PWS_16140_Replace_Manual_Chain_Hoist_by_Electric_Hoist.pdf

PERFORMANCE WORK STATEMENT

(PWS)

FOR

REPLACE MANUAL CHAIN HOIST WITH

ELECTRIC HOIST

WO#16140

BUILDING 212

CIVIL ENGINEERING 496 ABS/CEORM

(26 June 2017)

PERFORMANCE WORK STATEMENT (PWS)

TABLE OF CONTENTS

SECTION PAGE

1. DESCRIPTION OF SERVICES 5/11

2. SERVICES SUMMARY 11

3. GOVERNMENT FURNISHED PROPERTY AND SERVICES 11

4. GENERAL INFORMATION 11/14

5. APPENDICES 15/30

1. DESCRIPTION OF SERVICES. The contractor shall provide all management, tools, supplies, equipment and labor needed to replace existing 5 TM chain hoist, model ZKKE

HERBERT MORRIS LTD serial number 42323/27 by an 5 TM electric hoist, displacement and lifting kit, power supply and control lines, square channel installation on existing overhead crane 14 meter span and 30 meter length in Power Plant central bay, Building 212.

1.1. Description of Work.

The work will consist of:

Dismantling existing manual hoist, see attached sketches.

Kit of displacement and elevation for existing 5 Tm x 14 meters span overhead crane and 30 meters length, formed by:

2 drive wheel blocks Demag DRS 160-A45-A-65-B-X-A30.

2 non-driven wheel blocks Demag DRS 160 DRS-160-NA-A-65-B-X-X.

4 Weld able support structures.

2 Anti-moment support.

4 Mounting bolts assemblies.

2 HEB panels 200 mm.

4 cellulose tops.

Centering and alignment screws.

Electrical displacement devices.

Pushbutton on and radio control FST 512 DEMAG.

Connection cables.

Electrical Wiring Diagrams.

2 Demag AME 30 gear motor DD-M0-45-1-25.3 ZBA 90 A 4 B020.

Frequency Inverter.

Provide and install square channel 14+14 ml, F-111 quality in the two beams of the crane for the carriage of the new hoist.

Demag DR EZ Drum 5-5 4 / 1-6 Z-4.5 / 0.8-440-00-60 1400, equipped with push button and radio control.

Electric hoist Demag DR EZ DR-Com 5-5 4/1-6 Z-4.5/0.8-440-00-60 1400, including control keyboard and radio remote control.

Hoist power supply by means of Demag DCL-Pro DCL-Pro-GB-4-10-PE-30000 mm.

Electric hoist power supply by means of flat cable.

Electric panelboards.

1.1.1 Demag drive wheel blocks DRS 160 DRS-160-A45-A-65-B-X-A30:

Technical data:

Wheel assembly A

Wheel hub in accordance with DIN5480 N 45

Wheel diameter: 160 mm

Wheel width: 89 mm

Wheel base: 65.0 mm

Wheel contour: with two tabs

Wheel material: fonte nodulaire EN-GJS-700-2

Net weight approximate: 18.3 kg

Equipment:

Gear unit size: A30

Wheel set ready for mounting by bolts.

Wheel set ready for SPTE mounting against counterclockwise turn.

Wheel assembly and the driver temperature limits must be taken into account.

Wheel manufacturer certificate 2.2 according to DIN EN 10204.

Painting:

RAL 7001, silver gray.

Documentation:

Operating Instructions/Installation.

EU document according to the Machinery Directive.

1.1.2 Demag non-drive wheel blocks DRS 160 DRS-160-NA-A-65-B-X-X:

Wheel assembly NA

Wheel diameter: 160 mm

Wheel width: 89 mm

Wheel base: 65.0 mm

Wheel contour: with two tabs

Wheel material: fonte nodulaire EN-GJS-700-2

Net weight approximate: 18.3 kg

Wheel set ready for mounting by bolts.

Wheel manufacturer certificate 2.2 according to DIN EN 10204.

RAL 7001, silver gray.

1.1.3 Demag offset geared motor AME 30 DD-M0-45-1-25.3 ZBA 90 A 4 B020:

Construction code AME30DD-M0-45-1/25.3 - ZBA 90

A 4-B020

Output speed: 67.2 1/min

Engine speed: 1700 1/min

Power: 1,350 KW

Running factor 60 %

Motor protection degree IP 54

Operating temperature range -10...+50 °C

Mounting altitude ≤ 1.000 m

Transmission ratio: 25.30

Terminal box position: right 1

Motor mounting position: horizontal

Total weight, approximate net: 33 kg

Electric data:

Voltage D/Y: 250/440 V

Frequency: 60 Hz

Current: D/Y 5.l40/3.10 A

Brake Technical data:

Braking torque: 16.0 Nm

Voltage: 198 V CC

Current: 0.16 A

Rectifier for GE brake: 440V AC

3 thermal probes for disconnection at 160 °C.

Class F thermal insulation with phase insulation to inverter service.

Ventilation disc.

GE brake rectifier.

Non-standard brake tension.

Hollow shaft construction.

Involute solid shaft.

Direct input.

RAL 5009, blue.

