61983850 DATA.pdf

U-Bolt Bending Machine

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1. SCOPE

1.1. Scope. The purchase description set forth below describes the minimum requirements of the Government for a U-Bolt Bending Machine. It is the Government’s intent that a single primary contractor be awarded this turn-key contract and be responsible for the provision of equipment, and the accomplishment of all work detailed by this specification. This turn-key contract will include: installation of a new U-Bolt Bending Machine, NRTL certification, testing and training.

2. APPLICABLE DOCUMENTS

2.1. General. The documents listed in this section are cited in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

2.2. Government Documents.

2.2.1. Specifications, Standards, and Handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

FEDERAL STANDARDS

FED-STD-H28B ---------------------------- Screw Thread Standards for Federal Service

FED-STD-313F ----------------------------- Material Safety Data, Transportation Data and

Disposal Data for Hazardous Materials

Furnished to Government Activities

(Copies available online at http://quicksearch.dla.mil/)

MILITARY STANDARDS

MIL-STD-130N w/ Change 1 ------------ Identification Marking of U.S. Military Property

(Copies available online at http://quicksearch.dla.mil/)

NAVSEA

OSHECM Chapter 250 Rev 1 ------------ NAVSEA Occupational Safety, Health and

Environment Control Manual for Naval

Shipyards Chapter 250

(Copies available online at http://www.navsea.navy.mil/Home/Shipyards/Norfolk.aspx) http://quicksearch.dla.mil/ http://quicksearch.dla.mil/ http://www.navsea.navy.mil/Home/Shipyards/Norfolk.aspx

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2.2.2. Other Government Publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein.

Unless otherwise specified, the issues of these documents shall be the current edition at time of solicitation.

COMBINED FEDERAL REGULATIONS

29 CFR 1910 -------------------------------- General Industry, OSHA Safety and Health

Standards

29 CFR 1915 -------------------------------- Occupational Safety and Health Standards for

Shipyard Employment

40 CFR 82 ----------------------------------- Protection of Stratospheric Ozone

(Copies available online at http://www.gpo.gov/fdsys)

LOCAL ATTACHMENTS

Attachment A ------------------------------- Site Specific Regulations

(Copies attached to the solicitation)

2.3. Non-Government Publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents shall be the current edition at time of solicitation.

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION

ISO 4414 ------------------------------------- Pneumatic Fluid Power - General Rules and

Safety Requirements for Systems and Their

Components

(Copies available at http://webstore.ansi.org/ or American National Standards Institute, Dept. 969, 1430 Broadway, New York, NY 10018)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION

NEMA MG 1 ------------------------------- Motors and Generators

NEMA Z535.4 ------------------------------ Product Safety Signs and Labels

NEMA 250 ---------------------------------- Enclosures for Electrical Equipment (1000 Volts

Maximum)

(Copies available at http://www.nema.org or National Electrical Manufacturers Association, 1300 North 17th Street, Suite 1752, Rosslyn, VA 22209) http://www.gpo.gov/fdsys http://webstore.ansi.org/ http://www.nema.org/

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NATIONAL FIRE PROTECTION ASSOCIATION

NFPA 70 ------------------------------------- National Electrical Code

NFPA 79 ------------------------------------- Electrical Standard for Industrial Machinery

NFPA 86 ------------------------------------ Standard for Ovens and Furnaces

(Copies available at http://www.nfpa.org or NFPA, 1 Batterymarch Park, Quincy, MA

02169)

2.4. Order of Precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1. Design. The item offered shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

3.1.1. Design Basis. The design basis shall be to utilize a hydraulic system to bend a straight steel rod around a bend die to form a U-bolt. The machine shall overbend the U-bolt such that the U-bolt legs will spring back resulting in parallel legs. The machine shall utilize a single adjustment to change to the desired amount over overbend.

3.1.2. New Developments. The contractor shall identify any new developments that would improve the efficiency, accuracy or productivity of the equipment or would decrease its operating costs. The contractor shall notify the Contracting Officer and technical POC in order that the new developments may, at the Government's option, be included in the equipment. Reports of such developments shall be addressed to the Contracting Officer.

3.1.3. Measuring and Indicating Device Graduations. All measuring and indicating devices on the U-Bolt Bending Machine shall be graduated in the inch/pound or both inch/pound and metric.

3.1.4. Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's work station(s).

3.1.5. OSHA Compliance. The equipment installation and its component parts shall be in compliance with 29 CFR 1910, NFPA 70, NFPA 79 and NFPA 86. Approval shall be as http://www.nfpa.org/

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specified under the “Approval” and “Acceptance” criteria in the OSHA regulations Subpart

“O”, Machinery and Machine Guarding paragraph 1910.212 and Subpart “S” Electrical, paragraph 1910.303 and paragraph 1910.399.

