Attachment_1_DDRV_Bldg_66_Bay_D_VLM_Storage_Systems_SOW.pdf

SP3300-17-Q-5017

ATTACHMENT 1

Statement of Work

For Bldg. 66 D

VLM Storage Systems DLA Distribution Richmond, VA

Apr 30, 2014

5 Jun 17

Prepared By:

DLA Installation Support New Cumberland, PA

DS-FDI; Building 430 430 Mifflin Ave., Suite 2227

New Cumberland, PA 17070-5059

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 ----------------------------------------- 4

1.4 CONTRACT LINE ITEMS -------------------------------------------------------- 4

2.0 APPICABLE SPECIFICATIONS, STANDARDS AND CODES ----------- 6

2.1 GOVERNMENT DOCUMENTS -------------------------------------------------- 6

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

3.0 REQUIREMENTS ------------------------------------------------------------------- 8

3.1 GENERAL REQUIREMENTS ---------------------------------------------------- 8

3.2 EQUIPMENT SPECIFICATIONS ------------------------------------------------ 16

3.3 TRAINING ---------------------------------------------------------------------------- 25

3.4 ELECTRICAL REQUIREMENTS------------------------------------------------- 26

4.0 QUALITY ----------------------------------------------------------------------------- 28

4.1 LAYOUT ------------------------------------------------------------------------------ 28

4.2 SYSTEM MAINTENANCE ------------------------------------------------------- 28

4.3 SYSTEM CHECKOUT ------------------------------------------------------------ 29

4.4 INSPECTION AND TEST --------------------------------------------------------- 29

SECTION 1

1.0 SCOPE

This specification covers the necessary services, labor, material, equipment and control components required to supply and install two Vertical Lift Module (VLM) Storage Systems (here to after called VLMs) for Bldg. 66, Bay D at DLA Distribution Richmond, VA (DDRV) located at DLA Aviation Richmond, VA.

1.1 SITE

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

1.1.1 SITE DESCRIPTION

Bldg. 66 is a World War II general purchase storage warehouse constructed in 1942. The nominal dimensions of this warehouse constructed in 1942. The nominal dimensions of this warehouse are 1,100 ft. x 200ft. The layouts are depicted in DS 15-2-1. Bldg. 66 is divided into five 200 ft. 200 ft. warehouse sections, except section E which is 100 ft. x 200 ft. The area that the VLM’s will be installed in is the mapping shipping area in Bay D. The VLMs will be installed adjacent to the pack stations that will induct the DVDs for shipping into the existing automatic weigh and offer system (AWOS).

1.2 SYSTEM LAYOUT AND FUNCTION

Building 66 is the main storage facility for DDRV. Bay B is flatmap storage and pallet rack storage for bulk supplies of maps. Bay C is the package rack storage system for folded maps and CD/DVD storage. Bay D is the packing/shipping conveyor system and walk and pick rack. Bay E is the classified storage vault.

DDRV has started a new storage policy which is to reduce the amount of storage of CDs/DVD is the non-classified storage area in Bay C. The CDs/DVDs are stored in the bin racks. The CDs/DVDs have a special wire basket that was originally designed for storage of 70 CDs/DVDs per national stock number (NSN). Currently there are 32,042 NSN of CDs/DVDs stored in Bay C. DDRV used to store at least 70 CDs/DVDs per NIN. Now the new storage policy is to store only maximum five CDs/DVDs per NSN because the maps are updated frequently and DDRV has gone to a print on demand distribution system. This means that minimum 3 CDs/DVDs are stored in location and if the demand exceeds the quantity stored, the CDs/DVD are created for that particular order and then are shipped. Before the CDs/DVDs were produced off-site. Now they are produced at Richmond. To capitalize of the storage space that was gain by the storage draw down, DDRV is proposing to consolidate the CD/DVD storage in two VLMs in Bay D right next to the packing/shipping system to increase the productivity/efficiency of the current operations and to save the storage space in the bins for folded map storage. Under this statement of work, the VLMs will provide binnable storage for the CDs/DVDs currently stored in the bin/package rack system in Bldg. 66, Bay C.

