ATTACHMENT_1_-_A0005-_REVISED_SOW.pdf

ATTACHMENT 1

REVISED STATEMENT OF WORK

AMENDMENT 0005

Statement of Work For

Track Shoe Preservation System, Bldg. 595

DLA Distribution Red River, TX

20 Apr 2015 Revised 24 Jul 15

Prepared By:

DLA Installation Support for Distribution

S-Avenue; Bldg. 1-2

DS-FDI

New Cumberland, PA 17070

TABLE OF CONTENTS

1.0 SCOPE -------------------------------------------------------------------------------- 3

1.1 SITE ----------------------------------------------------------------------------------- 3

1.2 SYSTEM LAYOUT AND FUNCTION (EXISTING SYSTEM) ------------ 3

1.3 REQUIRED SYSTEM THROUGHPUT ----------------------------------------- 5

1.4 CONTRACT LINE ITEMS -------------------------------------------------------- 5

2.0 APPICABLE SPECIFICATIONS, STANDARDS AND CODES ----------- 7

2.1 GOVERNMENT DOCUMENTS -------------------------------------------------- 7

2.2 STANDARDS AND CODES ------------------------------------------------------ 7

3.0 REQUIREMENTS ------------------------------------------------------------------- 9

3.1 GENERAL REQUIREMENTS ---------------------------------------------------- 9

3.2 EQUIPMENT SPECIFICATIONS ------------------------------------------------ 19

3.3 AIR COMPRESSORS --------------------------------------------------------------- 32

3.4 TRAINING ---------------------------------------------------------------------------- 33

3.5 ELECTRICAL ------------------------------------------------------------------------ 34

4.0 QUALITY ----------------------------------------------------------------------------- 36

4.1 LAYOUT ------------------------------------------------------------------------------ 36

4.2 SYSTEM MAINTENANCE ------------------------------------------------------- 36

4.3 SYSTEM CHECKOUT ------------------------------------------------------------ 37

4.4 INSPECTION AND TEST --------------------------------------------------------- 37

SECTION 1

1.0 SCOPE

This Statement of Work covers the work, material, equipment and controls that shall be required to install and make operational a track shoe preservation system. The function of the track shoe preservation system is to transport track shoe bundles by inbound accumulating conveyor to dip tank, apply government-furnished P-1 preservative/solvent mix to material, dwell, dry material, and transport material to outbound conveyor lines to be shipped. Also included in this project is demolition and disposal of the existing system in accordance with all EPA and Federal Government regulations, and a new compressed air system. The Government d e s i gn for this system is shown on drawing D S 1 5 - 1 - 1 , and is included as a part of this Statement of Work. Contractor supplied equipment shall interface with and be completely compatible with all Government facilities. This specification establishes the minimum performance requirements for the system.

1.1 SITE

The site of work is located at the DLA Distribution Depot Red River (DDRT), on the site of Red River Anny Depot. DDRT is located approximately 18 miles west of Texarkana, Texas on Interstate 30. The Contractor entrance to the depot is

0.3 miles south of exit 206 and 0.2 miles east on U.S. Hwy 82. The installation of the work is located in Bldg. 595, Zone 6 . Bldg. 595 Zone 6 was built in 1954, 200' x 200' area, with an 8" concrete floor, CMU exterior walls, a 20 ft. clear stack height, and an EPDM roof. The distance from floor to ceiling is 24 ft.

1.2 SYSTEM LAYOUT AND FUNCTION OF NEW SYSTEM (REFER TO

DRAWING NO. 15-1-1)

. The function the new track shoe preservation system is to unitize preserve, and mark bundles of track shoes for storage or shipment.

