Attachment 1_Technical Specification_Conformed thru Amendment 0001.pdf

SP3100-08-R-0013

Conformed thru Amendment 0001

Attachment 1

TECHNICAL SPECIFICATIONS

FOR

ACTIVE ITEM CONVEYOR BUILDINGS 15/17

DEFENSE DISTRIBUTION DEPOT

SAN JOAQUIN, CA

December 18, 2007

PREPARED BY:

DEFENSE DISTRIBUTION DEPOT TRACY

FACILITIES & EQUIPMENT ENGINEERING BRANCH, DDJC-FA

Attachment 1

TABLE OF CONTENTS

SECTION 1

1.1 SCOPE

1.2 SITE

1.3 QUANTITY

1.3.1 SYSTEM LAYOUT AND FUNCTION

1.3.2 MATERIAL FLOW

1.3.3 THROUGHPUT REQUIREMENT

1.3.4 MATERIAL TO BE HANDLED

1.3.5 GOVERNMENT FURNISHED EQUIPMENT (GFE):

1.3.6 EQUIPMENT TO BE DISASSEMBLED AND REMOVED FROM SITE

1.3.7 ALTERNATIVE DESIGNS

SECTION 2

2.0 APPLICABLE SPECIFICATIONS, STANDARDS AND CODES

2.1 GOVERNMENT DOCUMENTS

2.1.1 FEDERAL SPECIFICATIONS

2.1.2 OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION

(OSHA) STANDARDS

2.2 NON-GOVERNMENT STANDARDS AND CODES

SECTION 3

3.0 GENERAL REQUIREMENTS

3.1 GENERAL

3.1.1 QUALITY

3.1.2 STANDARD PRODUCTS

3.1.3 MATERIAL AND OPERATING CONDITIONS

3.1.3.1 DISSIMILAR METALS

3.1.4 IDENTIFICATION OF MATERIAL AND FINISHES

3.1.5 STANDARDIZATION OF COMPONENTS

3.1.6 STATE-OF-THE-ART COMPONENTS

3.1.7 MAINTAINABILITY

3.1.8 LUBRICATION AND ADJUSTMENT

3.1.9 PAINTING

3.1.10 NOISE LEVELS

3.1.11 FASTENERS

3.1.12 METAL FABRICATIONS

3.1.12.1 WELDS

3.1.12.2 BOLTED AND RIVETED CONNECTIONS

3.1.12.3 CASTINGS AND FORGINGS

3.1.13 FLOOR MOUNTING OF EQUIPMENT

3.1.14 IDENTIFICATION MARKING

3.1.14.1 CONTROL IDENTIFICATION

3.1.15 SPECIAL PROVISIONS

Attachment 1

3.1.15.1 INTERRUPTION OF OPERATIONS

3.1.15.2 WORKING HOURS

3.1.15.3 REMOVAL OF WASTE AND DEBRIS AND EXISTING CONVEYOR

3.1.15.4 UTILITIES AVAILABLE FOR USE CONTRACTOR

3.1.15.5 DIMENSIONS

3.1.15.6 PROTECTION OF GOVERNMENT PROPERTY

3.1.15.7 UNLOADING OF EQUIPMENT

3.1.16 SAFETY REQUIREMENTS

3.1.16.1 GENERAL REQUIREMENTS

3.1.16.2 MISHAP REPORTING

3.1.16.3 INSTALLATION SAFETY PRACTICES

3.1.16.4 FIRE PREVENTION

3.1.16.5 FLAME CUTTING AND WELDING PROCESSES

3.1.16.6 CONTRACT DATA REQUIREMENTS

3.2 ELECTRICAL REQUIREMENTS

3.2.1 ELECTRICAL INSTALLATION

3.2.2 NEW 480V POWER

3.3 TOTE CONVEYOR SYSTEM

3.3.1 GENERAL

3.3.1.1 CONVEYOR ELEVATIONS

3.3.2 DESIGN AND FUNCTIONAL REQUIREMENTS

3.3.2.1 PHYSICAL CHARACTERISTICS

3.3.2.2 MOUNTING

3.4 NOT USED

3.5 PROGRAMMABLE LOGIC CONTROLLERS

3.5.1 BATTERY BACKUP

3.5.2 PORTABLE PLC PROGRAMMING DEVICE

3.5.3 PLC DIAGNOSTICS/DISPLAY

3.5.4 PLC CONTROL CABINETS

3.6 CONVEYOR CONTROLS

3.6.1 PHOTO-EYES

3.6.2 EMERGENCY CUTOFFS

3.6.3 INDUCTION STATIONS

3.7 MOTORS

3.7.1 MOTOR CONTROL

3.7.1.1 MAINTENANCE CONTROL STATIONS

3.7.1.2 START-STOP SWITCH

3.7.1.3 MOTOR DISCONNECT MEANS

3.7.1.4 SYSTEM CONTROL PANELS/MOTOR CONTROL CABINETS

3.7.1.5 MOTOR CONTROL CABINETS

3.7.2 AUTOMATIC CONTROLS

3.7.2.1 DIRECT MOTOR/ACTUATOR CONTROL:

3.7.2.2 START-UP WARNING HORN:

3.7.2.3 START-UP CONVEYOR INTERLOCKS:

3.7.2.4 JAM PROTECTION:

3.7.2.5 OPERATIONAL CONVEYOR INTERLOCKS:

Attachment 1

3.7.2.6 FULL LINE SENSORS:

3.7.2.7 FIRE SYSTEM DEACTIVATION:

3.7.3 COMPRESSED AIR SYSTEM

3.8 PROTECTIVE GUARDRAILS

3.8.1 GUIDE RAILS FOR ELEVATED INDUCTION STATIONS

3.8.2 VIDEO MONITORING SYSTEM – OPTIONAL ITEM

3.8.2.1 VIDEO CAMERAS:

3.8.2.2 VIDEO CAMERA MOUNTINGS:

3.8.2.3 VIDEO MONITOR:

3.8.2.4 VIDEO CONTROLLER KEYPADS:

3.9 TRAINING

3.9.1 OPERATOR TRAINING

3.9.2 MAINTENANCE TRAINING

4.0 QUALITY ASSURANCE PROVISIONS

4.1 LAYOUT OF WORK

4.2 SYSTEM MAINTENANCE

4.2.1 MAINTENANCE PRIOR TO FINAL ACCEPTANCE

4.2.2 SYSTEM MAINTENANCE WARRANTY PROVISIONS

(SUPPLEMENT)

