Attachment 1 PWS and Appendices for Two-Ton Bridge Cranes.pdf

PERFORMANCE WORK STATEMENT (PWS)

PEARL HARBOR NAVAL SHIPYARD (PHNSY & IMF)

2-TON BRIDGE CRANES (4 EA)

1.0 BACKGROUND:

1.1 Pearl Harbor Naval Shipyard & Intermediate Maintenance Facility (PHNSY & IMF) requires four new bridge cranes in its periscope shop building 683. Two cranes (683-8 and 683-9) are located in the cleanroom, and two cranes (683-5 and 683-6) are in the high bay of the building. The building is located at Pearl Harbor Naval Base outside of the Controlled Industrial Area (CIA).

2.0 SCOPE AND OBJECTIVE:

2.1 The intent of this specification is to manufacture four 2-Ton, radio controlled, overhead electric traveling (OET) cranes, with removable backup pendent control. The two cranes in the high bay (683-15 and 683-16) shall be single girder top running cranes that will run on the existing 30# ASCE rails. The two cranes in the cleanroom (683-18 and 683-19) shall be double girder under running cranes that run on the existing Cleveland Tramrail. As much as practicable the four cranes shall be similar in design to simplify maintenance. The cranes shall work independently or in pairs to lift and rotate the submarine periscope.

2.2 The contractor shall provide the cranes as specified in this contract, deliver and install the new cranes, remove and dispose of the existing cranes, replace existing electrical power rails, and field test the cranes with shipyard inspectors present to validate the load test. The load test shall be at 125% of rated capacity. The shipyard will provide the test load.

Each crane’s capacity, span, and hook height shall be as follows:

Location Crane number Capacity Span (ft-in) Runway (ft) Hook Lift (ft-in) Bldg 683 high bay 683-15 4,000 lbs 28’-11” 128’ 20’-8” Bldg 683 high bay 683-16 4,000 lbs 28’-11” 128’ 20’-8” Bldg 683 cleanroom 683-18 4,000 lbs 27’-4” 107’ 6’-1” Bldg 683 cleanroom 683-19 4,000 lbs 27’-4” 107’ 6’-1”

2.3 Installation Plan: The contractor shall verify all crane envelope clearances and other building interference including those identified in Appendix A prior to the design of the crane.

Contractor is responsible for developing their installation plan and verifying their installation plan will work.

2.3.1 Lift of the cranes shall be considered a critical lift and shall comply with the requirements of Appendix E.

2.3.2 Rigging by choking or sweeping using synthetic products, is not allowed unless approved by the Shipyard. Tilting of lifted or suspended load during installation when it is necessary shall only be performed using a chain-fall, ratchet hoists or similar equipment, and only done in a controlled manner following shipyard approval.

2.3.3 The plan shall include as a minimum, lifting configurations, center of gravity of the lifted load, laydown area, overhead interference and mobile crane hook height requirements. The Shipyard must approve the Installation Plan prior to hanging the cranes.

2.4 Removal Plan: The contractor shall remove the four existing 2-ton bridge cranes. Cranes 683-5 and 683-6 are located in the high bay. Cranes 683-8 and 683-9 are located in the cleanroom. Contractor is responsible for removing, transporting and disposing the cranes at a recycling facility on the island.

2.4.1 Lifting and lowering of the crane shall be considered a critical lift and shall comply with the requirements of Appendix E.

2.4.2 The crane contains hazardous materials such as lead paint, asbestos containing wire insulation, and oil in the gear boxes. Proper control of hazardous materials is required per Appendix C.

2.4.3 The contractor shall develop a Removal Plan to lower the crane and transport and offload the crane at a recycling facility on the island.

2.4.4 Rigging by choking or sweeping using synthetic products, is not allowed unless approved by the Shipyard. Tilting of lifted or suspended load during installation when it is necessary shall only be performed using a chain-fall, ratchet hoists or similar equipment, and only done in a controlled manner following shipyard approval.

2.4.5 The plan shall include as a minimum, lifting configurations, center of gravity of the lifted load, laydown area, overhead interference and mobile crane hook height requirements. The Removal Plan must be approved by the Shipyard prior to removing the cranes.

2.5 Runway Electrification:

2.5.1 The contractor shall remove and replace the runway electrification system for each crane runway, including all necessary hardware to the crane from a wall or column mounted disconnect switch. Runway conductors shall be sized for two cranes being operated at one time.

2.6 Performance Requirements: The rated speeds (plus or minus 10%), in feet per minute for both cranes shall be as follows:

Location Function Capacity (lbs) Rated speed (fpm) *Minimum Speed (fpm) High bay Bridge 4,000 60/6 6 High bay Trolley 4,000 30/3 3 High bay Hoist 4,000 30/3 3

Cleanroom Bridge 4,000 60/6 6 Cleanroom Trolley 4,000 30/3 3 Cleanroom Hoist 4,000 15/1.5 1.5

* The minimum speeds shall not exceed the values listed above

2.7 Signs: Contractor shall install markings (paint or stickers) on the crane identifying crane number and capacity in pounds on the bridge girder and directional marking (North-South- East-West). Markings shall be on the bottom of the bridge girder where visible from operating positions. Trolley directions shall be North-South and bridge directions shall be East-West. All lettering shall be visible from the floor. Capacity of the crane in pounds shall also be marked on the hook block.

3.0 DESIGN REQUIREMENTS: The design of the cranes shall conform to applicable requirements of CMAA 74 class D service, 29 CFR 1910.179, 291910.306 paragraph (b), ASME B30.2, ANSI/MMA MH27.1, NAVCRANECENINST 11450.2A and other requirements specified herein. All portions of the crane design shall be performed by, or under direct supervision of a registered professional engineer (PE) competent in the particular engineering discipline. Drawings and calculations shall be stamped and signed by a PE. All design drawing, including parts list, shall be submitted to the shipyard for review and approval prior to construction.