3.1.6. Safety Signs and Labels. Safety signs and labels in accordance with NEMA Z535.4 shall be securely attached to the equipment in visible locations, at the point of hazard(s), with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the signs.

3.1.7. Safety Guarding. Covers, guards, or other safety devices shall be provided per NFPA

86. The safety devices shall not interfere with the operation of the U-Bolt Bending Machine.

The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

3.1.8. Audible Noise Level. Audible noise emitted by the equipment shall not exceed 85 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment.

Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 85 dB requirements.

3.1.9. Hazardous Material Exclusions. Supplies or materials being provided as part of the equipment shall be free of known hazardous materials. Hazardous materials shall not be brought on site without prior approval of the Government Point of Contract and cognizant shipyard personnel. Hazardous materials not needed for this project are prohibited.

Definitions of hazardous materials are specified in the latest version, including revisions adopted during the term of the contract, of FED-STD-313. Notwithstanding any other hazardous material usage permitted in this contract, radioactive materials or instruments capable of producing ionizing radiation as well as materials which contain asbestos, mercury, lithium, methylene chloride, lead (= or >0.06%), or polychlorinated biphenyls (PCB’s) are prohibited. Nickel Metal Hydride and lithium batteries are permissible for memory backup.

Class I Ozone Depleting Substances as defined in 40 CFR 82 shall not be used in the performance of this contract, or be provided as part of the equipment. Exceptions to the prohibition of these materials must be referred to the Contracting Officer in writing, for consideration, not later than 60 calendar days after effective date of contract and prior to any work being performed.

3.1.10. Environmental protection. Under the operating, service, transportation, and storage conditions described herein, the U-Bolt Bending Machine shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

3.1.11. Interchangeability. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, UNCLASSIFIED

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bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts. Foreign-sourced replacement parts shall be interchangeable with domestically supplied components or be readily available from a domestic source.

3.2. Construction. The U-Bolt Bending Machine shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the U-Bolt Bending Machine to its maximum rating and capacity without distortion.

3.2.1. Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, or filling with solder or paste shall be used for reclaiming any defective part.

3.2.2. Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

3.2.3. Threads. All threaded parts, either US or SI, used on the U-Bolt Bending Machine and its related attachments and accessories shall conform to FED-STD-H28B and the applicable

"Detailed Standard" section referenced therein.

3.2.4. Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

3.2.5. Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

3.2.6. Corrosion Control. All system components shall be protected against corrosion and deterioration by appropriate material selection, application of coatings and sealants. The system and its parts shall be painted on all sides, prior to assembly, except mating surfaces such as mounting flanges and motor shafts. Painting shall result in a highly wear-resistant finish, which guarantees continued protection to the surfaces covered against the specified environment under all service conditions. Exposed ferrous parts such as screws, bolts, nuts, washers shall be treated to resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as chrome plating, galvanizing or other electrical/chemical process, or stainless steel is acceptable. Stainless steel parts shall be passivated. Aluminum parts shall be anodized or chemically treated followed by two coats of weather-resistant exterior paint. Dissimilar metals shall not be used in direct contact with each other without

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suitable means for preventing electrolytic corrosion. All paint shall be lead free and chromate free.

3.2.7. Workmanship. Workmanship of the U-Bolt Bending Machine shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

3.3. Components. The U-Bolt Bending Machine shall consist of not less than

3.3.1. Mechanical System. The mechanical system consists of not less than Upper Support

Block, Push Bar, Upper Support Arm, Housing, Bending Arms, Forming Rollers, Clamp, Bottom Die Holder Plate, Bending Die, Lower Support Block, and Floor Plate.

3.3.1.1. Upper Support Block. The upper support block supports the hydraulic cylinder and shall include an eyebolt or other rigging point to allow single point lift of the complete U-

Bolt Bending Machine.

3.3.1.2. Push Bar and Upper Support Arm. The pushbar and upper support arm are extended and retracted by the hydraulic system.

3.3.1.3. Bending Arms with Forming Rollers. The bending arms and forming rollers move downward and inward to slightly overbend the U-bolt. This shall result in a U-bolt with equal parallel legs.

3.3.1.4. Clamp. The clamp shall hold the rod firmly against the bending die.

3.3.1.5. Bottom Die Holder Plate. The bottom die holder plate holds the selected bending die in place.

3.3.1.6. Bending Die. The bending die is the interchangeable component selected for the specific U-Bolt bending operation. The required bending dies are listed below.

3.3.1.6.1. Round die 1.500 inch

3.3.1.6.2. Round die 2.000 inch

3.3.1.6.3. Round die 2.125 inch

3.3.1.6.4. Round die 2.250 inch

3.3.1.6.5. Round die 2.500 inch

3.3.1.6.6. Round die 2.750 inch

3.3.1.6.7. Round die 3.125 inch

3.3.1.6.8. Square die 4.500 inch 0.750 inch radius

3.3.1.7. Lower Support Block and Floor Plate. The lower support block supports the machine and places the die at a convenient operating height. The floor plate secures the machine to the floor.