4.2.2.1 SPECIAL TECHNICAL ASSISTANCE/MAINTENANCE

4.2.2.2 CONTRACTOR TECHNICAL REPRESENTATIVES

4.3 SYSTEM CHECK-OUT

4.4 INSPECTION AND TEST

4.4.1 RESPONSIBILITY FOR INSPECTION AND TESTING

4.4.1.1 COMPONENT AND MATERIAL INSPECTION

4.4.1.2 QUALITY CONFORMANCE INSPECTION AND TEST

4.4.2 EXAMINATION

4.4.3 IN-PROCESS INSPECTION

4.4.4 PERFORMANCE TESTS

4.4.4.1 FUNCTIONAL TEST

4.4.4.2 FINAL OPERATION TEST

4.4.5 STATIC AND OTHER TEST

4.4.6 TIME LOST

4.4.7 WARRANTY

4.4.8 FINAL ACCEPTANCE

4.4.9 DEFINITIONS

4.4.9.1 INTERRUPTION OF SERVICE

4.4.9.2 EQUIPMENT

4.4.9.3 INTENDED CAPACITY

4.4.9.4 NONDESTRUCTIVE TEST

Attachment 1

SECTION 1

1.1 SCOPE

This specification covers the necessary services, labor, material, equipment and control components required to replace an existing elevated tote conveyor system (in Building 15 Sections 1-5, Building 17 Sections 1-3 and in elevated tunnels connecting both buildings to Building 16) with a state of the art elevated powered roller tote conveyor system. The system shall consist of elevated tote transport conveyor, incline and decline belt conveyor, stock selector guide rails (at input stations) and an optional video monitoring system. The Contractor shall remove the existing conveyor and dispose of it off site; existing cantilever supports may be reused if the Contractor determines the supports are structurally sound. The Contractor shall provide, install, test and make operable the conveyor system. The Contractor shall train government personnel to maintain the conveyor system.

The contractor shall provide all 480V power required to satisfy the conveyor system needs at both buildings from existing power pole #2, located approximately 70 feet south of Building 15 Section 5 , and from existing pole #1, located approximately 70 feet west of Building 17 Section 1, (see drawing DDJC Bldg 15-17 Conveyor).

1.2 SITE

The site for this project is Defense Distribution Depot San Joaquin, California (DDJC), located in Tracy California. The conveyor system shall be installed in Buildings 15 and 17.

1.3 QUANTITY

The Contractor shall furnish, install, integrate, and make operational, the following equipment and building systems:

TABLE 1

Item Units Quantity CLINS Belt Driven Live Roller Tote Conveyor-Elevated LF 2150 001 Belt Driven Live Roller Tote Conveyor LF 65 001 Incline/Decline Belt Conveyor – Roller Bed LF 65 001 Zero Pressure Accumulation Conveyor LF 100 001 90 Degree Conveyor Curves EA 8 001 Wheel Stops at Elevated Loading stations LF 130 001 Protective Guardrails for Floor Level Conveyor and all conveyor legs

LF 200 001

480 Volt Electrical Service LOT 1 002 Disassemble & Remove Existing Conveyor System LOT 1 003 Optional Item: Video Monitoring System LOT 1 004

Attachment 1

1.3.1 SYSTEM LAYOUT AND FUNCTION

The purpose of the system is to provide an automated transport of conveyable items from Warehouse 15 and 17 to the tilt-tray sorter/packing area in Warehouse

16. The conveyor will run along the western side of Warehouse 15, through the connector enclosure to north end of Warehouse 16 and along the eastern side of Warehouse 17 and through the connector enclosure to the south end of Warehouse

16. The conveyor in-feed lines from Warehouse 16 to both 15 and 17 will also be replaced in both connector enclosures. A video monitoring system will be installed along the length of the conveyor system to allow monitoring of the flow of totes on the conveyor system at two control stations adjacent to the conveyor -one in Bldg 15 and one in Bldg 17.

1.3.2 MATERIAL FLOW

Totes will be introduced into the conveyor system at one of several induction locations. Each induction location shall sense the tote presence and shall automatically start the conveyor. The stock selector operator will bring the stock selector vehicle alongside the conveyor at one of the designated entry points, raise the vehicle and place the totes onto the elevated conveyor. The conveyor system will then transport the totes to Warehouse 16.

1.3.3 THROUGHPUT REQUIREMENT

The conveyor shall, as a minimum, be capable of handling a peak workload of 12 totes per minute.

1.3.4 MATERIAL TO BE HANDLED

Material to be handled consists of government furnished totes. The totes to be used on the conveyor system are 15” x 24” x 10” h and weigh from 8 lbs. to 150 lbs. (100 lbs. Foot for conveyor design).

1.3.5 GOVERNMENT FURNISHED EQUIPMENT (GFE):

As part of this contract, the Contractor shall be responsible for merge logic integration with the existing conveyor in Warehouse 16-1 (connecting to Warehouse 15-5) and Warehouse 16-5 (connecting to Warehouse 17-1). The two existing conveyors in Warehouse 16-1 to which the Contractor installed conveyor from Warehouse 15 will interface with is a Roach brand belt decline (east line) with a 21” conveying width and an Automation brand roller curve (west line) with a 21.5” conveying width. The existing conveyors in Warehouse 16-5 to which the Contractor installed conveyor from Warehouse 17 will interface with are both Roach brand roller curves with a 21” conveying width. Two Portec Spiral Glide conveyors (approx. outside diameter of 104”) will also be reutilized (one in Warehouse 15 Section 5 and one in Warehouse 17 Section 1) to transfer totes of receipt material from the elevated conveyor to the floor level conveyor. All transport totes for use on the conveyor system will be GFE.

