SP3300-15-R-0011_Attachment_1_SOW.pdf

Attachment 1 – SP3300-15-R-0011

Statement of Work

For Upgrade Mini-Load Systems, Bldg. 66

DLA Distribution Richmond, VA

10 Aug 15

Prepared By:

DLA Installation Support for Distribution

S-Avenue; Bldg. 1-2

DS-FDI

New Cumberland, PA 17070 i

Table of Contents

SECTION 1

1.0 SCOPE

1.1 SITE

1.1.1 SITE DESCRIPTION

1.2 SYSTEM LAYOUT AND FUNCTION

1.3 REQUIRED SYSTEM THROUGHPUTS

1.4 CONTRACT LINE ITEMS

2.0 APPLICABLE SPECIFICATIONS, STANDARDS AND CODES

2.1 GOVERNMENT DOCUMENTS

2.1.1 FEDERAL SPECIFICATIONS

2.1.2 MILITARY SPECIFICATIONS

2.1.3 OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA): ... 4

2.1.4 MILITARY STANDARDS:

2.1.5 U. S. ARMY CORPS OF ENGINEERS MANUAL

2.1.6 FEDERAL STANDARDS:

2.1.7 DRAWINGS

2.2 NON-GOVERNMENT STANDARDS AND CODES

SECTION 3

3.0 GENERAL REQUIREMENTS

3.1 GENERAL

3.1.1 MATERIALS AND OPERATING CONDITIONS

3.1.2 TREATMENT AND PAINTING

3.1.3 STATE-OF-THE-ART COMPONENTS

3.1.4 MATERIAL TO BE HANDLED

3.1.5 LUBRICATION AND ADJUSTMENT

3.1.6 DIMENSIONS

3.1.7 NOISE LEVELS

3.1.8 ELECTRICAL POWER SOURCE

3.1.9 SWITCHES AND CONTROLS

3.1.10 STANDARDIZATION OF COMPONENTS

3.1.11 FASTENERS

3.1.12 METAL FABRICATIONS

3.1.13 WELDS

3.1.14 BOLTED AND RIVETED CONNECTIONS

3.1.15 CASTINGS AND FORGINGS

3.1.16 MACHINE WORK

3.1.17 FLOOR MOUNTING OF EQUIPMENT

3.1.18 IDENTIFICATION MARKING

3.1.19 CONTROL IDENTIFICATION

3.1.20 SPECIAL PROVISIONS

3.1.21 INTERRUPTION OF WAREHOUSE OPERATIONS

3.1.22 INSTALLATION SEQUENCE

3.1.23 WORKING HOURS

3.1.24 REMOVAL OF WASTE AND DEBRIS

3.1.25 SAFETY REQUIREMENTS

ii

3.1.25.1 GENERAL REQUIREMENTS

3.1.25.2 INSTALLATION SAFETY PRACTICES

3.1.25.3 FIRE PREVENTION

3.1.25.4 FLAME CUTTING AND WELDING PROCESSES

3.1.26 CONTRACT DATA REQUIREMENTS

3.2 EQUIPMENT SPECIFICATIONS

3.2.1 HK SYSTEMS MODEL 750 S/RM - REQUIREMENTS

3.2.1.1 CONTROL ENCLOSURE

3.2.1.2 S/RM CONTROLLER

3.2.1.3 LAPTOP PC

3.2.1.4 OpNet EOA Software and OpInt Software

3.2.1.5 MANUAL CONTOLLER

3.2.1.6 ON-BOARD HUMAN MACHINE INTERFACE (HMI)

3.2.1.7 MOTOR CONTOLLERS

3.2.1.8 HORIZONTAL AND VERTICAL POSITIONING SYSTEMS

3.2.1.9 RETRACTOR POSITIONING

3.2.1.10 HORIZONTAL CONDUCTOR BAR SYSTEM

3.2.1.11 CARRIAGE POWER AND CONTROL

3.2.1.12 COMMUNICATIONS

3.2.1.13 EXISTING GOVERNMENT FURNISHED WINDOWS 7 BASED DSS/ECS

COMPUTER SYSTEMS

3.2.1.14 ENGINEERING DRAWINGS

3.2.1.15 S/RM ON-BOARD SAFETY

3.2.1.16 S/RM ON-GROUND SAFETY

3.2.1.17 ADJUSTMENT OF WATCH DOG TIMERS

3.2.1.18 END-OF-AILSE SPEED ADJUSTMENT AT P/D STATIONS

3.2.1.19 PROFILE GRIND RAIL

3.3 TRAINING

3.3.1 OPERATOR TRAINING

3.3.2 ON-SITE MAINTENANCE TRAINING

3.4 ELECTRICAL REQUIREMENTS

3.4.1 ELECTRICAL INSTALLATION

3.4.2 EXISTING PANEL BOARDS

3.4.3 SWITCHES AND CONTROLS

SECTION 4

4.0 QUALITY ASSURANCE PROVISIONS

4.1 LAYOUT OF WORK

4.2 SYSTEM MAINTENANCE

4.2.1 MAINTENANCE PRIOR TO FINAL ACCEPTANCE AND AFTER

ACCEPTANCE

4.2.2 SYSTEM MAINTENANCE WARRANTY PROVISIONS (SUPPLEMENT) .. 27

4.2.2.1 SPECIAL TECHNICAL ASSISTANCE/MAINTENANCE

4.2.2.2 CONTRACTOR TECHNICAL REPRESENTATIVES

4.3 SYSTEM CHECKOUT

4.3.1 RESPONSIBILITY FOR INSPECTION AND TESTING

4.3.1.1 COMPONENT AND MATERIAL INSPECTION

4.3.1.2 QUALITY CONFORMANCE INSPECTION AND TEST

iii

4.3.2 EXAMINATION

4.3.3 IN-PROCESS INSPECTION

4.3.4 PERFORMANCE TESTS

4.3.4.1 ECS TEST

4.3.4.2 FUNCTIONAL TEST

4.3.4.3 RELIABILITY TEST

4.3.5 STATIC AND OTHER TESTS

4.3.6 TIME LOST

4.3.7 WARRANTY

4.3.8 FINAL ACCEPTANCE

4.3.9 DEFINITIONS

4.3.9.1 INTERRUPTION OF SERVICE

4.3.9.2 EQUIPMENT

4.3.9.3 INTENDED CAPACITY

4.3.9.4 NONDESTRUCTIVE TESTS

