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EQUIPMENT SPECIFICATION

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Project – XXXXXX
Line XXXXX SPECIFICATION
KELLOGG'S SPECIFICATION NO.
Greensand/Iron Filters ES-223226
DATE (ORIGINAL):
PROJECT NUMBER: 04/11/11
XXXXXXX Global Specification REV DATE:
0
THIS TITLE SHEET IS THE FIRST PAGE OF THE SPECIFICATION AND IS A RECORD OF EACH ISSUE OR
REVISION AND THE DESCRIPTION OF THE REVISION SHOULD BE NOTED UNDER REMARKS.
REV DATE BY CK APPROVALS PAGES REMARKS
DEPT. PROJ. CLIENT-DATE
A XXXXX xxx All For Quote

THE FOLLOWING REFERENCED DOCUMENTS ARE ATTACHED AND ARE PART OF THIS SPECIFICATION.
DOCUMENT NO. DESCRIPTION TAG NO. DATE REV PAGES
Kellogg’s Machine Guarding Specifications 2/24/06 6.1 14
ES-262031 Electrical requirements for New 02/03/2011 4 10
Equipment
A-5307 Kellogg Nameplate Specification
Hygienic Checklist

ENTIRE SPECIFICATION SPECIFICATION ISSUED FOR


ISSUED THIS REVISION
REVISED PAGES ONLY REVIEW PURCHASE
ISSUED THIS REVISION CLIENT APPROVAL CONSTRUCTION
INQUIRY/BID

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TABLE OF CONTENTS

PART 1 - GENERAL....................................................................................................3
1.1 SCOPE---------------------------------------------------------------------------------------------------------3
1.2 APPLICATION-----------------------------------------------------------------------------------------------4
1.3 ITEM NUMBERS--------------------------------------------------------------------------------------------4
1.4 CODES AND STANDARDS------------------------------------------------------------------------------4
1.5 CONFLICTING REQUIREMENTS---------------------------------------------------------------------5

PART 2 - GENERAL DESIGN REQUIREMENTS........................................................5


2.1 PIPE MATERIAL AND FABRICATION-----------------------------------------------------------------5
2.2 ELECTRICAL-------------------------------------------------------------------------------------------------7

PART 3 - PROCESS DESIGN DATA – GREENSAND FILTER....................................7


3.1 GENERAL FABRICATION AND DESIGN REQUIREMENTS – GREENSAND FILTER- 7
3.2 INLET OPERATING CONDITIONS--------------------------------------------------------------------9
3.3 MATERIALS OF CONSTRUCTION – GREENSAND FILTER----------------------------------9

PART 4 - PROPOSAL..................................................................................................11

PART 5 - SUBMITTALS...............................................................................................12
5.1 SHOP DRAWINGS AFTER PURCHASE-----------------------------------------------------------12
5.2 OPERATIONS AND MAINTENANCE MANUAL--------------------------------------------------12
5.3 OTHER REQIREMENTS--------------------------------------------------------------------------------12
5.4 WARRANTY------------------------------------------------------------------------------------------------12

PART 6 - PREPARATION FOR SHIPMENT.................................................................12


6.1 NOZZLE PROTECTION & CRATING---------------------------------------------------------------12
6.2 SHIPPING TAGS------------------------------------------------------------------------------------------13

PART 7 - LOADING OF MEDIA...................................................................................13


7.1 NOZZLE PROTECTION & CRATING---------------------------------------------------------------13

PART 8 - START-UP ASSISTANCE.............................................................................13

PART 9 - TRAINING.....................................................................................................13
9.1 MAINTENANCE TRAINING----------------------------------------------------------------------------13
9.2 OPERATOR TRAINING----------------------------------------------------------------------------------14

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PART 1 - GENERAL

1.1 SCOPE

1. This specification defines the requirements for the performance;


design, fabrication, and testing of a greensand filtration system
(referred to as “System” in this document) for a food processing facility.
Please refer to P&ID which is included as reference, to depict the
system, and suggested scope of supply.