3.1 The two cranes in the cleanroom shall be designed to operate at the same time on 460VAC, 3-phase, 60Hz, 40A max. The two cranes in the high bay shall be designed to operate at the same time on 230VAC, 3-phase, 60Hz, 90A max.

3.2 Each crane shall be designed to operate in the space, and match the runway dimensions and rails shown on the sketches in Appendix A. Contractor is responsible for verifying the dimensions in Appendix A and design the crane to properly operate within the space.

3.3 The hook working envelope shall be the maximum practical consistent with good design, but shall not be less than that indicated in Appendix A.

3.4 Each crane’s maximum wheel loads (without impact) due to dead load and the rated capacity live loads, with the trolley in any position, shall not cause greater shear or moment in the runway girders than that produced by the design wheel loads and spacing shown in Appendix A.

3.5 The contractor shall also verify all clearances and other building/crane interface, including those features shown in Appendix A. Minimum clearance shall meet CMAA 74 requirements.

3.6 The following paragraphs clarify which “should” or “recommended” requirements from NAVCRANECENINST 11450.2A and any additional specifications that are required in the crane design. (NAVCRANECENINST 11450.2A paragraph numbers are listed in parentheses.)

3.6.1 Hooks:

a. Hook material shall be forged carbon steel. (2-3.15(d))

3.6.2 Brakes:

a. Hoist motor shall have two holding brakes. A spring-set disc brake (e.g. Stearns) and a mechanical load brake. (2-4.2.1(b))

b. Each travel motor (trolley and bridge) shall have a spring-set disc brake (e.g.

Stearns).

c. Brakes shall not be self-adjusting for friction lining wear. (2-4.2.1(d), 2-4.2.1(k))

3.6.3 Electrical:

a. Spare conductors shall be identified as such. (2-5.1(d))

b. Wiring around sharp edges, such as panel doors, shall be wrapped in protective sleeves (e.g., “spiral wrap” to prevent wiring insulation damage from chafing, cutting, or abrasion. (2-5.1(f))

c. Bushings or chafing protection gear shall be used on all panel conduit entries.

(2-5.1(h))

d. Only equipment that needs to be accessed from the panel door (i.e. key switches) shall be mounted on the panel door. (2-5.1(i))

3.6.4 Motors:

a. Motors shall be Totally Enclosed Non Ventilated (TENV) or Totally Enclosed Fan Cooled (TEFC). (2-5.5(l))

3.6.5 Controls:

a. No neutral wire shall pass through the contacts of an AC powered control relay or contactor, i.e., a device shall not be shut off or disengaged by breaking the device’s neutral conductor. (2-5.6(e))

b. Each function shall be controlled by AC Open Loop Variable Frequency Drive (e.g. Magnetek G+ Mini).

1. A crane designed parameter range shall be provided. This crane designed parameter range shall be the applicable portion of the drive's default range for each parameter and shall be the range in which each parameter can be safely tuned by the end user. At a minimum, the ranges for acceleration, deceleration and min/max speed parameters shall be provided. All drives shall have the latest software/firmware installed. (2-5.6(k))

c. Slow speed functionality operated by a switch on the radio remote controller is required. Slow speed mode shall be set at 20 percent of the rated speed of each function. (2-5.6.1.2(e))

d. Control panel shall be equipped with the following key switches on front door.

1. Maintained brake release key switch for testing mechanical load brake independently. Brake release key switch shall be labeled BRAKE RELEASE.

Switch positions shall be labeled NORMAL and RELEASE. (2-4.2.2(m)2.)

2. Three-position spring-returned keyed bypass/reset switch. Bypass/reset key switch shall be labeled HOIST BYPASS. Switch positions shall be labeled PRIMARY BYPASS, NORMAL and SECONDARY RESET. (2-5.15(g))

3. Maintained keyed override shall be provided on each crane to disable the capacity overload protective device when performing a load test. Override switch shall be labeled OVERLOAD BYPASS. Switch positions shall be labeled NORAML and BYPASS.

4. Maintained remote/pendant selector switch to select between operating stations. Radio/pendant selector switch shall be labeled RADIO/PENDANT SELECTOR. Switch positions shall be labeled RADIO and PENDANT.

Radio/pendant selector switch is not required if connection of pendant disables remote control capability.

3.6.6 Contactors and Relays:

a. Except for the POWER OFF-POWER ON circuit, the control circuit shall not be energized without energization of the mainline contactor. (2-5.7(c))

b. A hoist line contactor, which shall be wired to remove power from all hoist motors and brakes shall be used on hoist controls. (2-5.7(d))

3.6.7 Limit Switches:

a. Primary upper and lower limit switches shall be geared type (traveling nut or rotary). (2-5.15(d))

b. Secondary upper limit switch shall be weighted (gravity) type.

3.6.8 Operator Control Stations:

a. Each operator station shall have a separate black POWER ON momentary pushbutton and a red mushroom head STOP/POWER OFF pushbutton.

(2-5.16(c))

3.6.9 Pendant Control:

a. Pendant shall be removable.

b. Pedant shall be made of non-conductive material (2-5.16.1(d))

c. Pendant shall have the following buttons.

1. Black START/POWER ON momentary pushbutton.

2. Red mushroom head STOP/POWER OFF maintained pushbutton.

3. Two-speed directional momentary pushbuttons (UP, DOWN, NORTH, SOUTH, EAST, WEST) (2-5.16.1(f))

3.6.10 Radio Controls:

a. For each crane pair, radio shall be able to operate either crane or both cranes in tandem.

b. Each crane pair shall have its own radio controller. In addition, a spare controller shall be provided for each crane pair (total of two controllers for each crane pair).

