APP A - INBOUND BAGGAGE CONVEYOR.docx

TECHNICAL PROPOSAL QUESTIONNAIRE

FOR

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APPENDIX A

FOR

INBOUND BAGGAGE CONVEYOR

AT

JOINT BASE MCGUIRE/DIX/LAKEHURST, NEW JERSEY

BUILDING 1706

CSN: BMC3F8

DATE: 19 November 2019

PREPARED BY:

James Rowland

JAMES ROWLAND

AFLCMC/EZPAE

WRIGHT-PATTERSON AFB OH

REVIEWED BY:

Ronald D. Parsons

RONALD D. PARSONS

AFLCMC/EZPAE

WRIGHT-PATTERSON AFB OH

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Kadena Baggage Conveyor - Page 9 of 10 Table of Contents

JBMDL - Appendix A - Page ii

SCOPE

General Scope This appendix establishes the minimum performance, design, fabrication, installation, orientation, and test requirements for the complete removal and replacement of the inbound conveyor system for the 305th Aerial Port Squadron (APS) in the Air Passenger Terminal, Building 1706 at Joint Base McGuire/Dix/Lakehurst, JBMDL, New Jersey. The work shall be completed in accordance with this appendix, the Cover PD, and Air Force (AF) Drawing BMC3F8-01. This appendix covers all equipment, materials, and labor necessary to complete installation of the system. It also includes performing tests and making adjustments to the system as well as providing classroom and on-the-job instructions to Government personnel.

DEFINITIONS

Definitions shall be in accordance with Section 1.3. of the Cover PD.

APPLICABLE DOCUMENTS

Applicable documents shall be in accordance with section 2 of the Cover PD.

REQUIREMENTS

SYSTEM DESCRIPTION

The existing inbound baggage conveyor system shall be replaced with a new inbound conveyor system having the same characteristics as the existing conveyor system unless otherwise noted. The existing system is an endless closed loop crescent-plate conveyor with a center drive. The conveyor shall be crescent-plate conveyor. The new conveyor system shall consist of the conveyor, controls, wiring, overhead doors, and sensors required to transport baggage between the baggage loading area and the baggage claim area. The entire conveying surface shall be level. Inbound baggage will be unloaded onto the conveyor at the baggage loading area. If bags fail to be removed they will continue to cycle back through the baggage loading area and the baggage claim area until the baggage is removed from the conveyor or the conveyor is turned off. The conveyor shall be capable of handling suitcases, duffel bags, footlockers, wooden boxes, and other miscellaneous pieces of checked baggage. The conveyor shall be capable of handling all items within the following size limits:

Weight: Maximum: 150 pounds per bag Minimum: 1 pound per bag

Size: Maximum: 30" wide, 60" long, and 34" high Minimum: 3" wide, 12" long, and 3" high

The existing inbound conveyor system shall be removed and disposed of by the Contractor in accordance with all federal, Air Force, state, and local codes and ordnances. The existing conveyor system is shown below.

PERFORMANCE AND PHYSICAL Characteristics Speed The conveyor shall operate at 90 ± 5 feet per minute under all loading conditions. The conveyor shall rotate clockwise.

Load Capacity The conveyor shall have a minimum live load capacity of 100 pounds per linear foot. The conveyor shall be capable of starting or stopping in a normal fashion under fully loaded conditions. Fully loaded conditions shall be tested and shall include covering the entire surface area of the conveyor with baggage material of various weights. Each piece of baggage material shall not exceed 150 pounds.

Conveyor Dimensions At the baggage loading area the conveying height of the conveyor shall be 34 + 2 inches from driveway floor and 16 + 2 inches from the step-up, reference picture below.

In loading area the conveyor legs shall be either off set, current I-beam reused, or a concrete foundation shall be used to account for the uneven surface in this area. In the pick-up area the conveying height of the conveyor shall be 14 + 2 inches. The conveying width of the conveyor shall be 33 inches and the overall width shall be 40 inches.