1.3.6 EQUIPMENT TO BE DISASSEMBLED AND REMOVED FROM SITE

The Contractor shall disassemble and remove the existing conveyor system from

Attachment 1 the site. Existing cantilever supports may be reused if the Contractor determines the supports are structurally sound. Note the existing system in located in the same location as the proposed system provided in Table 1:

TABLE 2

Item Units Quantity Belt Driven Live Roller Tote Conveyor LF 2210 Incline/Decline Belt Conveyor – Roller Bed LF 15 90 Degree Conveyor Curves EA 7 180 degree Conveyor Curve EA 1 Wheel Stops at Elevated Loading stations LF 135

1.3.7 ALTERNATIVE DESIGNS

The design as specified represents the Government's model design for the process;

however, the Government also would like to utilize the Contractor's expertise to ensure the best material handling system is purchased to meet the performance requirements as stated in this specification. Therefore, an alternative system may be proposed provided that the system functions and has the same capabilities as the system specified. In addition, all technical data (equipment layout drawings and manufacturer's brochures for equipment) concerning an alternative system must be included with the alternative design to provide all information required for the Government to evaluate said design. No alternative system will be considered after contract award.

Attachment 1

SECTION 2

2.0 APPLICABLE SPECIFICATIONS, STANDARDS AND CODES

The following list of specifications, standards and codes shall apply to the work covered within this document. The Contractor shall be responsible to ensure that all such applicable regulations are satisfied. Special attention shall be given to Federal, State and Local requirements. The issue in effect of the following documents on the date of the solicitation form a part of the specification to the extent specified herein:

2.1 GOVERNMENT DOCUMENTS

2.1.1 FEDERAL SPECIFICATIONS

NN-P-71C Pallets, Material Handling, Wood, Stringer Construction, 2-way and 4-way (partial) UFC 3-310-01 Design: Structural Load Data UFC 3-600-01 Design: Fire Protection Engineering for Facilities

2.1.2 OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

STANDARDS

29 CFR 1910 Occupational Safety and Health Standards

2.2 NON-GOVERNMENT STANDARDS AND CODES

Standards of the National Electrical Manufacturer’s Association (NEMA) American Welding Society Standards Code of the American Society of Mechanical Engineers (ASME) Standards of the American Institute of Electrical Engineers National Electrical Code (NEC) Underwriters Laboratories (UL), Inc. Publication Standards American Society for Testing Material Standards (ASTM) American National Standards Institute (ANSI) B20.1 Safety Standards for Conveyors and Related Equipment American Iron and Steel Industrial Standards (AISI)

SECTION 3

3.0 GENERAL REQUIREMENTS

3.1 GENERAL

The Contractor shall supply the herein described equipment/system, which shall include all services, labor, material, equipment, control components, and engineering necessary to provide a completely operational system. The systems shall be tested by the Contractor prior to performance testing by the Government and shall be capable of undergoing the tests specified in paragraph 4.4 without deformation, breakdown, and failure of any component, or development of any other defect, and without any deviations from the performance requirements and cited standards of this specification. All equipment (each whole product with its integral software) shall be the manufacturer’s current, commercially designed and available or a commercial product that has been slightly modified to fit the proposed system. The commercial product must have proven, successful field application for at least two years immediately proceeding the issue date of this solicitation. The field experience of each specific equipment product shall have been gained by an identical or previous model to the one being offered. The design of the specific equipment product offered must be fully defined. Also, the Contractor shall identify any design changes during the two-year period of field experience. These design changes must be minor and insignificant or be demonstrated reliable through commercial application. Bid proposals shall include descriptive literature for all items of equipment offered. It is the Contractor’s responsibility to notify the Contracting Officer of any design deficiencies or site requirements, which affect or compromise the performance or operation of any portion of the system or the entire system. The Contractor shall be responsible for compliance with all regulations applicable to design and testing of equipment and controls supplied under this specification.

3.1.1 QUALITY

The system shall be in strict accordance with the requirements as herein specified and of high quality, free of any defects, which may affect function, appearance, serviceability, maintainability, or durability.

3.1.2 STANDARD PRODUCTS

Unless otherwise specified, the equipment to be furnished under this specification shall be the manufacturer’s current commercial product and shall have been in production, marketed and in use for a minimum of two years proceeding the issuance date of this solicitation. The introduction of product improvement changes in this two-year period shall be acceptable. Prototype or experimental devices or components shall not be furnished or installed. Where two or more units of the same type or kind of equipment are required, these units shall be identical models of a single manufacturer.

Attachment 1

3.1.3 MATERIAL AND OPERATING CONDITIONS

Materials shall be as specified herein. Materials not specified shall be selected by the Contractor and shall be subject to all provisions of the specifications. Unless otherwise specifically stated, all materials shall be new and of the most suitable grade for the intended purpose. All parts shall be manufactured to such standards that will permit replacement or adjustment without modification of system components. The system shall be capable of operating in an industrial environment and extremes of temperature from -10 to 110 degrees Fahrenheit and humidity from 10 to 99 percent relative (non-condensing).

3.1.3.1 DISSIMILAR METALS

Dissimilar metals shall not be used in intimate contact with each other unless protected against galvanic corrosion.

3.1.4 IDENTIFICATION OF MATERIAL AND FINISHES

The Contractor shall identify the specific material, material finish or treatment for use with components and sub-components and shall make information available, upon request, to the Contracting Officer or designated representative.

3.1.5 STANDARDIZATION OF COMPONENTS

Corresponding units and replaceable assemblies, subassemblies and parts in contact shall be physically and functionally interchangeable as complete items without modification thereof or of other articles with which the items are used.

Where dimensions, ratings and characteristics are not specified herein, the manufacturer’s published design limits shall be used to determine compliance with the foregoing.