List of Tables & Diagrams Table 1 Table 2 Table 3 Table 4 Diagram 1

SECTION 1

1.0 SCOPE

This specification covers the necessary services, labor, material, equipment and control components required to upgrade the controls of the two existing H K Systems Model 750 Cranes located in Building 66 at DLA Distribution, Richmond, VA. The cranes are located in a classified vault; therefore, all personnel working in this area must be able to pass a complete background check and will be escorted at all times during performance of work.

The Contractor shall provide all necessary services, labor, material, engineering, equipment and control components required to upgrade the electrical control system for two HK Systems (Now Dematic) Mini-load Cranes that were installed in 2006. The system includes 2 ea. 18 ft. tall cranes in Warehouse 66, Bay E with a two position workstation for each crane. The rack system was provided by UNICOR with the cranes installation. The HK Systems Model 750 cranes need to be upgraded because the existing electrical control system is obsolete and many control components are no longer commercially available. The final result will be a system, which is more reliable, easier to maintain, and easier to diagnose when a problem occurs.

While upgrading the S/RMs, the Contractor shall be responsible to ensure that the Mini-Load Systems meet or exceed the current S/RM performance. The entire supplied upgrade shall be completely operational with the existing rack system and work stations.

The Contractor shall also replace the existing MADC Software that is used to troubleshoot the cranes in semi-automatic and manual mode if this software is not compatible with the new software/firmware/hardware that the contractor will be supplied under this contract. The existing cranes communicate with the host system via an R/S 232 communications line which is connected to the DIGI system at the to the ECS control cabinet. The ECS system will send commands and receive status responses from the S/RMs such that the S/RMs shall perform picking and stow operations. This interface shall not change. The contractor controls upgrade for each crane shall be capable of meeting the performance parameters of this specification.

The project objectives and scope are as follows:

Provide electrical control system upgrades to address equipment life cycle issues associated with the following equipment control components.

1) Allen Bradley SLC 5/05 Processors

2) Allen Bradley 1746 I/O and associated interface modules

3) Allen Bradley Panel View 600 Maintenance Display

4) Sick DME3000 Laser distance Meters and Associated RS-422 Basic Interface

Modules

5) Host Interface IR Communications Modems

6) Horizontal, Vertical and Retractor Commander SE Drive Motion Controllers

7) MADC Maintenance and Diagnostic Software

1.1 SITE

The systems shall be installed at DLA Distribution Richmond, VA; 8000 Jefferson Davis Highway, Bldg. 66, Bay E; Richmond, VA 23297-5900.

1.1.1 SITE DESCRIPTION

Bldg. 66 is a World War II general purchase storage warehouse constructed in 1942. The nominal dimensions of this warehouse constructed in 1942. The nominal dimensions of this warehouse are 1,100 ft. x 200ft. The layouts are depicted in DS 15-2-1. Bldg. 66 is divided into five 200 ft. 200 ft. warehouse sections, except section E which is 100 ft. x 200 ft. The classified area for storage is located in Section E. The storage aisle is 133 ft. long and 18 ft. high with 18 storage levels. The system handles steel trays (bins). The tray size shall be nominal 26 ins. wide x 54 ins. deep x 6 ins. high. The stack height is nominal 18

ft. high.

