AMENDED_BTH DEVICE _ PERFORMANCE WORK STATEMENT.pdf

PERFORMANCE WORK STATEMENT

Test & Certify SWT

Below-the-Hook

Lifting Devices

TULSA DISTRICT

US ARMY CORPS OF ENGINEERS

SERVICE CONTRACT

W912BV20Q0074

12 May 2020

Test & Certify SWT Below-the-Hook Lifting Devices i

ORGANIZATION OF SPECIFICATIONS

1. This specification consists of a GENERAL section supplemented by EXHIBITS and APPENDICES.

2. A Table of Contents is provided on the following page.

3. The GENERAL section contains requirements that apply to all work to be performed under the provisions of the contract.

4. The EXHIBITS contain detailed listings or examples referred to in the GENERAL section and the Performance Requirements.

5. The APPENDICES contain power plant location details, descriptions & photos of the BTH lifting devices, and detailed descriptions of the work requirements.

6. Any reference to paragraphs or subparagraphs in this specification will refer to those in the general section unless otherwise noted.

ii

TABLE OF CONTENTS

Paragraph Paragraph Page Number Title Number

GENERAL

1 SCOPE OF WORK 1

2 DEFINITIONS 1

3 REFERENCES 5

4 INITIATION, EXECUTION, & ACCEPTANCE OF WORK 6

5 PERSONNEL 6

6 EQUIPMENT 7

7 MATERIALS AND SUPPLIES 7

8 PERFORMANCE REQUIREMENTS 8

9 CONTRACTOR QULAITY CONTROL 8

10 DEDUCTIONS FOR DEFICIENT WORK 8

11 SAFETY 9

12 CONTRACTOR’S FACILITIES 10

13 WORK SCHEDULES 10

14 REPORTING DEFECTIVE FACILITIES 10

15 BUILDING SECURITY 10

16 PREWORK CONFERENCE 11

17 CONTRACTOR SUBMITTALS 11

18 BILLING 12

19 ANTITERRORISM & OPERATIONS SECURITY REQUIREMENTS 12

EXHIBITS

1 QUALITY ASSURANCE REPORT 14

2 QUALITY CONTROL INSPECTION LOG 14

3 INVOICE FORMAT 15

APPENDICES

A DETAILED WORK REQUIREMENTS 16

B TABLE OF BTH DEVICES 26

C SUPPLEMENTAL INFORMATION 27

D EXAMPLE AS-BUILT TITLE BLOCK 40

E SUBMITTAL REGISTER 41

F BID/PRICING CLIN SCHEDULE 42

1. SCOPE OF WORK

The work required under this contract specification is the certification of twenty-two (22) below-the-hook lifting devices at seven (7) hydroelectric power plants within the geographic boundaries of the Tulsa District of the US Army Corps of Engineers (USACE). The certification process for a lifting device shall establish or verify compliance with applicable regulations, codes, and standards. The certification process requires thorough completion of the following tasks: visual inspection, non-destructive examination, load testing, marking, labeling, and documentation.

2. DEFINITIONS

2.1. Below-the-Hook (BTH)

A device that is used as an interface between a load and a crane or hoist. In some cases the device may not be below the hook but may actually contain the hook. See Lifting Device.

2.2. Catalog Item

A BTH device that is fabricated for that purpose and the design information is available from the manufacturer.

2.3. Contracting Officer (KO)

USACE contracting specialist that holds ultimate contract administration authority.

2.4. Contracting Officer’s Representative (COR)

Designated in writing by the KO, the COR assists in the technical monitoring or administration of a contract.

2.5. Contractor Quality Control (CQC)

The contractor’s system of controlling the quality of services provided under the provisions of the contract.

2.6. Deficient Service

Any service provided by the contractor that does not meet the Performance Standards specified in the Performance Requirements given in the Performance Work Statement.

2.7. Erection Devices

BTH lifting devices that are used to erect hydroelectric turbine and generator equipment. These are construction devices in contrast to operation devices.

2.8. Fit-for-Service (FFS)

Fit-for-Service means that the design, material, and fabrication quality/condition of a device/structure are at an appropriate level considering the risks and consequences of failure. A structure/device is fit for service when it functions safely and satisfactorily during its lifetime without reaching any serious limit state.

2.9. Fracture Critical Members (FCM)

Fracture Critical Members are tension members or tension components of bending members the failure of which would be expected to result in collapse of partial collapse of the structure (lifting device). Any attachment welded to a tension zone of a FCM shall also be considered a FCM when any dimension of the attachment exceeds 4 inches in the direction parallel to the calculated tensile stress in the FCM. All welds to FCM’s shall be considered fracture critical. Welds to compression members or compression areas of bending members are not considered fracture critical.

2.10. Government

The term "Government" as used herein means the Federal Government of the United States of America.

2.11. Hydraulic Steel Structure (HSS)

Structures which control or regulate water and are typically part of a larger navigation, hydropower, or flood control project. HSS is also defined to be a lifting device that is used for installing other HSS and outlet works gates (ER 1110-2-8157 6.a)

2.12. Lifting Beam

See Lifting Device.

2.13. Lifting Device

Any device used for attaching a load to a hoist. Further, a lifting device is not a part of the hoist or load and is not reasonably expected to be covered by codes/standards native to the hoist or load. However there are lifting devices that are reeved into hoist/crane systems, an example being a lifting beam integrally reeved as seen in Figure 1. This is intended to be the same as the terminology “below-the-hook lifting device” used by the ASME B30.20 standard.

Figure 1: From ASME B30.20, Figure 20-1.3-5

2.14. Load Handling Equipment (LHE)

Cranes and hoists used to lift and place equipment.