3.1.6 STATE-OF-THE-ART COMPONENTS

The Contractor shall furnish a system embodying features, which represent the current commercially available state-of-the-art in the development of his product.

Such features as plug-in electrical or electronic modules, trouble detection and condition status indicators, electronic diagnostic systems and applicable programmable logic controllers shall be utilized to the maximum extent where effective and practicable.

3.1.7 MAINTAINABILITY

Provisions shall be made for ready adjustment, servicing and replacement of all system components. All replaceable components shall be designed for ease of removal and ease of installation. All printed circuit boards shall be of the plug in type to the maximum extent practical. All electrical/electronic equipment shall be designed to permit the use of standard electronic test equipment for maintenance thereof. All parts with identical part numbers, such as rotors or printed circuit boards, shall be inter changeable without modification.

Attachment 1

3.1.8 LUBRICATION AND ADJUSTMENT

All equipment shall be greased, oiled or lubricated and properly adjusted by the Contractor to ensure satisfactory operation. Lifetime or automatic lubrication shall be utilized wherever effective and practicable.

3.1.9 PAINTING

All surfaces suitable for painting shall be painted with commercially available practices to provide a finished coat which is a smooth, even surface, free of runs, sags, blisters, chips, areas of no film or thin film or other defects. Color of the finish coat, except where specified in OSHA or other standards, shall be the manufacturer’s normal commercial color. The Contractor using paint of the same color, type, and manufacture, as the original shall touch up all factory painted surfaces that are damaged during system installation.

3.1.10 NOISE LEVELS

No single item of equipment shall produce an operating noise level in excess of 70 decibels within 4 ft. of the equipment and no combination of operating elements of equipment shall exceed an 8 hour time weighted average sound level of 84 decibels measured on the A scale, when measured in accordance with section 1910.95 (“Occupational Noise Exposure”) of 29 CFR 1910 (OSHA Safety and Health Standards).

3.1.11 FASTENERS

Unless otherwise specified, all threaded fasteners, washers and cotter pins required to fabricate the components of the system (except those designed to be in contact with oil in reservoirs) shall be plated to resist corrosion. Fasteners shall be S.A.E. Grade No. 5 minimum, and shall be plated with a metallic corrosion resistant metal. All fasteners for similar applications shall be identical.

3.1.12 METAL FABRICATIONS

Metals used in the fabrication of components shall provide original quality surface finish and shall be free from kinks and hard bends. Metals having corroded or pitted surfaces are not acceptable. Metal straightening or forming shall be done by methods that will not cause weakening or injury to the material.

Burrs and sharp edges in holes and on sheets, plates and members shall be removed sufficiently to assure correct fits and to prevent loosening of fasteners and damage to components. Flame cutting with a tip suitable for the thickness of metal may be employed instead of shearing or sawing. Splatter and slag shall be removed and exposed cuts ground smooth. Heated metals shall be allowed to cool slowly, except in the performance of designed heat treatment and overheating shall be avoided in accordance with the recommendations of the metal manufacturer. All bends of a major character and all modular assembly fabrication shall be made with controlled means to ensure uniformity of size and shape.

Attachment 1

3.1.12.1 WELDS

Welded joints shall be sound, thoroughly fused to the base metal, smooth, free from cracks, pits, holes, fissures, under cuts, rough projecting edges and sized to provide full strength for main members, at least 2/3 strength for secondary members and 1/3 strength for miscellaneous details. Joint details and production methods shall be in accordance with the applicable standards of the American Welding Society.

3.1.12.2 BOLTED AND RIVETED CONNECTIONS

Holes, in the sizes recommended in standard practice, shall be accurately punched, drilled or formed and shall have burrs removed. Bolts, studs and cap screws shall be provided with washers or lock washers. Self-locking nuts are acceptable in lieu of standard nuts and lock washers. All fasteners shall be correctly tightened and shall have full engagement. Rivet heads shall be full, neatly made, and concentric with rivet holes and in full contact with the surface of the member. Excessive upsetting of rivets to fill holes is not acceptable.

3.1.12.3 CASTINGS AND FORGINGS

Castings and forging shall be of the best quality normally used in commercial practice. They shall be of uniform quality and condition. They shall be free from blowholes, porosity, hard spots, cracks, tears, fins, spurs, flash, shrinkage defects, misplaced coring or other injurious defects. Castings and forging shall be commercially machinable, of such quality to preclude weeping of internal fluids through the body, permit machining leak free sealing at cover and closure points and shall not be repaired, plugged or welded in any manner that adversely affects strength, use or machinability.

3.1.13 FLOOR MOUNTING OF EQUIPMENT

All conveyors (bottom of frame) less than 7 feet above the building floor, incline/decline conveyor and equipment provided by the Contractor shall be ground supported, except non-load bearing system components such as electrical conduit. All floor mounted equipment shall be securely bolted to the concrete floor in accordance with Table 1.

TABLE 1

Bolt Engagement Type Schedule Number Bolts Required Diameter Length Conveyors Not less than one per support leg 3/8” 3-1/2 Elevated Conveyors Not less than two per support leg 3/8” 3-1/2 Equipment Enclosures Not less than two per support leg 3/4” 6”

3.1.14 IDENTIFICATION MARKING

All drives and transfer cases shall have identification plates permanently attached.

Identification data shall include, as a minimum, contract number, manufacturer, Attachment 1 serial number, model number and date of manufacture.

3.1.14.1 CONTROL IDENTIFICATION

Major items of electrical equipment and major components shall be permanently marked with an identification nameplate to identify the equipment by type or function and specific unit number as required by the National Electric Code (NEC). All start buttons, selection buttons, switches and control devices shall each be marked with a permanent identification label. Hand lettering or marking is not acceptable.