2. The equipment to be supplied by the Vendor shall generally include,


but not be limited to, the following: greensand filter, media, piping and
valves as illustrated on the P&ID. Other accessories, instruments,
controls and components specified herein or noted shall also be
supplied by the Vendor so as to provide a complete operating system.
Co

3. Greensand Filter – One unit to be rated at xxx gpm and capable of iron
removal. Vessel design to be ASME Code 100 psig with stamp and be
of carbon steel construction with suitable PVC or Epoxy lining suitable
for 100ppm chlorine dosing and rated for 150ºF temperatures. The
Greensand filter will provide feed water for a RO unit.

4. Control Panel Enclosures - All control panels and electrical enclosures


to be NEMA 4. Refer to Kellogg’s document ES-262031 Electrical
Requirements for New Equipment for control panel design
requirements.

5. Responsibility - The seller assumes total responsibility for any and all
engineering and design requirements necessary to guarantee that the
supplied components will effectively operate with all other system
components.

6. To achieve this requirement for overall system performance, the seller


shall become totally knowledgeable of the operations of the facility into
which his components will be installed. If required, an on-site visit can
be arraigned.

7. Seller further understands, that any and all scope definitions,


specifications drawings, sketches, instructions, etc. furnished are for
advisory purpose only. Any use of the aforementioned advisory
materials will not relieve the seller of any system performance
responsibilities and/or warranties.

8. It is the Manufacturer's responsibility to add or take issue with any


items in this outline specification. Unless Manufacturer does this in

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writing, it will be understood that all items in this outline specification
have been accepted by the Manufacturer.

1.2 APPLICATION

9. The system will be installed in an indoor location at a facility in


City/State. The purpose of the system is to supply xxx gallons/minute of
food grade product water to an existing RO storage tank.

1.3 ITEM NUMBERS

Item Number Description Quantity

GSF-1 Greensand Filter 1

1.4 CODES AND STANDARDS

All equipment and materials shall comply with the latest edition of the codes and standards
mentioned herein or otherwise applicable. These standards, orders, specifications and
regulations shall be included in this specification, in full, by reference.

10. ANSI Publications

11. OSHA Safety and Health Standards

12. National Electrical Manufacturers' Association (NEMA)

13. ANSI / Hydraulic Institute Standards

14. ANSI / NSF Standard 61

15. ANSI / AWWA B604

16. FM - Factory Mutual

17. OSHA Safety and Health Standards including, but not limited to, CFR
29 190.263

18. NEC - National Electric Code

19. All applicable NFPA Standards

20. ASME Unfired Pressure Vessel Code Sec VIII Div I, where applicable to
equipment furnished. The Greensand vessel shall be constructed in
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accordance with ASME pressure vessel standards; ASME stamp is
required. Supplier shall provide 3 copies of certified drawings in
accordance with ASME standards. Certified calculations shall be made
available to the FM Inspector upon request.

21. All applicable local codes and regulations

1.5 CONFLICTING REQUIREMENTS

This specification is written as a guide to achieve the best possible system. It is


recognized that different Manufacturers might recommend materials or methods that differ
from these outline specifications. All conflicts between the requirements of this
specification, and standards, shall be referred to the Purchaser for clarification before
proceeding with the manufacture of the equipment.
PART 2 - GENERAL DESIGN REQUIREMENTS

2.1 PIPE MATERIAL AND FABRICATION

2.1.1 Stainless Steel Alloys and Finishes: Unless otherwise specified, the
compositional analysis of the stainless steel alloys shall conform to the
following requirements.

1. Stainless Steel Sheet and Strip - All material used shall conform to the
chemical composition and mechanical properties specified. All
materials shall be cold rolled, solution annealed, pickled and re-rolled
to a No. 2B finish for sheet and a No. 2 finish for strip, unless
otherwise specified.

2. Stainless Steel Plate - All material shall conform to ASTM A240 for type
316 or 316L as specified. All plate shall be hot rolled, solution
annealed and pickled to a No. 1 finish

3. Stainless Steel Pipe - Commercial grade 304L welded unannealed


stainless steel pipe conforming to ASTM A778. Pipe must be pickled
and passivated after welding by manufacturer as per ASTM A380 to
maintain corrosion resistance.