Drive Assembly The conveyor shall be driven by a caterpillar-type drive, barrel-screw drive, or industry standard equivalent as approved by the COTR. The drive shall include two strands of precision heavy-duty roller chain, driven by an appropriately sized motor through a gear reducer. The roller chain shall be a minimum RC-60 conforming to ASME B29.100. The roller chain shall have pusher lugs which mesh with the roller cams, which are guided continuously along the centerline of the unit, underneath each crescent-plate or overlapping slat. The roller chain lugs shall engage at least two roller cams at all times. Drive sections shall be provided with a grease lubrication system for the face of all rollers. Lubrication shall be accomplished through a manifold system, located at one location on the drive frame. The drive unit shall be rigidly braced and guarded to prevent potential hazards or possible interference with personnel. The conveyor motor shall be as shown on AF Drawing BMC3F8-01.

Bearings The bearings shall be semi-precision, greaseable, anti-friction, pre-lubricated steel ball bearings. A screw-type chain take-up shall be provided with the idler shaft bearing mounts to compensate for initial chain break-in and normal chain wear.

Frames The frames shall have a minimum load capacity of 200 pounds per linear foot. All frames shall be rigidly cross-braced. Frames shall be bolted and not welded together to facilitate future removal or reconfiguration of the conveyor. Crossties shall be welded or bolted to side channels. Rigid cross bracing shall be furnished under all bed joints. A minimum 5-inch high, 3-inch deep toe space shall be provided around the conveyor in the baggage pick-up area. Engineering calculations supporting the rated load capacity shall be submitted with the shop drawings.

Supports All supports shall be suitable for the specified loads and equipped with an adequate means of leveling. All supports shall adjust a minimum of 4 inches, 2 inches up and 2 inches down, from the specified overall elevation. The overall elevation shall be measured from the supporting surface to the top of the treads. All supports shall be designed to provide infinite, fixed, nonslip adjustments. Supports shall be spaced at a maximum of 5 feet on center. The support base plate shall have a rubber surface which contacts the supporting surface. There shall be no protruding lugs or flanges to provide a potential hazard or to interfere with personnel/material along the conveyor.

Skirts Skirts shall be constructed from a minimum of 12 gauge steel, painted flat black, and installed with steel stiffeners and cross members. Skirts shall be bolted to the frames (not welded) and extend to floor level (variance not to exceed one inch). Skirts shall provide a toe space between the floor and the shroud. No protruding bolts, screw heads or any other fasteners not covered by trim shall be allowed on the sides of the skirt. Skirts shall be provided along the outer perimeter of the conveyor in the baggage pick-up area.

Shrouds and Angled Cover Plates Shrouds shall be formed to extend under the conveying surface to provide a seamless surface. All connections shall be smooth and flush without openings or projections on which bags or tags may catch. Fasteners shall be hidden from public view wherever practical to do so. Angled cover plates shall extend from the shroud to the conveying surface and shall act as a finger-guard. Angled cover plates shall not come in contact with the crescent plates or overlapping slats. The gap between angled cover plates and the conveying surface shall not exceed 1/8 inch. Angled cover plates shall be mounted to the shrouds along both sides of the entire length of the conveyor. In the baggage pick-up area shrouds and angled cover plates shall be constructed from a minimum of 12-gauge, number 4 finish, stainless steel. In the baggage pick-up area shrouds and angled cover plates shall be steel painted black.

Structural Alignment All junctions of skirts, shrouds, angled cover plates, guardrails, frames and push-button controls shall be properly aligned to eliminate gap and snag points. All components of the system shall be leveled and located and configured as shown on AF Drawing BMC3F8-01.

Face Panels Face panels shall be provided around the outside perimeter of the raised center and along the outer side of the conveyor as shown on AF Drawing BMC3F8-01. The face panels shall extend 9 inches + 2 inch above the angled cover plate of the conveyor in the pickup area and 18 + 2 inch above the angled cover plate of the conveyor in the drop-off Area. In the pickup area the face panels shall be minimum 12-gauge, number 4 finish, stainless steel. In the drop-off area the face panels shall be minimum 12-gauge, steel painted black. The face panels shall be rigidly braced to withstand repeated collisions by baggage being loaded onto and transferred by the conveyor. The face panels shall not exhibit plastic deformation under normal operating conditions.

