ATTACHMENT_1_-_DDRT_Bldg._499_Replace_Pallet_Conveyor_System_SOW_7_Mar_17.pdf

Statement of Work

For

Replace Pallet Conveyor System

Bldg. 499

DLA Distribution Red River, TX

7 Mar 17

Prepared By:

DLA Installation Support for Distribution

S-Avenue; Bldg. 1-2

DS-FDI

New Cumberland, PA 17070

SP330017Q5012

ATTACHMENT 1 - STATEMENT OF WORK

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 ----------- 8

2.1 GOVERNMENT DOCUMENTS -------------------------------------------------- 8

2.2 STANDARDS AND CODES ------------------------------------------------------ 9

3.0 REQUIREMENTS ------------------------------------------------------------------- 10

3.1 GENERAL REQUIREMENTS ---------------------------------------------------- 10

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

3.3 TRAINING ---------------------------------------------------------------------------- 48

3.4 ELECTRICAL ------------------------------------------------------------------------ 49

4.0 QUALITY ----------------------------------------------------------------------------- 51

4.1 LAYOUT ------------------------------------------------------------------------------ 51

4.2 SYSTEM MAINTENANCE ------------------------------------------------------- 51

4.3 SYSTEM CHECKOUT ------------------------------------------------------------ 52

4.4 INSPECTION AND TEST --------------------------------------------------------- 52

SP330017Q5012

1.5 EXPERIENCE OF PERSONNEL---------------------------------------------- 8

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 pallet packing conveyor system. The function of this system is to receive pallet loads of material from the tow line carts at spur 19 and the transport dock and process this material through one of 12 in-line pallet pack stations and the the offer stations at the end of the pallet pack lines. The Government d e s i gn for this system is shown on drawing D S 1 7 - 2 - 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. 499, Zone 2. Bldg. 499 was built in 1995 and the building is 1000 ft long by 640 ft wide x 30 ft. clear stack height. The dimensions of zone 2 are 320 ft wide x 380 ft. long.

1.2 SYSTEM LAYOUT AND FUNCTION OF NEW SYSTEM (REFER TO

DRAWING NO. 17-2-1)

. The function the pallet conveyor system is to receive pallet loads from the towline system and from the the transporter dock conveyor system and induct the material into the twelve pack stations, unitize the material by an in-line stretch wrap machine and the conveyor the material to a weighing/offer station for out-loading to commercial trucks.

1.2.1 PROCESS DESCRIPTION AND DESIGN CONSTRUCTION

CRITERIA CLIN 0001.

The system shall receive pallet loads on MIL pallets by the transporter dock conveyor track system and the towline system at spur 19. The material will be received by the transporter dock for material coming from the outlying buildings. The truck is capable of transporting 10 pallets which will off-load the pallets at Bay H.5 24. The 10 pallets (5 per each conveyor section) will index onto the two 23 ft long side by side conveyor sections. Once the truck driver hits the trave in button, leaves and closes the door the transporter dock will traverse back approximately a foot to clear the overhead door. The operator on the Transporter Dock Conveyor panel will will hit the travel in button to traverse

18 ft westward to the fixed pallet conveyor sections. The pallet from the north conveyor section will travel 19 ft west and start to transfer onto the main line.

After the north pallet conveyor section of the transporter dock is cleared and there is room for queueing of pallets the south pallet conveyor section of the transporter dock will off-load onto the south fixed conveyor section. These pallet will queue to the weigh station where the operator will determine which pack station the material will go to or the first outloading conveyor directly after the scale if the material is for a dedicated truck and is already packed. The same process will occur for material being received by the towline in spur 19 where the material is transferred by the pusher to the pallet induction line in Bay H-22.