4. Stainless Steel Pipe fittings - Commercial grade 304L welded


unannealed stainless steel fittings conforming to ASTM A774. Fittings
must be pickled and passivated after welding by manufacturer as per
ASTM A380 to maintain corrosion resistance. Fittings furnished in MSS
SP-43 dimensions with square cut ends.

5. Welding Filler Metal - Welding electrodes and filler metals shall


conform to AWS A5.4.

6. Piping shall be installed in longest practical lengths, avoiding insofar


as possible the use of short lengths and couplings.
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7. Flanges shall be ANSI Standard unless otherwise noted on the
drawing. Raised face steel flanges shall be used for pipe connections
unless indicated otherwise. All flat-faced flanged joints shall have full-
faced gaskets.

8. The inner edges of all pipe ends shall be reamed, filed, or ground to
remove burrs. All weld beads and splatter shall be removed.

9. Pipe lengths and fittings shall be accurately aligned. Flanges and stub
ends shall be square with pipe centerline. Cutting shall be by saw or
diamond cutter wheel.

2.1.2 Visual Quality and Workmanship - All welds shall meet the following
minimum requirements

1. Surfaces to be welded shall be free from injurious defects, scale, oil,


dirt and other harmful contaminants.

2. Each weld shall be uniform in width throughout its entire length. In


addition, the cover pass(es) shall be free of coarse ripples, grooves,
overlaps, abrupt ridges and valleys.

3. Each weld layer shall be visually free of slag, inclusions, cracks,


porosity and lack of fusion.

4. Grinding to meet the above criteria, and elimination of defects and


surface preparation of welds shall be done in such a manner as not to
gouge, groove or reduce the adjacent base metal below the minimum
required thickness.

5. Undercut shall not exceed the limits of the governing code or 1/32”,
whichever is less, and shall not encroach upon required section
thickness.

6. Internal mismatch, as determined by measuring the surface adjacent


to each side of the weld shall not exceed that specified by the
applicable code or 1/32”, whichever is greater.

2.1.3 Welding and General Workmanship

1. All welds shall be full penetration welds with complete fusion between
passes and between weld metal and base metal.

2. Longitudinal welds in pipe or fittings shall be made by the automatic


GTAW method only, utilizing an inert gas backup of welding grade
argon or helium.

3. Girth welds shall be made by the manual or automatic GTAW process.


An internal purge of argon, helium or dry nitrogen shall be used.
Where not accessible for removal after welding, purge dams shall be

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water-soluble material, Gilbreth Co. “Dissolvo WLD” purge paper, or
equal.

4. Tack Welds - Tack welds shall be made using the same welding
procedure and filler metal used for the final weld. All tack welds shall
have their starts and stops ground prior to incorporation into the final
weld. Tack welds shall be visually examined. Cracked or otherwise
defective tack welds shall be removed in their entirety.

5. Weld End Preparation - Square groove butt welds are acceptable only
for wall thickness up to and including 1/16” (1.59mm) (Sanitary O.D.
tubing). For wall thickness in excess of 1/16 inch, (1.59mm) the weld
end shall be beveled to a land thickness of 1/16 inch + 1/32 inch.

6. Cleaning, all weld spatter, slag and discoloration shall be removed


from the fabrication item by wire brushing, grinding or sand blasting
(metal grit blast is not permitted). All brushes, grinding wheels, etc.,
shall be constructed of stainless steel.

2.1.4 Vessel internal welding shall be in accordance with USDA guidelines. All
welds shall be continuous and free from pits, crevices, and undercuts.
All welding shall be performed using the TIG process with argon purge.
Filler material shall be used on all welds to prevent undercuts caused by
fusing material only. Fillet welds shall be of good quality and shall be
cleaned of discoloration. Grinding of fillet welds is not required. Butt
welds shall be ground smooth, polished and grained to match
surrounding finishes.