1.3 EXISTING SYSTEM THROUGHPUTS

The hours of operation of the system will be M-F 0700-1530. The average daily workload is as follows:

RECEIPTS PER VLM:

Average hourly throughput: 20 Maximum hourly throughput: 25

ISSUES PER VLM:

Average hourly throughput: 25

Maximum hourly throughput: 30

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 CLIN up to 180 days from the initial contract award. CLIN number 0001 is the base bid. CLINS 0002, 0003 and 0004 are optional CLINS. The performance period for CLIN 0001 is 180 days, and CLIN 0002 is 120 days days if awarded. The performance period for CLINs 0003 and 0004 will be for one year after acceptance of the entire new system.

1.4.1 CLIN NO. 0001 VLM STORAGE SYSTEM

QTY DESCRIPTION

1 ea. Vertical Lift Modules 1 ea. Ergonomic workstations 1 ea. 20 amp 120 volt, single phase electrical receptacles 21ea. Demo and dispose 5 ft. wide x 4 ft. deep x 8 ft. high subscription rack (5 storage levels)

1.4.2 CLIN No 0002 OPTIONAL VLM STORAGE SYSTEM

1 ea. Vertical Lift Modules 1 ea. Ergonomic workstations 1 ea. 20 amp 120 volt, single phase electrical receptacles

1.4.3 CLIN No 0003 OPTIONAL 1 YEAR MAINTENANCE CONTRACT

1 Yr Preventive and Corrective Maintenance Contract for CLIN

1.4.4 CLIN No 0004 OPTIONAL 1 YEAR MAINTENANCE CONTRACT

1 Yr Preventive and Corrective Maintenance Contract for CLIN

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

2.1.2 MILITARY SPECIFICATIONS

MIL-C-83286 Polyurethane Paint MIL-P-514 Plates, Identification, Instrumentation, and Marking 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

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

2.1.7 DRAWINGS

DS-FDI Drawing No. 17-3-1 DDRV Bldg. 66, Bay D VLM Storage Systems

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 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

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

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 3.4 are satisfied by the proposed design. The contractor shall provide all equipment, material, control components, engineering and labor necessary to provide completely installed systems ready for operation. The system shall be tested by the contractor prior to performance testing by the Government. All equipment (each whole product with its integral software) shall be the manufacturer’s current, commercially designed and available or a commercial product that has been slightly modified to fit the proposed system. The commercial product must have proven, successful field application for at least two years immediately preceding the issue date of this solicitation. The field experience of each specific equipment product shall have been gained by an identical or previous model to the one being offered. The design of the specific equipment product offered must be fully defined. Also, any design changes during the two year period of field experience shall be identified by the offeror. These design changes must be minor and insignificant or be demonstrated reliable through commercial application. Plastic piping for compressed air is prohibited except as a final carrier from solenoid to actuator. Pneumatic controls shall not be permitted.

3.1.1 MATERIALS AND OPERATING CONDITIONS

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

3.1.2 TREATMENT AND PAINTING

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

Material to be handled consists of DVD/CDs in Jewel cases nominal 5-10-/16 ins. W x 4-7/8” H ins. x 5/16 ins. thick. The trays shall be divided into 3 in. x 6 in. compartments and shall have a nominal storage capacity of 8 CDs/DVDs per compartment. The Government design will have 260 comparts per tray and 52 trays per VLM. The CDs/DVDs will be stored to make the storage height of each tray 4-7/8” H.

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/INSTALLATION

It shall be the contractor’s responsibility to connect all required electrical equipment to the existing or contractor supplied electrical power distribution panels. The existing main feed panel DH1 which is a 277/460 volt 800 amp service located on the wall in Bay K-7.

The contractor shall obtain power for the new system from this distribution panel. The conveyor panel for the existing system panel DH2 is located in Bay K-9. All required conduits, wires, electrical power distribution equipment, breakers, transformers, distribution panels/subpanels, and other electrical hardware shall be contractor furnished and installed in accordance with the National Electrical Code (NEC), National Fire Protection Association (NFPA), NEMA and other applicable state and local codes.

Contractor installed distribution system shall have an isolated ground and surge protection adequate to protect electronic equipment and computer terminals. All contractor installed electrical panels shall be clearly and permanently labeled to identify voltage and equipment serviced. 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.

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”

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 must be performed during non-duty hours (see paragraph 3.1.15.3).

3.1.15.2 INSTALLATION SEQUENCE

Installation of the conveyor systems shall be in the following order.

a. Ship and install VLMs #1.

b. Ship and install VLMs #2.

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 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 DLA Aviation Richmond 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 personal protective equipment (PPE) must be in accordance with OSHA Standards and must be worn by all contractor personnel throughout the system installation.

