Attachment_1_-_Replace_Bin_Conveyor_Technical_Specs.pdf

TECHNICAL SPECIFICATIONS

FOR

BIN CONVEYOR SYSTEM

DEFENSE DISTRIBUTION DEPOT

SAN JOAQUIN, CA

February 16, 2016

PREPARED BY:

DEFENSE ENTERPRISE SERVICE

TABLE OF CONTENTS

SECTION 1

1.0 SCOPE…………………………………………………………………

1.1 SITE……………………………………………………………………

1.2 CONVEYOR TO BE REMOVED

1.3 CONVEYOR TO BE INSTALLED………………………………………………5

1.4 SYSTEM AND LAYOUT FUNCTION………………………………………….6

1.4.1 SYSTEM DESCRIPTION AND MATERIAL FLOW

1.4.2 THROUGHPUT REQUIREMENT

1.4.3 MATERIAL TO BE HANDLED

1.5 EXISTING GOVERNMENT SYSTEMS AND CONTROLS

1.6 PROJECT SCHEDULE/DOWNTIME

1.7 ALTERNATIVE DESIGNS

SECTION 2

2.0 APPLICABLE SPECIFICATIONS, STANDARDS AND CODES

2.1 GOVERNMENT DOCUMENTS

2.1.1 FEDERAL SPECIFICATIONS

2.1.2 OSHA STANDARDS

2.2 NON-GOVERNMENT STANDARDS AND CODES

SECTION 3

3.0 GENERAL REQUIREMENTS

3.1 GENERAL………………………………………………………………

3.1.1 QUALITY

3.1.2 STANDARD PRODUCTS

3.1.3 MATERIAL AND OPERATING CONDITIONS

3.1.3.1 DISSIMILAR METALS

3.1.4 IDENTIFICATION OF MATERIAL AND FINISHES

3.1.5 STANDARDIZATION OF COMPONENTS

3.1.6 STATE-OF-THE-ART COMPONENTS

3.1.7 MAINTAINABILITY

3.1.8 LUBRICATION AND ADJUSTMENT

3.1.9 PAINTING

3.1.10 NOISE LEVELS

3.1.11 FASTENERS

3.1.12 METAL FABRICATIONS

3.1.12.1 WELDS

3.1.12.2 BOLTED AND RIVETED CONNECTIONS

3.1.12.3 CASTINGS AND FORGINGS

3.1.13 FLOOR MOUNTING OF EQUIPMENT

3.1.14 IDENTIFICATION MARKING

3.1.14.1 CONTROL IDENTIFICATION

3.1.15 SPECIAL PROVISIONS

3.1.15.1 INTERRUPTION OF OPERATIONS

3.1.15.2 WORKING HOURS

3.1.15.3 REMOVAL OF WASTE AND DEBRIS AND EXISTING CONVEYOR

3.1.15.4 UTILITIES AVAILABLE FOR CONTRACTOR USE

3.1.15.5 DIMENSIONS

3.1.15.6 PROTECTION OF GOVERNMENT PROPERTY

3.1.15.7 UNLOADING OF EQUIPMENT

3.1.16 SAFETY REQUIREMENTS

3.1.16.1 GENERAL REQUIREMENTS

3.1.16.2 MISHAP REPORTING

3.1.16.3 INSTALLATION SAFETY PRACTICES

3.1.16.4 FIRE PREVENTION

3.1.16.5 FLAME CUTTING AND WELDING PROCESSES

3.1.16.6 SAFETY PLAN

3.1.16.7 CONTRACT DATA REQUIREMENTS

3.2 ELECTRICAL REQUIREMENTS

3.2.1 ELECTRICAL INSTALLATION

3.3 PACKAGE CONVEYOR

3.3.1 GENERAL

3.3.2 DESIGN AND FUNCTIONAL REQUIREMENTS

3.3.2.1 PHYSICAL CHARACTERISTICS

3.3.2.2 MOUNTING

3.3.2.2.1 SEISMIC CONSIDERATIONS…………………………………………………20

3.3.3 OVERHEAD SCANNERS

3.4 PROGRAMMABLE LOGIC CONTROLLERS

3.4.1 BATTERY BACKUP

3.4.2 PORTABLE PLC PROGRAMMING DEVICE

3.4.3 PLC DIAGNOSTICS/DISPLAY

3.5 CONVEYOR CONTROLS

3.5.1 PHOTO-EYES

3.5.2 EMERGENCY CUTOFFS

3.5.3 FIXED BAR CODE READERS

3.6 MOTORS………………………………………………………………

3.7 MOTOR CONTROL

3.7.1 MAINTENANCE CONTROL STATIONS

3.7.2 START-STOP SWITCH

3.7.3 MOTOR DISCONNECT MEANS

3.7.4 SYSTEM CONTROL PANELS/MOTOR CONTROL CABINETS