1.2 SYSTEM LAYOUT AND FUNCTION

The Mini-load Systems through the equipment control system (ECS) maintains an inventory of Classified DVD Storage. During Automatic mode of operation, the S/RM delivers the DVD Storage Pans to the P/D. The loads are deposited on the left and right P/D Stations. The P&D stations have a tilt system that is activated when the cranes drops a tray for an issue. The left and right side P/D stations are both used for receipts/issues. Receipts are transported from P/D stations located at the end of the mini-load. The operator scans the barcode on the material and the (ECS) Equipment Control System then tells the operator which location to store the material. An operator then hits a return on the computer which tells the mini-load the address of a tray to be retrieved. In response to this selection, the S/RM travels to the selected storage tray, extracts the tray and brings it to the delivery point selected by the operator. The operator then places the material in the tray. At this point, the operator presses a control on the keyboard that causes the S/RM to pick up the tray and returns it to its assigned storage compartment for automatic storage.

Issues are downloaded from the mainframe computer from ECS. The screen on the operator’s computer tells the operator the NSN, the quantity to be picked, the location of the storage tray and the which compartment inside the tray that the material is stowed. The DSS System tells the crane to retrieve the tray. In response to this selection, the S/RM travels to the selected storage location, extracts the container and brings it to the P/D assigned by ECS. The operator then removes the material from the container and presses a control on the keyboard that causes the S/RM to pick up the tray and return it to the assigned storage location for automatic storage. The operator then places the picked material in a carton and packs the material for shipment.

1.3 REQUIRED SYSTEM THROUGHPUTS

The hours of operation of the system will be M-F 0700-1530. The contractor shall document the S/RM as to the current speeds and acceleration in the vertical, horizontal, and shuttle axis before the upgrade occurs. These will be the benchmark values. Upon completion of the upgrade, the speeds will be measured again. The upgraded cranes must be able to achieve the same benchmark speeds as was documented before the upgrade. The current throughput is 40 MHI dual cycles per crane.

1.4 CONTRACT LINE ITEMS.

The Offeror shall bid the system with separate prices for each contract line item.

The Government shall reserve the right to award each contract line item together or separately in order to match budget allocations with the maximum system capability. If the Government does not award all the contract lines during the initial award, the Government reserves the right to award each remaining CLIN up to 90 days from the initial contract award. CLIN number 0001 is the base bid.

CLIN numbers 0002 and 0003 are optional.

Table 1

CLIN No. Quantity/ Description 0001 Perform an electrical controls upgrade on the 2 existing HK

Systems 750 Cranes in Bldg. 66, Bay E per Section 3 requirements.

0002 (OPTION) Profile Grind Rail and Adjust bottom Guide Wheels 0003 (OPTION) Crane corrective and preventative maintenance for one year on all control components supplied under this contract for all crane upgrades that are awarded.

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 Offeror 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.

2.1 GOVERNMENT DOCUMENTS

2.1.1 FEDERAL SPECIFICATIONS

TT-P-645B Primer, Paint, Zinc Chromate, Alkyd Type TT-E-489H Enamel, Alkyd, Gloss, Low VOC Content W-F-408 Fittings for Conduit, Metal, Rigid (thick wall and thin wall

(EMT) type

2.1.2 MILITARY SPECIFICATIONS

MIL-D-1000 Drawings, Engineering, & Associated Lists MIL-C-46168 Painting of Industrial Trucks MIL-C-83286 Polyurethane Paint DOD-P-15328 Pretreatment Primer MIL-P-514 Plates, Identification, Instrumentation, and Marking

2.1.3 OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA):

29 CFR 1910 Occupational Safety and Health Standards

2.1.4 MILITARY STANDARDS:

MIL-STD-889 Dissimilar Metals MIL-STD-1474B (2) Noise Limits for Army Material MIL-STD-130G Identification Marking of U.S. Military Property MIL-STD-248 Welding and Brazing Procedures and Performance

2.1.5 U. S. ARMY CORPS OF ENGINEERS MANUAL

EM-385-1-1 General Safety Requirements

2.1.6 FEDERAL STANDARDS:

FED-STD-595 Federal Standard 595 A(9), Colors

2.1.7 DRAWINGS

DS 15-2-1: Upgrade Controls for HK 750 Mini-load Crane Systems, Bldg. 66, DDRV

2.2 NON-GOVERNMENT STANDARDS AND CODES

a. Standards of the National Electrical Manufacturer’s Association (NEMA)

b. American Welding Society Standards

c. Code of the American Society of Mechanical Engineers (ASME)

d. Standards of the American Institute of Electrical Engineers

e. National Electrical Code (NEC)

f. Underwriters Laboratories (UL), Inc. Publication Standards.

ANSI/UL-558 - Standards for Safety for Internal Combustion Engine.