Raised Platforms The conveyor shall be equipped with a raised platform as shown on AF Drawing BMC3F8-01. The raised platform shall consist of a plywood frame with a top covering of flame-retardant carpet. All carpet shall be attached, glued, and tacked securely to the plywood. The Contractor shall submit standard carpet sample pieces to the COTR for carpet selection. The elevated platform shall be constructed of a minimum of 3/4-inch-thick, fire- retardant plywood, rigidly braced to support the weight of a 250-pound person walking across the surface. This plywood structure shall be elevated 9 inches +/- 2 inches above the conveying surface. There shall be an angled cover plate around the entire perimeter of the carpet.

Treads All tread plates shall be flat crescent-shaped, conveying platforms. These platforms shall be a minimum of 1/4 inch thick steel plate. These conveying platforms shall be covered with a vulcanized or molded black urethane covering. This covering shall be a minimum .0625 inches thick, with a hardness of at least 75 durometer as measured on shore scale A. All tread plates shall be connected with self-aligning links and guide rollers. The tread plate-riding surface shall consist of two lines of anti-friction, urethane rollers with ball bearings mounted in removable neoprene grommets. Rollers shall be a minimum 2 inches in diameter and shall be mounted on not less than 8-inch centers. Each tread plate shall support a 250-pound person standing or walking on the tread plate.

Wall Openings and security doors The conveyor shall pass through two existing wall openings as shown on AF Drawing BMC3F8-01. The dimensions of the wall openings are nominally 48 inches wide and 50 inches tall. The conveyor shall be centered in the wall openings. The existing wall opening trim, security doors, and draft curtains shall be removed and replaced.

INSULATED FILL PLATE

The Contractor shall provide an insulated fill plate on each side of the conveyor in the wall opening. The insulated fill plates shall be the same thickness as the wall the conveyor passes through. The fill plates shall extend from the terminal floor to the conveyor bed surface. The fill plate shall be aligned with the roll-up security door to produce an even and gap free fit when the door is in the closed position. The fill plates shall match the wall in construction and shall be fire rated for a minimum of one hour. Fill plates shall be painted to match the walls.

Draft curtains Black vinyl or plastic draft curtains shall be provided at each wall opening for wind and temperature control during conveyor operation. The curtain strips shall be minimum 5 inches wide by 1/16-inch thick. Strips shall overlap each other by a minimum of one inch. Strips shall have rounded edges to prevent cutting. The curtains shall be mounted a minimum of three inches above the wall opening and shall overlap the door edges by a minimum of one-inch. The curtains shall extend to within one-half inch of the conveyor’s surface. The curtains and associated mounting brackets shall not reduce the size of the wall opening clearances. The curtains shall be mounted on the Personnel Area side of the building wall.

Jam Prevention The design of the conveyor and the controls shall prevent jams and other interruptions. Jams shall occur a maximum of 0.5 percent of the time (only 1 jam per 200 bags is acceptable).

Conveyor Drives and Drive Chains All drives shall be rigidly braced and completely enclosed in easily removable guards. Drives shall be located so as not to hinder inspection or maintenance nor interfere with normal operation of the conveyor system. A chain take-up shall be provided at all locations where chain is used for power transmission. Roller chain shall conform to ASME B29.100 and shall be minimum RC-60.

General Control Characteristics

3.2.5.2. Single operator

All controls and functions shall be operable by one person. All controls shall require less than 10 pounds of force to activate.

3.2.5.3. Interlocks

Control interlocks shall be provided wherever required to ensure safe, efficient, integrated operations as specified. Interlocks shall prevent motors from attempting to drive a component in opposite directions at the same time. Interlocks shall be provided wherever required to preclude unsafe movements and conditions that could endanger operating personnel or personnel standing near the equipment, or which could damage baggage, facilities, or equipment. When controlled by the operator from a console, interlocks shall prevent malfunctions and system errors that cause a component to become inoperable, unsafe, or to fail to operate as specified herein.