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3.3.2. Hydraulic System. The hydraulic system consists of a pump, hydraulic cylinders, reservoir, filters, valves, and hoses.

3.3.3. Electrical System. The electrical system consists of a 230 VAC three-phase motor, control box, remote foot controls, electronic valve assembly, surge protection device “SPD”, cables and connectors.

3.3.3.1. The machine shall conform to NFPA 70 and NFPA 79. The existing electrical power source available at the installation site is 230 Volts, 3 phase 20 amps. The machine’s electrical system shall be tolerant of voltage fluctuation of ± 10 percent. The electrical system shall be complete, including transformers required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device, controlling all electrical power to the equipment, shall be utilized on the machine with means of lockout in the off position only (the existing 230 V- 3 phase disconnect may be used). The SPD may be installed in the disconnect or downstream of the disconnect.

3.3.3.2. Solid-State Components. Solid-state design shall be employed throughout for electronic components. Use of selenium and other similar aging devices shall be permitted only in the application of voltage surge protection to other solid-state components. Solid-state components shall not be adversely affected when subjected to power line transients and surges typically experienced in industrial environments. Series and parallel connections of solid-state devices without forced sharing circuitry for voltage and current, respectively, is not permitted. Solid-state devices shall be capable of handling the electrical load imposed by operation of the machine to its maximum capability.

3.3.3.3. Electrical Enclosures. Electrical components of the equipment shall be contained in enclosures of drip-proof construction and of minimum size consistent with good design practices and ventilation of components, and shall be NEMA rated.

3.3.3.4. Facility Electrical Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

3.3.4. Energy Isolating Devices. The equipment shall be provided with energy isolation devices (e.g. power switches, safety devices, circuit breakers, valves) that protect personnel from the release of hazardous energy and are integral to the component being isolated and locked out. The devices shall be designed and manufactured such that they can be padlocked in the OFF position. This includes both mechanical and electrical devices. An energy isolation device shall be installed as the first energy control device on all major components of the system such that the component can be isolated at the component level.

3.4. Size and Capacity. The size and capacity of the U-Bolt Bending Machine shall be not less than specified in Table I.

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Table I Size and Capacity

Maximum Installation Space (W, L) W=108 inches L=72 inches

Minimum U-Bolt Size (dia, grade, c-c distance) .375 inch, A36, 1.5 inch

Maximum U-Bolt Size (dia, grade, c-c distance) 1.25 inch, Gr 8, 9 inch

3.5. Alignment and Accuracy Tolerances. The alignment and accuracy tolerances of the U-

Bolt Bending Machine shall be as specified in Table II.

Table II Alignment and Accuracy

Distance between legs +/- 0.04 inch

3.6. Marking on Instruments, Control Panels, and Plates. All words on instruments, control panels, and plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

3.6.1. Nameplate. A nameplate shall be permanently and securely attached to each machine.

The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

Nomenclature

Manufacturer's name

Manufacturer's model designation

Manufacturer's serial number

Power input (volts, full load amps “FLA”, phase, frequency)

Short Circuit Current Rating “SCCR”

Contract Number or Order Number

Date of manufacture

3.6.2. Identification Marking of Military Property. An Item Unique Identification

Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable

Information (HRI) shall be used in combination with MRI and free text.

3.7. Technical Data. Three (3) hard copies and one (1) searchable electronic copy of the following technical data shall be provided with the machine.

3.7.1. Operating and Maintenance (O&M) Manuals. O&M Manuals shall contain technical information, specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language. Technical Data shall contain at a minimum:

a. Data shall enable an average journeyman mechanic to operate, program, maintain, and repair the equipment.

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b. Complete instructions and information for all equipment, components, assemblies, subassemblies, attachments, and accessories.

c. Operating instructions including programming requirements, pre-operational checks, start up, shut down and emergency shutdown procedures.

d. Maintenance and service instructions, including all preventive maintenance schedules, and lubrication charts.

e. Trouble-shooting guides.

f. Parts list containing: illustrations, part numbers, part nomenclature, original manufacturer, cross reference numbers, and recommended spare parts, including quantities.

g. Energy control procedure, in accordance with 29 CFR 1910.147, to bring equipment to a zero energy state for maintenance.

h. All mechanical and electrical schematics with a table of contents showing discrete components, block diagrams, wiring diagrams with inputs and outputs identified, system electrical interface documents, and drawings for the specific model of all machine equipment/drives/controls supplied.

i. All final “as-built” contract drawings shall be provided on CD or DVD disc(s). The format of the drawing files shall be in AutoCAD version 2010 or older. Files shall have DWG or DXF extensions.