1.2.1 PROCESS DESCRIPTION AND DESIGN CONSTRUCTION CRITERIA.

The system shall transport track shoe bundles by inbound accumulating conveyor to dip tank, apply government-furnished P.-1 preservative/solvent mix to material, dwell, dry material, and transport material to outbound conveyor lines to be shipped. Material will be received from carriers and off loaded by fork truck and staged in a designated pre-strap staging area. Material will be transported via fork truck from pre-strap staging to designated induction work stations by G overnment personnel. Government personnel will strap and bundle loads. Material will be placed on the two (2) inbound conveyors by overhead bridge crane or by fork truck. Material will be automatically transported by the accumulation conveyor to the operator load station where the material will be manually loaded onto the trolley by pneumatic hoist or by forklift. The pallet accumulation conveyors will have a capacity of 13 pallets inbound, one pallet each turntable and one empty pallet staging behind the three turntables. The empty pallet will transfer to the pallet conveyor behind conveyor for staging until a finished load is ready to be shipped placed back on the empty pallet for shipping.

When material is loaded and hoisted to home position, the operator will select by panel or other automatic means the dip tank destination. A 5 second start-up warning light and electric horn will initiate movement of the load. The load will arrive at the destination and automatically lower and submerge the load by monorail in the P-1 preservative. The load will be programmed to remain submerged for 15 seconds. The load will then automatically return to home position and advance to the end of the dip tank. The load will dwell in this position for 1 minute. A minimum of 3 sequential loads will accumulate and dwell behind the lead load (minimum 4 loads total). At no time shall a load dwell over the dip tank more than 4 minutes.

A 5 second warning light will initiate movement of the loads to the drip pan destination. The loads will accumulate and dwell in this position no more than 5 minutes for secondary deposit of excess preservative.

A 5 second alternate warning horn will initiate movement of the load into the wind tunnel for drying. The loads will index and accumulate to the destination point inside the tunnel. An automatic fan/heating system and exhaust system will start the drying process, which will be accomplished in 10 minutes or less from the time the last load has accumulated and come to a complete stop. The Contractor shall be responsible for selecting the most efficient and effective means of drying the material within the required time frame. A material safety data sheet (MSDS) is located at Annex A. The system furnished shall be complete with manual override capability, automatic fire protection and operator- accessible emergency stop, and automatic controls and digital displays.

A 10 second alternate warning light will signal completion of the drying process. The drying system will automatically stop and loads will exit the tunnel and accumulate at the operator unload station. The material will be completely dry to the touch by the operator at the unload station. The system shall be programmed such that any load may by-pass any station and return to designated stops or specific stations along the monorail path. All loads will arrive and accumulate at the operator unload station. The operator will lower the load onto a pallet and disconnect the hoisting mechanism from the load and hit the conveyor control to manually advance the load along the outbound powered conveyor line. The outbound line sequence shall be that the west line will load with 6 finished pallets, then the north line will load with a total of 6 pallets. Government personnel will transport the load to a designated staging area for shipment.

Product Dimension in the Dipping Configuration. The Contractor shall design the system for the largest assembled Track Shoe bundles, which are 72 inches long by 28 inches wide by 28 inches tall when configured in the dipping position. Track Shoe bundles have a gross weight of 1,310 lbs.

1.2.2 MAINTENANCE CONTRACT FOR ONE YEAR AFTER FINAL SYSTEM

ACCEPTANCE

If CLIN 0004 is awarded; the contractor shall perform preventative and correct maintenance on the system supplied under this contract for a period of one year after final acceptance. The contract shall perform a quarterly PM on the entire system and shall maintain less than one hour response time per break down from the time the contractor is notified. The contractor must also maintain 98% up time throughout the period of operation between 0700 through 1530 Monday through Friday.

1.3 REQUIRED SYSTEM THROUGHPUTS

The hours of operation of the system will be M-F 0700-1530. The system shall have the following a throughput capacity of capacities.

Pallet Conveyor, Chain Hoist and Monorail Conveyor System:

Average hourly throughput: 30 loads per hour Maximum hourly throughput: 48 loads per hour Monorail Conveyor System Accumulation: 12 loads

Dip Tank and Wind Tunnel System

Average hourly throughput: 30 loads per hour Maximum hourly throughput: 48 loads per hour Accumulation inside tunnel: 8 loads

1.4 CONTRACT LINE ITEMS

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

Quantities specified are only estimates and shall be designed and verified by the contractor. 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 line items during the initial award, the Government reserves the right to award each remaining CLINs up to 180 days from the initial contract award. CLIN number 0001 and 0002 are the base bid. CLINS 3 and 4 are optional CLINS.

