Project Manual #1
BROWN - OUTAGAMIE - WINNEBAGO TRI-COUNTY PARTNERSHIP MRF EQUIPMENT ADDITION & SYSTEM MODIFICATION PROJECT
Project Manual Outagamie County, Wisconsin Department of Solid Waste
Proposal Specifications For Procurement of Material Recovery Facility Equipment Addition & System Modification
October 2013
Prepared by
SloanVAZQUEZ, LLC 18006 SKYPARK CIR. SUITE 205 IRVINE, CA 92614 866‐241‐4533 [email protected]
RFP/RFB Procurement of Material Recovery Facility Equipment Addition & System Modification
TABLE OF CONTENTS
SECTION 1 – BACKGROUND ...... 1 1.1 FACILITY DESCRIPTION ...... 1 1.2 WASTE TYPES & TONNAGES ...... 1 SECTION 2 – SCOPE OF REQUESTED SERVICES ...... 3 2.1 MRF EQUIPMENT DESIGN & INSTALLATION ...... 3 2.2 INTERRUPTION OF EXISTING OPERATIONS ...... 4 2.3 LIST OF CONTRACT DELIVERABLES ...... 4 SECTION 3 – DESIGN ...... 5 3.1 DESIGN FACTORS & OTHER CONSIDERATIONS ...... ………………….5 3.2 EQUIPMENT REQUIREMENTS ...... 5 3.3 EXCEPTIONS ...... 8 3.4 PERFORMANCE GUARANTEES ...... 8 3.5 ACCEPTANCE TESTING ...... 8
EXHIBIT A ...... 9
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RFP/RFB Procurement of Material Recovery Facility Equipment Addition & System Modification
SECTION 1 – BACKGROUND This section provides background information regarding existing conditions and planned future conditions. Please note that data provided are for general informational purposes only. The Owner/operator does not certify the accuracy of the information provided. Contractors should not rely solely on this section for developing proposals and associated costs. Contractors are responsible for an independent assessment of the project.
1.1 FACILITY DESCRIPTION
Existing The existing Outagamie County single stream MRF is part of a public works complex located on a 460-acre parcel of land owned by the County, including recycling, landfill disposal, landfill gas-to-energy, and highway facilities. The existing MRF building has a total floorplan of about 45,000 square feet. The facility is designed to process single stream recyclable materials.
Proposed The proposal shall identify all building features and modifications that are required or recommended.
1.2 WASTE TYPES & TONNAGES The projected single stream material composition is provided in TABLE 1.2-1. BOW recognizes that the composition of residential/commercial single stream material is dynamic and that specific commodities within distinct single stream material may vary widely from route to route and even within a single load. Contractors must guarantee that proposed systems will achieve the throughput and quality requirements for single stream material that may vary plus or minus 30% on each given commodity.
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RFP/RFB Procurement of Material Recovery Facility Equipment Addition & System Modification
Table 1.12-1 Material Composition
Projected Baleable Projected Percent Average Tons Material Commodity Annual Tons per Hour per Hour OCC 13.99% 12,311 3.38 3.38 ONP 27.95% 24,596 6.76 6.76 OMP 11.57% 10,182 2.80 2.80 PETE 4.07% 3,582 0.98 0.98 HDPE Color 1.25% 1,100 0.30 0.30 HDPE Natural 1.61% 1,417 0.39 0.39 Mixed Plastics 1.0% 880 0.24 0.24 Carton Containers 0.1% 88 0.02 0.02 Aluminum UBC’s 1.17% 1,030 0.28 0.28 Tin/Steel Cans 3.19% 2,807 0.77 0.77 HDPE Rigid Plastics 0.31% 273 0.07 0.07 Salvage Metals 0.42% 370 0.10 Glass 25.99% 22,871 6.28 Residual 7.38% 6,494 1.78 TOTAL* 100.0% 88,000 24.18 16.01
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RFP/RFB Procurement of Material Recovery Facility Equipment Addition & System Modification
SECTION 2 – SCOPE OF REQUESTED SERVICES
2.1 MRF EQUIPMENT DESIGN & INSTALLATION The Contractor will provide the complete design and installation for all aspects of the equipment addition and system modification including, but not limited to, field measurements, securing permits, process design, structural, mechanical, electrical, analyzing utilities and control elements. The awarded Contractor is responsible for any modifications to the facility beyond those completed by the Owner/operator as described in the RFP/RFB; and the installation of all components required to complete and operate the proposed additions and modifications, and meeting the performance criteria set forth in this RFP/RFB. The Owner/operator requires the selected Contractor to provide project leadership with integral responsibility for the successful completion of the project.