3.7.2. OSHA Approved Certification. The equipment and its installation specified herein shall be inspected, approved as defined in 29 CFR 1910.399, and labeled by a Nationally

Recognized Testing Laboratory (NRTL) as defined in 29 CFR 1910.7. The NRTL inspection shall include validation of the OSHA compliance requirements in paragraph 3.1.5. A satisfactory NRTL Field Evaluation Report shall be provided to the receiving activity.

3.7.3. Test Data Results Used for Evaluation of Equipment to Meet Specification

Requirements. The Contractor shall submit a written test report of all tests and results conducted at origin and destination. The test report shall be submitted within 10 working days after the tests are performed.

3.8. Installation. Contractor shall be responsible for attached Installation Responsibilities chart and Local Documents Attachment A for site specific facility requirements.

3.8.1. Structural Installation. The Contractor shall accurately set, align, plumb, field connect with sufficient bolts, or weld all structural steel required to make installed equipment permanent. Temporary bracing shall be provided, and subsequently removed, as necessary.

3.8.2. Mechanical Installation. The Contractor shall provide all labor, fluids, piping, interconnecting hoses, and any other materials to move, locate, set level, align, lubricate, and

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make ready to operate all equipment required by this contract. All machinery shall be installed to original manufacturer's tolerances.

3.8.3. Electrical Installation. The Contractor shall provide all labor, wiring, cables, disconnects, connectors, and any other materials for complete installation of any requisite electrical equipment from the government point of delivery. Installation shall include necessary power, control, and interconnecting wiring installed in conduit.

3.9. Hazardous Energy Control (HEC) Program, Lockout/Tags-Plus (LOTP). HEC/LOTP shall be accomplished in accordance with OSHECM Chapter 250 and 29 CFR 1915.89.

3.10. Training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is a United States citizen proficient in the English language, shall be provided for specialized training to familiarize receiving activity personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage. The training shall be for number of operators and be performed at customer facility and shall not be less than one 8-hour workday, between 7:00 am and 3:30 pm excluding any federal holidays. The course shall utilize as-built drawings and manuals provided under this contract, and shall include both classroom and hands-on portions. All printed training aids shall be supplied at no additional cost to the government, and be in the

English language.

4. QUALITY ASSURANCE

4.1. Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein. Except as otherwise specified in the contract or purchase order, the contractor may use his own facility or any other facility suitable for the performance of the inspection requirements specified herein, unless disapproved by the

Government. Only supplies that totally conform to the specifications shall be offered for inspection and test. The contractor's test schedule shall allow consecutive inspection and test of the supplies offered. The Government reserves the right to charge the contractor for any

Government re-inspection cost when supplies are not ready at the time requested by the contractor or when necessitated by prior rejection. The Government reserves the right to perform any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

4.1.1. Responsibility for Compliance. All items must meet all requirements of sections 3 and 4.

4.2. Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. Final Inspection/Acceptance test (Destination) (see 4.4).

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4.3. Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient conditions of 55 degrees F to 100 degrees F and 10 percent to 95 percent relative humidity.

4.4. Final Inspection/Acceptance Test (Destination). Final inspection and acceptance test shall be performed on the U-Bolt Bending Machine to ensure conformance with this purchase description. The acceptance test shall be performed only after the U-Bolt Bending Machine is installed at its final location. The acceptance test shall consist of the examination in 4.5 and all tests in 4.6. The machine shall pass the examination, all tests, and the final inspection to be accepted.

4.5. Examination. The U-Bolt Bending Machine shall be examined to determine compliance with all requirements of this purchase description.

4.6. Operational Test. The U-Bolt Bending Machine shall be operated to form the following

U-bolts. Each U-bolt shall meet the tolerance of paragraph 3.5.

4.6.1. A36 steel, 0.375 inch dia. rod: 1.500 inch round U-bolt

4.6.2. A36 steel, 0.375 inch dia. rod: 4.500 inch square U-bolt

4.6.3. A36 steel, 0.500 inch dia. rod: 2.000 inch round U-bolt

4.6.4. A36 steel, 0.500 inch dia. rod: 2.125 inch round U-bolt

4.6.5. A36 steel, 0.500 inch dia. rod: 2.250 inch round U-bolt

4.6.6. A36 steel, 0.500 inch dia. rod: 2.500 inch round U-bolt

4.6.7. A36 steel, 0.500 inch dia. rod: 2.750 inch round U-bolt

4.6.8. A36 steel, 0.500 inch dia. rod: 3.125 inch round U-bolt

INSTALLATION RESPONSIBILITIES

Government Contractor

(XX) ( ) a. Provide machine foundation in accordance with the manufacturer's design requirements.

) (XX) e. Furnish labor and material handling equipment for off-loading and placing item on foundation.

( ) (XX) f. Provide and install anchor bolts and nuts.

( ) (XX) g. Set and rough level the machine on its foundation.

( ) (XX) h. Level and align machine.

( ) (XX) i. Connect machine to the provided utilities hook-up.