1.4.1 CLIN NO. 0001 Track Dip Preservation System

QTY DESCRIPTION

12 ea Pneumatic Motorized Tractor Trolleys

4 ea Lowerators 200 ft Power and Free Monorail Conveyor 245 ft Pallet Accumulation Conveyor, 52 ins. wide 3 ea Pallet Turntables 1 ea Drying Tunnel with Fire Protection System 1 ea Dip Tank 20’ x 6’ x6’ 1 ea Drip Pan 20’ x 6’ x 1’ 4 ea Forklift Barriers 2 ea Ergonomic workstations 1 ea Install GFE Pallet Stacker with New Conveyor System

1.4.2 CLIN 0002 DEMO AND DISPOSE OF EXISTING SYSTEM

9 ea 12 ea. Pneumatic Motorized Tractor Trolleys 4 ea Lowerators

200 ft Power and Free Monorail Conveyor 245 ft Pallet Accumulation Conveyor, 52 ins. wide 3 ea Pallet Turntables 1 ea Drying Tunnel with Fire Protection System 1 ea Dip Tank 20’ x 6’ x6’ 1 ea Drip Pan 20’ x 6’ x 1’ 2 ea Workstations 4 ea Forklift Barriers

1.4.3 CLIN 0003 Air Compressor System

1 ea Air Compressor Distribution System (minimum 75 HP) 1 ea Air compressor Cover

1.4.4 CLIN 0004 1 Year Maintenance Contract

1 YR Preventive and Corrective Maintenance Contract for the

Entire System

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 forms a part of the specification to the extent specified herein:

2.1 GOVERNMENT DOCUMENTS

2.1.1 FEDERAL SPECIFICATIONS

NN-P-71 Pallets, Material Handling, Wood Stringer Construction, 2 way and 4 way (partial) TT-P-645 Primer, Paint, Zinc Chromate, Alkyd Type TT-E-489 Enamel, Alkyd, Gloss, Low Voc Content Aluminum W-F-408 Fittings for Conduit, Metal, Rigid (thick wall and thin wall

(EMT) type FF-B-171A Bearings, Ball, Annular (General Purpose) FF-B-185(4) Bearings, Roller, Cylindrical, and Bearings, Roller, self&

Aligning FF-S-325 Shield, Expansion, Nail, Expansion, and nail, Drive screw

(Devices, Anchoring, Masonry) QQ-S-741D Steel, Carbon, Structural Shapes, Plate & Bars

2.1.2 MILITARY SPECIFICATIONS

MIL-C-83286 Polyurethane Paint MIL-P-514 Plates, Identification, Instrumentation, and Marking MIL-C-16173 Corrosion Preventative Compound, Solvent Cutback, Cold

Application, (P-1) MIL-STD-686 Cable and Cord, Electrical, Identification Marking and Color

Coding MIL-STD-1472 Human Engineering Design Criteria DOD-P-15328 Pretreatment Primer

2.1.3 FEDERAL STANDARDS

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

2.1.4 OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

STANDARDS

29 CFR 1910 Occupational Safety and Health Standards 29 CFR 1926 Safety and Health Regulations for Construction

2.1.5 U. S. ARMY CORPS OF ENGINEERS MANUAL

EM-385-1-1 General Safety Requirements

2.1.6 MILITARY STANDARDS

MIL-PRF-61002 Identification Marking of U.S. Military Property MIL-STD-248 Welding and Brazing Procedures and Performance MIL-STD-1474 Noise Limits for Army Material MIL-STD-686 Cable and Cord, Electrical, Identification Marking and Color