3.7.5 MOTOR CONTROL CABINETS

3.7.6 AUTOMATIC CONTROLS

3.7.6.1 DIRECT MOTOR/ACTUATOR CONTROL

3.7.6.2 START-UP WARNING HORN

3.7.6.3 START-UP CONVEYOR INTERLOCKS

3.7.6.4 JAM PROTECTION

3.7.6.5 OPERATIONAL CONVEYOR INTERLOCKS

3.7.6.6 FULL LINE SENSORS

3.7.6.7 FIRE SYSTEM DEACTIVATION

3.8 COMPRESSED AIR SYSTEM

3.9 MAINTENANCE PLATFORMS/CATWALKS………………………………..25

3.10 PROTECTIVE GUARDRAIL

3.11 FIRE PROTECTION SYSTEM

3.12 VIDEO MONITORING SYSTEM

3.12.1 VIDEO CAMERAS:

3.12.2 VIDEO CAMERA MOUNTINGS:

3.15.3 VIDEO MONITOR:

3.12.4 VIDEO CONTROLLER KEYPADS

3.12.5 FURNITURE

3.13 TRAINING

3.13.1 OPERATOR TRAINING

3.13.2 MAINTENANCE TRAINING

4.0 QUALITY ASSURANCE PROVISIONS

4.1 LAYOUT OF WORK

4.2 SYSTEM MAINTENANCE

4.2.1 MAINTENANCE PRIOR TO FINAL ACCEPTANCE

4.2.2 SYSTEM MAINTENANCE WARRANTY PROVISIONS (SUPPL)

4.3 SYSTEM CHECK-OUT

4.4 INSPECTION AND TEST

4.4.1 RESPONSIBILITY FOR INSPECTION AND TESTING

4.4.1.1 COMPONENT AND MATERIAL INSPECTION

4.4.1.2 QUALITY CONFORMANCE INSPECTION AND TEST

4.4.2 EXAMINATION

4.4.3 IN-PROCESS INSPECTION

4.4.4 PERFORMANCE TESTS

4.4.4.1 FUNCTIONAL TEST

4.4.4.2 FINAL OPERATION TEST

4.4.5 STATIC AND OTHER TEST

4.4.6 TIME LOST

4.4.7 WARRANTY

4.4.8 TECHNICAL SUPPORT

4.4.9 CONTRACTOR TECHNICAL REPRESENTATIVES

4.4.10 FINAL ACCEPTANCE

4.4.11 DEFINITIONS

4.4.11.1 INTERUPTION OF SERVICE

4.4.11.2 EQUIPMENT

4.4.11.3 INTENDED CAPACITY

4.4.11.4 NONDESTRUCTIVE TEST

SECTION 1

1.0 SCOPE

This specification covers the necessary services, labor, material, equipment and control components required to furnish and install a package conveyor system in Building 16. The system shall consist of floor and elevated package transport and accumulation conveyor, incline and decline belt conveyor. Supporting equipment includes bar code scanners, diverts and a video monitoring system. The Contractor shall remove the existing conveyor and dispose of it off site. The Contractor shall provide, install, test and make operable the conveyor system. The Contractor shall train government personnel to maintain the conveyor system.

1.1 SITE

The site for this project is Defense Distribution Depot San Joaquin, California (DDJC), located in Tracy California. The conveyor system shall be installed in Building 16.

1.2 CONVEYOR TO BE REMOVED

Prior to installation, the contractor shall remove the existing conveyor along with the conveyor supports shown in drawings DDJC16BINCONV1 and DDJC16BINCONV2. The structural steel supports for the overhead conveyor currently in 16A-5 will remain and can be reused by the contractor. Conveyor quantities are listed in Table 1. The contractor shall be responsible for verifying actual quantities and demolition details.