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( ) (XX) j. Provide all necessary tools, gages, and instrumentation necessary to perform the required tests.

( ) (XX) k. Provide and charge all systems with fluids in accordance with manufacturer's instructions.

(XX) ( ) l. Material for performance testing at Government facility.

Attachment A, Site Specific Requirements for

Puget Sound Naval Shipyard & IMF, Bremerton Site and Naval Base Kitsap

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SCOPE

1.1. Scope. This attachment covers the site specific requirements of Naval Base Kitsap (NBK) and Puget Sound Naval Shipyard & Intermediate Maintenance Facility (PSNS & IMF) for contract work.

2. APPLICABLE DOCUMENTS

2.1. General. The following documents form a part of the site specific requirements to the extent specified herein.

2.2. Washington Administrative Code (WAC)

WAC-173-303 Washington Dangerous Waste Regulations

WAC-173-60 Maximum Environmental Noise Levels

WAC-173-304 Minimum Functional Standards for Solid Waste Handling

(Copies are available online at: http://apps.leg.wa.gov/wac/)

2.3. Code Of Federal Regulations (CFR)

29 CFR 1910.141 Sanitation

29 CFR 1910.146 Permit-Required Confined Spaces

29 CFR 1910.1200 Hazard Communication

29 CFR 1926.1153 Respirable Crystalline Silica

40 CFR Part 82 Protection of Stratospheric Ozone

40 CFR Part 89 Control of Emissions from New and In-Use Non-Road Compression-

Ignition Engines

(Information is available at: http://www.ecfr.gov/cgi-bin/ECFR?page=browse)

2.4. American Society of Mechanical Engineers (ASME)

ASME B30.26 - 2015 Rigging Hardware

ASME BTH-1 - 2017 Design of Below-the-Hook Lifting Devices(Information is available at: https://www.asme.org/)

2.5. American Society for Testing and Materials (ASTM)

ASTM E709 – 17 Standard Specification for Structural Steel

(Information is available at: https://www.astm.org/)

2.6. American Welding Society (AWS)

Puget Sound Naval Shipyard & IMF, Bremerton Site and Naval Base Kitsap

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D1.1/D1.1M:2006 Structural Welding Code – Steel

(Information is available at: http://www.aws.org/technical/d1/D1scope.pdf)

2.7. Military Standards

MIL-STD-2035 Nondestructive Testing Acceptance Criteria

(Information is available at: https://assist.dla.mil/online/start/)

2.8. Unified Facilities Criteria (UFC)

UFC 3-430-07 Operations and Maintenance: Inspection and Certification of Boilers and

Unfired Pressure Vessels

2.9. PSNS & IMF

Contractor Guide to Environmental and Safety Compliance

(Contact the Receiving Activity’s Point of Contact to obtain a copy of the guide)

2.10. NAVAL FACILITIES ENGINEERING COMMAND (NAVFAC)

NAVFAC P-307 Management of Weight Handling Equipment (June 2016)

(Copies available online at http://www.navfac.navy.mil/navfac_worldwide/specialty_centers/ncc/about_us/resources/ p307.html)

3. REQUIREMENTS

3.1. Prior to commencing work. The Contractor representative(s) shall meet in conference with the Receiving Activity’s Point of Contact, shop supervision, and other necessary Shipyard personnel to discuss and develop mutual understandings relative to environmental, safety, methods and schedules, security, waste management, and any other subject necessary for a smooth and successful execution of this contract. This meeting shall be held at the

Receiving Activity within 30 business days of contract award.

3.2. Methods and schedules. The work shall be executed in a manner and at such times as to cause the least practicable disturbance to the occupants of the buildings and normal activities of the Shipyard.

3.3. Plan of Action and Milestones. Within 30 business days of contract award the Contractor shall provide a Plan of Action and Milestones (POAM) detailing key events with dates of the following:

a. Design

Puget Sound Naval Shipyard & IMF, Bremerton Site and Naval Base Kitsap

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b. Manufacturing

c. Equipment Delivery

d. Equipment Set-up/Installation

e. Equipment Testing

f. Training

g. Final Completion Date

3.4. Field Supervisor. The Contractor shall provide a full-time (start of installation to final acceptance) Field Supervisor to direct installation and testing of the equipment. The Field

Supervisor shall be capable of reading, writing, and conversing fluently in the English language and have full authority to implement field decisions expeditiously. No work shall be accomplished when the Field Supervisor is not in the immediate work area. The

Field Supervisor shall be identified to the Receiving Activity’s Point of Contact prior to the start of the installation and be responsible for coordinating security clearances of all

Contractor personnel expected to perform on-site work. The Receiving Activity’s Point of

Contact shall be notified of any change in personnel performing this duty.

3.5. Calibration. The Contractor shall provide calibration control instructions for each calibrated item.

3.6. Outages and permits. The Government’s process of review/approval for Utility, Area, and

Track Outages may take up to 20 business days from the date the Contractor provides acceptable drawings, forms, and any other required information to the Receiving

Activity’s Point of Contact.