(2-5.16.4(f))

c. Each transmitter shall be portable weighing not more than eight pounds with batteries installed.

d. Each transmitter shall include:

1. ON-OFF maintained contact keyed switch for portable transmitter unit power.

2. START/POWER ON momentary pushbutton.

3. Red mushroom head STOP/POWER OFF maintained pushbutton.

4. Individual spring return joystick motion control levers for the hoist, trolley, and bridge (UP, DOWN, NORTH, SOUTH, EAST, WEST).

5. SPEED SELECT toggle switch. Switch positions shall be NORMAL and

SLOW SPEED

6. HORN momentary pushbutton. (2-5.17(g)

7. Crane selector switch to select between controlling either crane in pair or both cranes. Switch shall be labeled 683-15, 683-16, and BOTH (for high bay) and 683-18, 683-19, and BOTH (for clean room).

8. One or more LEDs indicating POWER ON, TRANSMITTING and LOW

BATTERY

e. Each radio remote control lever shall be in the OFF position before the associated crane function can begin.

f. The system frequency shall be within the unlicensed FCC Part 15 range. (2- 5.16.4(d))

g. The transmitter batteries shall be rechargeable type.

h. Battery assemblies shall be rechargeable. (2-5.16.4(h))

i. Not less than two sets of batteries shall be provided for each transmitter.

(2-5.16.4(i))

3.6.11 Operator Indicator Lights and Warning Devices:

a. Following lights shall be present. Lights shall be labeled as designated below.

1. A white POWER AVAILABLE light to indicate that power is available on the load side of the crane. (2-5.17(a))

2. A blue POWER ON light to indicate that the main contactor is energized.

(2-5.17(b))

3. A red FAULT light to indicate motor over-temperature. FAULT light shall also illuminate momentarily (2-3seconds) when crane is initially powered on.

(2-5.17(c))

4. A yellow/amber SLOW SPEED light to indicate crane is operating in slow speed mode. (2-5.17(e))

5. A green TANDEM light to indicate cranes are operating in tandem mode.

(2-5.17(f))

b. LED type lights shall be used for all indicator lights. (2-5.17(j)

c. Indicator lights shall be installed on the underside of cranes (mounted on bridge, control panel, separate panel, etc.) where they are visible from the operating position. (2-5.17(k))

3.6.12 Protective and Disconnecting Devices:

a. Each load side overcurrent device should be sized smaller than the line side overcurrent device that supplies it. (2-5.19(c))

3.6.13 Crane Disconnecting Means:

a. A disconnect switch shall be present on the crane. The disconnecting means should be a lever arm type switch located in a separate enclosure, such that when the disconnecting means is secured, there are no energized conductors in any control panels. (2-5.19.7(c))

3.6.14 Rigid Conductor Bar Systems:

a. Rigid conductor system shall be of the discreet rail type such that sections can be easily replaced if damaged. (2-5.20.1(b))

b. Rigid conductor bar systems shall be of the safety enclosed type for personnel safety.

c. The insulating cover for the ground conductor shall be green.

d. A guard shall be installed on the cleanroom cranes to prevent the hook block and wire rope from swinging into the conductors.

3.6.15 Festooned Conductor Systems:

a. Festooned conductor system shall be installed along the bridge.

3.6.16 Capacity Overload Protection:

a. Electro-mechanical capacity overload protection shall be used.

b. Capacity overload protection shall be set between 105 – 115% of crane capacity.

4.0 SUBMITTALS: The contractor shall submit to the contracting officer all items of technical documentation listed hereinafter. All developed drawing shall be provided in Autocad 2016 format;

all other submittals shall be provided in PDF format.

4.1 General Arrangement Drawings - The crane assembly and each major component shall be shown in plan, elevation, and end views to demonstrate proper interface with the facility building. All major features of the crane shall be shown including: clearances, lifts, spans, wheel spacing, speeds, hook approaches on both sides, maximum wheel loads, electrical power supply, and general locations of components such as: brakes, motors, speed reducers, and control panels (including size). The type of structural bolted connection shall be specified on the drawing. Torque value for structural bolts shall be indicated on the drawing.

Fastener installation torque values for base-mounted components shall be indicated on the drawing. In addition, estimated weights shall be shown for the completely assembled crane.

Approximate locations of center of gravity and location of lifting points for completely assembled crane and for each major component (girders, trolleys, and end trucks) shall be provided on the design drawings.

4.2 Structural Drawings - These drawings shall show the list of materials and fabrication details including all weldments, fastener joint details, location and size of all structural members:

4.2.1 Girder Fabrication

4.2.2 Bridge and Trolley End Truck Fabrication

4.2.3 Trolley Fabrication if applicable

4.3 Electrical Drawings - The drawings shall at a minimum include:

4.3.1 Complete schematic diagram with narrative of any special description of operation.

All components shown on schematics shall have labels that correspond to the nameplates that will be on the crane. Wiring type, size, and temperature ratings shall be included on schematic diagrams. All optional equipment not installed on the crane shall be removed from the schematic diagrams.

4.3.2 Motor nameplate data (including all information called for in NFPA 70, Section 430.7)

4.3.3 Rating and types of over-current protective devices.

4.3.4 Complete assembly (wiring) diagrams including a comprehensive component material list showing all electrical components used on the crane. These drawings shall show the layout of electrical equipment on the crane, including layout of control panel enclosures, motors, brakes, limit switches, conduits, and conductor systems.