The Contractors’ scope of work shall include, but is not limited to, the following items:
1) The ability to direct feed fiber materials to both balers.
2) If either baler is out of service, the fiber storage bunkers must be able to divert to the working baler
3) All equipment additions and plant modifications must be integrated into SCADA and other remote monitoring and control systems.
4) Equipment specifications should be presented for steel gauge, welds, surface preparation, and painting. Whether parts are bolted or welded should be noted.
5) Engineer, design, specify, detail and document all structural, metal fabrications, electrical, mechanical and control systems comprising complete and functional equipment additions and system modifications.
6) Produce system flow schematics and drawings (in both AutoCad and PDF formats) that meet system requirements. Meet the Owner/operator and its representatives to review and receive comment upon the proposed design. If requested by the Owner/operator, incorporate those changes into design.
7) Furnish and install all guards and safety items in accordance with the safety standards required by local, state and federal code or inspectors.
8) Furnish and install all equipment support structures and operator/maintenance access stairs, platforms and ladders. Include all handrails, railings, kick plates, floor plates and gratings as required.
9) Furnish, and wire all electrical equipment including motors, electrical drives, power panels, control panels and operator interface panels in accordance with the requirements of the specifications.
10) Meet applicable ANSI and OSHA specifications.
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11) Provide complete and accurate as-built drawings and Operation and Maintenance Manuals meeting the Owner/operator’s needs (operations and maintenance manuals are to be supplied 30 days prior to the date of the Acceptance Test).
12) Provide preliminary testing, startup, commissioning and Acceptance Testing of the completed system in accordance with the requirements of the specifications.
2.2 INTERRUPTION OF EXISTING OPERATIONS The Owner/operator intends to coordinate the building modification, and the equipment installation in such a way as to minimize the number of days that the existing processing operation is out of commission. Preference will be given to proposals that minimize plant downtime during the equipment installation and system modification process.
2.3 LIST OF CONTRACT DELIVERABLES Manufacturing, shipping, installation & start-up schedule
Schematic design documents
Schematic design cost estimate to include cost of equipment plus installation, transportation, motor controls, and electrical field wiring
Design development documents
Construction documents (if needed)
All operation manuals and plans
All maintenance manuals and schedules for preventative maintenance
All equipment warrantees
All manufacturer guarantees and liquidated damages
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RFP/RFB Procurement of Material Recovery Facility Equipment Addition & System Modification
SECTION 3 – DESIGN
3.1 DESIGN FACTORS & OTHER CONSIDERATIONS In order to accommodate the increase in tonnage, the following factors will need to be addressed.
BALE FIBER AT A BLENDED FIBER RATE OF 20 TONS PER HOUR It is important that the plant not be dependent upon a single baler. The addition of the second baler will relieve the continuous stress on the current baler (IPS) and make it possible to dedicate that baler to the baling of containers only (PETE, HDPE, Aluminum Cans, Tin/Steel Cans, Mixed Plastics, Cartons). The new baler will be dedicated to fiber baling; Cardboard (OCC), Newspaper (ONP), and Mixed Paper (OMP).
At minimum, the added baler must be capable of baling fiber at a blended practical rate of 20 tons per hour. Currently, the hourly production of fiber is 27% OCC, 52% ONP, and 21% OMP. The Owner/operator is not focused upon the technical capacity of the baler. Instead, the Owner/operator will require a production guarantee of 20 tons per hour to be accomplished under normal MRF operating conditions, using the bunker storage/delivery system and new baler in-feed conveyors to effectively deliver, on average, 20 TPH of fiber (blended rate) into the newly installed baler and produce export quality, high-density bales.
CONTAINER BAILING As currently configured, the container storage silos empty onto the IPS baler reclaim conveyor and are transferred to the inclined baler in-feed conveyor. It is expected that the new container storage silos will also be able to conveniently, efficiently deliver the mixed- plastic and carton (aseptic and gable-top) commodities onto the existing baler reclaim conveyor.
Although the owner/operator expects to bale all containers, recovered in the MRF operation in the existing IPS baler, the owner/operator also plans to create a back-up plan for continuing the baling of containers in the event of any failure in the 2-ram baling operation (IPS baler, Accent wire tier, feed conveyors). As such, the proposer must propose and describe a method(s) for the mechanical, or manual, delivery of containers to the new single-Ram baler.