3.1.15 SPECIAL PROVISIONS

3.1.15.1 INTERRUPTION OF OPERATIONS

Adjacent operations shall not be curtailed nor suspended except as absolutely essential during system installation. Any required curtailment or suspension shall be coordinated with at least 5 days notice to the Government through the Contracting Officer’s Representative. Operations shall not be curtailed nor suspended except as absolutely essential after the installation period if warranty work is required. Any required curtailment or suspension shall be coordinated with at least 5 days notice to the Government through the Contracting Officer’s Representative. Any interruption to warehouse operations greater than 15 minutes must be performed during non-duty hours (see paragraph 3.1.15.2).

3.1.15.2 WORKING HOURS

Normal working hours are 0700 - 1530 Monday through Friday excepting Federal holidays. The Contractor may be allowed, under extenuating circumstances, to perform work outside of regular hours. Where work is desired to be performed other than during regular hours, the Contractor shall request permission from the Contracting Officer’s Representative (COR) at least 24 hours in advance to allow for the necessary arrangements to be made.

3.1.15.3 REMOVAL OF WASTE AND DEBRIS AND EXISTING CONVEYOR

The Contractor shall maintain the work site and premises in a clean and neat condition during the project. All on-site waste and debris, and conduit generated in performing this contract shall be disposed of off-site at Contractor arrangement and expense. Contractor will disassemble and remove the existing tote conveyor system and floor mounted support brackets/hardware. Existing cantilever supports may be reused if the Contractor determines the supports are structurally sound.

Contractor shall provide containers for collecting disassembled conveyor materials and remove loaded containers to the Contractor pre-arranged off-site disposal location.

3.1.15.4 UTILITIES AVAILABLE FOR USE CONTRACTOR

Electricity (208 volt / 120 volt, 60 Hz receptacles), and nominal amounts of city water required by the Contractor will be furnished by the Government from existing sources. Make up and take down of connections and lines shall be

Attachment 1

Contractor’s responsibility.

3.1.15.5 DIMENSIONS

Where required to design, fit and install equipment for use in existing facilities, dimensions shall not be taken from drawings but shall be taken in the field from measurements at the site location. All dimensions in this specification are given in nominal values; therefore, the Contractor will be required to make on site measurements and will be responsible for accurate interface between all equipment and facilities modifications supplied and performed by the Contractor to assure smooth material flow throughout the system.

3.1.15.6 PROTECTION OF GOVERNMENT PROPERTY

This system is to be installed within an operational Government supply system.

The Contractor shall take all actions necessary and as directed by the Contracting Officer to protect Government property, including stock items, during system installation.

3.1.15.7 UNLOADING OF EQUIPMENT

The Contractor shall furnish the necessary personnel and special equipment (MHE, cranes, etc.) and shall be responsible for unloading of all Contractor furnished equipment/material delivered to the site. The Contractor shall give the Contracting Officer Representative 48 hours advanced notice of all Contractor material and equipment deliveries to work site.

3.1.16 SAFETY REQUIREMENTS

3.1.16.1 GENERAL REQUIREMENTS

3.1.16.1.1 These safety provisions are only general in nature and are not intended to be all-inclusive. The Contractor shall follow and will not be excused from following the safety requirements of EM 385-1-1, appropriate safety standards or other requirements established by DLA, National Electrical Code, OSHA, National Fire Code or other established safety requirements.

3.1.16.1.2 It is the responsibility of the Contractor to be aware of the safety requirements for personnel, equipment, buildings and materials. All protective coverings, shields, protective barriers, barricades, warning signs, etc., will be furnished and installed in accordance with ANSI and OSHA Standards by the Contractor where a hazard or potential hazard exists. Twenty-four (24) hours prior to the planned installation of protective barriers and barricades, the Contractor will coordinate with the COR for concurrence and approval. The removal of barricades and barriers will be accomplished by the Contractor at the completion of the work in the area.

3.1.16.1.3 The safety and health manager or his designated authority must approve all protective equipment. The Contractor shall notify the COR and get approval

Attachment 1 before commencing work.

3.1.16.1.4 The Contractor must comply with all OSHA Standards for the storage, handling, and application of flammable paints and liquids, combustibles and other hazardous materials. This includes the use of ventilation, personal protective equipment, and respiratory protection, monitoring for air contaminants and requirements to convey to workers the hazards associated with the operation.

3.1.16.1.5 The Contractor shall submit current material safety data sheets for all materials to be used on the project. This includes new materials selected and substitute materials.

3.1.16.1.6 The equipment and the controls, including any modifications and installation of same, shall conform to the requirements of ANSI/ASME B20.1-1984, Safety Standards for Conveyors and Related Equipment.

3.1.16.1.7 No torch cutting or welding work of any description shall be permitted within the installation boundaries without a permit issued by the Fire Chief, DDJC. Permits must be obtained on a daily basis by Contractor personnel calling telephone extension (209) 839-4492 or visiting the fire department, and identifying the location and type of work to be done.

3.1.16.1.8 All edges shall be beveled, ground smooth, or otherwise shaped to preclude sharp edges. Protruding parts will be designed to eliminate any hazards that could cause personal injury and will be installed only after approval by Contracting Officer or his designated Representative. The equipment and the controls, including any modifications and installation of same, shall conform to the requirements of ANSI/ASME B20.1-1984, Safety Standards for Conveyors and Related Equipment.

3.1.16.1.9 Safety Plan. The contractor shall submit a safety plan no later than two weeks prior to any on-site work. The safety plan will address/explain as a minimum:

monthly safety meetings, maintaining records for daily equipment checks, daily safety tailgate meetings, required Personal Protective Equipment (PPE) and the proper use/application, local emergency contact numbers and the phone number/location of the nearest hospital, protection of government employees from job hazards (i.e. noise, welding, MHE hazards, overhead hazards, etc.), procedures for obtaining fire permits for all welding/grinding operations and License and certification requirements for every employee involved with any confined space or abatement (i.e., Asbestos, Lead Based Paint removal, etc.).

Reference CDRL A009.