TABLE 1

Conveyor to be removed by the Contractor

Item Units Quantity CLINS Roller Conveyor LF 2,086 001 Incline/Decline/Belt Conveyor LF 540 001 Powered Roller Conveyor Curves (BDLR) EA 17 001 Powered Roller Merge EA 5 001 Tote Pusher/Divert EA 6 001

1.3 CONVEYOR TO BE INSTALLED

The Contractor shall furnish, install, integrate, and make operational, the following conveyor systems shown in drawings DDJC16BINCONV3 and DDJC16BINCONV4 and summarized in Table 2. The quantities are estimates based on the government’s concept design. The contractor shall be responsible for actual quantities required based on the final approved design. New conveyor supports shall be provided for all supplied conveyor.

TABLE 2

Equipment to be installed by the Contractor

Item Units Quantity CLINS Belt Driven Live Roller Package Conveyor LF 1,415 002 Zero Pressure Accumulation Package Conveyor LF 540 002 Incline/Decline Package Belt Conveyor LF 460 002 Powered Roller Conveyor Curves (BDLR) EA 16 002 Fixed Bar Code Scanner EA 3 002 Powered Roller Merge EA 4 002 Powered Roller Divert EA 5 002 Controls/Programming LOT 1 002

1.4 SYSTEM LAYOUT AND FUNCTION

The purpose of the system is to transport packages and totes within Building 16.

Building 16 is the bin hub for the depot. The building consists of 10 sections – with the “A” side being on the east and the B side on the west. The A and B sides both have five sections numbered from north to south. Small parcel receipts are received in 16B-3 and are automatically routed to the bin areas in 16A-1, 2, 3, 5 and 16B-4 for storage. Stock selections are packed in 16B-5.

1.4.1 SYSTEM DESCRIPTION AND MATERIAL FLOW

The conveyor in this building consists of two separate subsystems – one for delivery from receiving to storage (stow conveyor) and one for delivery from storage to packing (pick conveyor). The stow conveyor will convey totes exclusively while the pick conveyor may convey cartons along with totes.

All totes have barcodes on the sides which are used for tracking from the receiving section to the various storage sections. Each storage section has two destinations – one for the lower/main floor level and one for the upper/mezzanine level. Totes delivered to each bin section/level will be accumulated on the stow spur.

Periodically warehouse workers will visit these spurs to retrieve stock for storage.

Empty totes are stacked and eventually returned to the receiving floor via forklift.

Stock selections are put in totes and placed on the pick conveyor. No “routing” for picks is required. The pick conveyor runs directly to the packing area in 16B-5. In addition to totes, cartons can also be placed on the stow conveyor from the remote packing areas. Remote packing is performed in Buildings 15, 16B-2 and 17. The pick conveyor shall be sized to handle these cartons (see 1.3.4).

1.4.2 THROUGHPUT REQUIREMENT

The conveyor shall, as a minimum, be capable of handling a peak workload of 12 cartons/totes per minute. The contractor shall maximize the speed (up to 120 fpm) on long-run conveyors in sections 16A-1, A-2, A-5 and B-5 to minimize travel times.

1.4.3 MATERIAL TO BE HANDLED

The conveyor and sorter shall handle cartons with a footprint of 12” x 12” minimum to 27” x 17 ½” maximum and a weight range of 7 lbs to 40 lbs. The tubs to be used on the conveyor system are 15” x 24” x 10”h and weigh from 8 lbs. to 40 lbs. (50 lbs/ft for conveyor design).

1.5 EXISTING GOVERNMENT SYSTEMS AND CONTROLS

NOT APPLICABLE.

1.6 PROJECT SCHEDULE/DOWNTIME

70% of the depot workload flows through the bin hub. For the duration of this project, the government will have to manually transport stows and picks throughout the bin hub. The Contractor shall provide adequate resources to minimize the downtime of the project.