The owner/operator recognizes that a single-ram baler does not present the optimum design for container baling. It is important, however, that proposers offer a single-ram baling machine that has proven capable (even though less than optimum) of baling containers if required to do so.
Please provide at least two references for each proposed single-ram baler for customers that have used the machine (s) for container baling.
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RFP/RFB Procurement of Material Recovery Facility Equipment Addition & System Modification
MATERIAL MANAGEMENT The additional tonnage will require certain plant modifications in order to effectively recover and store the added commodities:
Added bunker (OMP) – Add a 3rd fiber bunker to handle Mixed Paper. The new bunker must include a reversible leveling conveyor that feeds a walking floor and bunker doors at each end of the bunker.
Modify existing bunkers (reverse & level) – Existing fiber bunkers must be modified to include reversible leveling conveyors and new bunker doors that will feed toward the west-end of the bunker and onto a new, in-ground, reclaim conveyor for delivery into the new inclined baler feed conveyor.
Manual container retrieval at IPS hopper – The reversing fiber bunkers will make it possible to bale fiber in either, the existing IPS baler, or the new fiber baler. However, because it cannot be accomplished without considerable capital cost, it will not be possible to feed containers to both balers in an automated fashion. As such, modifications to manually recover containers from the IPS baler hopper and deliver them to the new baler will be required.
Provide opportunity for the manual recovery of target recyclables from the polishing screen “unders”. This may be accomplished anywhere along the residue return conveyor. The modification should include a means to return the recovered materials to the container sort line for sortation.
MOTOR CONTROL INTERFACE OF ALL MODIFICATIONS The new baler, conveyors and all modifications to the plant must be controllable from the Motor Control panel in the facility’s control room. The vendor must be responsible for integrating the new equipment into the motor control program. Facility Ergonomics (Facility ingress and egress, Storage, handling)
New Baler Placement – The new baler must be installed in a manner to assure access for maintenance and the conservation of much needed floor space in the bale warehouse.
The new baler and conveyors must be installed in such a way as to preserve as much bale storage area & access to area between the new OMP bunker and the bale warehouse wall as possible.
Motor Control Interface for all modifications, including:
o New OMP bunker
o Modified bunker functions
o New baler in-feed
o New Baler
o New Carton Containers and Mixed Plastics Storage Silos
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RFP/RFB Procurement of Material Recovery Facility Equipment Addition & System Modification
3.2 EQUIPMENT REQUIREMENTS The County’s RFP/RFB request contains two (2) primary elements:
The first is the addition of a second baler which will be used primarily to bale each of three fiber grades recovered in the MRF operation. The modified baling operation also includes the modification of the existing fiber storage bunkers to make them reversible, and the addition of a new fiber bunker to capture and manage mixed paper (OMP).
The second is the modification of the container sort line to accommodate the manual collection, transfer, and storage of cartons (aseptic and gable-top) and mixed-plastics. Here, new, or modified, sorting stations must be proposed to facilitate the efficient manual recovery of the target commodities, the transfer of those commodities to two separate storage silos, and the efficient unloading of the new silos (bunkers) into the IPS (current) baler.
Baler: Practical fiber baling capacity of 20 TPH as described above.
Baler In-feed: New baler in-feed conveyor(s) capable of feeding fiber to the new baler at a practical blended rate of 20 TPH.
New OMP Bunker: New bi-directional OMP bunker, with reversible leveler, capable of feeding the new baler at a practical rate of 25 TPH.
Modification of Existing Fiber Bunkers: Modify existing fiber bunkers to become bi- directional, with reversible leveler, capable of feeding the new baler at a practical rate of 20 TPH.
Modification of Container Sort line: With the described modifications, the Owner/operator will begin to target and recover additional recyclable materials. Proposers will be asked to propose modifications to the existing container sort line to facilitate the recovery, handling and storage of specified materials.
Modification of Residue Sort-line: With the described modifications, the Owner/operator will begin to target and recover additional recyclable materials. Proposers will be asked to proposed modifications to the existing residue sort line to facilitate the recovery, handling and storage of specified materials.
Modification of IPS Baler Hopper for Manual Diverting/Recovery of Containers: Because capital costs for achieving the automated redundancy of container baling, proposers will be asked to propose modifications to the IPS baler hopper to facilitate the manual recovery of containers for delivery to the new baler.
Twelve 10-Yard Cages (6.5’ X 6.5’ X 6.5’): Proposers will be asked to supply 12, 10 cubic yard storage baskets as specified below.
