Attachment 1_Statement of Work.pdf

STATEMENT OF WORK

Bridge Crane Systems for Anniston Army Depot

1.0 Scope. This specification establishes the requirement for 2 separate bridge crane systems for Directorate of Public Works, to be provided to Anniston Army Depot (ANAD), Anniston, Alabama. One dual bridge 5 ton, each, bridge crane system shall be installed in Building (bldg.) 453 and one single bridge 1 ton bridge crane system shall be installed in bldg. 5.

The Bridge crane systems shall be designed and fabricated by the Contractor with all functionality, capabilities and features as described herein. The Contractor shall provide all resources necessary to design, manufacture, deliver, and demonstrate functional operation of the Bridge crane systems.

2.0 References. The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

Occupational Safety and Health Administration (OSHA)

OSHA 1910.179 Overhead and gantry cranes

American Society of Mechanical Engineers (ASME)

ASME B30.2

2.1 Order of Precedence. In the event of a conflict between the text of this statement of work and the references cited herein, the more stringent regulation or specification shall take precedence, unless a specific exception to this, order of precedence, is noted in this Statement of Work. Nothing in this statement of work, however, supersedes applicable laws and regulations unless a specific exemption has been obtained by the Government.

3.0 Requirements for Dual Bridge 5 Ton Crane System in bldg. 453. The following requirements are for one bridge crane system with two 5 ton bridges and electrical hoists.

3.0.1 The bldg. 453 crane shall be equipped with two top running crane bridges rated at 5 tons capacity for each bridge.

3.0.2 The bldg. 453 crane shall be electrically powered at 480 volt 3 phase 60 hertz power for hoists and motors

3.0.3 The bldg. 453 crane shall have approximately 43 foot span and must be minimum of 180 foot long runway. Overall height should be approximately 20 feet. Crane structure and runway shall be rated for 10 tons.

3.0.4 The bldg. 453 crane shall be freestanding on existing 8 inch reinforced concrete slab floor.

3.0.5 Each bridge shall be equipped with wireless remotes systems with Light Emitting diode (LED) warning lights and horns and must furnish a separate remote for each bridge.

3.0.6 The bldg. 453 crane shall be equipped with 6 function travel for bridge travel forward and reverse on the runway and hoist functions left, right, up and down. All crane functions shall be 2 speed. There shall be as a minimum two lift speeds with high being 25 feet as a minimum (ft/min) (plus 1.5, minus 1.5 ft/min); and the second speed being variable frequency drive (VFD) controlled. (Electromotive G+)

3.0.7 The contractor shall be responsible for conducting function and load tests of all bridge crane systems prior to acceptance of the completed installation of the depot Contracting Officer Representative (COR).

3.0.8 Contractor shall be responsible for installing all electrical connections from the crane to a disconnect that will be supplied by ANAD. Contractor shall recommend exact location where disconnect should be installed.

3.0.9 The bldg. 453 crane shall come equipped with pendant controls and remote pendant controls.

4.0 Requirements for Single Bridge 1 Ton Crane System bldg. 5. The following requirements are for the removal of one existing ½ ton crane and installing one bridge crane system equipped with one 1 ton underrunning bridge in bldg. 5.

4.0.1 The existing crane hoist shall be removed by the contractor. ANAD property book personnel will be responsible for disposition of the hoist. The remaining crane structure shall be placed in the appropriate scrap dumpster identified by ANAD shop personnel in bldg. 5.

4.0.2 The bldg. 5 crane shall be equipped with one 1 ton capacity on structure, bridge, and hoist.

4.0.3 The bldg. 5 crane shall be electrically powered 208 volt 3 phase 60 hertz power.

4.0.4 The bldg. 5 crane shall have approximately 12 foot bridge span and 118 foot long runway.

4.0.5 The bldg. 5 crane shall be rated freestanding on existing 6 inch concrete pad.

4.0.6 The bldg. 5 crane shall be equipped with 6 function travel for bridge travel forward and reverse on the runway and hoist functions left, right, up and down. All crane functions shall be 2 speed. There shall be as a minimum two lift speeds with high being 25 ft/min as a minimum (plus 1.5, minus 1.5 ft/min); and the second speed being variable frequency drive (VFD) controlled. (Electromotive G+)

4.0.7 The contractor shall be responsible for conducting function and load tests of all bridge crane systems prior to acceptance of the completed installation of the depot Contracting Officer Representative (COR).