3.1.16.2 MISHAP REPORTING

A copy of the report on each job connected injury, property damage, or motor vehicle mishap will be submitted to the facilities engineer and the safety and health office. This report may be made on either a Contractor’s report form, a

Attachment 1

DLA Form 1591 mishap report, or SY 91a (motor vehicle). The estimated absence in days, if any, by employee due to injury and/or cost of property or vehicle damages shall be included.

3.1.16.2.1 FIRE STOPPING MATERIALS

Conduit penetrations through fire-rated walls shall be fire stopped. A through-penetration fire stop system shall be installed to match the fire rating of the wall.

The UL system number (from the UL Building Materials directory) shall be submitted for approval.

3.1.16.3 INSTALLATION SAFETY PRACTICES

3.1.16.3.1 Personal protective equipment such as hard hats, safety glasses, safety shoes, etc., shall be worn in all areas and on all jobs as required by the safety and health office. Contractor-furnished signs shall indicate all hardhat areas. Safety and health office personnel may inspect the work site at any time for compliance.

3.1.16.3.2 All Contractor material shall be stored in a neat and stable manner so as to preclude leaning or falling stacks. Housekeeping will be maintained at a high level at all times. The Contractor will remove scrap material, such as empty cartons, wood crates, etc., at the end of each workday.

3.1.16.3.3 Smoking is prohibited except in designated areas.

3.1.16.3.4 Gasoline operated equipment used in the building will be kept to a minimum to preclude the build-up of carbon monoxide and other hazardous fumes. For welding, electric motor driven arc welders are preferred. If gasoline or diesel engine welders are used, the welder will be kept outside the building with welding cables run inside, or the engine exhaust will be ducked to outside the building subject to the safety and health manager’s approval.

3.1.16.3.5 Only a one - (1) day supply of flammable, combustible, corrosive and other hazardous materials is to be kept at the job site. All other stock of hazardous materials shall be stored in accordance with applicable OSHA Standards at a location remote from the job site and approved by the Government.

3.1.16.3.6 Safety markings shall be in accordance with 29 CFR 1910.144 & 145.

3.1.16.4 FIRE PREVENTION

The DDJC Fire Department will control the use of all fire hydrants. No unauthorized use of fire hydrants will be permitted. Fifteen feet clearance is required around all fire hydrants at all times. Fire aisles, building entrances and building exits will be kept clear of obstructions at all times. A 24-inch clearance will be maintained at firewalls at all times.

Attachment 1

3.1.16.5 FLAME CUTTING AND WELDING PROCESSES

3.1.16.5.1 Welding, cutting or use of flame devices require prior approval of the Fire Chief and shall be performed in accordance with ANSI Z49.1 (1975). A welding screen shall be used whenever welding is being done. The Contractor shall have a firewatcher on duty whenever there is welding, cutting or open flame devices being used.

3.1.16.5.2 At no time will Contractor use or block installed fire equipment, valve houses, or post indicator valve unless authorized by the fire department.

3.1.16.6 CONTRACT DATA REQUIREMENTS

The Contractor shall furnish contract data as required in DD Form 1423, Contract Data Requirements List (CDRL), included with this specification. Contract data, outlined in Table 2, shall be prepared in accordance with this specification or data item descriptions attached thereto, and submitted in the quantities and at the times specified for approval.

TABLE 2

Sequence Number

Title DID ID

A001 Installation Schedule DI-S-SAT1 A002 Drawings, Engineering, and Associated List, Layout

Drawings

DI-E-SAT2

A003 Drawings, Engineering, and Associated List, As-Built Drawings

DI-E-SAT2

A004 Commercial Manuals, Operating Manual DI-E-SAT1 A005 Commercial Manuals, Maintenance Manual with

Recommended Spare Parts List

DI-E-SAT1

A006 Technical Representative List TSP-001 A007 Training Manual DI-E-SAT A008 Power Requirements DI-P-SAT1 A009 Safety Plan DI-S-SAT1

3.2 ELECTRICAL REQUIREMENTS

All electrical construction, controls and equipment shall be manufactured and installed in accordance with NFPA 70 (National Electrical Code). All contractor installed electrical components will be NEMA rated: ICE rated components are not acceptable. ICE rated electrical components supplied as parts of a commercially available item are acceptable.

3.2.1 ELECTRICAL INSTALLATION

It shall be the Contractor’s responsibility to connect all required electrical equipment to the existing or Contractor supplied electrical power distribution panels. All required conduits, wire, electrical power distribution equipment

Attachment 1 including transformers, distribution panels, and other electrical hardware shall be Contractor furnished and installed. All electrical work shall be in accordance with the NEC and standards of NEMA. All Contractor installed electrical panels shall be clearly and permanently labeled to identify voltage and equipment serviced.

3.2.2 NEW 480V POWER

The contractor shall provide all 480V power required to satisfy the conveyor system needs.

The contractor shall install (3) new 50 KVA, 1 Phase Unit Delta-Wye Transformers (12.47KVA/480/277V) on existing power Pole #2 (reference drawing DDJC Bldg 15-17 Conveyor), located approximately 70 feet south of Warehouse 15, Sec 5. New (4) #10 ACSR XLP Quadraplex cable overhead shall be installed to a new 2” C wheatherhead (to be located on the south wall of Warehouse 15, Section 5).

The contractor install (3) new 50 KVA, 1 Phase Unit Delta-Wye

Transformers (12.47KVA/480/277V) on existing power Pole #1 located approximately 70 feet west of Building 17 Section 1. New (4) #10 ACSR XLP Quadraplex cable overhead shall be installed to a new 2” C wheatherhead (to be located on the west wall of Warehouse 17, Section 1).

3.3 TOTE CONVEYOR SYSTEM

The same manufacturer will supply all equipment integral to the flow of material on the conveyor system. Specialized equipment not available from the primary manufacturer shall be identified as such during the submittal process as part of

CDRL A002.

3.3.1 GENERAL

The tote conveyor system shall consist of belt driven live roller conveyor or powered belt incline roller bed conveyor sized to handle the material, reference paragraph 1.3.4. Line shaft type conveyor is not acceptable. All air requirements including filters, regulators, lubricators and all connections and piping shall be contractor’s responsibility.