1.7 ALTERNATIVE DESIGNS

SECTION 2

2.0 APPLICABLE SPECIFICATIONS, STANDARDS AND CODES

The following list of specifications, standards and codes shall apply to the work covered within this document. The Contractor shall be responsible to ensure that all such applicable regulations are satisfied. Special attention shall be given to Federal, State and Local requirements. The issue in effect for 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

UFC 3-310-01 Design: Structural Load Data UFC 3-600-01 Design: Fire Protection Engineering for Facilities

2.1.2 OSHA STANDARDS

29 CFR 1910 Occupational Safety and Health Standards

2.2 NON-GOVERNMENT STANDARDS AND CODES

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

SECTION 3

3.0 GENERAL REQUIREMENTS

3.1 GENERAL

The Contractor shall supply the herein described equipment/system, which shall include all services, labor, material, equipment, control components, and engineering necessary to provide a completely operational system. The system shall be tested by the Contractor prior to performance testing by the Government and shall be capable of undergoing the tests specified in paragraph 4.4 without deformation, breakdown, and failure of any component, or development of any other defect, and without any deviations from the performance requirements and cited standards of this specification. Bid proposals shall include descriptive literature for all items of equipment offered. It is the Contractor’s responsibility to notify the Contracting Officer of any design deficiencies or site requirements, which affect or compromise the performance or operation of any portion of the system or the entire system. The Contractor shall be responsible for compliance with all regulations applicable to design and testing of equipment and controls supplied under this specification.

3.1.1 QUALITY

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

3.1.2 STANDARD PRODUCTS

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, the Contractor shall identify any design changes during the two-year period of field experience. These design changes must be minor and insignificant or be demonstrated reliable through commercial application. Prototype or experimental devices or components shall not be furnished or installed. Where two or more units of the same type or kind of equipment are required, these units shall be identical models of a single manufacturer.

3.1.3 MATERIAL AND OPERATING CONDITIONS

Materials shall be as specified herein. Materials not specified shall be selected by the Contractor and shall be subject to all provisions of the specifications. Unless otherwise specifically stated, all materials shall be new and of the most suitable grade for the intended purpose. All parts shall be manufactured to such standards that will permit replacement or adjustment without modification of system components. The system shall be capable of operating in an industrial environment and extremes of temperature from 40 to 110 degrees Fahrenheit and humidity from 10 percent to 90 percent relative (non-condensing).

3.1.3.1 DISSIMILAR METALS

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

3.1.4 IDENTIFICATION OF MATERIAL AND FINISHES

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

3.1.5 STANDARDIZATION OF COMPONENTS

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

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

3.1.6 STATE-OF-THE-ART COMPONENTS

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

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

3.1.7 MAINTAINABILITY

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

3.1.8 LUBRICATION AND ADJUSTMENT

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

3.1.9 PAINTING

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

3.1.10 NOISE LEVELS

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

3.1.11 FASTENERS

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

3.1.12 METAL FABRICATIONS

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

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

3.1.12.1 WELDS

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

3.1.12.2 BOLTED AND RIVETED CONNECTIONS

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

3.1.12.3 CASTINGS AND FORGINGS

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

3.1.13 FLOOR MOUNTING OF EQUIPMENT

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

TABLE 3

Type Schedule Number Bolts Required Bolt Engagement Diameter Length

Conveyors Not less than one per support leg 3/8” 3-1/2 Elevated Conveyors Not less than two per support leg 3/8” 3-1/2 Equipment Enclosures Not less than two per support leg 3/4” 6”

3.1.14 IDENTIFICATION MARKING

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

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

3.1.14.1 CONTROL IDENTIFICATION

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

3.1.15 SPECIAL PROVISIONS

3.1.15.1 INTERRUPTION OF OPERATIONS

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

3.1.15.2 WORKING HOURS

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

3.1.15.3 REMOVAL OF WASTE AND DEBRIS AND EXISTING CONVEYOR

The Contractor shall maintain the work site and premises in a clean and neat condition during the project. All on-site waste and debris, and conduit generated in performing this contract shall be disposed of off-site at Contractor arrangement and expense. Contractor will disassemble and remove the existing package conveyor system and floor mounted support brackets/hardware. Contractor shall provide containers for collecting disassembled conveyor materials and remove loaded containers to the Contractor pre-arranged off-site disposal location.

3.1.15.4 UTILITIES AVAILABLE FOR CONTRACTOR USE

Electricity (480 volt / 120 volt, 60 Hz receptacles), and nominal amounts of city water required by the Contractor will be furnished by the Government from existing sources. Make up and take down of connections and lines shall be Contractor’s responsibility.