3.2.5.4. Console lockout

Two or more consoles with buttons, switches, or other controls that operate the same equipment shall have a lockout such that when one console is being used (a button is being depressed), all other consoles controlling that equipment shall be inoperable. The only exception shall be emergency stops, which shall always operate regardless, of which console is controlling the motion.

3.2.5.7. Labeling

All consoles, panels, and junction boxes shall be clearly labeled to indicate the equipment that is controlled by the enclosure. Labels for each button, switch, indicator, light, and all other operator control devices shall be etched aluminum, painted black, and mechanically attached to the console. Adhesive labels shall not be acceptable.

3.2.5.8. Diagrams, codes, AND DOCUMENTATION

The Contractor shall provide flow charts that clearly illustrate control and operation logic. The flow charts shall be submitted with shop drawings. Ladder diagrams, flow charts, all variable control settings, and disks containing source code for all control programs shall be submitted with maintenance manuals.

3.2.5.10. Sensors

Sensors shall be photoelectric, limit switch, or other device that senses the presence of baggage, door positions, and similar functions as required for proper and safe operation. Sensors shall be approved by the COTR. All sensors shall properly operate in all weather and lighting conditions at the point of operation. Sensor circuitry shall be totally solid state. All sensors shall be recessed for protection from the conveyed material. All sensors shall be shock and vibration resistant and shall be rigidly mounted on structural members attached to the structure. Sensors shall be rigidly mounted so that transmission of vibrations is minimized. No more than one penetration per sensor shall be allowed in conveyor guard rails and side guides. All sensors shall be capable of detecting minimum and maximum-dimensioned baggage. All sensors shall be the quick-disconnect type (not hard wired) to simplify maintenance. The Contractor shall provide any special tools needed to adjust the sensors, sighting, or other controls. Sensors shall be located in a position that allows for ease of inspection and maintenance.

Door POSITION sensors A door position sensor shall be provided on each security door to ensure that the security door is in the fully opened position (not blocking the wall opening) prior to conveyor movement. If the sensor detects that the door is not fully opened, the conveyor shall not operate. An indicator light on the control panels as specified in 3.2.18.5. shall indicate to baggage handling personnel the door is not fully open. If the door is lowered during conveyor operation, the conveyor shall immediately stop and the indicator light shall illuminate, indicating to personnel there is a problem with the door.

Jam Detection Sensors Jam detection sensors and timers shall be used to detect baggage jams. The sensors and control logic shall differentiate between long baggage items and jams. Jam detection shall take place at or near the security doors and other areas where jams are likely. The jam timer shall be manually adjustable over a minimum range of 0 to 30 seconds on maximum 1-second intervals. If a jam is detected, the conveyor shall stop and baggage-handling personnel shall be notified on the control panels as specified in 3.2.18.5. If jammed, the conveyor shall not restart until the jam has been cleared. Once the jam is cleared, the jam detection circuit shall automatically reset and the indicator light shall extinguish. The conveyor shall not automatically restart when the jam is cleared; an operator shall have to press the start button to resume baggage transfer. A false jam indication shall not be generated by baggage blocking the sensor if the conveyor has stopped for reasons other than a jam being detected.

Automatic System Stop SENSORS The inbound conveyor shall automatically stop after a pre-determined time interval has elapsed with no baggage on the conveyor. The time interval shall be manually adjustable over a minimum range of 1 to 15 minutes on maximum intervals of 1 minute. Sensors capable of detecting all baggage sizes shall be used. Once the conveyor times out, pressing the start button shall restart the conveyor.

3.2.15.12. Motor Control Center

The MCC shall be located as shown on AF Drawing BMC3C8-01. The MCC shall not exceed 78 inches in height and shall be mounted so that the height of the top operating handle shall not exceed 60 inches from the floor. The MCC door shall be provided with a lock and two keys. Schematics of the MCC shall be in a holder behind a translucent protective covering on the inside of the panel door. The MCC shall be in compliance with Article 384 of NFPA 70. The MCC shall have the following Diagnostic Display Panel (DDP) and control buttons as a minimum.