2.1.5 Care shall be taken during welding to prevent any warping or twisting of
materials. All items shall be checked after fabrication for trueness and
any items that require straightening shall be reworked prior to assembly

2.2 ELECTRICAL

1.2.1 All electrical enclosures to be NEMA 4.

PART 3 - PROCESS DESIGN DATA – GREENSAND FILTER

3.1 GENERAL FABRICATION AND DESIGN REQUIREMENTS – GREENSAND FILTER

3.1.1 Operation – Water shall be delivered through 304L Stainless Steel butt
welded piping. Water shall enter into a manifold which will direct flow for
filtration or for backwash. The product water shall inlet at the top of the
tank and discharge the water downwards through an outlet valve through
the bottom outlet. Backwash shall take the water through the same inlet
and deliver it to the bottom of the tank. The backwash water shall leave
the top of the tank and be piped to 6"(maximum) above finished floor so
it may discharge through a separate valved connection to the owner’s
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back wash tank. A flow control device shall be included to ensure that
proper flow rates are being maintained through normal process operation
and for backwashing.

3.1.2 Products - The greensand filters will be used for, removal of iron and
manganese, typical of a municipal potable water supply. Vendor is
required to perform their own water testing prior to equipment
manufacture so as to confirm this application.

3.1.3 Media flux rate shall be no more than 5.2 gpm/ft 2.

3.1.4 Media shall be a mixture of anthracite, greensand, and gravel furnished


by GE Water (or equivalent). All media furnished must be suitable for
potable water use.

3.1.5 The greensand filter shall be capable of easy and fast change outs by
two trained technicians; time not to exceed 8 hours.

3.1.6 The Manufacturer is required to provide at time of quotation the


recommended preventive maintenance procedures and frequencies for
change outs and potassium permanganate regeneration.

3.1.7 The greensand filter shall not adversely affect the quality of the product.

3.1.8 The clean filter pressure drop shall not exceed 5 psi. Vendor to state
actual pressure drop at stated flow rate in both clean and dirty cases.

3.1.9 Piping manifold shall be designed so that the unit may be back washed
and rinsed and regenerated through the use of automatic valves. Valves
3” and larger to be Keystone and have SS disc and stem with food grade
elastomers. Vendor is to size and furnish and all valves and pressure
regulators (including those required for instrument air) as required.

3.1.10 A complete “Air Wash” assembly shall be included as required for proper
operation.

3.1.11 Backwashing capability shall be sized to fully fluidize and clean


particulates from the greensand media.

3.1.12 Minimum vessel size shall be determined by the vendor. Vessels shall be
sized to hold the greensand and media specified and have 50%
available head space for backwashing.

3.1.13 The greensand tower shall be equipped with a slotted stainless steel
wedge wire under drain.

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3.1.14 The back wash inlet line shall have a flow an electronic flow meter.

3.2 INLET OPERATING CONDITIONS

3.1.15 Typical Plant City Water Analysis:

Component Units

Total Organic Carbon 3.6 mg/L

302.
Total Dissolved Solids mg/L
1

Turbidity 0.06 NTU

144.
Ca Hardness as CaC03 mg/L
7

Mg Hardness as CaC03 41.1 mg/L

185.
Total Hardness as CaC03 mg/L
8

Chloride 51.8 mg/L

Temperature 38 to 80oF

Pressure 25 to 70 psig

3.1.16 Vendor is required to confirm city water inlet conditions at the facility by
sampling. A copy of the sample analysis is required to be submitted by
vendor for documentation.

3.3 MATERIALS OF CONSTRUCTION – GREENSAND FILTER

3.1.17 Vessel - The shell shall be of carbon steel construction. Design pressure
shall be 100 psig with ASME Code stamp required. All covers shall be
lined (with same lining or coating as the vessel) carbon steel, hinged and
sealed. Lining must be NSF approved. Latches shall be quick acting
type.

3.1.18 Valves - The drain and air bleed valves shall be 304 S.S. and should not
be installed using any type of pipe sealing compound, Teflon tape is
permitted. All product and backwash valves shall be air actuated butterfly
valves Keystone with stainless steel disc and stem with food grade
elastomers. Manual valves 6” and larger to have gear operators.