3.1.15.5 DIMENSIONS

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

3.1.15.6 PROTECTION OF GOVERNMENT PROPERTY

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

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

3.1.15.7 UNLOADING OF EQUIPMENT

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

3.1.16 SAFETY REQUIREMENTS

3.1.16.1 GENERAL REQUIREMENTS

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

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

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

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

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

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

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

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

3.1.16.2 MISHAP REPORTING

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

3.1.16.3 INSTALLATION SAFETY PRACTICES

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

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

3.1.16.3.3 Smoking is prohibited except in designated areas.

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

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

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

3.1.16.4 FIRE PREVENTION

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

3.1.16.5 FLAME CUTTING AND WELDING PROCESSES

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

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

3.1.16.6 SAFETY PLAN

The contractor shall submit a safety plan no later than one week prior to the pre-construction meeting. The safety plan will address/explain, at a minimum, the following:

The contractor shall provide safety meetings once a month minimum and shall maintain and provide documentation to the Safety Office.

The contractor shall maintain records for daily equipment checks.

The contractor shall conduct safety tailgate meetings prior to the beginning of daily work which pertain to the operations for that day.

A thorough discussion on all required Personal Protective Equipment

(PPE) and the proper use/application All local emergency contact numbers and the phone number/location of the nearest hospital.

How to protect government employees from job hazards (i.e. noise, welding, MHE hazards, overhead hazards, etc.).

Where/how to get fire permits for all welding/grinding operations.

License and certification requirements for every employee involved with any confined space or abatement (i.e., Asbestos, Lead Based Paint removal, etc.). (Note: if using own company’s confined space documentation, the contractor shall submit the document to the facility’s Safety Office for review prior to work commencing.)

3.1.16.7 CONTRACT DATA REQUIREMENTS

The Contractor shall furnish contract data as required in DD Form 1423, Contract Data Requirements List (CDRL), included with this specification. Contract data, outlined in Table 4, 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 4

Sequence Number

Title DID ID

A001 Installation Schedule DI-S-SAT1 A002 Drawings, Engineering, and Associated List, Layout Drawings DI-E-SAT2 A003 Drawings, Engineering, and Associated List, As-Built Drwgs. DI-E-SAT2 A004 Commercial Manuals, Operating Manual DI-E-SAT1 A005 Commercial Manuals, Maintenance Manual with

Recommended Spare Parts List

DI-E-SAT1

A006 Technical Representative List TSP-001 A007 Power Requirements DI-P-SAT1 A008 Certificate of Compliance DI-E-SAT14 A009 Test Plan DI-E-SAT1

3.2 ELECTRICAL REQUIREMENTS

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

3.2.1 ELECTRICAL INSTALLATION

It shall be the Contractor’s responsibility to connect all required electrical equipment to the existing or Contractor supplied electrical power distribution panels. All required conduits, wire, electrical power distribution equipment including transformers, distribution panels, and other electrical hardware shall be Contractor furnished and installed. All electrical work shall be in accordance with the NEC and standards of NEMA. All Contractor installed electrical panels shall be clearly and permanently labeled to identify voltage and equipment serviced.

The Contractor shall utilize cable tray instead of conduit as much as possible to allow future flexibility and minimize installation costs for future power and communication/data lines. A separate cable tray shall be provided for power and communication lines (see Para. 3.9.3). Cable tray for communications/data lines shall be 8” x 4” deep wire basket type. Cable trays shall be used for both horizontal and vertical runs of power and communication lines and shall be attached to building columns, building roof beams and equipment including conveyors and the slat style sliding shoe sorters.

3.3 PACKAGE CONVEYOR

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

CDRL A002.

3.3.1 GENERAL

The package conveyor system shall consist of belt driven live roller conveyor (elevated and working height levels), powered roller bed belt incline/decline conveyor, powered rolled bed belt conveyor, associated brake metering belts at merge/sort points sized to handle the material, reference paragraph 1.3.4 The conveyor elevation at the operator interface locations will be 30” top of roller/belt. The conveyor elevation at the top of the inclines and for all elevated conveyor throughout the facility will permit a minimum of 123” vehicle clearance height unless otherwise noted on the drawing. Line shaft type conveyor is not acceptable. Conveyor pushers, overhead push-offs and swing arms are not acceptable means of diverting material/tubs on the package conveyor system. All air requirements including filters, regulators, lubricators and all connections and piping shall be contractor’s responsibility.

