Draft 6 ver1 PWS HH Crane Drum Repair.pdf

DRAFT Performance Work Statement for The Dalles Hammerhead Crane Drum Repair.

THIS IS NOT AN OFFICIAL WORK STATEMENT FOR AWARDABLE CONTRACT AND ALL

ELEMENTS OF THIS DOCUMENT ARE SUBJECT TO CHANGE.

All work under this Contract must conform to the standards and requirements set by EM

385 1-1. Contractor must provide all relevant information in all Data Requirement

Documents (DBDs) verifying specific DBD meets or exceeds EM 385 1-1 standards.

- CLIN 0001: Component deconstruction and removal from the Hammerhead Crane o DRD: Qualified individual to Develop and perform the Existing Condition survey Plan and Survey

KTR must provide an individual with at least 10 years of experience performing crane lifting machinery alignment

KTR must provide individual’s credentials and proof of experience.

o DRD: Existing Conditions Survey Plan

KTR must develop and provide to the Government a survey plan to review the existing conditions of the entire Hammerhead Crane lifting assembly for the purposes of establishing a baseline for final installation.

Plan must be developed by the KTR’s Qualified Individual.

• See DRD for Qualified individual.

KTR is solely responsible for providing all the necessary tools and personnel to perform the survey.

KTR must detail all critical dimensions and tolerances to be measured.

Survey plan must contain a blank template of survey results.

Government may reject survey plan if inadequate information is provided or if the KTR fails to demonstrate competency in their plan.

Survey Plan must include a ‘bluing’ test procedure of the loaded side of the gear teeth between the existing bull gear and pinion gear mesh to establish a base line contact pattern.

• Bluing test must be performed per AGMA 2000 standards o DRD: Existing Condition Survey

KTR must perform the survey as described in the Existing Conditions

Survey Plan.

Results of survey must be provided and received by the Government prior to component disassembly.

Contractor must notify the Government 14 days prior to the test being performed to allow Government personal time to prepare to be onsite to witness the Survey.

Survey must be performed by the KTR’s Qualified Individual.

o DRD: Component Disassembly and Removal Plan

KTR must provide a Component Disassembly Removal Plan detailing:

• Tools, equipment, and personnel needed to remove the Drum.

If the KTR elects to use any feature of the exiting Hammer Head Crane infrastructure to remove the drum as a means to hang or support removal tools including but not limited to chain falls, and pallet jacks, and KTR provided mobile crane(s), then all relevant data required for the Government to review the plan per EM 385 1-1 must be included.

Government may reject Removal Plan if insuAicient information is provided or if the Government doubts KTR’s competency to do the work.

Any additional items that need to be removed to access and remove the Drum must be identified and coordinated with the Government for storage on site using KTR provided storage facilities. Government retains the right to access the KTR provided storage facilities at any time.

Welding on any elements regardless of if they will be replaced as a part of this Contract’s scope is not permitted unless in written consent from the Government.

KTR must receive approval from the Government prior to disassembly and removal of any components and must notify the Government 14 days in advance.

Any damage to components onsite, must be either repaired or replaced by the KTR and no additional cost to the Government.

• Government reserves the right to reject a repair or replacement for any reason.

o Component(s) to be Removed from the Hammer Head Crane

Lifting Drum:

• Roughly 26’ long.

• Roughly 52” diameter drum.

• Roughly 18 tons.

• Bull Gear attached to one end of the drum shell o During the Drum removal operation, the bull gear must remain attached to the drum until after the KTR has performed the Fabrication Shop Inspection.

• Drum was fabricated and installed in 2006.

More details in provided contract drawings.

o DRD: Component Transportation Plan

KTR must submit a plan for transportation of all removed components identified for repair from The Dalles Dam to alternate work sites.

Must include:

• Tools, equipment, and personnel needed for transportation of components.

• Transportation Plan must safety requirements of EM 385 1-1

Any damage to components during transportation from The Dalles

Project Site to Contractor facility must be repaired or replaced by the

Contractor and no cost to the Government.

- CLIN 0002: Component(s) Disassembly and Inspection.

o DBD: Drum Shop Survey

KTR must survey the features of the existing drum to determine existing runouts of the following features of the drum.

• Journal bearing runout (shaft alignments)

• Bull gear face perpendicularity to axis of shell rotation

• Bull gear runout

Survey must be performed while the drum is in a horizontal lathe and must be done in the presence of the Government’s Representative.

• KTR must notify the Government 14 days in advance of when the Survey will be performed.

KTR must develop and execute a plan to verify the existing measurements of the drum assembly to establish a baseline for the final drum repair assembly.

KTR’s responsibility to identify any additional key features of the drum that need to be maintained and identify the correct measurements/dimensions and tolerances for those features.