3.2.15.12. Diagnostic display panel

The MCC shall be equipped with a DDP for controlling and troubleshooting the conveyor. The DDP shall be equipped with a keypad which shall control access to the DDP’s diagnostic screens.

3.2.15.12.6. Power on light

The MCC shall be provided with a power on indicator light. Whenever the MCC handle is moved to the “ON” position, the power on indicator light shall illuminate. This light shall remain illuminated until the MCC handle is moved to the off position or electrical power to the system is disconnected. This light shall be green in color.

3.2.15.12.8. Fault light

The MCC shall be provided with an orange “FAULT” light. This light shall illuminate when any condition preventing normal conveyor operation is present. The light shall remain illuminated until the condition preventing normal operation has been cleared or the power is turned off.

3.3.8. Hour meter

The MCC shall be equipped with an hour meter. It shall not be possible to reset the hour meter. The hour meter shall register a minimum of 9,999 hours. The hour meter shall be located on the front panel of the MCC or be available through the DDP operator control Panels The contractor shall provide three operator controls panels. One of the operator control panels shall be mounted on a pedestal as shown on AF Drawing BMC3F8-01. The other two operator control panels shall be mounted on the wall next to the security doors. The COTR will approve the control panel locations before final installation. The control panels shall be mounted at a convenient height for operator use, typically 48 inches above the ground. The operator control panel shall be configured as shown in Figure 1.

FIGURE 1 – Operator Control Panel Configuration

Start button The “START” button shall be a green momentary-contact push button. When the “START” button is depressed and the conveyor is at rest, the start-up warning devices shall activate in accordance with 3.2.20. If the conveyor is already moving, pressing the “START” button shall have no effect.

Stop button The “STOP” button shall be a red momentary-contact push button. When the “STOP” button is depressed, the conveyor shall stop and the security doors shall lower to the fully closed position. If the conveyor is already stopped and the security doors are in the fully closed position, pressing the “STOP” button shall have no effect.

raise door button The “RAISE DOOR” button shall be a black momentary-contact push button. When the “RAISE DOOR” button is depressed the security door associated with the control panel shall raise to the fully open position. The center control panel does not require this push button.

lower door button The “LOWER DOOR” button shall be a black momentary-contact push button. When the “LOWER DOOR” button is depressed the security door associated with the control panel shall lower to the fully closed position. The center control panel does not require this push button.

FAULT INDICATOR

An orange “FAULT” indicator located on the operator control panel shall illuminate when a security door is not in the fully raised position as specified in 3.2.16.6.1. or when a jam has been detected as specified in 3.2.16.6.2. or any other condition preventing normal operation. The light shall remain on until the condition preventing normal operation is cleared and the “Reset” button depressed, or the power is turned off.

reset button The “RESET” button shall be a black momentary-contact push button. When the “RESET” button is depressed and the condition causing the fault condition has been cleared, the “FAULT” indicator shall de-activate. The conveyor shall not restart.

Emergency stop buttons All “EMERGENCY STOP” buttons shall be illuminated, red, and shall be of the "mushroom" type. “EMERGENCY STOP” buttons shall be the maintained-contact type that are pushed to activate and pulled to deactivate. Activation of an “EMERGENCY STOP” button shall override all other control inputs and control logic. The conveyor shall immediately cease motion and shall not activate following an emergency stop until all “EMERGENCY STOP” buttons have been cleared, sensors indicate the equipment is ready to operate, and the “START” button is depressed. Pulling the “EMERGENCY STOP” button shall clear an emergency stop. The conveyor shall not automatically activate once the “EMERGENCY STOP” button has been cleared. All “EMERGENCY STOP” buttons for the conveyor shall illuminate when one is activated. The “EMERGENCY STOP” button that was activated shall be the only “EMERGENCY STOP” button to flash. All personnel interfacing with the conveyor system shall have easy access to an “EMERGENCY STOP” button. “EMERGENCY STOP” buttons shall be hard-wired. In additional to the “EMERGENCY STOP” buttons located on the MCC and the OCPs “EMERGENCY STOP” buttons shall be mounted on the conveyor and shall be recessed or guarded to prevent accidental activation and safety hazards. “EMERGENCY STOP” buttons for the conveyor shall be located as shown on AF Drawing BMC3F8-01 (labeled as “ES”).