2.15. Non-Destructive Testing (NDT)

A testing and analysis technique used to evaluate properties of a device or component without causing damage to the part being tested. Also called non-destructive examination (NDE).

2.16. Operation Devices

BTH lifting devices that are used to move gates which control or regulate water passage through the power plant structure.

2.17. Performance Requirement (PR)

The Government's requirement for each service provided under the contract.

2.18. Performance Standard (PStd)

A specification of the minimum standard of quality for each service provided under the contract.

2.19. Project

The term "project" as used herein means all Government property and easements at Tulsa District power plants.

2.20. Qualified Person

A qualified person shall be a registered mechanical engineer or civil engineer with structural focus with extensive knowledge, training, and experience with lifting beams who is capable of designing, analyzing, evaluating and specifying lifting beams and critical lift plans.

2.21. Quality

Conformance with the contract specification.

2.22. Quality Assurance

The procedure by which the Government determines CQC is functioning effectively.

2.23. Regulation

The term "regulation" refers to any local, state, or Federal law or regulation applicable to operation or maintenance of the project.

2.24. Rigger

A person that attaches the rigging and/or BTH device to LHE. The rigger is responsible for verifying that the rigging has been inspected and is appropriately sized for the intended lift.

Riggers shall be certified and copies of their certification shall be provided to the COR.

2.25. Shall

Indicates a contract requirement.

2.26. Should

Indicates a contract recommendation.

2.27. Sling

An assembly of flexible rigging that is pre-engineered and is provided with prescribed load ratings from the sling manufacturer. The upper portion of a sling is connected to the lifting mechanism, and the lower supports the load. Common examples of flexible rigging used in slings include wire ropes, straps, pendants, and chains. Slings also often contain components to connect flexible rigging such as shackles and links. Slings are not specifically covered under the requirements of this document. Per EM 385-1-1 (15.D.01) slings shall comply with the requirements of ASME B30.9.

2.28. SWT

USACE Tulsa District of the Southwest Division.

2.29. Workday

Any day, Monday through Thursday, exclusive of Federal holidays.

This definition should not be interpreted to mean work is not required by this specification on other days.

3. REFERENCES

Note that this document only highlights key requirements from the listed codes. This document does not explicitly address every element that is required to ensure BTH Lifting Device compliance with the listed codes.

EM 385-1-1

Corps of Engineers Safety and Health Requirements Manual (EM 385-1-1, current edition) is hereby incorporated into this specification. Full text available here:

http://www.usace.army.mil/SafetyandOccupationalHealth/Safetyan dHealthRequirementsManual.aspx

ASME B30.9 Slings

ASME B30.10 Hooks

ASME B30.20 Below-the-Hook Lifting Devices

ASME B30.26 Rigging Hardware

ASME BTH-1 Design of Below-the-Hook Lifting Devices

ANSI Z535.4 Product Safety Signs and Labels

OSHA 29 CFR 1926.251 Rigging Equipment for Material Handling

AWS D14.1 Specification for Welding of Industrial and Mill Cranes and Other Material Handling Equipment

ASTM E709 Standard Guide for Magnetic Particle Testing

ASTM E165 Standard Practice for Liquid Penetrant Testing for General Industry

ASTM E164 Standard Practice for Contact Ultrasonic Testing of Weldments

UFGS 09 90 00 Paints and Coatings

SP 10/NACE No.2, Near-White Blast Cleaning

SSPC-PS 26.00 Coating System, Type I http://www.usace.army.mil/SafetyandOccupationalHealth/SafetyandHealthRequirementsManual.aspx http://www.usace.army.mil/SafetyandOccupationalHealth/SafetyandHealthRequirementsManual.aspx

4. INITIATION, EXECUTION, & ACCEPTANCE OF WORK

Initiation and execution of work shall be in accordance with this specification.

4.1. Acceptance of Lifting Device Certification. The Government shall accept work unless the KO or the COR notifies the contractor of deficient services.

4.2. Notification of Deficiencies. Initial notification of

deficiencies may be written or oral; however, all oral notification shall be confirmed by the KO or the COR in writing within two (2) workdays. Written notification shall be provided by completing Parts I, II, and III of a Quality Assurance Report (SWT Form 982, Exhibit 1).

4.3. Corrective Work for Deficiencies. If the KO or the COR notifies the contractor of deficient work, the contractor shall acknowledge the notification and initiate action to schedule and accomplish corrective work. Refer to paragraph 10 for deductions of deficient work.

4.4. Documentation for the Correction of Deficiencies. The

contractor shall notify the KO and the COR when deficiencies have been corrected by completing Part IV of the QA Report.

When work has been corrected, the KO or the COR shall complete Part V of the QA Report and furnish the contractor a copy. A copy will also be filed at the Tulsa District Office.

5. PERSONNEL

The contractor shall provide qualified personnel as necessary to accomplish all work required by this specification within specified time limits.

5.1. Experience and Skills. The contractor shall provide personnel that are experienced and demonstrate proficiency in the skills required performing the various types of work specified.

5.2. Supervision

5.2.1. The contractor shall provide one site supervisor on the project who shall have full authority to direct any work required. This supervisor, and specified alternates, shall have full authority to execute the work and shall be designated in writing.

5.2.2. The contractor shall provide the KO and the COR the site supervisor’s contact telephone number (preferably a mobile telephone) through which the supervisor can be reached between 7:00 a.m. and 5:00 p.m. Central Standard Time on all days work is being performed.