Failure to wear PPE shall be considered an OSHA violation. Safety Personnel from DLA Aviation Richmond and DDRV and the COR will make random inspections to ensure compliance by contractor personnel.

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.

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. 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 by calling the DSCR Fire Department, Assistant Chief Cross at (804) 279-3630, and identifying the location and type of work to be done.

3.1.16.1.6 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.

3.1.16.1.7 MISHAP REPORTING

A copy of the report on each job connected injury, property damage, or motor vehicle mishap will be submitted to the COR 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 Assistant 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 DLA Aviation Richmond Base Fire Department Assistant 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

Sequence Title DID ID. Number

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 VLMs 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 VLMs shall be sighted along centerlines and aligned +/- ¼ inch in the horizontal/vertical planes. 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 VLMs

The Control System shall include applicable PCs, keypads, sensors, scanners and actuators required to provide the overall integrated routing/tracking trays to /from the operator workstations and the tray storage inside the VLMs. Contractor shall be responsible for design and installation of the entire installation of the VLMs. Power source shall be contractor supplied per paragraph 3.1.8. 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.

3.2.1.1 CONTROL PANELS

All control panels shall be located adjacent to the applicable VLM area. Control panels shall contain all control components/devices, and related equipment necessary for operation of VLMs in specified modes.

3.2.2 VERTICAL LIFT MODULE (VLM)

One VLM shall be supplied and installed in Bays E-F7 for CD/DVD Storage in bins /package racks in Bay C. There is an option in CLIN 0002 for one additional VLM to be installed next to the first VLM. The VLM System shall through the equipment control system (ECS) maintains an inventory of parts and materials. During Automatic mode of operation, the VLM delivers the tray to the front of the VLM. Receipts are received

Bldg. 98 and transported by forklift to Bldg. 66. The operator scans the barcode on the material and the Equipment Control System (ECS) then tells the operator which location to store the material. An operator then hits a return on the computer which tells the VLM the address of a tray to be retrieved. In response to this selection, the VLM selects the storage tray, extracts the tray and brings it to the workstation in the front of the VLM.

The operator then places the material in the tray. At this point, the operator presses a control on the keyboard on the Government DSS computer that causes the VLM to pick up the tray and returns it to its assigned storage compartment for automatic storage.

Issues are downloaded from the mainframe computer from ECS. The screen on the operator’s computer tells the operator the NSN, the quantity to be picked, the location of the storage tray and the which compartment inside the tray that the material is stowed.

The DSS System tells the VLM to retrieve the tray. In response to this selection, the VLM, extracts the tray and brings it to the VLM workstation. The operator then removes the material from the container and presses a control on the keyboard that causes the VLM to pick up the tray and return it to the assigned storage location for automatic storage. The operator then places the picked material in jiffy bags and packs the material for shipment and then places it on the take-away belt conveyor AWOS.

3.2.2.1 SELF SUPPORTING STRUCTURE

The systems shall have a self-supporting structure with a load-bearing profile framework and steel modular exterior panels. Vertical Lift Module (VLM) has a weight capacity of 132,000 lbs. including the trays. Outside cabinet dimensions, including external tray delivery station, of the VLM is approximately 22’- 0” tall x 15’0” wide x 13’6” deep. The storage tray dimensions must be at least 160” (13’ 4”) wide by 34.0” deep and offer a clear opening across the 160” width with no tray support components within the tray body. Vertical depth inside the tray must be at least 4.5”. Alternate designs acceptable provided that the cube and weight capacity are maintained and that there is clear maintenance access for the VLM units proposed.

3.2.2.2 CENTRAL ELEVATING PLATFORM

The central elevating platform is to be located between the front and rear columns of vertically stored trays. System will deliver trays to the external delivery area as requested by the operator. All vertical tray movement is to be accomplished through the use of steel or Kevlar® reinforced toothed belt drive system and a self-braking gear motor controlled by an inverter. Vertical positioning of trays is to be controlled by a count encoder. Tray stability is maintained through the use of eight rollers on the elevator mechanism.

3.2.2.3 EXTERNAL TRAY DELIVERY SYSTEM

VLM to include automatic tray delivery that is outside the machine enclosure in a single-level tray configuration. The maximum height of stored material must be no more than 5”. The external tray delivery system must provide ergonomic and unobstructed overhead access outside the enclosed VLM to the materials stored inside the tray. Once the user has completed the actions required in the first tray, the second tray is delivered automatically to the external access delivery point after the VLM returns the first tray to its first available stored position.