This material will travel eastward on the pallet conveyor 39 ft. the transfer southward on the right angle transfer to the pallet weigh station. Based on the weight and type of shipment and workload the operator will determine which pallet pack station the material will go to. The scale and keypad are the same for both the towline and transporter dock pallet induction. There is a keypad just east of line no. 1 (Pallet Pre-pack Consolidation out-put line) as shown on drawing no. 17-2-1 which is the east 32 ft. line where the first turntable is located. There is a keypad just west of line no. 2 (Pallet Pre-pack Consolidation input line) as shown on drawing no. 17-2-1 which is the west 32 ft. line where the second turntable is located. The two side by side pallet pack lines (Lines 3 and 4) are 182 ft long and are used to pack regular shipments. These main lines both have six pack stations which can receive and process two pallets per workstation. The bidirectional transfers pull the pallets off the main line to allow for transportation of additional pallets to other workstations. Once the pallets are packed the operator will select on his controls if the pallet is to be stretch wrapped. The material will the transfer back onto the main line and be stretch wrapped or pass through the stretch wrap machine to the pallet dimension/offer station. At the offer station, there is a combination turntable/in-line scale cubing system that is used to prepare the material for shipment. The operator prints the offer lable and manifest and release the material for out-loading. The system has the capability to queue four pallets via accumulation conveyor for out-loading. The material is then off-loaded by a forklift to be loaded into a truck. The last single main line is the dedicated truck packing line. Material coming from the main input pallet conveyor from the transporter dock, T-car induction or line 2 will divert to the first right angle transfer for the material to be packed. Once the material is packed it will be released by the operator at this workstation via his control to the outbound conveyor in the middle of the main line if the material does not have to be weighed and offered or go straight to the stretch wrap and dimension/offer stations. . At the offer station, there is a combination turntable/in-line scale cubing system that is used to prepare the material for shipment. The operator prints the offer lable and manifest and release the material for out-loading. The system has the capability to queue four pallets via accumulation conveyor for out-loading.

1.2.2 MAINTENANCE CONTRACT FOR ONE YEAR AFTER FINAL

SYSTEM ACCEPTANCE

If CLIN 0006 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 throughput capacities at detailed in drawing 17-2-1.

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 is the base bid. CLINS 2,3, 4, 5 and 6 are optional CLINS. Recommended performance period for CLINS 0001 is 270 days, CLIN 0002 is 90 days, CLIN 0003 is 120 days, CLIN 0004 is 120 days and CLIN 0005 is 30 days.

1.4.1 CLIN NO. 0001 REPLACE PALLET PACKING CONVEYOR SYSTEM

QTY DESCRIPTION

Traversing Transporter Dock

46 ft Indexing Pallet Conveyor on Traversing Bed with

Festoon

Induction Conveyor

180 ft Accumulation Pallet Conveyor, 48 ins. wide

5 ea Pallet turntables

3 ea Chain Pallet Transfers

1 ea Keypad Station

Two Pallet Pre-Pack Consolidation Stations (Lines 1 and 2) 64 ft Accumulation Pallet Conveyor, 48 ins. wide

1 ea Keypad Station

Pack Stations (Line 3)

185 ft Accumulation Pallet Conveyor, 48 ins. wide

6 ea 3 Pallet Position Pallet Transfers (Shuttles)

4 ea Forklift Barriers

1 ea In-Line Automatic Stretch Wrap Machine

1 ea Pallet Turntable

1 ea Pallet Cubing/Weighing System

Pack Stations (Line 4)

185 ft Accumulation Pallet Conveyor, 48 ins. wide

6 ea 3 Pallet Position Pallet Transfers

1 ea In-Line Automatic Stretch Wrap Machine

1 ea Pallet Turntable

1 ea Pallet Cubing/Weighing System

Dedicated Truck Main Line Pack Stations (Line 5)

185 ft Accumulation Pallet Conveyor, 48 ins. wide

1 ea 3 Pallet Position Pallet Transfers (Shuttles)

1 ea In-Line Automatic Stretch Wrap Machine

4 ea Pallet Turntable

1 ea Pallet Cubing/Weighing System

Towline Spur 18 Pallet Conveyor System

36 ft Accumulation Pallet Conveyor, 48 ins. wide

New Control Logix PLC System

1 ea Control Logix PLC

1 ea PLC Programming

1.4.2 CLIN 0002 DEMO AND DISPOSE OF EXISTING SYSTEM

Traversing Transporter Dock

46 ft Indexing Pallet Conveyor on Traversing Bed with

Festoon

Induction Conveyor

180 ft Accumulation Pallet Conveyor, 48 ins. wide

5 ea Pallet turntables

3 ea Chain Pallet Transfers

1 ea Keypad Station

Two Pallet Pre-Pack Consolidation Stations (Lines #1 and #2) 64 ft Accumulation Pallet Conveyor, 48 ins. wide