Government must review and approve the Drum Shop Survey submittal results prior to drum disassembly.

o Following components to be Disassembled by KTR in their shop:

Lifting Drum

• The welded shaft on the non-bull gear side of the drum.

o 10.25” D o ~33” Long o See provided drawings

• Bull Gear attached to one end of the drum o KTR to determine whether they want to remove the bull gear from the drum during drum repair or leave it on drum.

o In either case, the bull gear is not an item included in the repair scope. Any damage to it by the KTR will be the

KTR’s responsibility to repair or replace at no cost to the

Government.

o If the Bull Gear is removed from the drum for the repair work, it must be re-installed to the drum in the same position and manor as it was removed prior to the

Drum’s delivery back to the site.

• Welded Diaphragm plates on the non-bull gear side of the drum. (2 total) o 52” D o 1.5” thick o See provided drawings

• Further Requirements for Drum disassembly detailed later and in provided drawings.

o At a minimum of a month before the KTR has removed the Diaphragm plates and shaft from the drum, KTR must notify the government of their scheduled drum disassembly date to allow for the government to plan to have government weld inspectors on site at the KTR’s shop at the time after drum disassembly and before drum repair to perform evaluations on the base material of the drum shell. KTR must make the drum and bull gear available to the government for a minimum of (1) one week without any additional work being done on the drum to allow the government’s inspectors to perform NDT of the shell and bull gear. The drum must be installed on a horizontal lathe for ease or access and the KTR must manipulate the drum however the

Government inspectors request to evaluate the drum shell. Contractor will then allow the Government a maximum of 14 days to review the findings from the government inspectors and verify the repair procedures of the drum. No repair work for the drum will be allowed until the government has approved the appropriate path of repair for the drum, and any delays in the schedule to perform the drum inspection from the KTR will be done at the KTR’s own cost.

Reference drawings for more details.

KTR must remove the drum without damaging the outer shell or rope grooves of the drum shell, both drum shafts, and both sets of diaphragm plates. Use of a flame cutting via oxy-acetylene torch is not permitted.

KTR must clean the interior of the drum along its entire length to base metal to allow for a smooth clean surface for inspection and repair

- OPTION 0001: Drum Repair o Expected Scope of components to be repaired (reference provided drawings for more details):

Lifting Drum. The drum shell and grooves, and bull gear are not a part of the repair process and will not be modified unless directed to by the government.

• KTR to install new components on the lifting drum to match the tolerances and alignments from the Drum Shop Survey

• New diaphragm end plates (2 plates total).

o ASTM A36 Steel.

o ~52” OD, 14.25” ID, 1.5” thick o Dimensioned and Installed as shown in provided drawings.

• New Collar welded between Diaphragm plates o ASTM A519 Steel o ~14.5” OD, ~10” ID, ~13.5” long o Dimensioned and installed as shown in provided drawings

• New Drum Shaft.

o AISI 4140 steel.

o ~10”D, ~34” Long o Dimensioned and Installed as shown in provided drawings.

• Any additional repair for the drum will be determined by the government, however additional repair is not expected.

o Welding Requirements

All welds will be done as shown on Contract Drawings

All welds must be performed per AWS D1.1 requirements

All welds must be performed by qualified welders per AWS D1.1.

• Quals must be submitted to and accepted by the Government

Field welding is not permitted

Pre-heat and Interpass Temperatures

• Perform pre-heating as required by AWS D1.1.

Stress-Relief Heat Treatment

• Perform stress-relief heat treatment in accordance with the requirements of AWS D1.1, Subsection 5.8 STRESS-RELIEF

HEAT TREATMENT.

• All welds will be Stress relieved.

Temporary Welds

• For temporary welds required for fabrication and erection, perform all temporary welds using low-hydrogen welding electrodes by welders qualified for permanent work as required in this PWS. Furnish pre-heat for temporary welds as required by AWS D1.1 for permanent welds. In making temporary welds, do not strike arcs outside weld locations.

Remove each temporary weld after serving its purpose and grind flush with adjacent surfaces.

DRB: Contractor Quality Control (CQC) Welding Program.

• Inspect all welding to ensure that the welds conform to the requirements of this contract, AWS D1.1, and the approved welding procedure. Inspection will be performed in two categories:

o 1) The CQC Welding Program which guarantees complete compliance of all welds with the contract requirements.

o 2) The Government Quality Assurance Program (GQAP) which will be utilized to verify implementation and acceptability of the CQC Welding Program.

• 100% of all welds must be VT and MT inspected per AWS D1.1 by the KTR identified in the DRB: Welder Qualifications.

• Perform inspection under the CQC Welding Program in accordance with the PWS herein and Section 6 of AWS D1.1.