3.2.2.4 DUAL TRAY DELIVERY

Once the user has completed the actions required in the first tray, the second tray is delivered automatically to the external access delivery point while the VLM returns the first tray to its first available stored position. This option is preferred but not a firm requirement.

3.2.2.5 UNIT PERFORMANCE PARAMETERS

Unit Performance Empty Tray Fully Loaded Tray # Trays delivered per hour 92 66 Average Tray time delivery 19 seconds 23 seconds Maximum Tray Time Delivery 28 seconds 33 seconds

3.2.2.6 TRAYS

Trays are to be manufactured from galvanized sheet metal, have a steel reinforced design and welded construction with NO welded reinforcements inside the tray. All trays are to be manufactured to accept slotted walls on approximately 1 inch centers for the installation of side-to-side tray partitions and front-to-back tray dividers. Trays without slotted internal walls will not be acceptable. There will be a total of 60 trays, each approximately 160”wide x by no less than 32 and 35 ins. deep x 4.5” high. All trays will have a net load capacity of 1,100 lbs. Alternate size VLM units and trays are acceptable provided that they will fit in the foot print detailed on drawing no. 17-3-1 and that the equivalent storage weight capacity, an equivalent no. of storage locations and storage cube is provided as detailed in paragraphs 3.2.2.6 and 3.2.2.7 and no more than a total of units are provided for CLIN 0001 and CLIN 0002. The Government design has 60 trays per VLM assuming an average stack height of 5 ins.

3.2.2.7 PARTITIONS AND DIVIDERS

Partitions and dividers are constructed of galvanized steel and are compatible with the manufacturers slotted wall trays. The partitions and dividers will provide compartmentalization for the trays in any multiples on 1” centers. Partitions and dividers shall be provided by the manufacturer of the VLM equipment so as to ensure compatibility with the supplied trays. For two VLMs, twenty nine (29) front to back partitions (i.e. 32”-35” total length) per tray shall be supplied and five (10) left to right (i.e. 160” total length) dividers per tray shall be provided. The heights for the dividers and partitions shall be 4.5”. There shall be a total of 260 compartments per VLM and a total of 60 trays per VLM for a total of 15,600 locations per VLM capable of holding 8 CDs/DVDs.

3.2.2.8 OPERATOR CONSOLE

Operator Console shall be an industrial PC design and include:

• Graphical touch screen LCD

• 10.4” TFT color touch screen with 800 x 600 resolution ( VGA compatible)

• Microsoft Windows 7 Operating system (Windows 10 is also acceptable)

• Diagnostics touch screen feature in the event of an error or malfunction

• Can be used either in manual or semi-automatic mode.

• Operator console must be adjustable and capable of being positioned anywhere across the side-to-side track of the machine opening.

3.2.2.9 ELECTRICAL CABINET

All of the electronic devices for powering and automatically controlling the VLM are located within the front drawer sliding electrical cabinet and shall include:

• REMIO input/output board

• Connection to the Operator Console by use of an Ethernet port

• Incremental encoder input

• Inverters used for both vertical and horizontal speed control via CAN/BUS

• Digital I/O interface boards

• Complete electrical cabling with all required sensors and connections

• Exterior Paneling- VLM exterior to be clad with high strength sheet metal panels that provide a high level of heat and sound insulation. These panels are easily removed to provide access for maintenance.

3.2.2.10 SAFETY FEATURES FOR VLM

• Product measurement light curtains, located at the rear of the delivery bay, are required to measure the height of items stored in the trays as they enter the VLM. If a product is over height, or if there is not sufficient space within the VLM, the tray is rejected and returned to the operator.

• Personal Protection light curtains, located in the front of the delivery bay area, are required to protect operators while they load and unload trays.

• Machine diagnostics automatically performed at start up.

• Continuous operation control monitoring

• Vertical axis encoder status control

• Axis overrun safety switch that opens contacts and enables motor brake

3.2.2.11 GREEN FEATURE:

The unit shall be equipped with “Green” features which will assist in offsetting electrical usage. The Green device, allows the energy generated by the downward movement of the elevator to be re-utilized which would otherwise be dissipated in the form of heat on the relative braking resistors. The fundamental principle that allows such regeneration utilizes the DC-BUS technology in common among the various inverters. The Green solution is a special inverter which, being placed between the machine’s main switch and electrical panel, functions both as an “energy stabilizer” when the motor of the vertical axis absorbs, and as a generator when the motor of the vertical axis generates, rerouting the electrical energy produced to the customer’s grid.