Coding MIL-STD-1472 Human Engineering Design Criteria

2.1.7 DRAWINGS

DS 15-1-1 Replace Track Dip Preservation System, Bldg. 595, DDRT

2.2 STANDARDS AND CODES

Standards of the National Electrical Manufacturer’s Association (NEMA) American Welding Society Standards Code of the American Society of Mechanical Engineers Electronic industry association standards (EIA) Standards of the American Institute of Electrical Engineers American Society for Testing Materials (ASTM) Standards

ASTM 53

ASTM 120

American National Standards Institute (ANSI) B20.1 Safety Standards for Conveyors and Related Equipment B31.8 Gas Transmission and Distribution Piping Systems B30.16 Safety Standards for Overhead Hoists B30.19 Safty Standards for Cableways

National Fire Protection Association (NFPA) Publications National Electrical Code (NEC) Underwriters’ Laboratories, Inc., Publication Standards

ANSI/UL-558 - Standards for Safety for Internal Combustion Engine UL-583 - Standards for Safety Power Operated Industrial Trucks

American Iron and Steel Industrial Standards (AISI) Factory Mutual System (FM) Publications

IEEE-STD-112 Test procedures for Polyphase Induction Motors

SECTION 3

3.0 REQUIREMENTS

3.1 GENERAL REQUIREMENTS

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 are the responsibility of the contractor Alternate equipment and system architecture may be proposed by the contractor provided all firm performance requirements specified in Sections 1.3 through 1.4 and 3.1 through 3.5 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. The system shall consist of equipment of equal or greater quality than specified, to include but not limited the following:

a. Accumulation Conveyor (pressure-controlled zone accumulation conveyor (PCZAC) for incoming, outgoing and empty pallet distribution as specified on drawing. (Drawing DS 15-1-1).

b. Overhead Monorail Conveyor (for automatic and manual conveyance of trolley)

c. 12 Air Motorized Tractor Trolleys (1 ton capacity, pneumatic, PLC driven and manual override controls, w/ operator panel and fault detection capability, automatic dipping capability by pneumatic hoist or monorail design)

d. Preservative Application Dip Tank (pneumatic agitation, fusible link fire protection, Extra Heavy-Duty construction, sized as shown on drawing DS 15- 1-1).

e. 1 Air Compressor, related equipment (500 gallon holding tank, oil water separator and dryer to accommodate and fully support pneumatic equipment, filters, regulators, and dryers but shall be minimum 75 HP) as shown on DS 15-1-1.

f. 1 ea Wind Tunnel Drying System (for drying preservative on material after dipping, 10 minute maximum drying time, completely dry to touch after exiting tunnel, exhaust system, fire protection and safety devices, automatic w/manual override operation, sized to accommodate a minimum 8 loads, Heavy-Duty construction)

g. 4 Forklift Barriers (4"x4" steel square tubing at locations depicted on drawing. DS 15-1-1, safety yellow finish)

h. 1 Drip Pan (for secondary draining of excess preservative off material, heavy-duty construction, sized as depicted on drawing no. DS 15-1-1)

Unless otherwise specified, structure, motors, controls, air supply and safety features shall be determined by the Contractor in accordance with performance requirements, capacity, and space limitations as described herein and on drawing DS 15-1-1. The Contractor is responsible for manufacturing the system in compliance with existing OSHA regulations.

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

All surfaces not yet painted but suitable for painting, with the exception of plated surfaces, shall be thoroughly cleaned to provide a clean, dry surface, free of all mill scale, oil grease, dirt, rust or other inhibiting material, and shall be painted with paint conforming to Federal Specification TT-E-489H, consisting of one coat of base primer conforming to Federal Specification TT-P-645B and one coat of enamel applied in accordance with standard commercial practices to assure complete coverage and durability of finish. An alternative painting process which will also be acceptable is an on-line metal cleaning process, then a blown dry or baked dry preparation prior to painting. The dry metal material is painted using an electrostatic spray paint process. The pre-wash cleaning process deposits an iron phosphate coating which is then covered with an alkyd baking enamel. The finish coat, when dry, shall be a smooth, even surface, free of runs, sags, drips or other defects. Color of the finish coat shall be the manufacturer’s standard commercial color.