4.0.8 The contractor shall be responsible for installing all electrical connections from the crane to a disconnect that will be supplied by ANAD. Contractor shall recommend exact location where disconnect should be installed.

4.0.9 The bldg. 5 crane shall come equipped with pendant controls and remote pendant controls.

5.0 GENERAL SPECIFICATIONS FOR BOTH CRANES:

5.1 Standard Products: Materials and equipment shall be standard products of manufacturers regularly engaged in the fabrication of cranes. All crane components shall be painted yellow. Crane system shall be independent free standing and shall not be attached to existing building structure.

5.2 Nameplates: Each major component of equipment shall have the manufacturer's name, address, type or style, or catalog number, and serial number on a plate secured to the equipment. The lifting capacity shall be clearly indicated on both sides of the bridge girders.

5.3 Verification of Dimensions: The contractor shall coordinate the design and layout with the crane manufacturer to provide a bridge crane system (including runway and support structure) that maximizes headroom under the runway beams. The contractor shall verify all dimensions and necessary work to be performed in the field. If there are any discrepancies, the contractor shall advise the Contracting Officer before performing any work.

6.0 SUBMITTALS FOR BOTH CRANE SYSTEMS:

6.1 Shop Drawings: Four Copies of printed and one electronic copy of detail drawings shall be submitted and shall consist of a complete list of equipment and materials, including manufacturer's descriptive and technical literature, performance charts and curves, catalog cuts, and installation instructions. Detail drawings shall also contain complete wiring and schematic diagrams; and any other details required to demonstrate that the system has been coordinated and will properly function as a unit. Drawings shall show proposed layout and anchorage of equipment and appurtenances, and equipment relationships to other parts of the work including clearances for maintenance and operation. All technical data shall be furnished in English language

6.2 Operation and Maintenance Manuals: Four copies of printed and one electronic copy of operation and maintenance manuals shall be furnished for each bridge crane system.

Operation manuals shall detail the step-by-step procedures required for the system start-up, operation, and shutdown. Operation manuals shall include the manufacturer's name, model number, parts list, and brief description of all equipment and their basic operating features.

Maintenance manuals shall list routine maintenance procedures, possible breakdowns and repairs, and troubleshooting guides. Maintenance manuals shall include piping and equipment layout and simplified wiring and control diagrams of the system as installed. All technical data shall be furnished in English language

6.3 Spare Parts Data: The contractor shall furnish four copies of printed and one electronic copy of spare parts data for each different item of material and equipment specified.

The data shall include a complete list of parts and supplies, and source of supply. All technical data shall be furnished in English language.

7.0 ELECTRICAL REQUIREMENT FOR BOTH CRANES:

7.1 General: The hoist control shall satisfy the applicable requirements of National Electrical Manufacturers Association (NEMA), Industrial Control and Systems Standards. All wiring shall be in accordance with the National Electric Code. All electrical panels and boxes shall be marked and labeled in accordance with National Fire Protection Association (NFPA) 70e standards. The crane systems shall have written lockout/tagout procedures for this equipment must be provided and attached to lockout/tagout points.

7.2 Bridge Electrification: Power for the bridge drive motors, trolley, and hoist shall be derived from either bronze, stainless steel, rolled copper, or equal. The conductor rails shall be designed especially suited to the purpose and supported by insulators and clamps at not more than 5 foot spacing, and supported by or on the tracks. The rail shall be in the form of a channel with the bus bars rigidly mounted against the sides and top of the formed channel. The support brackets and conductors shall be supplied and coordinated by the same manufacturer. The conductors shall be protected with plastic insulating shields or metal cover arranged to reduce the risk of accidental contact. The use of a grounded transformer circuit to eliminate one conductor will not be acceptable. The connector bars and accessories shall be supplied and installed by the contractor along with the crane runway structure.

