C04a_Attachment 1_Specifications_1232SA26Q0539.pdf

Project Modernization of hot spot monitoring system for concrete grain elevator at USDA-ARS-CGAHR Manhattan, KS General Information

1.0 Scope of Work

The scope of this project involves modernizing our current grain monitoring infrastructure by replacing an obsolete, unsupported software platform with the Rolfes@Boone BTX PLC controller. This upgrade will restore critical communication with our existing Rolfes sensor network, ensuring reliable data recovery and real-time hazard monitoring that our current system can no longer provide. The contractor will check existing sensors installed on elevator legs, belts, fans, conveyers, and other elevator equipment and replace broken or obsolete sensors and install modernized software required for safe operation of grain elevator. This upgrade will ensure the hardware remains relevant for the next 10–15 years of facility operation.

2.0 Background

The USDA, ARS, CGAHR elevator facility requires a functioning hazardous monitoring system that protects workers by monitoring rub, bearing temperature, and motor speed and that shuts off electrical equipment to keep it from causing enough heat to become an ignition source that ignites the dust. Hazard monitoring systems are designed to enhance grain elevator safety by providing real-time feedback from a network of sensors installed on a range of machinery such as belt conveyors, bucket elevators, drag conveyors, fans, blowers, and more.

Agriculture facilities that store or handle grain, such as grain elevators, are required to monitor grain hazards by OSHA 1910.272. Currently, the elevator facility does not have a functioning and reliable hazardous monitoring system. The current monitoring system requires parts that are no longer available and several of the sensors are no longer communicating with the computer. An updated system is essential for preventing dust explosions. A system that is compatible with the current Rolfes@Boone system is required in order to utilize the existing infrastructure of cables and sensors and ensure seamless hardware compatibility.

Contractor Requirements

3.0 Technical Requirements / Tasks

The BTX Smart Monitor system by Rolfes is a versatile, scalable, and reliable commercial platform for monitoring hazards in grain elevators that is compatible with our existing infrastructure. Featuring an intuitive touch screen graphic display backed by robust PLC technology and functionality, the BTX Smart Monitor will allow to monitor equipment hazards in real-time to prevent dust explosions and maintain safe equipment operation.

The contractor shall provide a turnkey hazard monitoring and temperature control solution to include:

• All parts and labor to install BTX hazard monitoring app hardware and web portal apps at the grain elevator facility at USDA-ARS Center for Grain and Animal Health Research in Manhattan, KS.

• Monitoring software/system that accepts up to eight (8) type T sensors and one (1) MSD-200

• Updating the current Scan Center hazard monitoring system with a Rolfes@Boone BTX system.

• Testing bearing sensors and cables at Leg #1, Leg #2, Top Fan, Receiving Belt, Pilot Belt, Thirty Inch

Belt, North Fan, and South Fan to ensure they are functional and replace if needed.

• Ensuring that the system will monitor all bearing temperatures, motion (side to side motion of each leg) and speed (RPM) of each leg.

• Ensuring that each of the bearing temperature sensors and speed sensors will be displayed on Elevator office computer and constantly scanned.

• Installing a smart monitor has a built-in alarm that will warn and alarm with a rate of rise alarm and a hot alarm.

• Ensuring that the smart monitor will sound an alarm if a slowdown occurs and can be wired to shut down equipment if low-speed limits exceed.

• Ensuring that the smart monitor has a touch screen HMI for easy reading and monitoring.

• Ensure that monitoring software allows customization for facility equipment, with all equipment having individual screens, which show and depict each sensor in real time reading.

• Ensuring that the BTX hazard monitoring system can communicate mobile devices.

• Working directly with facility IT department to install all hardware and software to relay the temperature information to connected devices.

• Installation of the BTX Mobile App and web portal for 24/7 remote monitoring and real-time SMS/email alerts. Setting up initial administrator accounts.

• Onsite training for operator on how to grant and manage other employees’ access to secure mobile applications and how to operate system.

• Ensuring that users will be able to view current and historical data and receive critical alerts from the system.

• Ensuring that the app can have one “manager user” and at least four other sub-users.

• Configuration of wired or wireless communication protocols to link remote bins to the central BTX Hub.

• Verifying BTX Sensor

• BTX Sensor Verification Labor

• BTX-4PR WIRE: Wire is 4 duplex wires used to extend the sensor wire to reach the BRM board mounted at the opposite end of equipment.

• BTX-CTRL-WIRE: Wire is the RS485 communication wire used to communicate with the BRM board:

• BTX-INSTR HMI: BTX instrument with a HMI touch screen

• Miscellaneous mounting / hardware

• Delivery and Install of equipment at the Elevator Facility

1515 College Ave, Manhattan, KS 66502

4.0 Government Furnished

None.

5.0 Deliverables / Schedule

• Shipping costs must be included in the final quote price.

• All manufacturers, parts and accessories for the supplied model must be included.

• All manufacturers’ documentation (printed and electronic) must be supplied with this equipment, including testing and certification documents.

• Work must be completed within 90 days of quote award.

• Scalable PLC Architecture, including a system capable of expanding to future bins without replacing the main controller.

• Intuitive HMI, including a touchscreen interface showing a graphical layout of the facility for instant status checks.

• Historical Logging Time, to include stamped event logs and alarm history for insurance compliance and audit trails.

• Remote Access Full system to include visibility via the BTX Web Portal and Mobile App.

• Diagnostic Health Check Automatic to include notifications if a sensor or cable loses communication.

Item No.

Deliverable / Item Title

Description Frequency Reference Delivery Format

Due By

1 Site Audit & Configuration

Inspect existing system

Once Email or verbal communication with POC

3 weeks after award

2 Hardware and installation

Replace sensors/cables and install monitoring system

Once 6 weeks after award

3 System calibration

Ensure all sensor points are reporting

Once Onsite demonstration

8 weeks after award and network integration accurately to the BTX HMI, that mobile alerts are successfully triggered during a simulated test, and that the system has the ability to pull historical temperature reports for insurance purposes.

4 Staff Training & Final Handover

Ensure staff can use system independently and perform final checks to ensure system functionality

Onsite demonstration

10 weeks after award

6.0 Travel

Work must be done onsite at USDA-ARS Center for Grain and Animal Health Research 1515 College Avenue Manhattan, KS 66502

7.0 Contractor’s Key Personnel

Contractors must be able to install, test, and certify equipment that meets OSHA 1910.272 requirements.

8.0 Security Requirements

Must present state issued identification to obtain visitor’s badge to work onsite. Must check in at front desk and work must be performed during regular business hours 8:00 am to 4:30 pm M-F. Contractors must be U.S.

Citizens.

9.0 Data Rights

N/A

10.0 Section 508 – Electronic and Information Technology Standards N/A

11.0 Maximum Workweek

The following applies to all work performed on Government-owned property:

(a) Listed below are official Government holidays:

New Year’s Day January 1*

Martin L. King Birthday Third Monday in January

President's Day Third Monday in February

Memorial Day Last Monday in May

Juneteenth June 19*

Independence Day July 4*

Labor Day First Monday in September

Columbus Day Second Monday in October

Veterans Day November 11*

Thanksgiving Day Fourth Thursday in November

Christmas Day December 25*

Inauguration Day January 20* (for Washington D.C. Metropolitan Area (WDCMA))

If a Sunday, the next succeeding day is selected.

*In accordance with Federal regulations, if these holidays fall on a Saturday, the holiday will be observed on Friday, if Sunday, holiday will be observed on Monday.