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3.1.19 Piping - All piping and fittings shall be constructed of 304 stainless steel
all welded (not threaded) pipe and tubing, unless otherwise noted.
Headers and nozzles shall be easily removable for servicing and shall be
constructed of 304 stainless steel.

3.1.20 Fasteners - All fasteners shall be stainless steel. All bolts shall be
provided with appropriate S.S. washers, lock washers and nuts.

3.1.21 Skid or Legs – Painted carbon steel 4 vertical legs (splayed or angled
legs are not acceptable) shall be provided of such length so that the
lowest fitting on the vessel is a minimum of 24" above the finished floor
(AFF). Legs shall be pipe or square tubing and shall have a finish which
matches the vessel. Each leg shall have a round or square pad with 4 -
3/4" bolt holes. Legs shall not allow for any cracks or crevices that
cannot be easily cleaned. Seismic Zone 1 design applies.

3.1.22 Fittings – All wetted parts are to be 304 stainless steel

3.1.23 Product inlet / outlet Welded with flanged connection.

3.1.24 Backwash inlet-welded. Backwash water shall be supplied through a


separate backwash inlet line with a flanged connection. Backwater
source to be chlorinated RO water from client’s existing clearwell.

3.1.25 Backwash outlet-welded. Backwash outlet water shall be supplied


through a separate backwash outlet line with a flanged connection.
Backwash water to be sent to owner’s reclaim tank.

3.1.26 Product / backwash outlet and drain - Welded with flanged connection.

3.1.27 Air vent - Shall be placed in the top of the vessel and piped to within 5'
above the finished floor. Vent shall be a minimum of 1" welded piping
with 1" ball valve suitably piped to floor.

3.1.28 Man-way - Two (2) man-ways shall be provided. One in the top the tank
and one on the lower side wall. The sidewall man-way shall be placed to
ensure there will be adequate access.

3.1.29 Pressure gauges - Inlet and outlet connections shall have stainless steel
pressure gauges with a minimum dial size of 4 inches and polycarbonate
window (glass shall be avoided and used only with prior written
approval), Ashcroft or equal.

3.1.30 Pressure relief valve - Vessel shall have adequately sized (for this
application) pressure relief valve, piped full diameter, terminating at six
inches above the floor.
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3.1.31 Sample taps - The filter shall be fabricated with two stainless steel
sample ports located on the vessel inlet piping and on the vessel outlet
piping.

3.1.32 Welding Procedures

1. Care shall be taken during welding to prevent any warping or twisting


of materials. All items shall be checked after fabrication for trueness
and any items that require straightening shall be reworked prior to
assembly.

3.1.33 Lifting lugs and/or fork lift plates – Required on all skids or large items

PART 4 - PROPOSAL
Vendor proposal shall clearly identify equipment to be supplied by means of drawings and
narrative as well as offer information required in the specification, Instructions to Bidders or
other inquiry documents.

The vendor shall include the following information with the proposal as a minimum;
1. Pressure Drop Clean and Dirty for Normal Rated and Maximum Flows for
all equipment to be furnished

2. Indicate Backwash Flow Rate and Time

3. Overall Dimensional Drawings indicating (L x W x H) for all components

4. Connection Type and size

5. Design and construction features

6. Materials of Construction for Major Components

7. Operating Features and Sequence

8. Approximate Weight

9. Utility Requirements

10. Any special needs or construction issues

Please also respond to any concerns regarding the content of this specification with
regards to items that have a high cost impact with minimal impact on performance and
quality. Vendor suggested alternates are encouraged.