All inspectors, performing weld inspection in accordance with this document, are required to be qualified and have current certification in conformance with AWS QC1 as a certified welding inspector (CWI) or Senior Certified Welding Inspector

(SCWI). Designate an individual inspector as the "lead" inspector to be the primary point of contact for quality control of welding and fabrication. This individual will be responsible for all quality control functions. Individual(s) responsible for quality assurance/quality control may not serve as or report to production management. All personnel who perform NDT are required to be qualified in accordance with ANSI/ASNT CP-189

NDT Level II or III. All personnel performing NDT are required to be supervised by personnel possessing a Level III ASNT NDT certification. If requested, submit suAicient documentation demonstrating that the testing personnel are qualified at least

14 days prior to the testing. Submit copies of the certified weld inspector's qualifications and qualifications for all assistant inspectors o Weld inspectors Qualifications must be submitted to and accepted by the Government.

o DRB: Material Mill Certs.

All new materials described above must have their mill certifications submitted to the Government including but not limited to their molecular composition, and their tested yield and tensile strength.

Heat numbers must be provided as a part of the mill cert and all materials must have corresponding HEAT numbers on them to cross reference the Mill Cert with the replaced feature.

o DRB: Shop Drawings

Contractor must provide shop drawings detailing all features and components being replaced on the drum shell. Contractor is not permitted to re-submit the Government supplied Contract Drawings as their shop drawings.

Shop Drawings must be generated using industry standard CAD software and must include component dimension and tolerances per

ASME Y14.5

Dimensional control and tolerancing is required to repair the drum as determined in the Contract without any interferences or binding during operation.

It is the KTR’s responsibility to identify and measure all diAerences between the physical drum’s components to be replaced and the

Government provided Contract Drawings. DiAerences must be highlighted and clearly marked; it will be the Government’s responsibility to determine the path forward for given discrepancies if they exist.

Government reserves the right to reject the KTR’s shop drawings if they do not demonstrate to the Government an understanding of the final product to be fabricated in the shop.

Shop drawings may be developed before the drum arrives in the shop, but no fabrication or assembly of new components on the drum may occur until the Shop Drawings have been reviewed and approved.

Any purchases of replacement materials and work on those materials done prior to the approval of the Shop Drawings are done at the KTR’s own risk.

o Shop Painting of repaired Drum

Clean the entire surface of the drum using commercial blast cleaning in conformance with SSPC-SP 6/NACE No.3 to bare metal.

Clean welds and adjoining surfaces within a few inches (centimeters) thereof of weld flux, spatter, and other harmful deposits by blasting, power impact tools, power wire brush, or such combination of these and other methods as may be necessary for complete removal of each type of deposit. The combination of cleaning methods need not include blasting when preparation of the overall surfaces is carried out by the power tool method. However, brush scrubbing and rinsing with clean water, after mechanical cleaning is completed, will be required unless the latter is carried out with thoroughness to remove all soluble alkaline deposits. Limit wetting of the surfaces during water-washing operations to the weld area required to be treated and dry such areas before painting. Welds and adjacent surfaces cleaned thoroughly by blasting alone will be considered adequately prepared if weld spatter not dislodged by the blast stream is removed with impact or grinding tools. Prime all surfaces as soon as practicable after cleaning and in all cases prior to contamination or deterioration of the prepared surfaces. To the greatest degree possible, clean (and prime) steel surfaces prior to lengthy outdoor storage.

Provide a finished coating free from holidays, pinholes, bubbles, runs, drops, ridges, waves, laps, excessive or unsightly brush marks, and variations in color, texture, and gloss.

Paint system to be applied: 21-A-Z

• Apply the epoxy zinc-rich paint 19C in two single half-lapped spray coats to an average dry film thickness of a minimum of

3.0 mils and a thickness at any spot of not less than 2.5 mils or greater than 6.0 mils. After a drying period of not less than 6 hours or more than 96 hours, apply at least two coats of epoxy polyamide paint to produce an average dry film thickness totaling 12 mils and a thickness at any spot of not less than 10 mils. If the epoxy zinc-rich paint has been applied in the shop or otherwise has been permitted to cure for longer than 96 hours, it must be abraded and recoated with an additional thin tack coat of the zinc-rich paint, which in turn must be overcoated within 96 hours with the first coat of the epoxy polyamide paint. Apply MIL-DTL-24441 in accordance with the manufacturer's recommendations regarding type of thinner, amount of thinning, and required induction time. The drying time between non-zinc coats must not be less than 12 hours nor more than 96 hours.

o DRD: Surface preparation and painting inspections:

Must be conducted by an inspector certified as meeting one of the following designations: SSPC-PCI Level 2, NACE-CIP Level 2. The inspector will inspect and document all work phases and operations on a daily basis and submit a daily status report.

o DRD: Paint Sample Verification.