7.3 Motors: Motors shall be of ample capacity to operate the hoist service. Motors shall be designed with a 30 minute time rating, 55 degree centigrade rise, and with torque and speed characteristics especially suited to the service.

7.4 Pendant Control Station/Remotes: The pendant control station shall be suspended from the crane by a strain chain or 1/4-inch (minimum) wire rope strain lead of corrosion resistant steel. The pendant station shall be free-floating. The pendant control station enclosure shall be National Electrical Manufacturers Association (NEMA) Type 4. The push buttons shall be designed for heavy duty industrial applications. The push buttons shall be dust and oil tight, and shall have distinctly felt operating positions. The push buttons shall be constructed that they cannot become hung-up in the control case. Pendant shall include a separate set of push buttons for each motion and shall have a power on and power off button. All operating characteristics of each crane and hoists are to be controlled from the appropriate pendant located at the hoist hook.

The crane shall have all movements controlled by wireless remotes. Two remotes shall be supplied with each bridge system.

7.5 Transformers: Transformers shall be of the dry type, shall carry full load continuously at rated voltage, and frequency without exceeding an average temperature rise of 115 degrees Celsius (C) above an ambient temperature of 40 degrees C. The transformer shall have a totally enclosed case, which shall be furnished to resist corrosion. The transformers shall be fully encapsulated, except for those specifically designed for use as an isolation transformer for static power.

8.0 RUNWAY AND SUPPORT COLUMNS: The runway shall be an American Society of Civil Engineers (ASCE) crane rail with all hardware for installation. The runways shall meet all Crane Manufacturers Association of America (CMAA) standards for size, and true and parallel runs. The support columns shall be placed as close to the walls as possible. The runway shall be designed such that two bridges can be in the same bay (side by side).

9.0 ACCEPTANCE TESTING:

9.1 Crane Acceptance Test: Both bridge crane systems shall pass the following tests and inspection made by ANAD and contractor personnel.

9.1.1 Test Sequence: Both bridge crane systems shall be tested according to the applicable paragraphs of this procedure in the sequence provided.

9.1.2 Equipment Monitoring: During the load test, improper operation or poor condition of safety devices, electrical components, mechanical equipment, and structural assemblies shall be monitored. Observed defects critical to continue testing shall be reported immediately to the Contracting Officer and testing shall be suspended until the deficiency is corrected. During and immediately following each load test, the following inspections shall be made:

a. Inspect for evidence of bending, warping, permanent deformation, cracking or malfunction of structural components.

b. Inspect for evidence of slippage in wire rope sockets and fittings.

c. Check for overheating in brake operation; check for proper stopping. All safety devices, including emergency stop switches and power off push buttons, shall be tested and inspected separately to verify proper operation of the brakes.

d. Check for abnormal noise or vibration and overheating in machinery drive components.

e. Check wire rope sheaves and drum spooling for proper operation, freedom of movement, abnormal noise or vibration.

f. Check electrical drive components for proper operation, freedom from chatter, noise or overheating.

g. Inspect external gears for abnormal wear patterns, damage, or inadequate lubrication.

9.2 No-Load Testing:

9.2.1 Hoist Operating and Limit Switch Test: The load hook shall be raised and lowered through the full range of normal travel at rated speed and other speeds of the crane. The load hook shall be stopped below the geared limit switch upper setting. In slow speed only, proper operation of upper and lower limit switches for primary motion shall be verified. The test shall be repeated a sufficient number of times (minimum of three) to demonstrate proper operation. Brake action shall be tested in each direction.

9.2.2 Trolley Travel: The trolley shall be operated the full distance of the bridge rails exercising all primary drive speed controls in each direction. Brake operation shall be verified in each direction.

9.2.3 Bridge Travel: The bridge shall be operated the full distance of the runway exercising all primary drive speed controls, in each direction. Brake operation shall be verified in each direction.