UL-583 - Standards for Safety - Power Operated Industrial Trucks

g. American Society for Testing Material Standards (ASTM)

ASTM 53

ASTM 120

h. American National Standards Institute (ANSI)

• B20.1 Safety Standards for Conveyors and Related Equipment

• B31.8 Gas Transmission and Distribution Piping Systems

• B30.13 Safety Standards for Automated S/RMs

i. American Iron and Steel Industrial Standards (AISI)

j. National Fire Protection Association (NFPA) Publications

k. Factory Mutual System (FM) Publications

l. Rack Manufacturers Association (RMA) Standards

m. Steel Structural Painting Console (SSPS) Specification

SECTION 3

3.0 GENERAL REQUIREMENTS

3.1 GENERAL

The general requirements cited herein shall apply to any system or equipment proposed by the Contractor. The final design of the system and the capability of the designed system to meet the firm performance requirements of this contract is the responsibility of the Contractor. Alternate equipment and system architecture and layout may be proposed by the contractor provided all firm performance requirements specified in Sections 1.2 through 1.3 and 3.1 are satisfied by the proposed design.

The Contractor shall provide all equipment, material, control components, engineering and labor necessary to provide completely installed systems ready for operation. The system shall be tested by the Contractor prior to performance testing by the Government. 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 preceding 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, any design changes during the two-year period of field experience shall be identified by the Offeror. These design changes must be minor and insignificant or be demonstrated reliable through commercial application. Plastic piping for compressed air is prohibited except as a final carrier from solenoid to actuator.

Pneumatic controls shall not be permitted.

3.1.1 MATERIALS AND OPERATING CONDITIONS

Unless otherwise specifically stated, all material shall be new and of the most suitable grade for the intended purpose. All parts shall be manufactured to such standards as will permit replacement or adjustment without modification to system components. All system equipment must be capable of operating in an industrial environment with temperatures from 50 to 100 degrees Fahrenheit and from 5 to 95 percent relative humidity (non-condensing). Dust and other airborne particle shall be filtered by a replaceable air filter. Electronic components will be equipped with cooling fan to protect the systems from heat damage.

3.1.2 TREATMENT AND PAINTING

During the upgrade, any bare metal surface that is added or created (example: new control enclosure), must be prepared in accordance with the Steel Structure Painting Console, (SSPC) Specification SSPC.SP6-63 for commercial solvent cleaning. After cleaning, the S/RM, the exposed surface is to be primed with one

(1) coat of primer and finished with two (2) coats of high-visible alkyd enamel.

The paint described is expected to be for new enclosure or “touch-up” painting.

There is no major repainting of the S/RMs required.

3.1.3 STATE-OF-THE-ART COMPONENTS

The systems supplied by the contractor shall embody features that represent the current commercially available state-of-the-art products. Such features as plug-in electrical or electronic modules, solid-state circuitry, and trouble detection lights, and electronic diagnostic systems shall be utilized when practical to do so.

Automatic or lifetime lubrication shall also be utilized where applicable.

3.1.4 MATERIAL TO BE HANDLED

Material to be handled shall consist of 26” x 54”x 12” trays with cartons and loose material that will be place inside the storage compartments on the trays.

The maximum weight of each tray shall 650 lbs. per tray with no overhang above the tray container.

3.1.5 LUBRICATION AND ADJUSTMENT

Any new mechanical systems or modified conveyor shall be greased, oiled or lubricated and properly adjusted by the Contractor when installing equipment to insure satisfactory operation. Lifetime lubrication shall be utilized wherever possible.

3.1.6 DIMENSIONS

Dimensions required to design and install equipment for use in facilities shall not be obtained from drawings, but shall be taken from measurement of the site location.

3.1.7 NOISE LEVELS

No single item of equipment shall produce an operating noise level in excess of 70 decibels within 4 feet 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). Noise levels shall also be in compliance with MIL-STD-1472.

3.1.8 ELECTRICAL POWER SOURCE

All electrical shall be re-utilized from the existing power panels for the existing 2 S/RMs. The power source is 480 VAC, 3 phase, 60Hz. Each S/RM has it’s own end of aisle 30 A rated, fused safety switch that allows for “locking out” the 480 VAC power. The disconnect feeds power to the horizontal conductor bar system mounted at the top of the racks. Pickup shoes on each S/RM bring the power down to the S/RM’s main electrical control enclosure. All conduit, wire, electrical power distribution equipment, including transformers, and other electrical hardware, and labor necessary to provide power to the new Contractor installed equipment shall be Contractor furnished and installed in accordance with the National Electrical Code (NEC), National Fire Protection Association (NFPA), and other applicable state and local codes. All wiring runs shall be enclosed in heavy walled rigid conduit or thin-wall electrical Metallic Tubing (EMT) with threaded fittings. Conduit runs shall not obstruct personnel, vehicle, or other material flow patterns. All electrical work shall be in accordance with the NEC.

3.1.9 SWITCHES AND CONTROLS

All start buttons, switches, selection buttons, and other control devices shall be marked with a permanent identifying label. All wires used in control circuits shall be identified at each junction or end with a wire number, which corresponds to the number, used in the Contractor's electrical control drawings specified in (CDRL A002) of this document. Wiring terminal strips shall be used to the maximum extent practicable. No more than two wires may be terminated on any on terminal point.

3.1.10 STANDARDIZATION OF COMPONENTS

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

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

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. All fasteners for similar applications shall be identical. If torch cutting or welding is required permits must be obtained per paragraph 3.1.25.1.7.