6. EQUIPMENT

The contractor shall furnish equipment necessary to accomplish all work required by this specification within specified time limits with one exception. The Denison BTH device cannot be away from the location for more than 10 days. If more time is needed, the work will need to be completed on-site in which case the project intake gantry crane may be used. Use of the crane must be requested and approved. Government personnel must operate the crane. Equipment maintenance and calibration records shall be submitted to the KO and COR prior to beginning work. Upon request, the contractor shall make equipment available to the KO or the COR for inspection. The KO or the COR shall establish the time for these inspections.

6.1. All equipment must be in good operating and mechanical condition and shall comply with EM 385-1-1.

6.2. For work being done on-site at a powerhouse, all electric equipment shall be powered by 115 Volts AC. Approval shall be requested in writing to the COR for use of all equipment over the 115 Volts AC. There is no guarantee this request will be granted.

6.3. For work being done on-site at a powerhouse, vehicles shall be operated and parked only by legally licensed drivers only on roads, parking areas, or pullouts unless the KO or the Site Manager approves use of other areas. Contractor vehicles shall be parked in designated areas per the COR.

7. MATERIALS AND SUPPLIES

7.1. Contractor Furnished

7.1.1. The contractor shall furnish all materials and supplies necessary to accomplish all work required by this specification within specified time limits.

7.1.2. All materials and supplies shall be in good repair in

accordance with EM 385-1-1. All materials and supplies are subject to review by the KO or the COR to verify compliance with this specification.

7.2. Government Furnished

The Government will provide the Lifting Devices listed in Appendix B. If required, and with prior approval, the Government can provide the use of the Denison intake gantry crane.

8. PERFORMANCE REQUIREMENTS

PRs for work performed under this specification are given in Appendix A. Contractor performance will be evaluated using these PRs as follows:

8.1. Services provided by the contractor will be inspected for compliance with the PStds. Those not meeting the PStds shall be considered deficient. Major or recurring minor deficiencies will result in a letter of correction being issued by the COR.

8.2. Deficient services are determined during an initial QA

inspection since the purpose of QA is to determine how well Contractor Quality Control is functioning. The results of inspections are not changed as a result of satisfactory re-performance.

9. CONTRACTOR QUALITY CONTROL

The contractor shall establish and execute a CQC Program in accordance with clause 52.246-4 "Inspection of Services" to assure that all work required by this specification is completed on schedule and in accordance with the PRs.

10. DEDUCTIONS FOR DEFICIENT WORK

Deductions from the contractor's scheduled earnings shall be made for services that do not meet the PStds. Deductions for documented defects will be made in accordance with the following procedures:

10.1. Each service found deficient and re-performed by the contractor, and accepted by the KO or COR: No deduction.

10.2. Each service found deficient and performed by the Government:

Deduction for loss in value shall be based on the Government's cost for performing the work.

10.3. Each service found deficient and performed by another

contractor: Deduction in the contract price paid the other contractor to perform the work.

10.4. Each service found deficient and not re-performed, or work not performed at all: Deduction for loss in value of activity shall be based on the estimated cost to the Government to have the deficient or neglected work performed.

11. SAFETY

11.1. Safety Plan. The contractor shall furnish the KO and the COR a safety plan to implement the general policies and procedures for safe execution of the work in accordance with EM 385-1-1. The Government will review one safety plan for all facilities. The safety plan shall include, but not be limited to the following:

11.1.1. Procedures for training employees in responsibilities for safety of others, including the general public.

11.1.2. Requirements for wearing or utilizing personal safety equipment and apparel.

11.1.3. Procedures for handling, reporting, and correcting unsafe conditions, practices, and safety violations.

11.1.4. Procedures for treating and transporting injured persons to medical facilities.

11.1.5. Fire prevention plan.

11.2. Safety Violations. If a contractor's employee persists in not following the safety requirements of this specification or the contractor's safety plan, the employee shall be permanently denied access to the Government Facility upon the written request of the KO.

11.3. Personal Clothing and Safety Apparel. Contractor personnel shall wear clothing suitable for the weather and working conditions. The minimum shall be short-sleeve shirt and long trousers (no sleeveless shirts or tank tops, or shorts), steel toed boots, hard hat and safety glasses. Clothing shall be in good repair. Personnel will wear additional protective apparel when required by Section 5, EM 385-1-1.

11.4. Accident Reports.

11.4.1. The contractor shall immediately notify the KO and the COR of all known accidents and near misses to people and equipment that occur while contract work is being performed and result in or could have resulted in death, serious injury or equipment damage.

11.4.2. The contractor shall investigate all accidents involving contractor or subcontractor employees that result in death, traumatic injury, occupational disease, or damage to property, materials, supplies and equipment incidental to work performed under this specification. The results of investigations shall be reported to the KO and the COR immediately, and in writing on ENG Form 3394, Accident Investigation Report, within one (1) workday following the accident.

11.5. Exposure Reports. The contractor shall maintain an

accurate record of exposure data (man-hours worked) and submit the figure in writing by the 2nd workday of each month following completion of work at a project. Invoices will not be considered as received until receipt of the exposure report.

12. CONTRACTOR’S FACILITIES

The contractor shall be responsible for storage of materials, supplies, and equipment to maintain the services required by this contract.

13. WORK SCHEDULES

The contractor shall furnish the KO and the COR a schedule for performing all work. The initial schedule shall be provided within two weeks of contract award. A revised schedule shall be furnished to the KO and the COR prior to the contractor implementing changes.

14. REPORTING DEFECTIVE FACILITIES

For work being done on-site at a powerhouse, contractor personnel shall observe the condition of Government facilities. Damaged, defective, and/or inoperative facilities shall be reported to the KO or the COR each workday.