Stackable/Nestable, expanded metal walls, Heavy steel bottom, Heavy steel frame (crossbraces & angle iron), 4-way bottom channel
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3.3 EXCEPTIONS The number and significance of the Contractor’s exceptions to the RFP/RFB and contract terms will be assessed and considered in the overall evaluation of each proposal.
3.4 PERFORMANCE GUARANTEES The Contractor guarantees the Owner/operator that the proposed equipment additions and system modifications will maintain or improve plant operations as follows: 1) the production capacity (throughput) of the existing operation, 2) the quality of recovered commodities.
3.5 ACCEPTANCE TESTING The Owner/operator desires that all modifications to the MRF be completed with minimal plant downtime. Only after the Acceptance Test is passed will the Owner/operator accept ownership and render final payment. Successful completion of the System Acceptance Test will require that the Contractor meet the requirements stated in Exhibit A - System Acceptance Test and the following:
a) Product quality – Equipment additions and system modifications will maintain or improve the quality of recovered commodities.
b) Throughput Acceptance Test Standard – the average throughput for the added baling system must be equal to or greater than twenty (20) tons per hour as described above in Section 3.1 for the period of the Acceptance Test.
The baler performance will be measured against the manufacturer’s published specifications. The Contractor shall submit published manufacturer’s specifications to the Owner/operator before the award of the Agreement. The Baler specifications and Baler Acceptance Test must demonstrate the following:
a) Performance items - baler stroke speed, bale density (OCC, ONP, and OMP), bale rate, bale system reporting capabilities and remote access.
b) Baler operations cost - wire usage detail and cost per ton to operate.
c) Electrical power consumption – The Contractor will complete the RFP/RFP Pricing Breakdown Form (Attachment B) which details the power consumption by the baler. During the time period of the Baler Acceptance Test, power consumption will be monitored and will need to comply with the power consumption figures on this document submitted by the Contractor.
The performance testing must be completed within five days after the completion of all system modification and equipment installation.
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RFP/RFB Procurement of Material Recovery Facility Equipment Addition & System Modification
EXHIBIT A Systems Acceptance Test
GENERAL TESTING REQUIREMENTS AND ACCEPTANCE STANDARDS The purpose of Systems Acceptance Test is to verify that the system, as constructed, is capable of operating at the performance required under the Agreement.
During Acceptance Test, the Contractor shall operate the system in accordance with staffing plan and specified method of operation that has been submitted by the Contractor and approved by Owner/operator in the MRF Operating Plan prior to the signing of the Agreement and Acceptance testing. For the purposes of the Acceptance Test, the Contractor shall not operate the facility in any manner which is not consistent with the approved Facility Operating Plan, nor shall the Contractor utilize additional personnel above and beyond those specified in the approved Facility Operating Plan to achieve Acceptance.
The Contractor shall be responsible to fully install, start-up, and test all aspects of the MRF modifications and equipment additions to demonstrate compliance with all requirements of the Agreement and all manufacturers’ warrantee requirements, and this Acceptance Test. The Contractor will conduct the Acceptance Test in the presence of representatives from the Owner/operator and its Consultants if appropriate.
ACCEPTANCE TEST PROCESS MATERIALS The Process Materials for the Acceptance Test will be a mix of the current residential/commercial single-stream materials as delivered to the MRF facility.
ACCEPTANCE TEST RUN TIME All modifications are subject to a four hour dry-run test. That is, the entire system will be started and run, without material, for a period of four hours. During that period, all added components must operate without stopping and respond to motor control commands, as directed.
The baler, baler infeed conveyor, and the added/modified fiber bunker system must complete the following performance tests before acceptance by the Owner/operator.
Four consecutive one-hour production tests during which the practical fiber baling rate of twenty blended fiber tons per hour must be achieved. If a singular test fails, the entire four “consecutive one-hour tests” requirement will be started over.
For a period of four consecutive shifts (e.g. day 1 – shifts 1&2, and day 2 – shifts 1&2); the baler infeed conveyor and the added/modified fiber bunker system must be available, on-demand, for 7.2 hours (seven hours and 12 minutes) of each eight hour shift (90.0% availability). Failure to achieve the availability requirement during any shift will constitute failure and the entire four “consecutive shifts tests requirement” will be started over.
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RFP/RFB Procurement of Material Recovery Facility Equipment Addition & System Modification
PRODUCT QUALITY TEST The Product Quality Test will be conducted simultaneously with the Performance/Acceptance Test, as follows:
The size, density, and weight of the fiber bales produced during the performance testing period must be sufficient to assure that outbound containers, vans, or boxes are capable of being loaded to the maximum legal weight limit.
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