(TBD)

- Additional items to be supplied in Contract o New wire ropes as identified in the provided government drawings

1” D

6x36, RR XIP IWRC

• Right Regular Lay, Extra Improved Plow Steel o DBD: Wire Rope Product Tensile Strength report

Perform a tensile test to verify the wire rope meets the accepted industry standards for nominal strength. The rope sample from the same mill run as the wire rope must be selected, and tested to rated breaking strength to be sure the expected performance level has been met. The test must meet or exceed the requirements of FS RR-W-410, using suitable tension testing equipment and qualified personnel, both furnished by the Contractor.

Certifications must be traceable to the crane and to the hoist to which the wire rope is installed. Wire rope must conform to ASTM A1023 and

ASTM A931.

Provide Test report for the Government to review. Wire rope failing to meet the standards listed above will not be accepted and wire rope not having a test report verifying strength will not be accepted.

- OPTION 0002: Component Delivery, Installation, and Testing on Hammerhead

Crane o KTR is responsible for delivering the newly repaired drum, and purchased wire ropes back to The Dalles Site, first installing the drum back as close to exact as it was originally removed, then installing and reaving the wire ropes back through around the drum, through the lifting blocks and sheaves exactly as shown in supplied reference drawings.

o All operations must meet EM 385 1-1 Safety requirements.

o KTR will then perform a series of a minimum of four load tests using weighted blocks before and after the ropes have been installed

Load Test 01, No Load Test

Load Test 02, No Load Test with wire rope reaved

Load Test 03, 100% Weighted Load

Load Test 04, 125% Weighted Load o Definitions and requirements of tests are listed below o KTR should be aware that these functional tests are meant to test crane functionality and confirm machinery alignment based on the results of the original alignment survey. If the KTR does not meet the alignment requirements, they must perform multiple iterations of the same test Load test until they have reached satisfactory and alignment.

o Wire rope must have a minimum 3 dead wraps around each section of the drum.

o DBD: Delivery plan

KTR must submit a plan for transportation of all components identified above from their fabrication shop back to The Dalles Dam.

Must include:

• Tools, equipment, and personnel needed for transportation of components.

• Must meet EM 385 1-1 Safety requirements

Any damage to components during transportation from The Dalles

Project Site to Contractor facility must be replaced by the Contractor and not cost to the Government.

Government must be informed 14 days prior to shipping from the

KTR’s shop to the Dam.

• Date should include expected day of delivery to the site.

o DBD: Installation Plan

KTR to develop and provide an installation plan for the repaired lifting drum. Requirements are the same as the removal plan. The

Installation Plan must detail:

• Tools, equipment, and personnel needed to install all removed components.

• Lifting plan meeting EM 385 1-1 safety requirements.

KTR must receive approval from the Government prior to installation of any components.

As an additional part of the installation plan, KTR must install the Wire

Ropes and reave the Government furnished lifting beam with the existing crane platform and the repaired drum.

KTR must notify the Government 30 days prior to installation of the drum in the hammerhead drum.

Installation plan may be developed and submitted at the same time as the Disassembly and removal plan.

o DBD: Load testing/alignment procedure plan

KTR must develop a test procedure for performing each of the four alignment and load tests. Plan must include all

• Tools, equipment, and personnel needed to perform each test.

• For all bluing test results will be evaluated as described in

AGMA 2000 Appendix D, Figure D-4.

• Meet EM 385 1-1 Safety requirements.

• Perform inspection in accordance with ASME B30.2, Overhead and Gantry Cranes (periodic inspection)

• All Load testing will in conformance with ASME B30.2 in addition to the times below

KTR to be aware that the trolley of the crane does deflect underload.

No load test:

• Bull gear meshing test via bluing without wire rope installed

• Test must be performed per AGMA 2000

• Results of test will be measured against the original disassembly alignment testing to confirm accuracy of initial installation.

Load test with wire rope reeved

• Bull gear meshing test via bluing with wire rope installed and reeved through the Government furnished lifting beam and crane

• Test must be performed per AGMA 2000

100% Weighted load test

• Bull gear meshing test via bluing while crane is at 100% of it’s rated load (100 ton)

• Test must be performed per AGMA 2000

• Final required alignment across the gear teeth under 100% load should be 80%

125% Weighted load test.

• No gear alignment testing is required.

o DBD: Final Alignment Survey

KTR must perform another test identical to the Existing Condition

Survey to prove to the Government that all components, including the drum and bull gear, are installed and aligned identical to the component’s placement prior to their removal and repair.

Requirements are the same as the Existing Condition Survey

• Contractor must verify that alignment dimensions of the installed drum and bull gear match the values measured in the

Existing Condition Survey using the same report template and datums of the Existing Condition Survey

• Tolerances and alignment

Contractor must receive approval from the Government that components have been installed correctly before tear-down of equipment and tools from the site.

END