3.7. Excavation or drilling. An Excavation Permit request form will be provided to the contractor by the Receiving Activity’s Point of Contact. Prior to any excavation or drilling, the contractor shall:

3.7.1. Perform a Locate Service Survey of the installation site to locate and identify any subsurface interference(s). A copy of the Subsurface Interference Survey Report and a completed Excavation Permit form shall be provided, in electronic format, to the

Receiving Activity’s Point of Contact for review, and approval by NAVFAC, no later than

20 business days prior to the start of excavation or drilling.

3.7.2. Post the approved Excavation Permit onsite from the beginning of excavation or drilling through completion.

3.7.3. Concrete excavation and drilling shall be accomplished in accordance with the process applicable section of 29 CFR 1926 Respirable Crystalline Silica.

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3.7.4. Construct adequate containments around the excavation or drilling site to minimize dust, and to prevent foreign material from becoming airborne, and intrusion on or into existing equipment in the vicinity.

3.7.5. Two Waste Information Sheets (WIS, Section 8.2) shall be submitted for concrete cut water. One for pH less than 11, and one for pH 11 or greater. The Environmental Safety and Health Office (Code 106.33) will classify each type of concrete cut water. The

Contractor shall supply the pH test strips for determining pH level of concrete cut water

3.7.6. Upon completion of excavation or drilling, the Contractor shall provide the information on the Excavation Permit indicating completion and submit the permit to the Receiving

Activity’s Point of Contact for closing.

3.8. Building columns. Welding, drilling, cutting, or clamping to original building columns and column bracing is restricted. Prior to performing any of these evolutions, the Contractor shall submit a request to the Receiving Activity’s Point of Contact for approval. The request shall include locations, components, materials, static loads, dynamic loads, moment forces, and structural calculations demonstrating that the load will not adversely affect the structural integrity of the column or its bracing.

3.9. Internal combustion engine operation inside buildings. The Contractor shall utilize the following ventilation controls when operating internal combustion engines inside buildings:

a. Open doors, windows, roof vents, and/or use blowers or other mechanical systems to move fresh air through work areas. In the event internal combustion engines will be operated for more than 30 continuous minutes, the receiving activity’s Environmental, Safety, and

Health Department shall be notified in advance to survey the area to ensure there is adequate ventilation.

b. When operating internal combustion engines longer than 30 continuous minutes with less than 3 minutes between operations, attach an approved ventilation exhaust hose and exhaust the fumes to the exterior of the building where they cannot re-enter the workplace.

Regularly inspect the hose for defects and damage, and repair or replace as required. The

Contractor shall provide an engineering solution for the use of long exhaust hoses to prevent engine back pressures.

c. Ensure internal combustion equipment is properly maintained and routinely inspected to minimize exhaust emissions.

d. Use of internal combustion equipment shall be coordinated with the Building Manager. This pre-planning will help ensure that indoor air quality issues are minimized.

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3.10. Non-Road Engines. All non-road engines rated 50 horsepower and above shall be identified to the Receiving Activity’s Point of Contact prior to being brought on to PSNS

& IMF or NBK to prevent violation of Title V, Air Operating Permit. C/106.31 will determine the need for additional air pollution controls when using non-road engines (i.e.

skid or trailer mounted generators and pumps).

3.11. Boilers and Unfired Pressure Vessels. Boilers and unfired pressure vessels which meet the below criteria shall be identified to the Receiving Activity’s Point of Contact prior to being brought onto PSNS & IMF or NBK. The boilers and unfired pressure vessels that meet the below criteria shall be certified in accordance with UFC 3-430-07 Inspection and

Certification of Boilers and Unfired Pressure Vessels.

a. Greater than 5 cu ft in volume and 250 psi design pressure

b. Greater than 3 cu ft in volume and 350 psi design pressure

c. Greater than 1-1/2 cu ft in volume and 600 psi design pressure

3.12. Utilities. Reasonable amounts of shop air (80-90 psi) and electricity (120 Volt) will be made available adjacent to the installation site at no cost to the Contractor. The

Contractor shall be responsible for any costs incurred in connecting, converting and transferring the utilities to the work.

3.13. Storage. Lay-down area(s) will be provided within the vicinity of the installation site for storage of Contractor’s materials and tools. The Contractor shall submit an Area Outage

Request to the Receiving Activity’s Point of Contact no later than 20 business days prior to the outage date. The Government does not accept responsibility for security of

Contractor’s materials or tools. The area must be kept clean and orderly, free of rags, paper, and other debris. Failure to maintain the area in a clean condition may result in the loss of the area. The Contractor shall be responsible to restore the storage area to original condition after use.