3.3.1.1 CONVEYOR ELEVATIONS.

Conveyors transporting totes from Warehouse 16 to Warehouse 15 will travel through the elevated tunnel at 30” above the floor of the tunnel and emerge into Warehouse 15 at an elevation of 15’3”. The conveyor will end at a gravity spiral conveyor and totes will descend to the floor level. Conveyors handling totes from Warehouse 16 to Warehouse 17 will travel through an elevated tunnel at 30” above the floor of the tunnel and emerge into Warehouse 17 at an elevation of 17’. The conveyor will end at a gravity spiral conveyor and material will descend to the floor level. Conveyors handling issues from Warehouse 15 to Warehouse 16 will travel at an elevation of 17’ along the west wall of Warehouse 15. After

Attachment 1 turning east, the conveyor will incline to a height of 19’3” before entering the elevated tunnel. Conveyors will travel through the elevated tunnel at an elevation of 5’ and connect with the existing conveyors in Warehouse 16. Conveyor handing totes from Warehouse 17 to Warehouse 16 will travel at an elevation of 17’ along the east and north walls of the warehouse before entering the elevated tunnel. Conveyor will travel through the elevated tunnel at a height of 3’ and enter Warehouse 16 at an elevation of 17’ where they will connect with existing conveyors in Warehouse 16.

3.3.2 DESIGN AND FUNCTIONAL REQUIREMENTS

3.3.2.1 PHYSICAL CHARACTERISTICS

Conveyor shall have the following characteristics.

Galvanized rollers

Carrying rollers on 3 inch centers.

Rollers of easy pop-out design for conveyors under 7’ elevation.

Roller axles shall be spring loaded so that rollers can be removed and replaced without use of tools.

Bearings for carrying, pressure and return rollers shall be ABEC-1 or equivalent with ball bearings securely mounted in a noise suppressing nylon housing, which is swaged into the roller tube.

All drive motors shall be 480 volt, 60 hertz, 3 phase, single speed, and totally enclosed with permanently lubricated sealed bearings.

All drive motors shall have a minimum horsepower of ¾ HP with the exception of spurs and curves, which shall have a minimum of ½ HP motors.

Motors shall be provided with sliding frames designed for ease of tension adjustment.

For the purpose of estimating the required horsepower on accumulative conveyor, Contractor shall use 100 pounds per linear foot live load.

Electric clutch/brake assemblies are required on all metering conveyors, incline/decline conveyors and other conveyor sections subject to frequent starts/stops.

Equipment such as turning wheels or guides will be incorporated into the

Contractor's design at spurs and curves to minimize material orientation

Attachment 1 change (rotation) as it flows through the spurs and/or curves.

Totes shall queue on the accumulation conveyor in front of either a photo eye controlled conveyor section or a powered material stop. The photo eye or material stop(s) shall be used to control the release of totes.

Mechanical sensor rollers will not be acceptable.

All conveyors shall have adjustable guardrails with the exception of work areas that require horizontal movement of material on/off the conveyor.

Conveyors over 7’ high shall have 12” solid guard rails along each side of the conveyors to keep material from falling off the conveyor. One side will have a 12 inch clear plastic guardrail to allow operators to see tote pans of material being transported on the conveyor. The other side shall have a solid metal 12 inch guardrail.

All powered roller conveyors shall be no longer than 100 ft in length and not begin in one building section and extend though a deluge tunnel into the next building section.

Line pressure shall be true “zero pressure” between accumulated packages on accumulation conveyor prior to the merge point of the existing conveyor system and the new conveyor system in Building 15 Sec. 5 to prevent jamming of totes.

3.3.2.2 MOUNTING

All service (electrical, air lines, etc.) shall be installed below the conveyor frame and inline with the conveyor frame centerline. No mounting hardware or services shall protrude into the aisle-way or work area. Mounting shall not prohibit clean up of floor or work area with hand tools such as brooms, etc. Overhead/elevated conveyor shall be wall (cantilever) mounted where possible.

3.3.2.2.1 SEISMIC CONSIDERATIONS

See UFC 3-310-01, Design: Structural Load Data, for seismic design data.

Base/city is Stockton/San Joaquin. Contractor is responsible for ensuring that all equipment is designed and installed to meet these conditions.

3.4 NOT USED

3.5 PROGRAMMABLE LOGIC CONTROLLERS

The Contractor shall furnish, install, and make operational a programmable logic controller (PLC) to control the entire Contractor furnished conveyor system. The PLC shall be an Allen-Bradley model SLC 5/05 with Ethernet (or equal). PLCs shall include an Allen-Bradley Information Processor Backplane Dynamic Data

Attachment 1

Exchange (DDE) Server (or equal) for integrating PLC data into DDE compatible Windows applications. PLCs shall be sized such that no more than 75% utilization of inputs, outputs and memory occurs. PLCs shall have sufficient internal control relays, timers and counters to accommodate the necessary programming. The Contractor shall provide all necessary documentation, ladder diagrams and schematics for the software/programming supplied with the PLCs to facilitate troubleshooting, repair and program changes (CDRL A005). Personal Computers (PCs) based control systems are not acceptable.

3.5.1 BATTERY BACKUP

PLCs shall be protected from loss of programmed logic due to power loss by an internal battery backup power source. The contents of the memory shall be protected for at least 30 days in the event of a power failure of shut down. An indicator light located on the PLC shall be activated when the battery is in use.

