode – The conveyor system automatically releases the container at the “HVI” workstation once the RFID has been successfully scanned and the samples have been delivered to the HVI.

Electrical Controls

General Requirements for system:

1. There shall be a minimum of (1) Start/Stop Label for each of the two systems (Capable of Starting either one or both conveyor systems simultaneously)- Activation shall control all conveyors each conveyor system.

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

3. Each motor with more than 110v power shall have its own disconnect, located adjacent to the motor’s location and shall be equipped with phase protection.

4. The main control panel should include a Start/Stop button.

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

6. The location of the main control panel (HMI) shall be collaborated with USDA. 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.

7. PLC Features

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

b. Only one PLC shall be utilized for each conveyor system.

8. Control Cabinets

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

b. The system shall contain a UPS system to hold power for a maximum of 30 minutes to allow the system to automatically shut down properly in the event of a power failure in the facility.

Main computer system

1. A database program should be installed for tracking purposes.

2. The database shall track the number of containers processed per workstation per unit of time.

a. Processed container must be tracked using a query for PA Id numbers, beginning and ending date, beginning and ending time.

b. A report can be generated with a column for PA Id numbers, number of containers, and time based on the input time and a file generated for download.

3. The database shall track stalled containers and container transfer errors.

a. Errors will be designated with a numeric code for each section (e.g. loader = 100. Classer =200, HVI=300, trunk = 400.

4. The diagnostic program will have the ability in off-line mode (manual mode), of activating all pneumatically driven devices, individually power rollers, and all sensors for troubleshooting purposes.

5. The diagnostics shall have the capability in on-line mode to display the state of the pneumatic devices and sensors.

6. The diagnostic and database program shall run from the main control console, as well as, the tablets supplied for the system, with the possibility of running the programs from other handheld devices. Contractor shall supply 4 tablets for communication with the conveyor systems.

CLASSING TABLES and FILL CONVEYOR & PERIPHERAL MOUNTS (3 tables and associated mounts per conveyor system)

1. Overall dimensions of the classer table are 20 inches (D) x 30 inches (W) x electronic adjustable from 32-44 inches (H). Refer to drawing

2. Overall dimensions of the fill workstation conveyor are 120 inches (L) x 30 inches (W) x electronically adjustable from 24-34 inches (H). Refer to drawing

3. The frame shall be constructed from 80/20 materials.

4. The top shall be of matte finish to reduce reflection.

5. There must be 6-inch sides as shown as powder coated 10-gauge steel.

6. Opening shall be circular at the back of the table. Collaborate with USDA on size.

7. Drop chute shall be included underneath the same as opening in the tabletop.

INSTALLATION / TESTING

This project is to be "turnkey" from start to finish. All utility services to make the conveyor system fully operational shall be provided to include electrical service and mechanical systems including compressed air plumbing and communication cabling required to make the conveyor system and all workstations fully functional. The workstations shall contain 110-volt power for accessories and communication cabling meeting USDA specifications to ensure a fully operational workstation/s shall 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 ensure 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.

· Each conveyor system must be evaluated such that no personnel are needed at any of the workstations except for the fill workstation where cotton is placed in the containers and the barcodes are scanned. Discussion of how this would work would be collaborated with USDA prior to programming. The reading of RFID tags, container movement in and out of workstations, and subsample conveyance at the HVI workstation shall be simulated as though a person is there processing samples based on their maximum processing speeds.

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 meet 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.

REPAIR SERVICE

The Contractor shall maintain the capability to provide repair service and spare parts within twenty-four hours of malfunction notification for the duration of the maintenance period.

MAINTENANCE SERVICES (INCLUDING PRE & POST SEASON REQUIREMENTS)

The contractor shall provide a minimum of 5 years’ maintenance of the system. The maintenance program shall provide an annual inspection and any repairs needed to correct deficiencies. An inventory of spare parts shall be provided at the facility. The inventory shall be coordinated between the contractor and the USDA.