9.2.4 Hoist Loss of Power No-Load Test: Using primary drive, the hook shall be raised to a height of 8 feet. While slowly lowering the hook, the main power source shall be disconnected verifying that the hook will not lower and that both brakes will set.

9.2.5 Travel Loss of Power No-Load Test: With the hook raised to clear obstructions and the trolley traveling, the main power source shall be disconnected verifying that the trolley will stop and that the brake will set.

9.3 Load Test:

9.3.1 Hoist:

a. Hoist Static Load Test: Holding brakes and hoisting components shall be tested by raising the test load approximately 1 foot. The load shall be held for 10 minutes.

b. Dynamic Load Test: 100 percent test load shall be raised and lowered through the full range operating in each speed. The machinery shall be completely stopped at least once in each direction to ensure proper brake operation.

c. Hoist Loss of Power Test: After raising 100 percent test load to approximately 8 feet, slowly lower the test load, the main power source and the control shall be released verifying that the test load will not lower and that both brakes will set.

d. Trolley Dynamic Load Test: While operating the trolley the full distance of the bridge rails in each direction with test load on the hook (one cycle), the proper functioning of primary drive speed control points and proper brake action shall be tested.

e. Bridge Dynamic Load Test: With test load on the hook, the bridge shall be operated for the full length of the runway in both directions with the trolley at end of the bridge. Proper functioning of all primary drive speed control points and brake action shall be verified. Binding of the bridge end trucks shall indicate malfunction.

9.3.2 Trolley and Bridge Loss of Power Test: Using a test load of 100 to 105 percent of rated load, the load shall be raised clear of any obstructions on the operating floor. Starting at a safe distance from walls or other obstructions, a slow speed shall be selected using the trolley and bridge primary drive. While maintaining a safe distance to obstructions, the main power source shall be disconnected, the brakes shall be verified to have set, and the equipment shall stop within the distance recommended by the manufacturer.

9.4 All labor and equipment for acceptance testing shall be supplied by the contractor.

10.0 INSTALLATION: The bridge crane systems shall be installed by the contractor. The contractor shall be responsible for all plant, labor, and materials required to complete the installation. The contractor shall be responsible for insuring that the installation is compatible with existing facilities. Unless otherwise approved by the Contracting Officer, installation shall be done during normal depot working hours. The area where the equipment is to be installed is in operation. The contractor shall not interfere with ongoing Government operations and production unless otherwise authorized by the Contracting Officer. The bridge crane systems shall be operational and installed within 8 weeks after contract award.

10.1 Electrical: All electrical work shall comply with American National Standards Institute (ANSI) Publication C2 - National Electric Safety Code and With National Fire Prevention Association (NFPA) Publication No. 70 - National Electrical Code. All materials used in the installation shall conform to applicable National Electrical Manufacturers Association (NEMA) and Underwriters Laboratories (UL) listings. Workmanship shall be in accordance with standard commercial practice. Runs shall be installed perpendicular and parallel to existing facilities and the equipment being installed. When equipment is installed near existing power lines, equipment shall be located for proper clearances in accordance with ANSI C2. New equipment shall not be connected to Government power without prior approval of the Contracting Officer. No high voltage work will be accomplished without prior approval of the Contracting Officer. All connections to Government power and all high voltage work shall be performed in the presence of a qualified Government electrician.

10.1.1 The Government will provide utilities within 20 feet of the equipment installation site. The capacities of the utilities (wire sizes, pipe sizes, etc.) will be based on information supplied by the contractor under instructions for installation noted above.

10.1.2 The Government will run electrical lines and tie into depot installed main disconnect. The Government will furnish only one voltage to the site. The contractor shall be responsible for providing the information needed for the disconnect needed and installation location for each crane at time of award.