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.

3.1.13 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 strength necessary to suit the intended purpose. All welds shall be smooth, continuous, with complete heat penetration and shall transmit stress without permanent deformation or failure when the equipment supplied is subjected to normal service and the testing in Section 4 of this statement of work.

The contractor's welders, welding operators and welding procedures shall be qualified to meet the requirements of MIL-STD-248, the American Welding Society (AWS) Standards or American Society of Mechanical Engineers

(ASME).

3.1.14 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.

3.1.15 CASTINGS AND FORGINGS

Castings and forgings shall be of the best quality normally used in commercial practice and not produce any deleterious effects for the intended purpose.

3.1.16 MACHINE WORK

All parts shall be manufactured to gage through the use of correct jigs, fixtures, tape-controlled machines or combination thereof.

3.1.17 FLOOR MOUNTING OF EQUIPMENT

All equipment not mounted to the S/RM (i.e. “On Ground” equipment – such as the end of aisle horizontal reflector) shall be floor supported, except non-load bearing system components such as conduit, and shall be securely bolted to the concrete floor in accordance with Table 2.

Table 2

Type.

Schedule

Number of Bolts Required Dia Length

ADP hardware, tables, electrical equipment and other components.

Not less than one per support leg 5/16" 2"

3.1.18 IDENTIFICATION MARKING

All equipment and major components shall have identification plates permanently attached. The information contained on the plates shall be as indicated herein and as specified in MIL-STD-130. Identification data shall include, as a minimum, contract number, manufacturer, serial number, model number and date of manufacture.

3.1.19 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 shown on the drawings and as required by 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.

3.1.20 SPECIAL PROVISIONS

3.1.21 INTERRUPTION OF WAREHOUSE OPERATIONS

Warehouse 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 (besides the crane that the contractor is working on) greater than 60 minutes must be performed during non-duty hours (see paragraph 3.1.23).

3.1.22 INSTALLATION SEQUENCE

The Contractor will be given one S/RM at a time. The Contractor will expediently retrofit and upgrade the first S/RM using Working Hours as described in paragraph 3.1.23. Upon completion of testing and Government acceptance of the S/RM, the Contractor will begin on the second S/RM. The first crane to be started on is crane # 1. The crane order shall be determined based on the workload and operational capability of the crane when contractor is ready to start work. The second crane shall be crane #2.

3.1.23 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.

3.1.24 REMOVAL OF WASTE AND DEBRIS

All on-site waste and debris, old conveyor, and conduit generated in performing this contract shall be disposed of off-site at Contractor arrangement and expense.

The contractor shall comply with FAR 52-236-7. The Contractor shall maintain the work site and premises in a clean and neat condition during the installation.

3.1.25 SAFETY REQUIREMENTS

3.1.25.1 GENERAL REQUIREMENTS

3.1.25.1.1 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 Electric Code, OSHA, National Fire Code or other established safety requirements.

3.1.25.1.2 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.

3.1.25.1.3 All protective equipment must be approved by the safety and health manager or his designated authority. The Contractor shall notify the COR and get approval before commencing work.

3.1.25.1.4 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, respiratory protection, monitoring for air contaminants and requirements to convey to workers the hazards associated with the operation.

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

3.1.25.1.6 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.

3.1.25.1.7 No torch cutting or welding work of any description shall be permitted within the installation boundaries until the site of the proposed work has been inspected by the base fire department, and a permit has been issued. Permits must be obtained on a daily basis by Contractor personnel calling telephone extension 4-7298 or visiting the fire department located in Building CA-11, and identifying the location and type of work to be done.

3.1.25.1.8 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 the 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.

3.1.25.1.9 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 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.

3.1.25.2 INSTALLATION SAFETY PRACTICES

3.1.25.2.1 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.

3.1.25.2.2 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.

3.1.25.2.3 Smoking is prohibited except in designated areas.

3.1.25.2.4 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 ducted to outside the building subject to the safety and health manager's approval.

3.1.25.2.5 Only a one (1) day supply of flammable, combustible, corrosive and other hazardous material 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.

3.1.25.2.6 Safety markings shall be in accordance with 29 CFR 1910.144 and 145.

Alternating green and white stripes on the floor shall designate location of safety equipment.

3.1.25.3 FIRE PREVENTION

The use of all fire hydrants will be controlled by this center's fire department. 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.

3.1.25.4 FLAME CUTTING AND WELDING PROCESSES

3.1.25.4.1 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 on duty at such times and as required by the Defense Supply Center Richmond Fire Chief when welding, cutting or using open flame devices, a fire watcher who shall be a qualified fire fighter with not less than three years consecutive experience.

3.1.25.4.2 "Hot tapping" or other cutting or welding on a flammable gas or liquid transmission or distribution utility pipeline shall be performed by a crew qualified to make hot taps. For a gas pipeline, see 841-28 in "Gas Transmission and Distribution Piping Systems," ANSI B31.8 (1968).