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, 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

Pallets to be handled will conform to Federal Specification NN-P-71, with dimensions of 40 inches long by 48 inches wide by 5 inches high (unloaded).

The system furnished shall be designed to handle the following products on MIL pallets:

Track Shoe

Length Width Height . Weight. (lbs.)

9316 61" max. 29" max. 31" max. 1080(lbs.) bundle

50" max.

58" max.

50.5”max.

72” max.

52” max

29" max.

28" max.

27”max.

25”max.

25”max.

15.5" max.

16" max.

16”max.

27.5”max.

13”max.

608 (lbs.) bundle 1,248 (lbs.) bundle 1,150(lbs.)bundle 973 (lbs.) bundle 1,248(lbs.) bundle

3.1.5 LUBRICATION AND ADJUSTMENT

All equipment 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 equipment shall be taken from the main electrical power distribution panel in Bay D-1 as shown on drawing no. DS 15-1-1 which is 400 amp, 480 volt, 3 phase, 60 Hz. All conduit, wire, electrical power distribution equipment, including transformers, and other electrical hardware, and labor necessary to provide power to the 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. The contractor shall also remove all conduit from the old system that was removed.

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.

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 manufacturer’s 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 3.1.16.1.7.

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.

3.1.12.1 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 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).

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

3.1.12.4 MACHINE WORK

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

3.1.13 FLOOR MOUNTING OF EQUIPMENT

All equipment 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 1.

Type Schedule Number of Bolts Required Diameter Length

IT hardware, tables, Electrical equipment and other components requiring light

Not less than one per support leg

5/16” 2”

Conveyors 30” or less from the floor to the top of the Conveying Surface

Not less than one per support leg

3/8” 3-1/2”

Conveyors greater than 30” from the floor the top of the conveying surface (Shall be floor supported)

Not less than one per support leg

½” 3-1/2”

Table 1

3.1.14 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.

3.1.14.1 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 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.

3.1.15 SPECIAL PROVISIONS

3.1.15.1 INTERRUPTION OF WAREHOUSE OPERATIONS

The installation shall be phased to minimize downtime the warehouse operations shall not be curtailed nor suspended except as absolutely essential. 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 (such as shutdown of electrical power to the building) must be performed during non-duty hours (see paragraph 3.1.15.3). As a workaround for when the old system is being removed and the new system is being installed, the non-mechanized dip tank in Bay H-1 will be used to maintain operations until the new system is in place and operational.

3.1.15.2 INSTALLATION SEQUENCE

Installation of the Track Shoe Preservation System shall be in the following order.

If a CLIN is not exercised then the contractor shall move onto the next CLIN after the previous CLIN is completed:

a. Remove old pallet conveyor system.

b. Install new pallet conveyor system.

c. Remove old dip tank and fire protection system.

d. Install new dip tank and fire protection system.

e. Remove drying old tunnel.

f. Remove old power and free conveyor and crane system with 12 ea pneumatic motorized tractor trolleys and hoists.

g. Install new drying tunnel.

h. Install new power and free conveyor and crane system with 12 ea pneumatic motorized tractor trolleys and hoists.

i. Install new air compressor system.

3.1.15.3 WORKING HOURS

Normal working hours are 0700 through 1530 Monday through Friday excluding 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.

3.1.15.4 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.

3.1.15.5 PENETRATION OF FIREWALLS

Firewalls may be penetrated for installation of electrical and communications cables and air lines pending inspection and approval by the Warner Robins Air Force Base Fire Department. Cables shall be enclosed in rigid conduit completely through the wall. The opening around the conduit/pipe shall be sealed with builder’s mortar and finished to original appearance.

3.1.15.6 WALL OPENINGS

The walls will be carefully cut to prevent undue damage. All permanent new openings shall be protected with masonry lintels and angle iron frames with steel jams. Head and sill members shall be not less than 2 inches by 2 inches by 5/16 inch angles and steel plate material shall be not less than ¼ inch in thickness.