Start-Up Warning Devices The conveyor shall be equipped with start-up warning devices. The start-up warning devices shall be located as shown on AF Drawing BMG3F8-01. The start-up warning devices shall meet all requirements specified in ASME B20.1. The start-up warning devices shall consist of horns and rotating lights. The horns shall have a frequency between 200 and 5000 hertz and the volume shall be manually adjustable over a minimum range of 0 to 90 dB(A). The rotating lights shall be amber in color. The warning devices shall not be placed where subject to damage from conveyor operation or loading and unloading operations. The warning devices shall be visible and audible in all areas where personnel may come into close proximity to the conveyor. A combined horn and rotating light is acceptable. The COTR prior to installation shall approve the exact location of the warning devices. The warning devices shall activate when the conveyor is at rest, the start button is depressed, and all sensors indicate the conveyor is operational (i.e., no emergency stops, uncleared jams, closed security doors, etc). The length of time the warning devices operate prior to the start of the conveyor shall be manually adjustable over a minimum range of 0 to 10 seconds on maximum 1-second intervals. A minimum of two horns and four rotating lights, or two horn/rotating and two light devices shall be provided for the conveyor.

QUALITY ASSURANCE PROVISIONS

Inspections The system shall be inspected to verify that it meets all the requirements of sections 1, 2, and 3 of this appendix and the Cover PD. These inspections shall be completed as part of the system checkout test and again as a part of the quality conformance test.

Tests The following test shall be performed on the system as part of the system checkout test and again as a part of the quality conformance test.

Pass: _____ Fail: _____

3.2.14.3.

Test to ensure baggage does not jam at a rate greater than 0.5 percent and does not snag. Using 10 test loads of different sizes and weights (at least one item having the minimum dimensions and weight and one item having the maximum dimensions and weight identified in 3.1., transfer each item on the conveyor a minimum of 20 cycles. If more than one jam occurs on any conveyor, or if any bags snag on gaps, openings, or protrusions, the system fails this test.

3.2.16.6.1.

3.2.18.5.

Test operation of the door sensors. Attempt to start the conveyor with a security door not fully raised. Raise the door to the fully open position and attempt to start the conveyor. Lower the door with the conveyor operating. Repeat for all doors on the conveyor. If the conveyor starts with the door not fully raised, if the conveyor does not start with the door fully raised, if the conveyor does not stop when the door is lowered, if the door fault light does not illuminate when the door is not fully raised, or if the fault light illuminates when the door is fully open, the system fails this test.

Certifications The Contractor shall provide certification that the following requirements have been met in accordance with the Contract Data Requirements List.

3.2.2.

3.2.6.

The conveyor has a minimum structural load capacity of 200 pounds per linear foot and a minimum live load capacity of 100 pounds per linear foot.

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JBMDL – Appendix A – Page 20

INBOUND BAGGAGE CONVEYOR

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Appendix A – Inbound Baggage Conveyor, 19 November 2019

The Offeror shall complete this questionnaire. All entries to this questionnaire shall be typed. The questionnaire will be used to determine the Offeror's understanding of the requirements and acceptability of the proposed equipment. Please attach any exceptions to the Cover Purchase Description.

Conveying width: ____________ inches Overall width: ______________ inches Centerline dimension: _______ inches

Conveyor frames have a load capacity of ________ pounds.

Face panels will extend ________ inches above the conveying surface of the conveyor in the pickup Area.

Face panels are _______ gauge ______________.

The carpet enclosure will support the weight of a ______ pound person walking across the surface.

Quantity of emergency stops provided on the inbound conveyor (not including control panel emergency stops): ____________

EXCEPTIONS

Attach any exceptions taken to the Purchase Description Appendix. Please outline those concerns in detail. Your exceptions will be reviewed to determine acceptability.

Are exceptions taken?

Number of pages attached: ____________________________________

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