4.3.5 Layout diagrams showing component placement in control panel enclosures.

4.4 Mechanical Drawings

4.4.1 Drive arrangements (including assembled components)

4.5 Product Data - Manufacturer’s catalog data shall be provided for all major components of the crane. The catalog cuts shall be marked-up or supplemented with additional sheets to clearly identify the model or size, selected options, features, and/or modifications to demonstrate compliance with specification requirements. Catalog cuts which show modifications beyond the standard options and all supplemental pages shall bear original signatures and dates of the equipment manufacturer’s authorized representative. Each catalog cut and each supplemental sheet shall clearly identify the item to which it applies. All catalog cuts shall be submitted in one file viewable in Adobe Acrobat and bookmarked as to the location of each catalog cut. In accordance with Exhibit A, the contractor shall submit for approval the catalog cuts listed below:

4.5.1 Speed Reducers including gear ratio

4.5.2 Brakes (including electrical information)

4.5.3 Hoist (if packaged)

4.5.4 Bearings and Bearing Housings

4.5.5 Couplings

4.5.6 Load Blocks

4.5.7 Bumpers

4.6 Structural Calculations

4.6.1 Calculations verifying load cases in accordance with Section 3 of CMAA #74 for any noncommercial items.

4.6.2 Calculations verifying girder design in accordance with Section 3 of CMAA #74 any non-commercial items.

4.6.3 Calculations verifying bridge and trolley end truck design in accordance with Section 3 of CMAA #74 for any noncommercial items.

4.6.4 Calculations verifying trolley design in accordance with Section 3 of CMAA #74 for any non-commercial items

4.6.5 Calculations verifying design of bridge rail stops and all bumpers in accordance with

AIST TR-06.

4.7 Mechanical Calculations

4.7.1 Calculations verifying compliance with Section 4 of CMAA #74 for any noncommercial items

4.7.2 Calculations verifying brake selections for non-packaged hoists

4.7.3 Calculations verifying coupling selections for non-packaged hoists

4.8 Electrical Calculations

4.8.1 Minimum required horsepower for each drive motor - Motor power ratings shall be based upon the formulae given in CMAA #74. For hoist motor sizing calculations, the factor "Kc" shall not be less than 1.0. For the bridge drive the minimum acceleration time to rated speed shall be 4 seconds. For the trolley drive the minimum acceleration time to rated speed shall be 3 seconds. Calculations are not required for packaged hoists, but packaged hoists shall still meet acceleration and deceleration requirements.

4.8.2 Overcurrent protection

4.8.3 Conduit fill calculations (using tables from NFPA 70, Chapter 9 or manufacturer’s data sheets)

4.8.4 Protective device coordination study showing proper coordination for any overcurrent devices that have the same rating as another overcurrent device upstream

4.9 Test Reports

4.9.1 Hook and Nut Non-Destructive Test (NDT) Report

4.9.2 The contractor shall provide a certification that the NDT vendor meets the requirements of ASTM E543.

4.9.3 The contractor shall submit for review the NDT vendor’s procedures, including technique sheets specific to the types, shapes, and size of the parts being examined (e.g., shank hook, eye hook, duplex hook, eye bar, nut). For the magnetic particle method, the procedures shall adequately describe the orientation of the hooks, nuts, or pins with the magnetizing equipment. Procedures must be reviewed and bear the signature of an SNT-TC-1A qualified Level III examiner stating they are independent of the vendor.

4.9.4 Prior to performing any operational testing of the crane, the hook and hook nut shall be inspected by the magnetic particle method over their entire surface area in accordance with NAVSEA Technical Publication T9074-AS-GIB-010/271. ASTM A 275 may be used with the following restrictions: DC yokes (including switchable AC/DC yokes used in the DC mode) and permanent magnet yokes shall not be used;

automatic powder blowers or any other form of forced air other than from a handheld bulb shall not be used for the application or removal of dry magnetic particles; arc strikes shall be removed; and equipment ammeters shall have an accuracy of +/- 5 percent of full scale (equipment ammeter accuracy other than that stated is acceptable provided the magnetic particle method procedure states that a magnetic field indicator is used to establish and verify adequate field strength for all aspects of the inspection). If NDT cannot be performed on surfaces inside holes, those surfaces shall be visually inspected to the maximum extent practical. Acceptance criterion shall be no linear indications greater than 1/16 inch. The NDT report shall be provided to the Government and shall be traceable to the unique ID number of the hook and nut.

4.10 Certificates - All certifications shall be dated and shall bear the original signature (above the printed name) of the authorized representative of the contractor or the manufacturer of the items or equipment being certified. Each certification shall clearly identify the crane, the drives, components, and location (as applicable) to which it applies:

4.10.1 Wire Rope- The contractor shall provide the wire rope manufacturer’s certification that the rope meets the published breaking strength of samples taken from reels and tested. Certification shall be traceable to the hoist, crane and reel.

4.10.2 Periodic Overload Testing - The contractor shall certify that the crane is capable of being load tested semi-annually up to 125% of the rated capacity without any detrimental effects.

4.11 Hazardous Material

4.11.1 The contractor shall certify that the crane contains no asbestos, lead paint, Polychlorinated Biphenyl’s (PCB’s), or elemental mercury. Chromates should be avoided where feasible.

4.12 Loss of Power Test

4.12.1 The contractor shall certify that the hoist loss of power test as identified in Appendix F can be performed without any detrimental effects to the electronic control system.

4.13 Coupling Alignments

4.13.1 Contractor shall submit coupling alignment data records with certification that the alignment of all shafting connected by means of flexible couplings are within manufacturer's installation tolerances. The data records shall be taken after the coupling's final installation and after installation of shear bars and dowel pins in all base-mounted components which can be found on the NCC website at:

https://www.navfac.navy.mil/navfac_worldwide/specialty_centers/ncc/about_us/resou rces/downloads.html

4.14 Hook and Hook Nut Proof Test

4.14.1 Contractor shall submit certification that the hook and hook nut have been proof tested and satisfies the acceptance criteria of ANSI B30.10.