3.5.2 PORTABLE PLC PROGRAMMING DEVICE

Provide all hardware (portable programming terminal, interface cards, modems, cables, etc.), software (operating system, communication, PLC programming, etc.) and documentation required to program and troubleshoot the various PLC controlled equipment on-site and remotely with the use of communication modems. PLC programming and troubleshooting hardware/software shall include as a minimum:

Intel Pentium M 2.4 GHZ Processor (or equal) Clock Speed, 100 Gigabyte

Hard Drive, 1 Gygabyte RAM, Windows XP Professional operating system, 15 inch Super VGA Screen with 3.5” disk drive, DVD/CD R/W capability, Standard 9 pin RS232c Serial Port, 2 ea PCMCIA Type II slots, 56K data/fax Modem, carrying case

Allen-Bradley 1784-PCMK PCMCIA card

Allen-Bradley 1770-KF2 Interface Module Data Highway/DH+RS-

232/422

Asynchronous Interface Module

Allen-Bradley 1400e PanelBuilder configuration software

Rockwell RS Logic with Links

3.5.3 PLC DIAGNOSTICS/DISPLAY

The Contractor shall provide a diagnostics/ display package including all necessary hardware, software and programming to graphically display fault and alarm conditions on two separate VGA (minimum 10-inch) color flat panel monitors. The display monitors shall be installed on the associated PLC

Attachment 1 enclosure doors and provide a graphic representation of equipment/system controlled and associated control devices. Fault and alarm conditions with locations shall be displayed, including emergency stops. Typical display information shall include type of alarm at the affected location to allow operators/maintenance personnel to easily identify errors or anomalous conditions, which require resolution.

3.5.4 PLC CONTROL CABINETS

The control cabinets will be located in Building 15 Section 5, on the south wall and in Building 17 Section 1, on the north wall. The control cabinet/displays will allow operators and maintenance personnel to see and correct fault conditions/ jams along the entire length of the conveyor system within the building.

3.6 CONVEYOR CONTROLS

All conveyor and equipment controls shall be electric (pneumatic controls not permitted). Positioning on conveyor shall be centered via photo switch or electrical limit switches with time delay as required and controlled by a Contractor furnished and installed programmable logic controller. Electric controls shall activate electrical, pneumatic or hydraulic actuators. As a minimum the automatic controls shall:

Prevent the entry of material onto/into a conveyor that is occupied, stopped, or otherwise not operationally ready to receive the material.

Such controls shall automatically allow entry of material at such time the conveyor/equipment becomes operationally ready to receive it.

Be automatic, but shall maintain all conveyors/equipment within the control of the operator at all times.

Provide the complete range of functions (accumulation, stop, indexing, release, etc.) for all conveyors/equipment identified in this specification.

Unless otherwise specified, deactivate any conveyor that has been running for more than 5 minutes without having conveyed any material and reactivate any conveyor when material is waiting to be conveyed.

Once a conveyor section has been activated, all conveyors in the product flow path shall be activated sequentially.

Placement of controls, panels, switches and all other apparatus that control the operation/function of all Contractor equipment shall allow the operator full visual view of equipment being activated/deactivated. Controls shall not protrude into aisle ways and work areas or impede/restrict an operator's movement.

Attachment 1

3.6.1 PHOTO-EYES

Photo-eyes shall be mounted on rigid mounting brackets secured with at least two bolts to prevent rotation and misalignment. Photo-eyes shall not be mounted to adjustable fixtures that can be misaligned during operational periods, example:

adjustable guardrails, equipment guards, etc.

3.6.2 EMERGENCY CUTOFFS

All floor/tunnel mounted powered conveyors installed shall be equipped with cutoff switches actuated by cables. Cables shall be located on both sides of the floor level conveyor and be easily visible. A push-button cutoff shall be located on the wall, under the conveyor in each warehouse section (Warehouse 15 Sections 1-5 and Warehouse 17 Sections 1-3). Cutoff switches shall lock out upon actuation and the equipment adjacent to the cutoff switch will remain inoperable until the cutoff switch is reset. Safety cables shall be highly visible orange plastic covered stranded steel with a minimum diameter of 3/16 inches. The cable runs shall be straight run lengths to the maximum extent practicable, and shall run along the entire length of conveyor being controlled. Cutoff cables shall extend through associated conveyor equipment in a straight run and cutoff this equipment. The conveyor shall remain deactivated until reactivated at the main system power switch located on the master system control station. The master system control station shall have a visual display indicating which conveyor line had an emergency cutoff activated. In addition, each cutoff switch shall have a red light mounted on top to assist maintenance personnel in locating the activated cutoff switch.

3.6.3 INDUCTION STATIONS

All overhead induction sites will be provided with an automatic conveyor start feature when totes are introduced.

3.7 MOTORS

Motors furnished under this specification shall be in accordance with NEMA standard MG-1 and be of sufficient size for the duty to be performed and shall not exceed the full-load rating when the driven equipment is operating at specified capacity under the most severe conditions likely to be encountered. Unless otherwise specified, all motors shall be drip proof, totally enclosed, open framed and continuous-duty classification based on a 40 degrees C. ambient temperature of reference. Poly-phase motors shall be squirrel cage type, having normal-starting-torque and low-starting-current characteristics, unless other characteristics are specified elsewhere. When electrically driven equipment furnished under other sections of these specifications materially differs from the contemplated design, the Contractor shall make the necessary adjustments to the wiring, disconnect devices, and branch-circuit protection to accommodate the equipment actually installed. All motors shall be wired for 480 volts, 3 phase, 60-cycle service.

3.7.1 MOTOR CONTROL

Each motor or group of motors requiring a single control, and not controlled from a motor-control center, shall be provided with a suitable controller and devices

Attachment 1 that will perform the functions as specified for the respective motors. Each motor of 1/2 horsepower or larger shall be provided with thermal-overload protection.

Poly-phase motors shall have overload protection in each ungrounded conductor.

The overload protection device shall be integral with the motor or controller, or shall be mounted in a separate enclosure. Unless otherwise specified, the protective device shall be of the manually reset type. Single or double pole tumbler switches specifically designed for alternating current operation only may be used as manual controllers for single-phase motors having a current rating not in excess of 80 percent of the switch rating. Automatic control devices such as thermostats float or pressure switches may control the starting and stopping of motors directly, provided the devices used are designed for that purpose and have an adequate horsepower rating. When the automatic control device does not have such a rating, a magnetic starter shall be used, with the automatic control device actuating the pilot control circuit.