3.14. Contractor Training. The following training is available for Contractors whose work requires it. The training classes are held on Naval Base Kitsap (NBK) and are provided at no cost to the Contractors. For access to NBK see section “Access to NBK”.

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3.14.1. Contractors that anticipate generating or encountering hazardous waste during the performance of this contract shall attend Site Specific Hazardous Waste Accumulation

Area Operator Training for Contractors, Course HW49 prior to generation of waste. This training is typically held on the third Thursday of each month and is approximately three

(3) hours in length. 5-business days prior to training the Contractor shall provide a list of names to the Receiving Activity’s Point of Contact of those who will be attending the training. The Receiving Activity’s Point of Contact will coordinate this training with the

Shipyard Environmental, Safety, and Health Office (Code 106.33).

3.14.2. Any welding, burning, flame cutting or grinding occurring at PSNS & IMF or NBK requires a Hot Work Permit and Fire Watch Training. This training is typically held on the third Thursday of each month, is approximately one (1) hour in length, and is provided without charge. 5-business days prior to training the Contractor shall provide a list of names to the Receiving Activity’s Point of Contact of those who will be attending the training. The Receiving Activity’s Point of Contact will coordinate this training with the

Shipyard Fire Inspector.

3.15. Lifting and rigger services. The use of privately owned cranes, multi-purpose machines, material handling equipment, or other construction equipment that may be used in a crane-like application to lift suspended loads on NBK and PSNS & IMF property by Contractor personnel is restricted (see NAVFAC P-307 Management of Weight Handling Equipment for information and forms). Contractors requiring this type of equipment in the performance of this contract shall provide the Receiving Activity’s Point of Contact with sufficient information (crane manufacturer documentation of maximum axle loads in a traveling configuration, crane manufacturer documentation of maximum outrigger loads

(loaded and unloaded), compliance certification, crane certification, operator qualifications, crane wire certification, lifting sketches and designs, loads, locations, time, etc.) at least five (5) business days prior to equipment arrival for arranging Government inspection services and approvals. The Contractor shall furnish labor and provide all material handling and lifting equipment, rigging support services, and other support equipment (such as cranes, forklifts, Bobcats, man-lifts, etc.) necessary for continuous support of the installation and shall provide qualified personnel to operate it.

3.16. Crane clearance envelope. To allow for the safe travel of overhead traveling cranes, jib cranes, and hoists the Contractor shall not modify existing buildings or place equipment or temporary structures in any way, which would affect the working envelope of overhead traveling cranes, jib cranes, and hoists. Minimum clearances for working envelopes are:

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3.16.1. Top clearance. A minimum of three (3) inches between the highest point of the crane and the lowest overhead obstruction must be maintained. In areas where truss sag may become a significant factor, the Government will evaluate the need to increase the minimum clearance.

3.16.2. Side clearance. A minimum of two (2) inches between the end of the crane and side obstructions (building columns, knee braces, walls, etc.), assuming the crane is skewed in the worst case situation on the runway rails or when jib cranes are rotated, shall be maintained. Piping, electrical conduits, etc. must not reduce this clearance.

3.17. Lift points. The equipment shall be readily liftable via lift points meeting the requirements of this section to allow lifting by crane during equipment off-loading, installation, operation, and removal. Lift points shall be located, designed, and marked per the following to ensure the equipment is readily liftable when it arrives.

3.17.1. Integral (i.e., not bolt-on), lifting point items such as lugs, thru-holes, pad-eyes, trunnions, and ISO container corner fittings are suitable for use at PSNS & IMF.

3.17.2. Removable lift points such as swivel hoist rings, eye bolts, etc., are not preferred for use at PSNS & IMF due to the corrosive environment. To be permitted, the contractor must receive approval from the Receiving Activity POC prior to contract award.

3.17.3. Lift points shall accommodate ASME B30.26 common rigging gear (e.g., shackles, wire rope pendants/grommets, etc.).

3.17.4. Lift point allowable strength shall be based on ASME BTH-1 (latest revision), Category

B, Service Class 0.

3.17.5. Welding involved shall comply with applicable AWS Standards.

3.17.6. When possible, to maximize stability, locate lift point(s) symmetrically around, and above, the Center of Gravity (CG), on the same horizontal plane. This helps ensure equal length slings converging to a common point will lift the equipment visually level.

3.17.7. Locate the lift points such that the routing of rigging gear is clear of obstructions. This is to avoid damaging equipment, chaffing, etc.

3.17.8. The minimum lift point Working Load Limit (WLL) shall be based on the entire weight of the equipment plus 10%. Account for additional loads induced by 45° sling angles with respect to horizontal.

3.17.8.1. Lift points for three- or four-point lifts shall be sized such that any two points carry the entire load based on worse case load distribution with respect to center of gravity.

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3.17.8.2. For padeyes, align their primary planes toward the CG so that the slings do not pull out of plane by more than 5°. Exceptions may be acceptable if they are designed to account for the resultant out-of-plane loading.