3.3.2 DESIGN AND FUNCTIONAL REQUIREMENTS

3.3.2.1 PHYSICAL CHARACTERISTICS

Conveyor shall have the following characteristics.

Galvanized rollers

Carrying rollers shall be 1.9” diameter.

Carrying rollers on 3 inch centers (belt driven roller conveyor)

Carrying rollers on 6 inch centers (powered roller bed belt conveyor)

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

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

Bearings for carrying, pressure and return rollers shall be high quality

ABEC-1 or equivalent securely mounted in a noise suppressing housing, which is swaged into the roller tube. They shall have dust tight, double-sealed ball bearings and shall be lifetime grease packed.

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

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

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

For the purpose of estimating the required horsepower on accumulative conveyor, Contractor shall use 50 pounds per linear foot live load.

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

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

Contractor's design at spurs and curves to minimize material orientation change (rotation) as it flows through the spurs and/or curves.

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

Mechanical sensor rollers will not be acceptable.

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

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

Belt-driven roller conveyors shall be no longer than 100 ft in length (for belt tracking purposes) and shall not begin in one building section and extend though a deluge tunnel into the next building section.

Line pressure shall be true “zero pressure” between accumulated tubs on accumulation conveyor to prevent jamming of tubs.

Angles of incline/decline on powered belt conveyor sections will not exceed 15 degrees.

3.3.2.2 MOUNTING

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

3.3.2.2.1 SEISMIC CONSIDERATIONS

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

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

3.3.3 OVERHEAD SCANNERS

3.4 PROGRAMMABLE LOGIC CONTROLLER

The Contractor shall furnish, install, and make operational a programmable logic controller (PLC) to control the entire Contractor furnished conveyor system. The PLC shall be Allen-Bradley model SLC 5/05 with Ethernet (or equal). PLC shall be sized such that no more than 75% utilization of inputs, outputs and memory occurs. PLCs shall have sufficient internal control relays, timers and counters to accommodate the necessary programming. The Contractor shall provide all necessary documentation, ladder diagrams and schematics for the software/programming supplied with the PLCs to facilitate troubleshooting, repair and program changes (CDRL A005). Personal Computers (PCs) based control systems are not acceptable.

3.4.1 BATTERY BACKUP

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

3.4.2 PORTABLE PLC PROGRAMMING DEVICE

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

6th Generation Intel Core i5 Processor (or equal) 2.1 GHz, 1 TB Hard

Drive, 8 Gigabyte RAM, Windows 10 Home Premium operating system, 17 inch Super VGA Screen with DVD/CD R/W capability, Standard 9 pin RS232c Serial Port, 2 ea PCMCIA Type II slots, 56K data/fax Modem, carrying case

Allen-Bradley 1784-U2DHP USB to DH+

Allen-Bradley 2711E-ND1 PanelBuilder configuration software

Rockwell RS Logic with Links

Rockwall RS Logix 500

3.4.3 PLC DIAGNOSTICS/DISPLAY

The Contractor shall provide a diagnostics/ display package including all necessary hardware, software and programming (along with all programming software) to graphically display fault and alarm conditions on a VGA (minimum 15-inch) color flat panel monitor, located in Building 16A-2. The monitor shall be installed on the associated PLC enclosure doors and provide a graphic representation of the entire length of the conveyor system and associated control devices. Fault and alarm conditions with locations of fault shall be displayed, including all emergency stops. Typical display information shall include type of alarm at the affected location to allow operators/maintenance personnel to easily identify errors or anomalous conditions, which require resolution.

3.5 CONVEYOR CONTROLS

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

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

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

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

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

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

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

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

3.5.1 PHOTO-EYES

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

adjustable guardrails, equipment guards, etc.