15. BUILDING SECURITY

For work being done on-site at a powerhouse, the names of contractor personnel authorized to perform work under this contract shall be furnished the KO and the COR prior to initiating any work. Only those persons whose name appears on this list shall be granted facility access. Persons on this list shall have completed all training and E-Verify requirements, shall sign in and out each day with signature, date, and time. Failure to comply with security requirements can result in the KO requiring the permanent removal of an employee from this effort.

16. PREWORK CONFERENCE

The COR shall conduct a Pre-work Conference with the contractor to discuss the provisions of this specification and the contractor's submittals listed below in paragraph 17 and in in Appendix E. At a minimum, the officer of the company that signed the contract and the on-site supervisor shall represent the contractor. The COR shall establish the location, date, and time of the Pre-work Conference after consultation with the contractor.

17. CONTRACTOR SUBMITTALS

Unless otherwise noted, the contractor shall submit the documents listed below to the KO and the COR. Submittals shall be approved by the government PRIOR to initiating work. All submittals, other than copies of contracts, shall be typed and submitted in electronic format to the KO and the COR. If the KO or the COR determines any of the submittals do not comply with this specification, the contractor shall resubmit these documents within one (1) week. The KO shall have the final decision if there is a disagreement as to the validity of a submission.

17.1. Name of supervisor and alternate(s). Submit prior to initiation of work and prior to changing designated employees.

(Subparagraph 5.2.1.)

17.2. Safety Plan for on-site work. Submit and await approval prior to initiation of work. (Subparagraph 11.1.)

17.3. Exposure reports. Submit by 2nd workday of the month following completion of work at a project. (Subparagraph 11.5.)

17.4. Work schedules for on-site work. Submit prior to initiation of work and prior to changing schedules. (Paragraph 13.)

17.5. Names of personnel authorized to perform work under this contract for on-site work. Submitted and await approval prior to initiation of work. (Paragraph 15.)

17.6. For on-site work, contractor must pre‐screen Candidates using the DHS E‐verify Program (http://www.dhs.gov/E‐Verify) and must ensure that the Candidate has two valid forms of Government issued identification prior to ensure the correct information is entered. An initial list of eligible Candidates must be provided to the COR no later than five (5) business days after the initial contract award. All employees who will work on any Project must be pre-screened prior to entry into any Project.

http://www.dhs.gov/E%E2%80%90Verify

17.7. For on-site work, AT/OPSEC Training Certificate for all employees, supervisors, and manager. (Paragraph 19.)

17.8. Copy of Certificate of Liability Insurance proving minimum required general liability and workers compensation insurance.

17.9. List of any subcontractors and amount of work to be performed by each.

17.10. Hazardous Debris Containment and Disposal Plan for on-site work. Provide containment plan of how debris and dust will be contained, tested, and disposed.

18. BILLING

18.1. The contractor shall submit the original and one copy of invoices at the end of each month for all completed work.

18.2. Invoices shall be prepared in the format shown in Exhibit 2.

18.3. Exposure reports shall be submitted with each invoice and must be received before an invoice will be accepted.

18.4. Invoices and supporting documents shall be delivered or mailed to the COR.

19. ANTITERRORISM & OPERATIONS SECURITY REQUIREMENTS

For on-site work, the Contractor shall be responsible for ensuring all personnel, to include sub-contractor personnel, comply with the training requirements and procedures identified in the document titled “Antiterrorism/Operations Security Requirements” in Section H, Special Contract Requirements. When items for which training is identified, the Contractor shall ensure that all personnel complete acknowledgement for the specified training; the Contractor is responsible for ensuring all training acknowledgments, when applicable, are submitted to the COR or KO within 10 calendar days of contract award (or NTP for construction contracts). In no event shall any contractor or sub-contractor personnel be on-site prior to completion of any applicable training, submission of training verification, and initiation of background check.

19.1. Training materials and verification forms will be provided by the KO within two business days of Contract Award.

19.2. Per the ANTITERRORISM/OPERATIONS SECURITY REQUIREMENTS, Jun

2015, incorporated in SECTION H, Item 2b:

19.2.1. For contractors who do not require CAC, but require access to a DoD facility or installation: Contractor and all associated sub‐contractors employees shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC‐III) and Terrorist Screening Database (TSDB) (Army Directive 2014‐05 / AR 190‐13), applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative, as NCIC and TSDB are available), or, at OCONUS locations, in accordance with status of forces agreements and other theater regulations.

19.2.2. Contractor personnel who are intended to access

Government Facilities unescorted MUST provide the following to the Tulsa District Security Officer prior to attempting to access Government Facilities:

1. PSIP Form completed (Form will be provided upon request)

2. OF 0306 completed

3. Two copies of FD 258 (finger print cards) completed

4. Copy of birth certificate, passport, or Certificate of

Naturalization

5. Copy of State issued driver’s license or state ID

6. Simple Resume' covering past seven years

7. Employees will need to complete the SF 86 and retain this copy.

Employees should retain copies of all the above forms.

19.2.3. Once the above forms are turned over the background check will be initiated. The Employees will receive notification/email from the Office of Personnel Management providing them information to fill out an SF 85 on-line. Failure to complete this step will result in the Employee not being allowed access to the Project.