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

3.1.26 CONTRACT DATA REQUIREMENTS

The Contractor shall furnish contract data as required in DD Form 1423, Contract Data Requirements List, 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 3

Sequence Title DID ID. Number 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 DI-E-SAT1 A006 Technical Representative List DI-E-SAT11 A007 Training Material and Schedules DI-E-SAT

A008 Power Requirements DI-P-SAT1 A009 Design Data and Calculations DI-E-2440A A010 Certificate of Compliance DI-E-SAT14 A011 System Test and Verification Plan DI-T-SAT1 A012 Software Documentation Manual DI-S-SAT-2

3.2 EQUIPMENT SPECIFICATIONS.

All upgrades to the 2 existing HK Systems Model 750 Cranes must meet the safety and design requirement of ANSI/ASME B30.13-1991 and addenda B30.13-1994 Safety Standards for Storage/Retrieval Machines (S/RM) and Associated Equipment. All mechanical /electrical equipment and components of S/RMs shall be properly designed to continue interfacing with their existing environment. The 2 HK Systems 750 Mini-load Cranes shall have any new / upgraded components located such as to not interfere with current machine operations. The 2 S/RMs will continue to interface with the two existing P/D stands. All equipment supplied shall be designed and installed in compliance with seismic zone 1 requirements, providing a rigid/stable structure capable of handling all anticipated loads/stresses. Contractor shall ensure equipment design does not cause/result in buildup of static electricity, and install protective devices as required.

3.2.1 HK SYSTEMS MODEL 750 S/RM - REQUIREMENTS

The 2 HK Systems Model 750 Cranes are fully automatic vehicles. Each section below will describe the current electrical control system components and the required upgrade.

3.2.1.1 CONTROL ENCLOSURE

The main control enclosure is mounted off of the base/mast of the S/RM. The existing enclose can be reutilized provided that the old control components are removed.

3.2.1.2 S/RM CONTROLLER

The existing controller is an Allen Bradley SLC 5/05 which will be eliminated.

The current controller is to be replaced with an Allen Bradley Compact Logix Model 1769-L33ER or equivalent. The new PLC hardware will be located in a similar panel location as the SLC 5/05. The contractor shall supply the PLC and the associated I/O Modules including electrical disconnects, fusing and electrical safety devices. The interface between the Host Material Control System (ECS and DSS) will be replicated so that no Host changes will be necessary. The contractor will develop the PLC program using RSLogix5000 programming software. The contractor will provide a completely documented program as a deliverable as part of the project. (CDRL A011). A laptop maintenance PC and the RS Logix 5000 software are to be provided by the contractor. The contractor will install the PLC SRM control programs on the laptop. Most of the existing MADC end of aisle applications will continue to operate. Due to the PLC upgrade, certain functions will reside in alternate programs. For example, the diagnostic functionality will be available through the contractor supplied RSLogix5000 software and going “on line” with the PLC code. The exerciser (motion command) functionality will continue to be provided through MADC.

Rack mapping changes can be done using RSLogix5000. Current MADC functions for the SRM motion and exercise function will be continued to be supported for control room operation. PLC program support, diagnostics, and rack mapping functions will be performed when the laptop maintenance PC is plugged into the port on the new SRM PLC. This PLC shall have sufficient inputs and output to accommodate all devices necessary. Memory capacity shall be sufficient to accommodate all programming steps necessary for machine controls. PLCs shall also have sufficient internal control relays, timers and counters to accommodate the necessary programming. PLCs shall be protected from the loss of programmed logic due to the power loss by an internal battery back-up power source and R-PROM or EE-PROM Chip. An indicator light located on the PLC shall be activated when the battery is in use. The contractor will provide Allen Bradley I/O modules where appropriate. This shall include local 1769 Compact Logix I/O modules or equivalent and 1734 POINT I/O modules or equivalent. The contractor will provide a new full subpanel for the Master Control Cabinet (MCC) that will be wired, configured and tested by the contractor engineers before shipping. The completed and tested subpanel will then be shipped to DDMA for installation into the existing main control enclosure. This will reduce field installation and start-up time. The general requirements are as follows:

3.2.1.2.1 CONTROLLER MODULES

The PLC will coordinate the operation of the S/RM control system by monitoring the state of inputs, scanning and solving logic, and controlling the state of outputs.

The following are modules that shall be contained in the PLC System:

a. Main Processor Module (CPU) - The main processor module is the core of the PLC system. It provides the program, storage, memory management, and program execution capabilities necessary to operate the control system. Connection to the main processor allow for communication peripheral devices and other processors. This module is located at the left most slot of the local I/O chassis.

b. I/O Chassis - The PLC I/O chassis provides housing for I/O modules used in the PLC system. The chassis should be sized for the appropriate number of I/O modules required for the control system.

c. Power Supply – The PLC power supply provides DC bus power for the modules housed in the I/O chassis. Each I/O chassis requires a power supply.

d. Input Modules – Input devices associated with the control include limit switches, photoelectric eyes, proximity switches and push buttons. These field devices are wired to PLC input modules. Each module contains circuitry that switches to 120 VAC or 24 VDC field device signals to logic level signals from the PLC to 120 VAC field signals used to power the output devices.

e. Output Modules – Output devices associated with the control system include motor starters, solenoids, and indicator lights. These devices are wired to the PLC Modules. Each modules contains circuitry that switches the logic signals from the PLC to 120 VAC field signals used to power output devices.

f. Communication Modules - PLC modules are required to establish communications over several types of networks. Appropriate communication to intelligent drives, the host computer, remote PLC I/O racks, and other control systems, etc.