3.2.2.12 ELECTRICAL REQUIREMENTS

The contractor will provide electrical installation for each VLM per paragraph

3.1.8. The VLM supplied shall be designed for 480 volt, 3phase, four wire power.

All work shall comply with NEC and shall be performed by an electrician licensed in the state of VA.

3.2.2.13 SOFTWARE REQUIREMENTS

The VLM contractor will be responsible for providing the necessary software to meet the Government’s minimum requirements for the following:

(A) Allow user to retrieve trays by tray number or Government part number. Bar code scanning and bar code reading capability/host interface capability shall be included.

(B) Allow user to perform VLM parameter modifications, manage fault diagnostics/ fault recovery and operate in manual or semi-automatic mode.

(C) Inventory management via ECS/DDS interface of all customer inventories for all VLMs supplied.

The software will provide these basic services as standard features:

• Use of a modern relational data base

• Data backup and restoration in the event of software malfunction

• Customizable grid screen layout

• Advanced filtering options that allows customizable searches and orders

• Advanced user/operator rights management

• Hierarchal list management (kitting)

• Graphical location management for both the VLM as well as items stored in manual pick areas such as shelving and racks.

• Configurable integration with enterprise management systems via an ASCII files exchange.

• Data exchange via ODBC driver, XML files and Excel spreadsheets

• Packing List Management

• Capability to batch pick items picked from different locations

• Capability to manage internal material movement between different areas

• Capability to create custom reports with an intuitive report tool

• Automatic database maintenance that will optimize software performance

In addition to the above, the Software package provide by the VLM supplier will include these advanced capabilities:

• Advanced security management, with the capability to limit access to trays and items depending on the user’s role or area of responsibility.

• Associate images to items

• Group items into families to define common characteristics

• Group items into categories to improve search and filtering functionality

• Manage supplementary attributes for items and orders.

• Extend the systems basic movement management features by providing:

A) Packing list management

B) Assembly kit management

C) Batch picking management that will work in conjunction with the LED Indicator bar.

D) Transit material management for items such as boxes and totes

• VLM Manufacturer is to provide factory certified installation of the complete system, including, operator training and support for the operational software provided.

3.2.3 ECS INTERFACE

3.2.3.1.1 ECS PERSONAL COMPUTER

The existing ECS PC which is GFE supplied is connected by the existing Ethernet hub utilizing a RJ45 cable. The Government supplied ECS PC specifications are described below. The application software for this computer is Government designed and supplied.

Qty Description Manufacturer

1 Intel Core 2 Duo E8500 (3.33 GHz, 6M, L2 Cache, 1333 FSB Dell

1 MB L2 Cache

4 GB Dual Channel DDR2 SDRAM, 800 MHz – 2 DIMMS

Windows XP Professional Operating system – With OS,Drivers, and systems documentation included. (If not available from manufacturer, purchase with either Window 7 and overlay with XP as the operating system.)

19” Wide Screen Color Monitor WXGA Anti Glare Flat LCD

512 M NVIDIA GeForce G310 (DVI + HDMI)

320 GB Serial ATA Hard Drive (7200 RPM)

PCI 32-bit LAN Card (10BASET)

1200 Watt Power Supply

Tower Chassis

Keyboard, Standard 101 Key

2 ISA, 3 PCI, 2ISA/PCI Slot Shared

Single drive 16 X DVD ROM

Microsoft Mouse

1 Parallel, 2 Serial Ports

1 DIGI Port Server I (8 Port) DIGI Part # 70000860

1 RJ45 Cable 25-ft. N/A

3.2.4 DDRV VLM System Rules of Communications

The Interface allows for communications between the ECS and the DDWG PLC.

Communication protocol - RS-232 Serial ASCII-7 bit 9600-Baud Asynchronous.

3.2.4.1 PLC to ECS Message

MESSAGE

TYPE

MESSAGE

DESCRIPTION

MESSAGE

FORMAT

03 Dimension, Weight and Control Number Message Message from PLC at DDWG scanner #3.

(Map location A/B11?)