Openings shall be finished in a neat, quality workmanship like manner and any damage resulting to the walls or floors or any part of the warehouse shall be repaired with material of a kind, texture and quality to match existing materials.

The contractor is required to obtain approval from the Contracting Officer’s Representative prior to making any permanent or temporary firewall or exterior wall openings other than those identified in this specification. The contractor is required to provide and install fire protection for all temporary or permanent openings made in the firewalls of the warehouses, including removal of fire doors.

All fire protection equipment planned for or used will be installed in accordance with NFPA codes. All contractor installed fire protection equipment shall be tested in accordance with the procedure found in paragraph 4.5.

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 Electric 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 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.

3.1.16.1.4 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, 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 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 coordinating the request through Mr. Billy Roberts, DDRT Safety, (903) 334-2641 and Red River Army Depot (RRAD) Fire Department (903) 334-2627 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 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.

3.1.16.1.9 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.

3.1.16.2 INSTALLATION SAFETY PRACTICES

3.1.16.2.1 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. All hard hat areas shall be indicated by contractor furnished signs.

Safety and health office personnel may inspect the work site at any time for compliance.

3.1.16.2.2 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. Scrap material, such as empty cartons, wood crates, etc., will be removed by the contractor at the end of each work day.

3.1.16.2.3 Smoking is prohibited except in designated areas.

3.1.16.2.4 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.

3.1.16.2.5 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.

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

Location of safety equipment shall be designated by alternating green and white stripes on the floor.

3.1.16.3 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.

3.1.16.4 FLAME CUTTING AND WELDING PROCESSES

3.1.16.4.1 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 RRAD Fire Department 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.

3.1.16.4.2 “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).

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

3.1.17 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.

Sequence Title DID ID. Number

A001 Installation Schedule DI-S-SAT1

A002 Layout Drawings DI-E-SAT2

A003 As-Built Drawings DI-E-SAT2

A004 Operating Manual DI-E-SAT1

A005 Maintenance Manual DI-E-SAT1

A006 Contractor Technical Representative List DI-E-SAT11

A007 Training Material and Schedules DI-E-SAT

A008 Power Requirements DI-P-SAT1

A009 Design Data Calculations DI-E-24040A

A010 Certificate of Compliance DI-E-SAT14

A011 Test Plan DI-T-SAT1

Sequence Title DID ID. Number

A012 Software Documentation Manual DI-S-SAT-2

Table 2

3.2 EQUIPMENT SPECIFICATIONS

All mechanical/electrical equipment and components shall properly be interfaced to ensure the package conveyor, and pallet conveyor, are capable of delivering material at the maximum rates specified in paragraph 1.3. All equipment supplied shall be designed and installed in compliance with seismic zone 2 requirements, providing a rigid/stable structure capable of handling all anticipated loads/stresses. All conveyors shall be sighted along centerlines and aligned +/- ¼ inch in the horizontal/vertical planes. Line shaft driven conveyor shall not be provided. Contractor shall ensure equipment design does not cause/result in build up of static electricity, and install protective devices as required. Penetrations of firewalls shall be accomplished in accordance with the requirements of paragraph

3.1.15.5 and 3.1.15.6.

3.2.1 CONTROL SYSTEMS FOR PALLET AND POWER AND FREE

MONORAIL CONVEYOR

Conveyor Control Systems shall include applicable PLCs, keypads, sensors, scanners and actuators required to provide overall integrated routing/tracking of track loads throughout the Track Dip Preservation System. All conveyor/equipment controls shall be electric (pneumatic controls are not acceptable). Contractor shall be responsible for design and installation of the entire conveyor electrical system, including power feeder to motor control centers, connections to motors, and wiring of all controls. Power source is 480 volt, 3 phase, 60 Hz. All photocells shall be polarized with the exception of sick eyes. All photoeyes shall have screw off connections or plug in type for easy replacement and shall be guarded from impact by the operator. The new systems installed by the contractor shall be completely integrated with the existing overhead bridge crane system so that all the systems work concurrently together without interruption of material flow.