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PART 5 - SUBMITTALS

5.1 SHOP DRAWINGS AFTER PURCHASE

Vendor shall submit to Purchaser for review three (3) black line prints. The initial submittal
shall precede fabrication unless otherwise agreed upon with Purchaser. In addition the
vendor shall supply data CD in AutoCAD .DWG and Adobe PDF format to facilitate layouts
of the equipment. The submittal procedure shall be repeated until all corrections have been
made to Purchaser’s satisfaction. After fabrication and inspection, Vendor shall furnish one
(1) set “As Built” drawings for Purchaser’s record.
5.2 OPERATIONS AND MAINTENANCE MANUAL

The Vendor shall furnish three (3) copies of operation and service manuals, submitted to
the Purchaser prior to shipment of equipment. Each manual shall incorporate a full set of
“as-built” drawings. Two (2) CD’s containing the manual and as built drawings in Adobe .pdf
format shall also be provided.
5.3 OTHER REQIREMENTS

The unit shall be fully assembled at the factory and tested for leaks (hydrotest
documentation required) and control sequence operation before shipment. A spark test
report is required for all lined or coated vessels. Vendor shall also furnish a completed Bill
of Materials and Recommended Spare Parts List.
5.4 WARRANTY

The unit shall be warranted by the manufacturer for a minimum of one year from the first
date of use. The warranty shall be for all defective labor, materials and equipment. The
warranty shall cover all shipping costs for replacement unit and or parts. The warranty on
all interior lined or coated vessels to be five years minimum.
PART 6 - PREPARATION FOR SHIPMENT

6.1 NOZZLE PROTECTION & CRATING

Flanged openings shall be protected and made waterproof with bolted full size steel or
plywood covers with sponge rubber gaskets. Threaded openings shall be fitted with caps or
plugs of the same materials as the equipment part and sealed with suitable sealant. The
equipment and components shall be supplied with suitable attachments and lugs to aid in
rigging.
6.2 SHIPPING TAGS

The unit and all loose bags and cartons shall be tagged with the following information
as a minimum:
1. Purchaser Name and Project Number
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2. Purchase Order Number

3. Specification Reference and Item Number

PART 7 - LOADING OF MEDIA

Vendor to include in their proposal a complete cost for the proper installation supervision of
all media to be loaded in the greensand filter vessels
7.1 NOZZLE PROTECTION & CRATING

Flanged openings shall be protected and made waterproof with bolted full size steel or
plywood covers with sponge rubber gaskets. Threaded openings shall be fitted with caps or
plugs of the same materials as the equipment part and sealed with suitable sealant. The
equipment and components shall be supplied with suitable attachments and lugs to aid in
rigging.
PART 8 - START-UP ASSISTANCE

Vendor to include in their proposal all associated costs for the complete start up and
commissioning of all equipment items furnished.

Start up cost to include a pre start up checkout of the equipment installation.


PART 9 - TRAINING

The vendor is to include a separate line item in their quote for training requirements, which
shall consist of maintenance and operator training. All training will take place on site at the
client’s facility in City/State. The Vendor is to state the number of days required for
complete training. Training personnel will be required to have flexible hours to meet the
operating hours of the facility personnel.
9.1 MAINTENANCE TRAINING

Maintenance training is required as a service from the Vendor for this piece of equipment.

9.1.1 The Vendor shall provide personnel well versed in training and
technically competent to train the maintenance staff in City,State.

9.1.1 Maintenance training shall include but not be limited to the following
maintenance of:

1. Major components

2. Lubrication and grease schedules

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3. Common troubleshooting

4. Preventive maintenance schedule

5. Maintenance operators shall be trained in the complete operation of the


equipment and understand the operating limits of the unit.

6. Provide all necessary operating and maintenance manuals for the


referenced piece of equipment.

9.2 OPERATOR TRAINING

9.2. Operator training as well as maintenance training is required as a service


from the Vendor for this piece of equipment.

9.2.2 The Vendor shall provide personnel well versed in training and
technically competent to train the operations staff in City/State.

9.2.3 Operator training shall include but not be limited to the following:

1. Complete overview of the piece of equipment,

2. Technical discussion on the operation of the unit including start up and


shutdown

3. Emergency procedures

4. Safety precautions

5. Manual and automatic mode operation

6. Methods for adjusting machine operating parameters (i.e., change of


product pattern, change of product)

9.2.4 Vendor’s training personnel shall be equipped with the necessary tools
such as overheads, handouts, and self-tests, etc. for the duration of
training.

**END OF SPECIFICATION**

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