3.2.1.2.2 PLC Functional Responsibilities

The PLC level controls are responsible for performing all required machine functions including:

a. Safety: Provide software safety interlocks (in addition to the always provided hardwired safety circuits) to ensure the safety of all personnel and equipment.

b. Motion Control: The PLC receives the commands from the manager and sends the command out to the proper axis; horizontal, vertical and shuttle.

Depending upon the control configuration, this can be the actual drive control (speed and direction) or interfacing through serial communications cards to intelligent motion control systems.

c. Host Communications: The S/RM must interface to the ECS (Equipment Control System) Host to provide load completion status information. For example; pick-up, deposit, move, and alarm cleared.

d. Monitoring: Provide fault detection and orderly S/RM shutdown, alarm annunciation and S/RM equipment status information to the ECS as required by the system.

3.2.1.2.3 PLC Program

The contractor is responsible for the PLC code that is responsible for automatic control of the S/RM. Program code is to a contract deliverable in accordance with CRL A012. Functionality includes, but is not limited to the following:

a. Manual jog controls.

b. Host communication for receiving motion commands.

c. Host communication for sending status responses.

d. Safety/Fault Logic.

e. Sequential control of automatic cycle.

f. 3 axis – Positioning systems.

g. 3 axis – Drive motion control.

The memory of the PLC is to be organized in a logical manner to allow a modular approach to program development and troubleshooting. It is to be organized into several logic modules as described in the following sections:

a. Aisle (horizontal) Control

b. Hoist (Vertical) Control

c. Shuttle control

d. Manual Controls

e. Fault Logic

f. Communications

Each of the above modules should process all inputs and outputs related to the appropriate axis of the S/RM control. This includes push-button lights for manual control, extreme travel limit sensors, positioning sensing inputs, and fault logic for automatic control. This section also supports the connectivity to the corresponding motor drives and positioning system.

3.2.1.2.4 CONTROL SYSTEM MODES OF OPERATION

There shall be three modes of control system operation, automatic, semi-automatic and manual mode. A description is as follows:

a. Automatic Mode: In the automatic mode of operation, the PLC receives

Pick-Up and Deposit Commands from the Government ECS/DSS Host computer and controls the operation of the 3 axis to perform the command. All safety provisions are observed and if a failure occurs, proper diagnostic information is passed up to the Host ECS/DSS Computer. Upon completion of the command, the Host is notified and the inventory database is updated.

b. Semi-Automatic Mode: In the semi-automatic mode of operation, the PLC receives Pick-Up and deposit commands from an end of aisle PC or workstation. The software for this mode of operation shall be supplied by the contractor. Commands may be passed that control the operation in the three axis required to perform the command. All safety provisions are observed and if a failure occurs, proper diagnostic information is passed back to the command issuing device with an orderly shutdown of the S/RM. The Host is not notified upon completion of the command (no host inventory update). There is a requirement to issue semi-auto commands from a PC at both the front and of each aisle. The system shall properly be designed with a safety system which is designed such that the S/RM cannot receive motion commands from more than one point/source at a time.

c. Manual Mode: Manual mode in enabled through a selector switch “on-board” the S/RM. In manual mode, all commands from the host computer are ignored and the manual push buttons are enabled for jogging the specific axis desired. The safety provisions are still observed while the S/RM is in manual operation, and only reduced speeds are allowed.

An end of aisle switch is required at the front and back end of the aisle to set on-line off-line operation.

3.2.1.2.5 CONTROL SYSTEM INTERFACES

The new S/RM control system will support the following interfaces below:

a. PLC Local Interface – On Board Control for the S/RM Base and Mast

Assemblies. This is the interface between the PLC and its I/O. There is a discrete interface to field devices such as limit switches, photo eyes, positioning controllers, and motor starters.

b. PLC Remote Interface – On-Board Control for the Carriage Assemblies.

The PLC will communicate through a remote I/O network to carriage mounted I/O Modules. This will minimize the hardwired I/O between the carriage and main control enclosure.

c. PLC to Host Interface - Off-Board to on-Board Control.

3.2.1.3 LAPTOP PC

Contractor is to supply one (1) laptop PC for each of the two cranes with the following characteristics to maintain the HK 750 Mini-load Cranes.

Table 4

The Contractor may supply 1784-PCMK card and cables for each Laptop supplied. Note that if channel 0 is used, it must be available for “on line” troubleshooting.

