C04_Attachment 2_SOW_1232SA27Q0004.pdf

USDA ARS Cotton Ginning Research Unit

Statement of Work

Micro Gin Controls with Programmable Logic Controllers (PLC) and Human Machine Interface (HMI)

General Information (A):

A1: The USDA ARS Cotton Ginning Research Unit in Stoneville, MS is requesting turn-key submissions for design, supply, and installation of one Gin Control Console equipped with PLC and HMI to replace existing hardwired devices and controls. Commissioning will be the joint responsibility of contractor and

USDA personnel.

A2: Existing service is provided by three on site transformers providing 480 volts via a delta configuration with a corner grounded “B” phase. The current service configuration will not change.

Special consideration need be applied to application of variable frequency drives with the grounded “B” phase.

A3: Supply must include all devices and controls, wiring, connectors, and any additional conduit/cable tray to convert existing 480-volt starters to 24-volt DC or 120-volt AC coils. All wiring and hardware must meet applicable local and national codes. Contractor must utilize existing 600-amp service panel on wall at East end of building 26.

A4: Due to the complexity and age of the existing configuration, it is strongly recommended that a contractor’s representative make at the minimum one site visit prior to bidding for the contract.

A5: Contractor must provide all equipment and supplies necessary for installation. USDA personnel will provide assistance as needed in receiving shipments and providing access to forklifts and personnel lifts for installation.

A6: All components must be designed, manufactured and tested in accordance with the latest applicable standards of NEMA, ANSI and UL 845.

A7: The manufacturer of this equipment must have produced similar electrical equipment for a minimum period of five (5) years. When requested, an acceptable list of installations with similar equipment must be provided, demonstrating compliance with this requirement.

A8: Equipment must be handled and stored in accordance with manufacturer’s instructions. One (1) copy of the instructions must be included with the equipment at time of shipment.

A9: Equipment operation and maintenance manuals must be provided with each assembly shipped and must include instruction leaflets, instruction bulletins and renewal parts lists where applicable, for the complete assembly and each major component.

Specifications (B):

B1 - Voltages: 480 volt, 60HZ 3 phase. Control voltage transformer to provide 24V DC. 120- and 240-volt single phase provided by existing 45 kVa transformer.

B2 - Total connected horsepower: 332.75. Design for 400 total connected horsepower. See section 2 of the Appendix for full motor and motor control method tables.

B3 - Wiring: Nema Class I, Type A. Existing wiring to be utilized to what extent is practical.

B4a Starters: Existing wall-mounted fused disconnects must remain in-place as located and wired. The new starters must be 600-volt class suitable for operation on a three-phase 60 HZ Delta system with a corner grounded B phase. System operating voltage is 480 volt, 60HZ 3 phase. Control voltage 24V DC or

120V AC.

B4b - Type: The starters must be non-reversing NEMA 1 type with electronic overload relays, one each

NO and NC contacts, all mounted in NEMA 1 enclosure with front panel mounted reset button.

B4c - Motor Controllers: Combination starter units must be full-voltage, non-reversing and must utilize

High-magnetic Motor Circuit Protection (HMCP) devices for short circuit protection.

Magnetic starters through size 3 must be equipped with a minimum of one (1) normally open auxiliary contact and one (1) normally closed auxiliary contact. Coils must be of molded construction. All coils to be color coded, marked with voltage, frequency and part number.

Overload relays must be of the solid-state type, equivalent to Eaton C440.

Variable frequency drives (VFD) must be provided as per attached schedule. VFD must be same as or equivalent to Schneider Altivar ATV320, Eaton Power XL DX1, Mitsubishi FR-A800 or Automation Direct

BRX series. Drives must have communication cards such as ModbusTCP.

PLC (C):

C1: Examples of acceptable PLCs are Schneider M340, Allen Bradley COMPACTLOGIX 5380, Siemens

SIMATIC S7-1500, Omron NX1P2, or Automation Direct BRX.

C2: Requires robust input/output capacity, high-speed processing and secure communication protocols.

C3: I/O capacity must support both digital (discrete) signals such as motors, air valves and on/off switches, and analog signals for continuous measurement as in temperature, pressure and flow rates, via

4-20mA and RTD sensors. See section 2 of Appendix.

C4: Built-in mathematical processing and loop control such as proportional-integral-derivative (PID), feedforward control and alarming functions.

C5: Must support standard industrial Ethernet protocols such as EtherNet/IP (or Profinet in the case of the Siemens SIMATIC S7-1500 unit) or ModbusTCP.

C6: Must integrate smoothly with HMIs, SCADA software and smart field instruments (transmitters, actuators & valves, data loggers, etc.)

C8: Ability to make online program edits without interrupting facility operation.

C9: High-speed CPU(s) and adequate memory to handle complex batch sequencing, data logging and rapid response times.

C10: Must be able to withstand harsh facility conditions (air-borne fiber and dust), wide operating temperatures, humidity and electrical noise or interference.

C11: See section 3 of Appendix for additional comments and specifications.

HMI (D):

D1: HMI(s) must provide real-time visualization (process graphics, instantaneous analog updates and clear trend charts for tracking variables over time) employing a graphical machinery layout of the process flow.

D2: Priority-based alarms with visual alerts for abnormal states, and historical alarm logs with time stamps.

D3: Password protected security and access control.

D4: Clear visual emergency stop and interlock status display, sequential motor start/stop stations with visual run indication, and setpoint adjustments with confirmation prompt.

D5: Storage for production batches, run times and cycle counts with recipe management for loading production parameters and export capabilities for compliance and quality control. Ability to edit sequencing from HMI without needing to connect an external computer or use of additional software.

D6: NEMA 4X industrial grade for dust and moisture, reliable communication protocols such as

EtherNet/IP, Profinet, or ModbusTCP to link with PLC.

D7: HMI(s) must be of the size and resolution to clearly display fifty (50) motor start/stop stations on one screen. For example, 25” panel at minimum Full HD 1920x1080 resolution.

D8: Motor interlocks configurable from the HMI without needing to connect an external computer or use of additional software.

D9: See section 4 of Appendix for additional comments and specifications.

Installation (F): Contractor must provide the services of a qualified representative to perform installation of the equipment specified under this section.

Contractor must follow the installation instructions supplied by the manufacturer.

Control wiring must be as shown on the contract drawings except as modified by the approval and submittal process. Interface all local and remote devices into the control wiring and operational systems for each load.

Training (G): The Contractor must provide a training session for up to five (5) owner’s representatives for 2 normal workdays at the job site or other office location chosen by the owner.

A manufacturer’s qualified representative must conduct the training session.

Period of Performance (H): The period of performance will be four months from the date of award.