Pre-Season Scope (Controls Tune-Up)

The pre-season scope shall be to inspect, check, and tune the controls and web based elements of the conveyance system for proper maintenance and operation (as originally designed and intended per the as-sold specifications) before start-up of the upcoming cotton classing season. Minor repairs that fit within the time frame of the PM may be corrected while the controls engineer and/or controls technician is conducting the controls PM. After each pre-season PM, contractor should provide a detailed report on what needs repair (not remedy while on site) and the accompanying quote to make such recommended repairs.

Following each pre-season PM visit, contractor shall provide a detailed written report (including photos) identifying any deficiencies or recommended repairs that were not completed during the visit, together with a corresponding quotation for performing such recommended repairs that identifies any passing or failing elements based on the checklist below:

PLC(s)

Scanners

Sensors

Cards

HMI(s) / GUI(s) Pre-Season Controls PM Contractor shall provide at minimum (1) controls engineer and (1) controls technician for three (3) full consecutive working days to inspect, tune, and recalibrate the controls of the cotton classing conveyor system prior to the commencement of each cotton classing season.

Such services shall be performed no later than July of each season during which the agreed-upon Maintenance Contract remains in effect, unless otherwise mutually agreed in writing by the parties.

Post-Season Scope (Electro-Mechanical PM)

The post-season scope shall be to inspect and check the electro-mechanical elements of the conveyance system for proper maintenance at the conclusion of each site's cotton classing season. Minor repairs that fit within the time frame of the PM may be corrected while the field service technicians are on site conducting the electro-mechanical PM.

Upon completion of each post-season PM service, contractor shall provide a detailed written report (including photos) on what needs repair and the accompanying quote to make recommended repairs that identify any passing or failing elements based on the checklist below:

Disconnect - Check condition of switch and conduit. Lock out.

Guards - Check condition.

Motor – Check hold down bolts and conduit.

Variable Speed - Check belt, hold down bolts, and keyway.

Coupling - Check insert, keyways, and set screws for tightness.

Reducer – Check oil level if site glass exists or leaking, hold down bolts and breather.

Chain - Check for cleanliness, lubrication and tension.

Sprockets - Check set screws for tightness, and condition of keyway.

Pulleys/Rollers - Check for trapped foreign material, cracked welds, and shafts for signs of movement. Visually check the drive pulley lagging for condition and signs of wear.

Post-Season Electro-Mechanical PM

Contractor shall provide a minimum of two (2) field service technicians for three (3) full consecutive working days to inspect the conveyance system, perform the annual electro-mechanical preventive maintenance (“PM”) service, and make minor adjustments following the conclusion of the cotton classing season.

Such services shall be performed upon completion of the cotton classing season of the Corpus Christi Classing Office.

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.

PROPOSAL

The proposal should provide a breakdown of the pricing for materials and labor. The proposal shall provide a breakdown of pricing for the maintenance program that will be provided including annual inspection, spare parts and any necessary trip costs for on-site repairs. The proposal shall also provide information that shall be evaluated for the purposes described below. The company experience, history, staffing and a gant chart for expected delivery of the requirements stated above are examples of some of the information necessary for the evaluation of the proposal.

The proposal shall be evaluated upon the following criteria.

Relevant Experience: Offeror shall demonstrate an understanding of the system in place and its capability to perform the requested work.

Past Performance: Offeror shall demonstrate its capabilities through previous jobs its capabilities to fulfill contract requirements successfully and in a timely manner.

Delivery: Offeror shall provide its capabilities to provide the requirements in the statement of work in the required time.

ACCEPTANCE:

The USDA personnel shall have 20 business days to operate and test the conveyor system performance prior to acceptance.

APPLICABLE STATE AND FEDERAL 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.

OSHA 29 CFR 1926.555 (Conveyors) OSHA 29 CFR 1910.147 (Lockout/Tagout) ASME B20.1-2024 (Safety Standard for Conveyors) Points of Contact Jarvis Franklin (Macon, GA):

Phone:

478-258-7962

Geremy Moore (Memphis, TN):

Phone:

901-384-3030

Mike Harris (Memphis, Tn):

Phone:

901-384-3030