EXHIBIT 1

QUALITY ASSURANCE REPORT

SWT Form 982 Quality Assurance Report is provided in SECTION J as Attachment 1

EXHIBIT 2

QUALITY CONTROL INSPECTION LOG

SWT Form 990 Quality Control Inspection Log is provided in SECTION J as Attachment 2

EXHIBIT 3

INVOICE FORMAT

INVOICE

Address

NAME

U.S. ARMY CORPS OF

ENGINEERS

Phone: ADDRESS

E-mail: CITY, STATE

Contract

Job Date of Service Invoice #

BTH: Test & Certify

Payment Terms: Net 30

Item # Description Unit - Job

Unit Price Price

TOTAL $

APPENDIX A: DETAILED WORK REQUIREMENTS FOR BTH DEVICES

1. GENERAL REQUIREMENTS:

This contract requires the certification of twenty-two (22) below-the-hook lifting devices. The devices and associated details are tabulated in Appendix B. The certification process for each lifting device shall comply with the applicable standards listed in Paragraph 3 of this contract section (Appendix A.) This work is required at seven(7) of the eight (8) hydroelectric power plants within the geographic boundaries of the Tulsa District of the US Army Corps of Engineers (USACE). The specific work required is summarized here and detailed in subsequent paragraphs:

a. Produce As-Built drawings for each of the devices.

b. Engineering analysis to determine safe working load limit.

c. Remove paint (if required for NDT).

d. Initial visual inspection and non-destructive testing.

e. Measure & record the weight of each component for all devices.

f. Load test each device.

g. Follow-up visual inspection and non-destructive examination.

h. Painting (if required).

i. Marking & labeling.

NOTE: Repair and/or replacement of deficient below-the-hook assemblies/devices, if necessary, shall be performed and paid for by contract modification(s).

2. DISCLOSURE:

The contractor should assume the devices contain lead-based paint.

Testing to verify the presence of hazardous materials is the sole responsibility of the contractor. The abatement and containment of any hazardous material encountered is the sole responsibility of the contractor.

3. STANDARDS:

All work shall comply with the following regulations and standards:

a. USACE EM 385-1-1

b. ASME B30.9 Slings

c. ASME B30.10 Hooks

d. ASME B30.20 Below-the-Hook Lifting Devices

e. ASME B30.26 Rigging Hardware

f. ASME BTH-1 Design of Below-the-Hook Lifting Devices

g. ANSI Z535.4 Product Safety Signs and Labels

h. OSHA 29 CFR 1926.251 Rigging Equipment for Material Handling

i. AWS D14.1 Specification for Welding of Industrial and Mill

Cranes and Other Material Handling Equipment

j. ASTM E709 Standard Guide for Magnetic Particle Testing

k. ASTM E165 Standard Practice for Liquid Penetrant Testing for

General Industry

l. ASTM E164 Standard Practice for Contact Ultrasonic Testing of Weldments

m. UFGS 09 90 00 Paints and Coatings

n. SP 10/NACE No.2, Near-White Blast Cleaning

o. SSPC-PS 26.00 Coating System, Type I

4. LOCATIONS, FREQUENCIES, AND TIMES OF SERVICES:

Work IS NOT required to be completed on-site at the powerhouses, but this is an available option. With prior approval, work can be completed on-site but not inside of the powerhouses. On-site access requires a written request and COR approval in addition to the submittals required in General Sections 17 and 19. If work is being performed on-site, it is the contractor’s responsibility to provide temporary work facilities. If work is being done on-site, it shall be performed Monday thru Thursday, excluding Federal holidays. All on-site work shall be accomplished between 7:00 a.m. and 4:00 p.m.

CST. For off-site work, the contractor shall arrange for transportation of the devices to the contractor’s facility.

5. EXPERIENCE:

The contractor shall demonstrate a history of recent & relevant experience and shall submit records documenting work that is similar in scope. Provide a minimum of five (5) projects completed within the past three (3) years. Include the year completed and a brief description of the project scope of work. Records of relevant work shall be submitted at the time of the contractor’s bid for the contract.

6. WORK PLANS:

Work shall be completed for one (1) power plant at a time. For each power plant, the contractor shall submit to COR for approval a written work plan with the following:

a. Scope of Work that specifies the means & methods of NDT and load testing the plant-specific BTH devices.

b. Schedule which details a timeframe for completion.

c. A list of all contractors/subcontractors involved with the project, along with contact information and assigned tasks.

d. For off-site work, specify a plan and schedule for transporting the device(s) to the contractor’s facility and specify that location.

e. For on-site work, include a power plant access request.

f. For on-site work, include a Lead Compliance Plan in accordance with 29 CFR 1910.1025; 29 CFR 1926.62 and EM 385-1-1 2014 Section 06.C.02.

NOTE: If the Contractor fails to deliver all devices by the approved scheduled duration or if any device remains in the Contractor’s possession past the approved scheduled duration without prior Government authorization, the Contractor may be charged for loss or damages to the Government, including without limitation, replacement of the device(s).

7. EXISTING CONDITIONS:

The Government shall perform an existing condition inspection which shall be documented by photographs prior to the contractor taking possession of any device. While not required, the contractor may attend the existing condition inspection.

8. INITIAL INSPECTIONS:

The following paragraphs specify the acceptable types of nondestructive inspections, the required qualifications of the inspectors, and at a minimum what must be inspected. Unless stated otherwise, weld inspection procedure and acceptance criteria must be in accordance with AWS D14.1, as applicable to the material being inspected. Submit copies of the certifications of all the personnel who will be performing inspections. For each of the BTH devices, disassemble to the fullest extent, and complete a thorough inspection. At a minimum, the welds, pins, pin bores, fasteners, hooks, and all load path components must be inspected using VT and either PT, MT, or UT methods for identifying cracks and other anomalies both before and after load testing. These inspections must be performed by a qualified person. NDT must be completed in accordance with this specification. Reassemble after inspection is complete.

a. Visual Testing (VT)

For visual testing, conform to requirements of the applicable material standard. Document all indications exceeding the acceptance standards permitted by the applicable material standard.