4.15 Welding Certifications

4.15.1 The contractor shall provide a certificate stating that all welders, welding operators, weld inspector(s) and welding procedure (qualification) meet the requirements of AWS D 14.1 for all work performed in manufacturing this crane. The contractor shall provide a certificate stating that all welders, welding operators, weld inspector(s), and welding procedure (qualification) meet the requirements of AWS D 1.1 for all work performed in installing/welding parts supporting the crane at/to building interfaces.

4.16 Design Review by Professional Engineer

4.16.1 The contractor shall provide a certificate stating that the initial design has been reviewed by a professional engineer. The certificate shall indicate the name, state of licensure and license number of the professional engineer.

4.17 Field Test Procedure

4.17.1 The contractor shall develop and submit a field test procedure that will demonstrate operation, performance, and safety of the crane. The test procedure shall be submitted and approved prior to conducting the field test. As a minimum, the test procedure shall conform to those requirements specified in Appendix F of this specification.

4.18 Accident Prevention Plan (APP)

4.18.1 The APP shall be prepared in accordance with Appendix B (Safety), and Exhibit A and B and shall be submitted for review and comment by the Contracting Officer.

4.19 Brake Adjustment Records

4.19.1 The contractor shall provide a brake adjustment record for each brake on the crane.

The brake adjustment records shall be submitted on the official form, which can be found on the NCC website at:

https://www.navfac.navy.mil/navfac_worldwide/specialty_centers/ncc/about_u s/resources/downloads.html.

4.20 Field Test Record

4.20.1 The contractor shall follow the test procedure found in Appendix F that will demonstrate satisfactory operation, capacity, and safety of the crane. Any deviations to the field test required by the crane contractor must be approved by the Government. Upon successful completion of all testing, the contractor shall submit records of all test data.

4.21 Operation and Maintenance Data

4.21.1 The contractor shall submit the crane’s operation and maintenance manual to the Government for review. The operation and maintenance manuals shall include a table of contents for operation instruction, preventive maintenance, parts information, drawing list, supply list, catalog cuts, photographs, and calculations. The body of the technical manuals shall include the following: contractor’s detailed written procedures, operation instructions, preventive maintenance information, drawings, parts information, supplies needed, catalog cuts, photographs, and calculations.

Maintenance information shall include recommended maintenance procedures and manufacturer’s installation and maintenance manuals (for purchased components) and lubrication instructions. Operation information shall include detailed crane operating and safety instructions. Parts information shall include all information on all contractor-designed parts, all purchased sub-assemblies and components including the manufacturer’s part number. The information shall be broken-out to the smallest replacement part. Within these sections the following information shall also be included:

a. Maintenance and programming instructions for the drives.

b. Maintenance instructions including maintenance, alignment, adjustment, and calibration instructions for commercial components and parts lists.

c. Operating instructions and special precautions for starting/stopping, operation, and safety.

d. Preventive maintenance instructions including location of lubrication points, type of lubricant to be used, and the frequency of lubrication, which shall agree with the lubrication drawing provided.

e. Recommended spare parts list.

f. A complete listing of all control system parameters with an explanation of their functions.

4.22 Control System Parameter Record

4.22.1 After the crane has passed the final field test, the contractor shall complete a control system parameter record for the crane and provide the crane parameter file downloaded from the crane at time of acceptance, if applicable. The record shall include the contract number, contractor’s name and address, date, all control system parameters and their final settings. Each control system parameter shall be designated as either used or unused.

4.23 List of Parameters and Crane OEM's Approved Crane Range

4.23.1 After the crane has passed the final field test, the contractor shall submit Appendix F for each electronic drive to document the crane designed parameter ranges in which each parameter can be safely tuned by the end user for each parameter specified in Appendix F used on the crane. The crane contractor determined design range shall be the applicable portion of the drive’s default range for each parameter. The crane contractor must provide justification for each range of each parameter on the list.

When necessary, the justification shall include appropriate calculations.

5.0 PERFORMANCE REQUIREMENTS:

5.1 The Contractor shall provide all labor, supervision, tools, design, transportation and machinery to assemble and install/remove the cranes. A post award meeting shall be performed with the shipyard after the contract has been awarded. The post award meeting shall be completed within 30 days after contract award.

5.2 PERIOD OF PERFORMANCE: The crane fabrication, delivery, installation and testing shall be completed within 12 months after award of the contract. The project shall begin with a post award meeting no later than 30 days after the contract award date. To minimize disruption to the Periscope Fabrication Shop, installation of the crane shall be coordinated with the shipyard. Installation/removal of the cranes in building 683 shall take less than 6 weeks.

Testing of the canes shall take less than 2 weeks.

5.3 WORKMANSHIP & TESTING: After the Contractor has installed and powered the crane, the Shipyard will inspect the crane prior to testing the crane to verify compliance with OEM instructions, this contract requirements and good workmanship practice. Contractor will notify the government 3 days prior to all inspections; the government inspection will take a half day per crane. After the Shipyard has inspected the crane, crane testing will be performed per Appendix F. The Shipyard shall witness the testing.

5.4 SAFETY: The Contractor shall comply with Original Equipment Manufacturer (OEM) requirements and all applicable Federal and State of Hawaii Occupational Safety and Health Administration (OSHA) requirements. Contractor must comply with the Shipyard safety requirements in Appendix B.

5.5 WARRANTY: The contractor shall warranty the cranes for parts and labor for a period of one year after successful completion of the load test.

5.6 SERVICE DELIVERY SUMMARY TABLE A

Performance Element Paragraph No. Note Performance threshold

2-Ton bridge crane, (2) each for the cleanroom Paragraph 2.0 100% delivery and compliance.

2-Ton bridge crane (2) each, for the high bay Paragraph 2.0 100% delivery and compliance.