10.2 Concrete: Concrete used in the installation of the equipment shall be Class A and shall have a minimum allowable compressive strength at 28 days of 3,000 pounds per square inch (PSI) unless otherwise specified. Samples for concrete strength tests shall be provided, stored, and tested as directed. Unless otherwise specified, the contractor shall be responsible for the design of all concrete work, including formwork and reinforcing. Ready-mixed concrete shall be used and must be delivered and discharged within 45 minutes after the introduction of water to the cement and aggregate. Placing of concrete shall conform to Chapter 4 of the American Concrete Institute (ACI) Standard ACI 318. Workmanship shall be in accordance with standard commercial practice.

10.3 Foundation Hardware: All foundation hardware shall be furnished and included in the total bid price.

10.4 Coordination of Trades: Coordination of trades installing the equipment shall be the responsibility of the contractor.

10.5 Instruction for Installation: Four copies of printed instructions and one electronic copy of instructions for installation shall be provided as specified on attached DD Form 1423.

The government will use these instructions to review utility and space requirements of the proposed equipment. The contractor shall provide ANAD all information necessary for installation within 30 days of the contract award. This installation manual shall include, but not be limited to, the following:

a. Floor plan drawing of the machine and major machine components showing floor space required.

b. Space required around the machine after installation for maintenance purposes.

c. Foundation requirements, if any.

d. Maximum overall length, width, and height dimensions.

e. Approximate location of utility connections on the machine.

f. All utility requirements including electrical, air, water, steam, drains, etc. include amps, GPM, etc.

g. Minimum doorway opening required to bring equipment into the building.

h. Industrial waste disposal requirements, if any.

i. Ventilation requirements, if any.

j. Approximate weight of the equipment.

10.6 Site Visit: A site visit is recommended prior to bid proposal to insure that the proposed equipment will be compatible with existing facilities. A pre-work meeting will be scheduled once award is made.

10.7 Shipping, Handling, and Storage: The contractor shall be responsible for all shipping, storage, and handling of the equipment and all materials. The Government will not be responsible for furnishing any labor, equipment, or warehouse space for the loading, unloading, and storing of any materials. The Government will make available if possible, space for a contractor furnished trailer or van for the storage of the materials. Trailer space will be made available as close to the job site as possible, depending on the parts stored in that area. If the contractor wishes to not furnish a trailer for their equipment storage, then the contractor shall coordinate with the contracting officer the date and time the contractor shall deliver their equipment to the building.

11.0 SAFETY PRACTICES AND GUIDELINES: The Contractor shall conform to all federal OSHA standards applicable to the work performed and all safety practices and guidelines contained within this Statement of Work. Contractor shall strictly adhere to the contract clause entitled "Accident Prevention", Army Material Command (AMC) Regulation (R) 385-100, Safety and Occupational Health Regulation ANADR 385-1, Engineering Manual (EM) 385-1-1, 29 Code of Federal Regulations (CFR) 1926/1910, other related Department of Transportation (DOT) Regulations (49 CFR), and all local policies.

11.1 If a contractor employee is observed performing an activity in a manner inconsistent with any of the above cited regulations or is engaged in any activity that is dangerous to life, limb, or government property, the ANAD Safety Representative will have the authority to notify the employee and/or the contractor’s on-site supervisor of the hazardous activity and require correction of the hazardous activity. This authority does not preclude the Safety Representative from notifying the Contracting Officer’s Representative of the hazardous condition or safety violation in appropriate situations.

11.2 If there is a safety issue, the ANAD Safety Representative has authority to require the contractor and/or their employees to stop hazardous activity. The contractor shall take corrective action to eliminate the hazardous condition or safety violation. Once the corrective action has been made, the contractor will be notified by the COR when they can resume work. If this action has to be taken, it shall be at no cost to the Government and shall not be considered to be the basis of a claim.

11.3 The contractor shall notify ANAD Safety Office immediately of Reports of Inspections and/or Notices of Violation or other enforcement actions (including warning letters) received from by local, State, and Federal Regulators in which the violation is attributed to the action of the contractor or its subcontractors while working or providing services on ANAD’s installation. The contractor shall provide ANAD with a copy of the Inspection Report, Notice of Violation or other enforcement action, and all supporting documentation.