1 ea Keypad Station

Pack Stations (Line #3)

160 ft Accumulation Pallet Conveyor, 48 ins. wide

6 ea 3 Pallet Position Pallet Transfers (Shuttles)

1 ea In-Line Automatic Stretch Wrap Machine

1 ea Pallet Turntable

1 ea Pallet Dimension/Weigh Offer Station with Turntable

Pack Stations (Line #4)

160 ft Accumulation Pallet Conveyor, 48 ins. wide

6 ea 3 Pallet Position Pallet Transfers

1 ea In-Line Automatic Stretch Wrap Machine

1 ea Pallet Turntable

1 ea Pallet Dimension/Weigh Offer Station

Dedicated Truck Pack Stations (Line #5)

165 ft Accumulation Pallet Conveyor, 48 ins. wide

1 ea 3 Pallet Position Pallet Transfers (Shuttles)

1 ea In-Line Automatic Stretch Wrap Machine

4 ea Pallet Turntables

1 ea Pallet Dimension/Weigh Offer Station

Spur 18 Accumulation Conveyor

36 ft Accumulation Pallet Conveyor, 48 ins. wide

1.4.3 CLIN 0003 AWOS

QTY DESCRIPTION

1 ea Automated Weigh and Offer System

1.4.4 CLIN 0004 Repair of Towline spurs 18 and 19

QTY DESCRIPTION

1 ea Repair Towline Spurs 18 and 19

1.4.5 CLIN 0005 ERGONOMIC WORKSTATIONS

QTY DESCRIPTION

15 ea Ergonomic workstation Tables

15 ea Ergonomic Chairs

1.4.6 CLIN 0006 1 Year Maintenance Contract

QTY DESCRIPTION

1 YR Preventive and Corrective Maintenance Contract for the

Entire System

ATTACHMENT 1 - STATEMENT OF WORK

1.5 EXPERIENCE OF PERSONNEL

The Contractor shall ensure that personnel to be utilized on the project have the following levels of experience in installing similar material handling systems.

Key personnel including the site superintendent, supervisory/work leaders for the installation (mechanical and electrical) crews and software programmers (s) have a minimum of 5 years’ experience.

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 17-2-1 DDRT Bldg. 499 Replace Pallet Packing Conveyor System

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. 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 17-2-1. 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) to

55 inches high loaded. The system furnished shall be designed to handle material on MIL pallets. Material to be handled consists of non-uniform packages of mixed stock. Cartons shall range in size from 6 inches long by 6 inches wide x 9 inches high to 30 inches long by 24 inches wide by 24 inches high and in weight from 5 pounds to 50 lbs. Material place on the shipping conveyor system for shall also include jiffy bags which are padded envelopes as small as 4 x 6 x .5 inches thick and weighing as little as .5 lbs.

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 J-21 as shown on drawing no. DS 17-2-1 which is 200 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 Pallet Conveyor 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 transporter dock.

b. Install new transporter dock.

c. Remove old main line pallet induction conveyor.

d. Install new main line pallet induction conveyor.

e. Remove pallet prepack consolidation lines (Lines 1 and 2) and east pallet packing line with six pack workstations and offer station (Line 3)

f. Install new pallet prepack consolidation lines (Lines 1 and 2) and east pallet packing line with six pack workstations and offer station. (Line 3)

g. Remove center pallet packing line with six pack workstations and offer station. (Line 4)

h. Install new center pallet packing line with six pack workstations and offer station. (Line 4)

i. Remove dedicated truck packing line. (Line 5)

j. Reinstall dedicated truck packing line. (Line 5)

k. Remove and install pallet conveyor, spur 18.

l. Repair towline spurs 18 and 19.

m. Install AWOS.

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

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 CONVEYOR AND

MISCELLANEOUS EQUIPMENT

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.