b. Penetrant Testing (PT) For liquid penetrant tests and inspection, conform to the applicable requirements of ASTM E165 and the manufacturer's instructions. Document all defects disclosed by the penetrant test exceeding the degree permitted by the applicable material standard. At a minimum, the individual performing the PT tests is required to be qualified in accordance with ANSI/ASNT CP-189

NDT Level II, with a minimum of 1 year of current experience at this level. An ASNT Level III may conduct tests if that person provides documentation of having passed a Level II practical examination within the last three (3) years.

c. Magnetic Particle Testing (MT) For magnetic particle tests and inspection, conform to the applicable requirements of ASTM E709. Document all indications exceeding the acceptance standards permitted by the applicable material standard. At a minimum, the individual performing the MT tests is required to be qualified in accordance with ANSI/ASNT CP-189 NDT Level II, with a minimum of 1 year of current experience at this level. An ASNT Level III may conduct tests if that person provides documentation of having passed a Level II practical examination within the last three (3) years.

d. Ultrasonic Testing (UT) For ultrasonic testing, conform to requirements of the applicable material standard. Document all indications exceeding the acceptance standards permitted by the applicable material standard. At a minimum, the individual performing the UT is required to be ANSI/ASNT CP-189 NDT Level II, with a minimum of 1 year of current experience at this level. An ASNT Level III may conduct tests if that person provides documentation of having passed a Level II practical examination within the last three

(3) years.

9. PAINT REMOVAL (Optional Bid Item):

If required for non-destructive testing, paint shall be removed from the devices. If the contractor can demonstrate, based on previous experience, that the NDT results can be accurate without paint removal, the Government may waive this option. If required, paint shall be removed as specified by SSPC-SP 10/NACE No.2, Near- White Blast Cleaning. Lead-based paint must be removed and disposed in accordance with applicable local, state, and federal codes and requirements.

10. ENGINEERING ANALYSIS:

An engineering analysis with hand calculations is required to determine the Safe Working Load Limit for each device. The term “hand calculations” does not exclude the use of computers in the analysis. Calculations can utilize Excel, Mathcad, and/or other programs. Finite Element Analysis (FEA) can be utilized. FEA shall not be used in lieu of hand calculations. If FEA is utilized, the presentation of results shall not be limited to output graphs or tables. All details of the FEA setup must be provided in addition to the outputs and a discussion of the results. Hand calculations are required for all devices including those which undergo FEA.

The Engineering Analysis shall determine or verify the Design Category per ASME BTH-1.

Calculations shall follow the criteria established by ASTM BTH-1.

Calculations shall consider stresses resulting from the application of a rated load plus the weight of the lifting device. Calculations shall determine the safe working load limit. Secondary calculations shall be done with an applied load of 125% of the rated load listed in Appendix B. If any device does not sufficiently satisfy the engineering analysis at 125% of the rated load, the contractor shall report the results and await approval & guidance from the Government before proceeding to the load test.

For cases in which the material composition is unknown, calculations shall assume ASTM A7. If the results indicate that any device does not satisfy the criteria established by ASTM BTH- 1, then a material analysis must be performed and the calculations shall be repeated using the results from the material analysis. A request to remove material for composition analysis must include the proposed removal site and shall be submitted to the COR for approval. The results of the material analysis shall be included with the submittal of the Engineering Analysis.

All calculations and supporting documents shall be signed and stamped by a licensed professional engineer with at least 15 years of experience in design of cranes and crane components.

11. LOAD TEST:

Load test each of the lifting devices at 125% of the rated load specified in Appendix B. Each device shall be loaded in a way that accurately recreates how it would be loaded during operation.

Appendix C contains guidance and requirements for recreating the loading conditions. Load tests can be performed using hydraulic rams or certified weights. Devices shall be fully loaded and the duration of the test shall be at least five (5) minutes.

Prior to performing a load test, the contractor shall submit for approval a Load Test Plan that specifies how each device is to be loaded, the test weight, and a description of the type of load.

The test load shall not include the weight of the device itself or rigging.

If a request to perform a load test on-site is approved and the proposed method of loading is water bags, the following requirements must be met:

a. Government-owned equipment including cranes will not be available for Load Testing.

b. Specify the method of loading in the Load Test Plan.

c. Maintain clearance of 50 feet in all directions from all electrical equipment.

d. Provide means of pumping water into the water bags from the tailrace and after testing a means of draining the bags into the tailrace.

e. Water bags must not be drained into on-site drainage systems.

f. Water bags and associated hoses and valves must be checked for leaks prior to use on-site. Equipment that leaks during testing must be replaced to keep spilled water to a minimum.

g. Use pumps, piping/headers, and valves sized such that the total time to fill the water bags from 0-100 percent is no longer than four hours.

h. Standard basket strainers approved by the pump manufacturer must be used on the pump inlet.

12. SECONDARY INSPECTIONS:

After load testing is complete, secondary or follow-up inspections shall be performed. The secondary inspections shall be performed in the same manner in which the initial inspections were completed.

For example, if MT is the mode of NDT during the initial inspections, then MT shall also be the mode of NDT used during the secondary inspections. If the results of the secondary inspections differ in any way from the results of the initial inspections, the discrepancies shall be documented.

If the load test of any device results in failure, an analysis of failure is required. For this case “failure” shall be defined as the deformation of any component and/or the development of any cracks, defects, or anomalies that were not present during the initial inspection. The analysis of failure shall document the type and extent of failure. The analysis of failure shall include a recommendation for the repair or replacement of the failed device or component. The analysis of failure shall be submitted with the BTH Devices Inspection Report.