Crane Installation Plan Paragraph 2.3 100% delivery and compliance.

Crane Removal Plan Paragraph 2.4 100% delivery and compliance.

Remove and Install New Runway Electrification Paragraph 2.5 100% delivery and compliance.

Signs Paragraph 2.7 100% delivery and compliance.

Controls Paragraph 3.6.5 100% delivery and compliance.

Pendant Controls (4) each Paragraph 3.6.8 100% delivery and compliance.

Radio Remotes (6 ea) Batteries (12 ea) Paragraph 3.6.9 100% delivery and compliance.

Drawings, general arrangement, structural, mechanical and electrical Paragraph 4.1 to 4.4 100% delivery and compliance.

Product Data Paragraph 4.5 100% delivery and compliance.

Calculation Paragraph 4.6 to 4.8 100% delivery and

Test Reports Paragraph 4.9 100% delivery and compliance.

Certificates Paragraph 4.10 100% delivery and compliance.

Hazardous Material Paragraph 4.11 100% delivery and compliance.

Loss of Power Paragraph 4.12 100% delivery and compliance.

Coupling Alignment Records Paragraph 4.13 100% delivery and compliance.

Hook / Nut Proof Test Paragraph 4.14 100% delivery and compliance.

Welding Certification Paragraph 4.15 100% delivery and compliance.

PE Review Paragraph 4.16 100% delivery and compliance.

Field Test Procedure Paragraph 4.17 100% delivery and compliance.

Accident Prevention Plan Paragraph 4.18 100% delivery and compliance.

Brake Adjustment Record Paragraph 4.19 100% delivery and compliance.

Completed Field Test Records Paragraph 4.20 100% delivery and compliance.

Operation & Maintenance Data Paragraph 4.21 100% delivery and compliance.

Control Parameter Records Paragraph 4.22 100% delivery and compliance.

OEM Approved Range Paragraph 4.23 100% delivery and

6.0 QUALITY ASSURANCE:

6.1 The Contractor is responsible for implementing and maintaining a Quality Control Program (QCP) to ensure that the work performed meets or exceeds contract requirements and results in the correction of potential and actual problems. The QCP shall be implemented on the first day of contract performance.

7.0 GOVERNMENT FURNISHED UTILITIES AND SERVICE:

7.1 Utilities: If available the use of electrical wall outlets is allowed. Any damage that results from exceeding the rated circuit capacity shall be borne by the Contractor.

7.2 Test Weights: The Government will provide test weight when required.

8.0 CONTRACTOR QUALIFICATIONS/REQUIREMENTS:

8.1 The contractor shall have a minimum of 5 years of experience designing, removing and installing cranes for Navy Crane Center.

8.2 Portable Electronic Devices (PEDs): PEDs include pagers, mobile/cellular telephones (with/without cameras), personal digital assistant/job performance aids, laptop/notebook/handheld computers, digital imagery (still/video) devices, analog/digital sound recorders (e.g. I-PODs), video game devices, USB devices and devices of similar capability, functionality or design. The Contractor shall strictly comply with PHNSY & IMF procedures and policies concerning the use and possession of PEDs while working on PHNSY&IMF property.

8.3 ENTERPRISE-WIDE CONTRACTOR MANPOWER REPORTING APPLICATION: N/A

9.0 SECURITY REQUIREMENTS:

9.1 The contractor/instructor shall pass a background check to gain access onto the base. The contractor will coordinate with PHNSY & IMF to obtain a gate pass at building 3455 Pass Office. It is not unusual for the pass process to take an hour or more. Contractor/instructor must be a U.S. Citizen and must pass a security background check. Only those individuals with favorable investigations shall be utilized on this contract. Prior to the start of work, the Contractor shall provide the COR (on company letterhead) a request for access and include the following information – full name of all personnel working on this contract; Social Security number; date of birth, place of birth, and citizenship. The contractor shall state that information has been verified and shall have supporting records on file, if required for examination. Contractor’s employees must be a U.S. Citizen and registered with the Defense Biometric Identification System. See APPENDIX D for additional security requirements.

9.2 Contractor personnel must meet the requirements for unescorted entry, green badge, to PHNSY&IMF areas. Escorted access to CNIAs and NWAs must be coordinated with the cognizant Department Security Coordinator to ensure that the area is sanitized and the escort is properly briefed/knowledgeable of the area. The Contractor shall follow the applicable requirements listed below in 9.0 ATTACHMENTS and brief their personnel to ensure compliance. Non-compliance with applicable items in Attachments is a material violation of the contract. Should Contractor personnel receive or suspect they have learned unauthorized sensitive information, they shall identify and immediately report suspicions to the TPOC.

10.0 CONTRACTOR PERSONNEL:

10.1 The Contractor shall furnish sufficient personnel to perform all work specified within this performance work statement. Contractor is required to comply with Public Law 105-270, Section 5(2)(A). This law states that contractors will not perform inherently governmental functions. Section 5(2)(A) of this Public Law defines the term “inherently governmental function” as “a function that is so intimately related to the public interest as to require performance by Federal Government employees.” Per Section 5(2)(B), inherently governmental functions include management of Government programs requiring value judgments, conduct of foreign relations, selection of program priorities, and the direction of intelligence and counter-intelligence operations. Per Section 5(2)(C), inherent governmental functions DO NOT include, (i) gathering information for or providing advice, opinions, recommendations, or ideas to Federal Government officials; or (ii) any function that is primarily ministerial and internal in nature.”

10.2 Contractor personnel shall not establish an employee-employer relationship with Government personnel under this contract.