Start of Text: Hex 02 Length: 24 Message Type: 03 Package Length: ## Package Width: ## Package Height: ## Package Weight: ###.## Control Number: CCCCCCC Carriage Return: Hex 0D Line Feed: Hex 0A

02 Scanner Reply Message from DDWG Confirmation Scanner #3 (Map location A11)

Start of Text: Hex 02 Length: 14 Message Type: 03 Scanner Number: ## Control Number/Conveyance ID :

CCCCCCC

Carriage Return: Hex 0D Line Feed: Hex 0A

PLC to ECS Message PCS

3.2.4.2 ECS to PLC Message

MESSAGE

TYPE

MESSAGE

DESCRIPTION

MESSAGE

FORMAT

01 Destination and Control Number Message

Start of Text: Hex 02 Length: 17 Message Type: 01 Scanner Number: xx Destination: ### Control Number/Conveyance ID :

CCCCCCC

Carriage Return: Hex 0D Line Feed: Hex 0A

ECS to PLC Message PCS

3.2.5 WORKSTATION EQUIPMENT FOR VLMs

The various pieces of equipment listed shall be installed by the contractor as necessary to create a work environment that will be conducive to worker productivity and efficiency.

All interfaces between the operators, the workload and the installed system shall be optimized to produce a layout using effective and approved ergonomic principles. The equipment will be used for Government operations of PC’s and printers in a material handling operation. All workstation equipment shall be submitted for approval in accordance with CDRL A002.

3.2.5.1 WORKTABLES

The contractor shall provide 1 assembled worktable for each VLM supplied. The tables shall have a walnut Formica top, adjustable table legs, a back stringer and one drawer. All non-painted surfaces shall be galvanized. The tables shall have the following features:

A. WALNUT FORMICA TOP OVER STEEL TABLE TOP

The high density Formica top shall be attached directly over a fabricated 12 gauge steel top rated at 250 lbs. per sq. ft. The top shall be warp and splinter proof and resistant to impact, moisture and oils. Overall table top dimensions shall be 72 inches wide by 30 inches deep.

B. TABLE LEGS

Table legs with supports shall be fabricated from 16 gauge steel (minimum) and be adjustable from 30-3/4 in to 34 ¾ in. Cross support members are welded or bolted to vertical legs for strength and durability. The legs shall bolt to the table top and allow for mounting of a back stringer.

C. BACK STRINGER

Stringer shall be fabricated from 16 gauge steel (minimum) to 4 to 7 inches wide that will hold the legs rigid. It shall bolt to the back legs.

D. DRAWER

There shall be two drawers per worktable with all mounting hardware included. The drawers shall operate on ball bearing rollers within its own case. Automatic stops shall limit the drawer travel. Drawer size shall be nominal 17 ¼ in W x 20 in. D x 6 ½ in. H. Drawer shall also have a built in lock.

E. TOP SHELF, LIGHT AND CPU POCKET

The workstation shall also be supplied with a top shelf, a florescent light and a CPU pocket for a medium size desk top computer (16 D x 16 H x 7 W).

3.2.5.2 INDUSTRIAL CHAIRS

The contractor shall supply 1 assembled chair for each VLM worktable supplied for the Bldg. 66 VLM Storage System. The chair shall provide functional ergonomic seating, be engineered to maximize comfort and increase productivity. It shall be built to withstand heavy industrial use. The seat height, back depth lumbar tilt and seat pan tilt shall be adjustable by the operator while seated to meet his requirements. The chair shall have automatic adjustments for height and a single control for automatic adjustment of seat tilt and back depth. Seat height adjustment will be at least from 24 to 32 inches. Pneumatic lift shall provide at least 6 inches of Adjustment with a lever control. Center support column shall be adjustable at least 12 inches for high or low seating. Micro cellular, self-skinning polyurethane shall be molded over the seat, back and footrest. The large seat (minimum 17 in wide x 16 in deep) will have contoured support with waterfall front. The extra high back (minimum 15 in wide x 12 in high) tilts for lumbar support and adjusts for height. The chair shall have a five-legged base with three-level footrests of heavy gauge steel, finished with baked powder epoxy that offers durability and stability. The base shall have high impact, oil resistant glided.

3.2.5.3 FLOOR MATS

Floor mats shall be supplied with each workstation and will be antistatic, anti-fatigue, solid heavy-duty mats ½ in. to 5/8 in thick.