Submit for approval the BTH Devices Inspection Report recording inspection findings for all devices inspected. This report must include all NDT results. This report must include photographs of the lifting devices and any cracks, defects, or anomalies found.

Photographs must be hi-resolution digital images with at least 300 pixels per inch. A file of all digital images must be submitted with the inspection report. Provide inspection results including photos and descriptions of any defects in addition to the corresponding analyses of failure. All welding repair proposals must be included in the report.

If repair proposals are approved, specifications and payment for additional work will be done through contract modifications.

13. AS-BUILT DRAWINGS:

An As-Built drawing is required for each device. All drawings shall be signed and stamped by a licensed professional engineer with at least 15 years of experience in design of cranes and crane components.

As-Built drawings shall be dimensioned, scaled CAD drawings with a populated title block. The scale to be used is 1:6. The drawings shall include a plan view, an elevation view, and an isometric view. Drawings shall include dimensioned details including but not limited to bolt holes, pin bores, pins, pin keeper plates, and all associated fasteners. The drawings shall include weld details.

The title block shall be formatted as shown in Appendix D.

The following additional information shall be included in the drawing title blocks: device weight*, safe working load limit (as determined by the engineering analysis), load test date & weight, Design Category and Service Class.

The contractor shall submit two (2) 12” x 18” paper copies of each As-Built drawing. The contractor shall submit a compact disc with hi-resolution (300 pixels per inch or greater) images of the drawings. Acceptable image file types are JPEG or TIF. The contractor shall submit a compact disc of all final CAD files that are produced in the As-Built drawing process.

* The device weight shall be measured and recorded by the contractor using a calibrated measuring device prior to the Load Test.

14. PAINT APPLICATION (Optional Bid Item):

If paint removal is required for successful NDT, the devices shall be repainted after load testing and inspections have been completed. Clean, prepare and repaint surfaces per SSPC-PS NO.

26.00, Type I. Paint shall be applied by spraying.

Paint shall not be in the following places: pins, pin bores, bolt holes, bolt shafts, and bolt threads. Provide a finished coating free from holidays, pinholes, bubbles, runs, drops, ridges, waves, laps, brush hairs, blisters, overspray, mud cracking, brush marks, and variations in color, texture, and gloss.

15. MARKING AND LABELING:

Provide stenciled working load limit markings, to the nearest tenth of a ton, on both sides of the lifting device in accordance with the requirements of ASME B30.20 paragraph 20-1.2.1.(a). Characters must be easily legible from the powerhouse floor when the lifting device is at its highest elevation on the bridge crane. Generally, select the largest font size that will fit on the device. Submit the working load limit markings for approval, including but not limited to documentation of the measured weight of the existing device, the size and color of the stenciling, and the proposed locations.

After successful load testing and secondary inspections of each device, provide one new nameplate for each device in conformance with ASME B30.20 paragraph 20-1.2.1.(b), including but not limited to the following:

a. Contractor's name and address.

b. Year of fabrication (if known).

c. Serial Number (SWT BTH # if the S/N is unknown)

d. Rated capacity in tons.

e. Load test weight in tons.

f. Date of Load Test.

g. Weight of the lifting device.

h. ASME BTH-1 Design Category A.

i. ASME BTH-1 Service Class 0.

Do not provide vinyl logos and lettering for nameplate. Install new, corrosion-resistant metal plate to the lifting beam with corrosion-resisting steel fasteners. Submit for approval a Nameplate Drawing including but not limited to the proposed nameplate, material, dimensions, wording, character sizes, color of background and lettering, description of fasteners or fastening method, and location on the lifting device; location must be accessible. Nameplate lettering must be easily legible from a distance of five feet.

Provide new safety label in conformance with ASME B30.20 paragraph 20-1.2.1 "Marking", subparagraph (d) "Product Safety Labels" including but not limited to the appropriate signal word, according to ANSI Z535.4 (4.14), to bring the label to the attention of the operator, and cautionary language to provide danger, warning, or caution notice to operators and others against:

a. Exceeding the working load limit.

b. Operating a damaged or malfunctioning device.

c. Lifting people.

d. Lifting suspended loads over people.

e. Leaving suspended loads unattended.

f. Removing or obscuring warning labels.

g. Not staying clear of the suspended load.

h. Lifting loads higher than necessary.

i. Making alterations to the lifting device.

Do not provide vinyl logos and lettering for label. Install new, corrosion-resistant metal plate to the lifting beam with corrosion-resisting steel fasteners. Generally, select the largest font size that will fit on the device. For each device, submit for approval a Safety Label for Lifting Device drawing including but not limited to the proposed label, material, dimensions, wording, character sizes, description of fasteners or fastening method, and location on the lifting device; location must be accessible. Assume a Minimum Safe Viewing Distance of 8 feet and select Letter heights from Table B1 (ANSI Z535.4) accordingly.

16. DOCUMENTATION:

Upon concluding work for each power plant, the contractor shall submit all outstanding documentation showing compliance with all requirements. Documentation shall include photos documenting before and after conditions, documentation of all inspections and tests, copy of any lab results, engineering analysis, as-built drawings, and any additional supporting documents such as FEA results and corresponding hand calculations.

17. RETURN DEVICES:

After the COR has received and approved all submittals, the contractor shall return possession of the devices to the Government. For off-site work, the contractor is responsible for shipping the devices back to the powerhouse of origin. The contractor shall take final condition photos of each device. These photos shall be submitted to the COR with a copy of the shipment packing list and shipping invoice.

18. DISPOSAL OF HAZARDOUS MATERIAL:

All hazardous material shall be handled in accordance with applicable local, state and federal requirements and codes.