10.3 Contractor shall not provide personal services.

10.4 Contractor personnel will make clear to all individuals they engage with that they are Contractor employees and not Government employees. When participating and introducing themselves during official events wherein Government, non-Government, or foreign personnel are present, Contractor personnel will identify themselves as employees of the Contractor. Contractor personnel must be clearly identified (i.e. company shirt, pin, visible company ID, etc.) in a visible location as to who their employer is.

10.5 Contractor personnel shall not manage, supervise, or task Government employees or military personnel. Contractor personnel may not make any commitment to non-Government personnel, including a foreign official, which commits the expenditure of U.S. Government resources.

10.6 Normal business hours of operation are 6:30 a.m. through 3:00 p.m. with a 30-minute lunch break, Monday through Friday, excluding Federal Holidays. The contractor may request working outside the regular hours but approval is not guaranteed.

10.6.1 If a holiday falls on a Saturday, the holiday is observed on the preceding Friday. If a holiday falls on a Sunday, the holiday is observed on the following Monday.

10.6.2 Federal Holidays:

New Year’s Day 1st of January Dr. Martin Luther King’s Birthday 3rd Monday in January President’s Day 3rd Monday in February Memorial Day 4th or 5th Monday in May Independence Day 4th of July Labor Day 1st Monday in September Columbus Day 2nd Monday in October Veteran’s Day 11th of November Thanksgiving Day 4th Thursday in November Christmas Day 25th of December

11.0 ATTACHMENTS:

APPENDIX A – BUILDING 683 SPACE ENVELOPE AND PHOTOS

APPENDIX B – SAFETY AND HEALTH WORK PRACTICES FOR CONTRACTORS WORKING

WITH PEARL HARBOR NAVAL SHIPYARD AND INTERMEDIATE

MAINTENANCE FACILITY (PHNSY & IMF)

APPENDIX C – CONTRACTOR ENVIRONMENTAL SPECIFICATION GUIDELINES

APPENDIX D – SECURITY REQUIREMENTS APPLICABLE FOR PEARL HARBOR NAVAL

SHIPYARD & IMF’S CONTROLLED INDUSTRIAL AREA, OTHER SENSITIVE

AREAS, CONTROLLED NUCLEAR INFORMATION AREAS, AND/OR NUCLEAR

WORK AREAS

APPENDIX E – CRANE CONTRACTORS ON BASE

APPENDIX F – SAMPLE FIELD TEST PROCEDURE

APPENDIX A

APPENDIX B

SAFETY AND HEALTH WORK PRACTICES

FOR CONTRACTORS

WORKING WITH PEARL HARBOR NAVAL SHIPYARD

AND INTERMEDIATE MAINTENANCE FACILITY (PHNSY & IMF)

Ref: (a) 29 CFR 1915, OSH Standards for Shipyard Employment

(b) 29 CFR 1910, OSH Standards for General Industry

(c) NAVSHIPYARDPEARL INST 11320.5, Shipyard Fire Regulations

(d) NAVSEA Technical Publication S0570-AC-CCM-010/8010, Industrial Ship Safety Manual for Fire Prevention and Response (8010 Manual)

Attachment: (1) Contractor Safety & Mishap Prevention Form

1. Purpose/Scope

a. Worker safety is the Navy’s first priority. Ships undergo a variety of availabilities, all of which involve considerable repair, maintenance or refit work. This heavy industrial work is beyond the scope of normal shipboard operations and presents unique hazards. Safety and occupational health precautions and standards apply to all workers, military and civilian, but may differ slightly depending on the employer.

(1) Contractors working on Navy ships follow Federal Occupational Safety and Health Administration (OSHA) standards including references (a) and (b) above, which are invoked by the Naval Sea Systems Command (NAVSEA) Standard Items. These Standard Items may invoke specific, unique requirements, such as daily fire safety and housekeeping inspections.

(2) Navy safety standards are based on OSHA regulations, and promulgated via the Navy Occupational Safety and Health (NAVOSH) Program Manual, OPNAVINST 5100.23 series. Pearl Harbor Naval Shipyard and Intermediate Maintenance Facility (PHNSY&IMF) civilian and military employees are also required to comply with local safety and health requirements.

(3) Ship's Force personnel follow safety standards contained in OPNAVINST 5100.19, NAVOSH Program Manual for Forces Afloat.

While the NAVSEA Standard Items, NAVOSH Program Manual and local Occupational Safety and Health (OSH) instruction differ slightly in application, they all comply with Department of Labor OSHA standards, references (a) and (b). Compliance with occupational safety and health standards, instructions and/or rules is an employer responsibility. Employers retain all legal obligations and liabilities for the safety and health of their employees.

b. The purpose of this Memorandum of Agreement (MOA) is to establish safety and health requirements for all project maintenance activities, ensure that contractor personnel comply with applicable safety and health requirements, and partner with PHNSY&IMF to ensure safe project sites throughout the availabilities.

c. PHNSY&IMF is recognized as a STAR site under OSHA's Voluntary Protection Programs (VPP).

The contractor shall commit to operating an effective occupational safety and health management system that embraces the four basic elements of OSHA’s VPP in support of this effort. These four elements include:

(1) Management Leadership & Employee Involvement. Top management must be visible.

They must be “on the deck plates” on a regular basis discussing safety issues, demonstrating interest and dedication to safety and health performance, and encouraging dialogue with employees.

(2) Work Site Analysis. New or modified equipment processes, and materials are analyzed and evaluated. Self-inspections of all work sites are performed, hazards related to individual jobs and processes are analyzed and related safety and health training is provided.

(3) Hazard Prevention and Control. Identified hazards must be eliminated or controlled in a timely manner. A hierarchy of controls must exist, beginning with engineering out or eliminating hazards; and extends to enclosing, barricading, or isolating the hazards;

developing administrative procedures and controls; and finally to use of personal protective equipment (PPE).