3.17.8.3. The use of spreaders or strongbacks is not preferred. If spreaders or strongbacks are required, a lift sketch detailing the required spread, capacity and orientation of that gear shall be submitted.

3.17.9. Lift point supporting structures shall be designed to sustain the various loads imparted by the lifting arrangement.

3.17.10. Provide all arrangement drawings, lift sketches, calculations required for the design and usage, and manufacture’s documentation of the lift points. All calculations required for the design of the lift points shall be stamped by a Professional Engineer. A minimum of ten business days is required for Government reviews and approvals of design(s). The

Government will determine if lift sketch labels are required.

3.17.11. When required, lift sketch labels shall be permanently and conspicuously located on the equipment and must be suitable to withstand outdoor, potentially corrosive, environments.

Lift sketch labels shall include, at a minimum, the following:

3.17.11.1. The maximum weight of the equipment expressed in pounds.

3.17.11.2. The CG location(s).

3.17.11.3. The lift point locations and their capacity.

3.17.11.4. Recommended minimum sling lengths and capacities.

3.17.12. Permanently label all lift points, or immediately adjacent to them, with the WLL, and test date.

3.17.13. Load test lifting points to 125% (+5%, -0%) of the WLL and hold for at least two (2) minutes. Acceptance criteria shall be: no bending, cracking, or permanent deformation of the lift points or associated structure. The contractor shall perform load tests plus a pre-and post-load visual inspection (VT) in accordance with applicable standards prior to painting. Documentation of satisfactory results shall be submitted prior to Government acceptance.

3.17.13.1. Alternative to a load test, a magnetic particle testing (MT) of the lift point welds per

ASTM E709 is permitted. The acceptance criteria is Section 6.2 of MIL-STD-2035A, or equivalent standard(s) as approved by the government, provided the testing is performed by a certified third party. Documentation of satisfactory results shall be submitted prior to

Government acceptance.

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3.18. Arrival of personnel. The Receiving Activity’s Point of Contact shall be notified no less than 48 hours prior to the arrival of Contractor personnel associated with the contract.

3.19. Shipment of materials. Shipment of materials shall be coordinated with site preparation and installation. Material transportation from the manufacturer’s facility to the work site shall be the responsibility of the Contractor. Limited secured storage areas at the receiving activity will not permit the Government to store material for extended periods of time. Early shipment of materials, without the permission of the Receiving Activity’s

Point of Contact will be refused.

3.20. Packing material. The use of shredded paper, whether newspaper, office scrap, computer sheets, or wax paper, in packing material for shipment to Navy activities, is prohibited.

3.21. General security requirements. The Contractor shall comply with security regulations imposed by the installation Commander and/or agency occupying the space where the work is to be performed. Access badges/passes and vehicle permits are obtained at Pass &

ID (Bldg. 981) from 7:00 am -3:20 pm, Monday through Friday except federal holidays.

3.22. Access to NBK. A Defense Biometric Identification System (DBIDS) card will be issued at the Pass & ID office once the Department of the Navy Local Population I.D. Card/Base

Access Pass Registration form (SECNAV 5512/1) has been processed and a satisfactory background check has been performed. The DBIDS card will allow access to NBK.

3.22.1. A Department of the Navy Local Population I.D. Card/Base Access Pass Registration form (SECNAV 5512/1), provided by the Government, shall be completed by the contractor. The Contractor shall hand-carry the completed form along with a valid government issued photo identification and proof of United States citizenship to Pass &

ID when picking up a badge/pass. Valid proofs of United States citizenship are:

a. Birth Certificate (with a raised state seal)

b. Valid U.S. Passport or valid U.S Passport Card

c. Certificate of Citizenship (Form N-560 or Form N-561 issued by the Immigration and

Naturalization Service)

d. Certificate of Naturalization (Form N-550 original only)

e. Report of Birth Abroad (Form FS-240)

f. Certificate of Birth (Form FS-545 or Form DS-1350)

g. Current and valid enhanced state driver’s license.

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3.22.2. Foreign Nationals shall submit a copy of their valid passport and the Department of the

Navy Local Population ID Card/Base Access Pass Registration (SECNAV 5512/1), when submitting the Visitor Badge Request to the Receiving Activity’s Point of Contact. This will allow Immigration and Customs Enforcement (ICE) to complete a background check prior to arrival at NBK.

3.23. Access to the Controlled Industrial Area (CIA). The Contractor shall require access to the

Controlled Industrial Area (CIA) of PSNS & IMF and shall be admitted to the work site only after they have been issued a NAVSEA badge from Pass & ID. The NAVSEA badge is separate from the DBIDS card.

3.23.1. Persons who are currently on probation or parole from a felony conviction cannot qualify for a NAVSEA badge and will be denied access to the CIA.

3.23.2. Contractor personnel requiring unescorted entry into the CIA will be required to provide personal background…