19. DISCLAIMER:

The Government reserves the right to omit any device listed in Appendix B from the contract requirements for any reason.

APPENDIX B: TABLE OF BTH DEVICES

1 Fort Gibson Lifting Trunnion for Generator Rotor FTG101 A 0 100

2 Fort Gibson Main Shaft and Runner Lifting Device FTG102 A 0 51

3 Tenkiller Ferry Rotor and Shaft Lifting Device TNK104 A 0 76

4 Tenkiller Ferry Runner Lifting Device TNK105 A 0 30

5 Eufaula Rotor Shaft Lifting Device EUF101 A 0 135

6 Eufaula Turbine and Main Shaft Lifting Device EUF102 A 0 77

7 Keystone Rotor Lifting Beam KEY101 B 0 177

8 Keystone Rotor Lifting Device KEY102 A 0 171

9 Keystone Exciter Lifting Device KEY103 C 0 12

10 Keystone Turbine Lifting Device KEY104 A 0 69

11 Keystone Generator Shaft Lifting Device KEY107 A 0 35

12 Keystone Head Cover Lifting Device (1 of 2) KEY108.1 C 0 13

13 Keystone Head Cover Lifting Device (2 of 2) KEY108.2 C 0 13

14 Broken Bow Shaft and Runner Lifting Device BRB102 A 0 *

15 Broken Bow Rotor Lifting Device BRB103 A 0 161

16 Broken Bow Butterfly Valve Lifter (1 of 2) BRB104.1 C 0 *

17 Broken Bow Butterfly Valve Lifter (2 of 2) BRB104.2 C 0 *

18 Webbers Falls Gate Barrel Lifting Device WBF102 See Note † 0 See Note †

19 Webbers Falls Spreader Beam WBF101 B 0 163

20 Webbers Falls Main Shaft Lifting Fixture Upstream WBF104 A 0 See Note †

21 Webbers Falls Main Shaft Lifting Fixture Downstream WBF103 A 0 See Note †

22 Denison Intake Power Gate Lifting Device DEN106 B 0 *

# BTH IDPower Plant Device Rated Load

(ton)

Marking & Labeling Category

Service Class

Three of the Webbers Falls items require special consideration for Analysis & Load Testing Configuration. One item requires special consideration for Marking and Labeling.

Specific guidance is included in Appendix C.

For devices with currently Unknown Rated Loads, the Engineering Analysis requirement shall Determine the Safe Working Load Limit. The results shall be submitted prior to Load Testing.

Load testing shall not commence without approval.

APPENDIX C: SUPPLEMENTAL INFORMATION FOR BTH DEVICES

FORT GIBSON

Fort Gibson Powerhouse 23191 Hwy 251A Ft. Gibson, OK 74434

The Fort Gibson Powerhouse has two (2) devices which are covered by this contract. The Lifting Trunnion for Generator Rotor (item No. 1 in

Appendix B) and the Turbine & Main Shaft Lifting Device (item No. 2 in

Appendix B) are shown in Figures A-1 and A-2, respectively.

The Lifting Trunnion for Generator Rotor shall be loaded axially or parallel to the longitudinal or vertical axis. The Load Test Weight shall be 125% of the known rated load of 100 tons.

The Main Shaft and Runner Lifting Device has a rotating link and secondary pin. It shall be fully assembled and shall be loaded axially or parallel to the longitudinal or vertical axis. The Load Test Weight shall be 125% of the known rated load of 51 tons.

A-1: Generator Rotor Lifting Device A-2: Turbine & Main Shaft Lifting Device

TENKILLER FERRY

Tenkiller Ferry Powerhouse 447273 East 984 Rd.

Gore, OK 74435

The Tenkiller Ferry Powerhouse has two (2) devices which are covered by this contract. The Rotor & Shaft Lifting Device (item No. 3 in Appendix

B) and the Runner Lifting Device (item No. 4 in Appendix B) are shown in Figures A-3 and A-4, respectively.

The Rotor & Shaft Lifting Device shall be loaded parallel to the longitudinal or vertical axis. The Load Test Weight shall be 125% of the known rated load of 76 tons.

The Runner Lifting Device has a rotating link and secondary pin. It shall be fully assembled and shall be loaded axially or parallel to the known rated load of 30 tons.

A-3: Rotor & Shaft Lifting Device A-4: Runner Lifting Device

EUFAULA

Eufaula Powerhouse 430720 Hwy 71 Porum, OK 74455

The Eufaula Powerhouse has two (2) devices which are covered by this contract. The Rotor & Shaft Lifting Device (item No. 5 in Appendix B) and the Runner Lifting Device (item No. 6 in Appendix B) are shown in

Figures A-5 and A-6, respectively.

The Rotor & Shaft Lifting Device shall be loaded axially or parallel to the longitudinal or vertical axis. The Load Test Weight shall be 125% of the known rated load of 135 tons.

The Turbine & Main Shaft Lifting Device shall be loaded axially or parallel to the longitudinal or vertical axis. The Load Test Weight shall be 125% of the known rated load of 77 tons.

A-5: Rotor & Shaft Lifting Device A-6: Turbine & Main Shaft Lifting Device

KEYSTONE

Keystone Powerhouse 23115 West Wekiwa Rd.

Sand Springs, OK 74063

The Keystone Powerhouse has seven (7) devices which are covered by this contract. Appendix B items No. 7 through No. 13 are shown in Figures

A-7 through A-12.

The Rotor Lifting Beam shall be loaded axially or parallel to the longitudinal or vertical axis. The Load Test Weight shall be 125% of the known rated load of 177 tons.

The Rotor Lifting Device…