(4) Safety and Health Training. Training must foster a positive atmosphere that instills the belief that safety is a team effort and includes everyone from top managers to line workers. Employee training should incorporate awareness of hazards, safe work procedures, and emergency situations.

d. PHNSY&IMF OSHE Office Points of Contact

2. General

a. The contractor shall ensure that their employees and sub-contractors comply with all applicable Federal and State OSH standards and regulations and/or specific Navy OSH requirements (e.g., NAVSEA Standard Items). The contractor shall submit a “safety and accident prevention plan” to PHNSY&IMF Occupational Safety, Health, and Environment Office (Code 106), for concurrence prior to start of work that addresses hazards inherent to the work planned, with appropriate controls described for those standards. The written plan shall include, but is not limited to:

(1) Work involving hazardous constituents (e.g., lead or chromate containing paint, asbestos, silica) that requires specific health controls and/or air monitoring. The contractor and sub-contractors are responsible to contract for their own industrial hygiene support as required.

(2) Hot work operations conducted on-board ship and in-and-around the dry dock basin. The contractor shall identify the type of hot work being performed, means of fire prevention and control, firefighting equipment and capabilities, and emergency actions and procedures in the event of a fire. The contractor shall conduct housekeeping and fire prevention inspections required by NAVSEA Standard Items; ensure good housekeeping, and store materials and equipment in an orderly manner.

(3) The contractor shall provide the name, phone number, and pager number of the individual(s) responsible for the contractor’s OSH regulatory compliance oversight.

Office Title Code Office Number Cellular OSHE Office 106 (808) 473-8000, ext. 4459 (808) 368-0106 Safety & Health Division 106.1 (808) 473-8000, ext. 2876 (808) 330-4074 Health Branch 106.11 (808) 473-8000, ext. 5831 (808) 754-9912 Safety Branch 106.12 (808) 473-8000, ext. 4448 (808) 368-0572 Waterfront Branch 106.13 (808) 473-8000, ext. 4437 (808) 347-3197

b. The contractor shall notify the project manager and PHNSY&IMF OSH Office of injuries and occupational illnesses occurring on the project as soon as possible. If a serious injury/illness or electrical shock occurs, the Contractor shall notify the Regional Dispatch Center (RDC) by dialing 911 on any Shipyard phone or 474-1271. Copies of the completed mishap report shall be provided to PHNSY&IMF Code 106.13. Notify the project manager and Code 106.13 of planned mishap critiques. Provide copies of the completed critique reports to the OSH Office.

(1) The contractor shall provide total hours worked to PHNSY&IMF OSH Office on a monthly basis. Contractors who hire subcontractors shall provide the subcontractor’s total hours worked as well (per OSHA Directive CSP 03-01-002-TED 8.4 VPP: Policies and Procedures Manual).

(2) The contractor shall provide Total Case Incident Rate (TCIR) and Days Away, Restricted, or Transferred (DART) rate data to PHNSY&IMF OSH Office (per OSHA Directive CSP 03-

01-002-TED 8.4).

(3) The contractor shall provide PHNSY&IMF Code 106.12 with a copy of their OSHA 300 Log annually (only injuries or occupational illnesses related to contract work) not later than 15 January of each year.

c. Maintain work areas in the highest reasonable state of cleanliness consistent with the work. As a minimum, trash, industrial waste and mechanical or grinding debris will be removed at least daily.

If mechanical or grinding debris contains lead/chromate-containing paint debris, additional packing/labeling requirements and environmental disposal requirements may apply.

d. The Project Superintendent of contractor work shall oversee work that may impact the health or safety of PHNSY&IMF personnel. This includes work with or on hazardous materials or for work requiring boundaries and/or containments. Boundaries or containments shall have prominent signage indicating hazards and PPE required entering the area. Work shall be coordinated with the Project Superintendent to ensure PHNSY&IMF personnel are adequately protected and/or removed from the immediate work area as required. PHNSY&IMF may elect to have workplace monitoring conducted around the perimeters of work requiring boundaries and/or containments, in the interest of the Navy and to ensure adequate protection for PHNSY&IMF employees. Such monitoring will not replace any industrial hygiene sampling the contractor is required to perform according to the contract, nor will Navy monitoring results be used to determine potential exposures to contractor personnel.

e. The contractor shall ensure that work performed by their employees does not create safety or health hazards for PHNSY&IMF personnel.

f. The contractor shall ensure that their employees comply with posted PPE requirements (e.g., safety glasses with side shields, hard hats, safety shoes, hearing protection. etc.) while going to, working on, and leaving the ship.

(1) Safety glasses with side shields shall be worn when personnel are conducting eye hazardous operations and when in or passing through an eye hazardous area. This includes:

(a) All portions of submarines, surface craft, and other vessels undergoing modification, alteration, repair, or overhaul.

(b) Dry docks (topside and basins) where submarines, surface craft, and other vessels are undergoing modification, alteration, repair, or overhaul. Topside includes the area around the dry dock between the chain guardrails and the outer portal crane track.

(c) Portions of lay down areas around dry docks and along piers, shops, and buildings throughout PHNSY&IMF where eye hazardous operations are conducted.

(2) Hard hats shall be worn in designated areas, in situations where injuries can be prevented by wearing hard hats, and where signs indicate the use of hard hats, pier areas where surface craft, submarines, and other vessels are undergoing repair availability. Hard hats shall be worn when going onboard the ship and while working on the exterior of the vessel as well as in the dry dock basin and topside around the dry dock. Topside includes the area around the dry dock between chain guardrails and the outer portal crane track. Hard hats shall be worn when working under the hull of the ship and when working under Herculite and other plastic (shrink wrap, polyethylene, etc.)

covered staging structures.

g. The contractor shall ensure their employees and sub-contractors understand the PHNSY&IMF Fire Safety Plan,…