3.2.1.1 CONTROL PANELS AND MOTOR CONTROL CENTERS

All conveyor control panels and motor control centers shall be located adjacent to the applicable conveyor area. Control panels and motor control centers shall contain all control components/devices, motor starters and related equipment necessary for operation of conveyor loops, spurs, and merges/diverts in specified modes.

3.2.1.2 OPERATOR CONTROL STATIONS

Personnel safety, ease of conveyor operation and pallet movement efficiency shall be primary considerations in design of package and pallet conveyor controls and location/configuration of various operator control stations. Contractor shall submit locations of operator control stations for approval in conjunction with other design submittals. Control stations shall be protected against fork truck damage.

3.2.1.2.1 SUPERVISORY CONTROL STATIONS

Contractor shall provide supervisory control panels at major operating areas to monitor/control the entire Track Dip Preservation System. As a minimum, supervisory control panels shall include the following controls:

a. Jam/fault indicator lights and reset push buttons.

b. System Start/Stop push button with run light.

c. On/off selector switches for each conveyor or workstation.

d. Emergency Stop push button.

e. Queue full indicator lights.

f. Any other controls necessary for package and pallet conveyor operation.

3.2.1.2.2 MAINTENANCE CONTROL STATIONS

Each conveyor drive shall have an Auto/Off/Man selector switch. This selector switch shall be on Auto selection for normal operations. In Off position, the motor starter shall be disabled. The Man position shall be spring returned to off and shall be used for running or jogging the motor when system is in manual mode.

3.2.1.2.3 MOTOR STARTERS

Motor starters may be contained in IEC or NEMA 12 Motor Control Center Cabinets located for least cost installation and ease of maintenance. Master controls for conveyor system shall be completely enclosed in an electrically grounded metal enclosure consistent with good commercial practice. Operator control voltage shall not exceed 120 volts, single phase, 60 HZ. Push button/keyboard height shall be maintained at the 30 inches.

3.2.1.2.4 PANEL AND SWITCH DESIGN

Panel and switch construction shall meet all safety requirements for NEMA 12, oil tight panel board for interior and shall be securely installed, readily accessible and of sufficient capacity for the rated load. Surface preparation and finish application shall be as specified herein. Stainless steel shall not be painted.

Switches shall be of push-button type. Stop buttons shall readily identifiable.

Emergency stop push buttons shall be mushroom head, push-to-stop/pull-to-reset type and shall be labeled EMERGENCY STOP. There shall be no electrical device or other protrusions mounted above the floor to impede fork truck traffic or provide hazard.

3.2.1.2.5 PHOTOELECTRIC SWITCHES

Product sensing shall be via photo eyes. Photoelectric switches shall be located at points where conveyor control and/or status is required. Switches shall be able to operate under ambient temperature and humidity conditions indicated in this specification. Units shall be sealed to prevent damage due to moisture, vibration, shock and other environmental factors encountered on a conveying line. All switches shall be mounted securely to conveyor frame and not attached to guardrails. Switches shall be completely guarded to prevent inadvertent misalignment caused by personnel, conveyed material, or equipment incidental to contract.

3.2.1.2.6 MODES OF OPERATION

For control purposes, there shall be two modes of operation; a two position switch shall be provided at operator load and unload station to select the mode of operations. A manual mode shall be provided for maintenance/diagnostics, which will permit line-of-sight control of all switches, motors, etc. An automatic mode shall be provided for normal operations, with capability of routing trolleys from either operator load or unload station based on operator input and/or PLC control. To prevent excitation of motors, switches, etc., a change of state shall require positive flow of current. A positive signal must be used to change the state of any device. Any error condition which could result in damage to material, equipment, or operating personnel shall cause that portion of the system containing the error condition to shut down.