3.2.1.4 OpNet EOA Software and OpInt Software

OpNet Software will be provided for performing maintenance and diagnostics functions with the upgraded SRM. This Windows based software will run on the new contractor supplied laptop maintenance PC. The OpNet software provides features for SRM diagnostics, status, semi-auto commands and modification of rack and parameter data. The Ethernet channel of new MDS RF modems will be utilized by OpNet to communicate with the upgraded SRM from an Ethernet port on the end of aisle communication panel. This product is a diagnostics and troubleshooting tool for DDRV’s maintenance team. The contractor shall all provide OpNet software and all programming required on the each of two Government PCs at the front of the aisle to replace the existing Panther Software which interfaces with the Window 7 Professional DSS/ECS Platform on the Government DSS/ECS Computer PCs located between the two P/D stations at the front of each S/RM aisle.

Windows 7 Professional Operating System, and Windows 8 Office Professional Operating System that can be loaded at any time to replace Windows 7 without affecting the interface capability and functionality of any PLC Program Quad Core Intel Pentium Processor

15.4 inch Wide Screen Super VGA or Higher Resolution Video Adapter and Screen DVD/CD Writer Combo Drive Min. 500 Gigabyte Hard Drive Min 1.6 GHz/2MB Cache/ 400 MHz FSB) Min. 3 GB Shared DDR SDRAM, 2 DIMMS Standard 9 pin RS232c Serial Port Qty 1 – PCMCIA Type II slots Built-in 56kbs Modem Carrying case Internal Network Card Internal Wireless Networking Card ( 802.11 b/g, 54 Mbps) Cables for interfacing to the Compact Logix units.

Allen Bradley RS Logix 5000 software and license

3.2.1.5 MANUAL CONTOLLER

The current S/RMs uses a wired manual controller. This unit shall be reutilized unless it is not compatible with the contractor’s control design. If this is the case, then the contractor shall provide a new wired manual controller. One manual controller is dedicated to each crane. The hand controller provides functions to manually drive the shuttle, vertical and horizontal motors. Override safety capability is required.

3.2.1.6 ON-BOARD HUMAN MACHINE INTERFACE (HMI)

A new Allen Bradley PanelView Plus 700 or equivalent Human-Machine Interface (HMI) will be moiunted to the front of the main control enclosure. The 6.5” HMI will provide a graphic display for operator and maintenance personnel with enhanced SRM HMI Diagnostics and Maintenance Functions. The HMI functions shall include the following:

1) Alarm annunciation with text message descriptions of alarms.

2) Diagnostics information on motion and position of all three machine axes.

3) Manual SRM jog control.

4) Diagnostic information of all discrete I/O states.

5) Display and modify rack map position data.

6) Communication status.

7) Machine calibration and setup (Configuration and System Parameters).

8) Alarm history for the most recent 100 alarms.

3.2.1.7 MOTOR CONTOLLERS

The existing Commander SE AC Drives will be replaced with Emerson Techniques M400 AC Drive Controllers or equivalent for horizontal, vertical and retractor axes. New dynamic braking resistors will be provided. The existing motors, brakes, and gearboxes will be reused along with the motor cables for axes. The existing motor and reducer assemblies will be retained. The Emerson Panel Mount drives are standard AC input, AC output modules for installation within a control panel. The modules shall be easy to install, commission and shall be able to be applied in a wide range of applications. These motor control units shall be able to be configured using the keypad to operate in the following modes:

1) Open loop Vector or V/Hz AC Induction Motor Control.

2) Enhanced open loop rotor flux control for induction motor control.

3.2.1.8 HORIZONTAL AND VERTICAL POSITIONING SYSTEMS

The existing horizontal and vertical positioning systems are SICK DME 3000 optic laser positioning system. The contractor is to remove the existing laser positioning systems and replace them with a new SICK Optical DL 100 optic laser positioning systems or equivalent. The DL-100 units use a visible laser to determine current position to a reflector. The horizontal axis will have a laser mounted on board the Storage and Retrieval Machine pointed at a reflector at the end of the aisle in a maintenance area. As the SRM moves horizontally back and forth down the rail, the distance between the reflector and the laser changes. The laser broadcasts this information in a SSI format to the CompactLogix Processor.

Similarly, the vertical axis will have the laser mounted to the base of the SRM and aligned with a reflective target mounted on the carriage. As the carriage raises and lowers, the distance to the laser changes. This position data is also transmitted to the CompactLogix in SSI format. The lasers used are absolute devices where no “homing” or reference point is required. These devices use phase correlation to measure the transit time of light from a semiconductor class 2 laser. This is used to calculate the distance from the SRM to the reflective target at the end of the aisle. The contractor shall run an exercise program that checks and corrects the mapping of each rack storage location for the two cranes before the operating tests as described in section 4. The new position systems shall provide the following benefits:

1) Improved S/RM position accuracy. The laser position systems shall be capable of +/- 4 millimeters (.1574 inches).

2) The laser position systems will allow the S/RM…