3.5.2 EMERGENCY CUTOFFS

All powered conveyors installed at floor level or working level shall be equipped with cutoff switches actuated by cables. Cables shall be located on both sides of these conveyors and be easily visible. A push-button cutoff shall be located on the wall or conveyor supports, under the elevated conveyor in warehouse section (Building 16 A-5) Cutoff switches shall lock out upon actuation and the equipment adjacent to the cutoff switch will remain inoperable until the cutoff switch is reset. Note, the system will only shutdown conveyor within the immediate vicinity of the affected conveyor to minimize the impact on other operations. Safety cables shall be highly visible orange plastic covered stranded steel with a minimum diameter of 3/16 inches. The cable runs shall be straight run lengths to the maximum extent practicable, and shall run along the entire length of conveyor being controlled. Cutoff cables shall extend through associated conveyor equipment in a straight run and cutoff this equipment. The conveyor shall remain deactivated until reactivated at the main system power switch located on the master system control station. The PLC display monitors shall indicate which conveyor line had an emergency cutoff activated. All E-stops switches to have separate input to identify switch location on HMI. In addition, each cutoff switch shall have a red light mounted on top to assist maintenance personnel in locating the activated cutoff switch.

3.5.3 FIXED BAR CODE READERS

Contractor shall install fixed bar code readers prior to all conveyor diverts in 16B- 1, 2 and 3 to facilitate the transportation of tubs to locations assigned at receiving.

Bar code readers must read 4 digit, 3 of 9 bar codes (ladder orientation) attached to the sides of the tubs.

3.6 MOTORS

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

3.7 MOTOR CONTROL

Each motor or group of motors requiring a single control, and not controlled from a motor-control center, shall be provided with a suitable controller and devices that will perform the functions as specified for the respective motors. Each motor of 1/2 horsepower or larger shall be provided with thermal-overload protection.

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

The overload protection device shall be integral with the motor or controller, or shall be mounted in a separate enclosure. Unless otherwise specified, the protective device shall be of the manually reset type. Single or double pole tumbler switches specifically designed for alternating current operation only may be used as manual controllers for single-phase motors having a current rating not in excess of 80 percent of the switch rating. Automatic control devices such as thermostats float or pressure switches may control the starting and stopping of motors directly, provided the devices used are designed for that purpose and have an adequate horsepower rating. When the automatic control device does not have such a rating, a magnetic starter shall be used, with the automatic control device actuating the pilot control circuit. When combination manual and automatic control is specified and the automatic control device operates the motor directly, a double throw, three position tumble or rotary switch shall be provided for the manual control; when the automatic control device actuates the pilot control circuit of a magnetic starter, the latter shall be provided with a three position selector switch marked manual-off-automatic. Connections to the selector switch shall be such that only the normal automatic regulatory control devices will be by-passed when the switch is in the manual position: All safety control devices, such as low or high pressure cutouts, high temperature cutouts, and motor overload protective devices, shall be connected in the motor control circuit in both the manual and the automatic positions of the selector switch. Control circuit connections to any manual on/off and automatic switch or to more than one automatic regulatory control devices shall be made in accordance with wiring diagram. If such diagram is not included on the drawings, approval by the Contracting officer is required.

3.7.1 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. The system shall continue normal operation when a switch is in the “off” or “man” position with the exception of the motor being switched. The HMI shall indicate each switch status.

3.7.2 START-STOP SWITCH

All powered equipment shall be equipped with individual start-stop switches located in line of sight of the equipment controlled. The enclosures shall be NEMA type 1 or 4 as required by NEMA ICS 6.

3.7.3 MOTOR DISCONNECT MEANS

Each motor shall be provided with a disconnect. For single-phase motors, a single or double pole toggle switch, rated only for alternating current, will be acceptable for capacities less than 30 amperes, provided the ampere rating of the switch is at least 125 percent of the motor rating. Enclosed safety switches shall be horsepower rated in conformance with UL standard no. 98. Switches shall disconnect all ungrounded conductors.

3.7.4 SYSTEM CONTROL PANELS/MOTOR CONTROL CABINETS

The conveyor control panels and motor control cabinets shall be new and shall contain all control components/devices, motor starters and related equipment necessary for operation of the conveyor system. All conveyor control panels and motor control cabinets shall be located within or adjacent to the applicable conveyor area.

3.7.5 MOTOR CONTROL CABINETS

Current for all motors shall be drawn from each local warehouse section. The contractor shall provide a new remote motor control panel for each section. An E-Stop and Jam Reset button will be provided on each remote panel.

3.7.6 AUTOMATIC CONTROLS

In addition to all controls required to provide the operational requirements of the system, the contractor shall provide the following:

3.7.6.1 DIRECT MOTOR/ACTUATOR CONTROL

Direct motor/actuator control shall be provided that will allow maintenance personnel to activate motors, diverts, etc., using the system operator…