3.2.1.2.6.1 MANUAL MODE

Selection of this mode shall cause the PLC to execute a system shutdown. This mode shall permit operation of switches and actuators from the immediate area of the affected conveyor. Activation of switches and actuators shall be from the applicable control panel/station through the PLC. Purpose of this mode of operation shall be for diagnostics/maintenance purposes.

3.2.1.2.6.2 AUTOMATIC MODE

This mode shall permit routing of trolleys based on operator load stations, dip tank, drip pan, wind tunnel and operator unload station. Rerouting capability shall also be made part of the controls. The purpose of this mode shall be for normal operations.

3.2.1.2.7 CONVEYOR INTERLOCKS

Several conveyors forming a transport series shall be electrically interlocked so that the conveyor farthest down-stream shall start first, followed by the second, and so on in the sequence. Stopping of any conveyor shall stop those conveyors upstream. There shall be an adjustable time delay (approximately 2 seconds) between starting successive conveyors. Several conveyors of small horsepower in close proximity, such as powered curves and short section, may be group started without a separate time delay. This shall be limited to a maximum of 3 HP group.

3.2.1.2.8 JAM PROTECTION

Contractor shall provide sensors specifically designed to sense jams at all merges, diverts, and right angle transfers. When jams are detected, feeding conveyors shall stop and a red lantern located to be visible to operating personnel shall illuminate. Clearing of the jam shall require activation of a reset button to allow conveyor to restart. Controls shall also be provided to prevent entry of an item onto a conveyor or other item of equipment which is occupied, stopped, or otherwise not operationally ready to receive the item. Such controls shall automatically allow entry of product at such time as conveyor/equipment becomes operationally ready to receive it.

3.2.1.2.9 FULL LINE SENSORS

All workstations shall have equipment such as photo sensors in order to detect a full line condition. In addition to preventing more material from entering a workstation when it is full, a full line light shall be illuminated at the supervisory control panel.

3.2.1.2.10 ENERGY CONSERVATION

Contractor shall provide controls to deactivate any conveyor which has been running for more than three minutes without having conveyed any material, and automatically restart when necessary for operation. Certain conveyors may be excluded from this requirement based on Government/Contractor agreement regarding practicality of this feature for individual conveyors.

3.2.1.2.11 EMERGENCY CUTOFFS

All powered conveyors and associated equipment installed under this specification shall be equipped with cut-off switches actuated by cables which are easily accessible and easily visible from any point along both sides of conveyors, where accessible to personnel. Cut-off switches shall lock out upon actuation and equipment shall remain inoperable until the cutoff switch is reset. Cut-off switches shall be readily accessible to personnel to reset. Safety cables shall be highly visible red plastic covered steel, with a minimum diameter of 3/16 inch.

3.2.1.2.12 PROGRAMMABLE LOGIC CONTROLLERS

The contractor shall furnish and install Allen Bradley Programmable Control Logix Controllers (PLCs) to control all contractor supplied conveyors and all contractor furnished equipment and to be compatible with PLCs for the existing tote transportation conveyor and tote return conveyor systems for which the contractor shall tie in the new conveyor systems into. These PLCs shall have sufficient inputs and outputs to accommodate all devices necessary. Memory capacity shall be sufficient to accommodate all programming steps necessary for all 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 backup power source. An indicator light located on the PLC shall be activated when the battery is in use. A laptop PC capable of performing all programming modifications possible including debugging and producing a hard copy printout of the existing program shall be provided by the contractor for each PLC furnished. The laptop PC (Minimum Intel 2 Duo P9600 with VT Processor (2.8 GHz/6MB L2 Cache/ 1066 MHz FSB) with minimum 160 GB hard drive, 2 GB, DDR2-800 SDRAM,1 Dimm, 24X CD Burner/DVD Combo Drive and 15.4” Wide Screen Display and Wireless LAN 802.11 Card will be utilized to load the PLC in the event that the memory is lost. The laptop shall also be used for if trouble shooting is required or PLC modifications are required to be made by the DDRT Maintenance Department.