1.1.4 Demag Hoist DR EZ DR-Com 5-5 4/1-6 Z-4,5/0,8-440-00-60 1400 X: The standard supply includes the following equipment:

Gear 10 years maintenance free.

Motor protection by Microtherm contacts integrated in the winding against overheating.

Four contacts precision gears limit switch, two of which are configured by default for emergency switch-off at the top and bottom and two freely selectable switches

(for example, prior switch-off for lifting and lowering).

The visco-elastic plastic cable guide also offers safe operation in difficult conditions.

Lubricant for the cable in the first commissioning.

Easy-to-use bottom bracket with two handles for easy guiding and handling.

Plug-in connectors integrated in terminal boxes for easy and quick installation.

Control of electromechanical stresses according to the EC Machines Directive for customer evaluation.

Electrical data:

Network voltage: 440 V

Operating voltage: 48 V

Network frequency: 60 Hz

Network type: Three-phase current

Hoist technical data:

Load capacity: 5 Tm

Group FEM/ISO: 2m/M5

Hook stroke: 6.00 m

Provision of branches: 4/1

Cable diameter: 9.0 mm

Lift speeds approaching: 5.40/0.96 m/min

Lift motor: ZBR 100 E 12/2 with separate control brake

Brake: BR050

Rated power: 1.42/9.30 kW

Gear factor: 40/20 % FM

Hoist protection grade: IP 55

Insulation class: F

Ambient temperature: -10 °C to +45 °C

Environmental conditions: standard, use in a bay

Approximate weight: 450 kg (net)

Carriage translation mechanism technical data:

Carriage width: 1,400 mm

Rail width: 45 mm

Carriage travel speed: 5-24 m/min without stepping

Rated power: 0.37 kW

Gear factor: 60 % FM

Drive motor: ZBA 71 B4 with control brake

Brake: B007

Travel motor protection degree: IP 55

Surface protection and painting:

Lifting mechanism painting: RAL 5009/7001

Bottom painting: RAL 1007

Hook painting: RAL 9005

Translation mechanism painting: RAL 5009

The parts of the cable hoist are fitted with a powder coating and are thus well protected against corrosion.

Control:

Cable hoist electrical equipment includes a terminal strip for the connection of electrical cables. The following functions must be accomplished by the control to ensure safe and trouble-free lifting service.

250 ms reconnect lockout after stopping the hoist, or applying the brake.

Inhibition of mechanical braking from speed V2 (SGDM function).

Brake position control switch to prevent the hoist from starting with the brake applied.

Connect the brake module in 3 phases.

Perform continuous brake control when switching.

Other features:

Frequency inverter.

Carriage limit switch 2 steps for rapid switch-off of fast speed to slow speed and general switch-off.

Loose cable detection: Detects the drive of the cable without load and stops the downward movement.

Brake Starter Relay SGDM-1.

Screwed stop KP-S: Carriage limitation for bi-rail.

EZDR Car Trawler.

EU Documentation according to the Machinery Directive

DR hoist

1.1.5 Compact line Demag DCL-Pro-GB-4-10-PE-30000 mm: Straight track with 4 copper conductors, including protective conductor. The DCL-Pro is a DCL-based contact line system that is suitable for supplying variable-displacement electricity consumers in straight and curved stretch constructions. The DCL-Pro is characterized by the following properties:

Compact closed construction.

Rigidness increased.

Improved joints connection for easier assembly.

Fast and effortless replacement of straight sections without the need to completely dismantle the joined sections.

Possibility of inspection and dismantling of the electrical outlet in each joint at the end of sections.

Absorption of temperature expansion at all joints.

Easy mounting by simple fixings on ceilings and metal structures.

Tire outlet with optimized bearings to ensure a service with minimum wear.

Tire outlet with wheels of geometry adapted for translation by straight sections or straight and curved sections.

Main power supply line damage proof built into the tire outlet.

Optional universal power points at the ends or at a point in the contact line.

Multiple pole design: 4 to 7 conductor arrangement.

In addition to this, the DCL-Pro contact line provides the following safety features: The narrow opening of the casing profile makes contact with the bus bars almost impossible, so this power supply can also be used in areas within reach of the hand without additional measures of protection. In addition, the DCL contact line complies with the UL94 V-0 fire protection standard. It must be considered that with cable lengths of connection>

3,000 mm it is necessary in all cases to secure the current carriage.

Body: PVC

Track layout: straight

Length of the track: 30.00 m

Distance between supports: 2.00 m

Max working speed: 200 m/min 100m/min step cones.

Number of active conductors: 3/4

Max connection voltage: 690 VAC

Max conductors capacity: L1-L3 65 A at room temperature 35°C

Service factor: 100 %

Protection degree: IP23

Ambient temperature range: -30°C - +70°C

Capacity bronze contacts - L1-L3+PE: 40 A, 80% FS

The current capacity of the conductor section depends on the ambient temperature and the service factor. In case of higher temperatures and service factors it is necessary to reduce the current or choose a larger conductor section (see technical data).

Consideration should also be given to the busbar permissible voltage drop.

Point of service technical data:

Max conductors capacity L1-L3: 65 A

Max control conductors capacity: 65 A

Ambient temperature: 35°C

Service factor: 100%

1.1.6 FST 512 Demag: Keyboard and radio control.

FSE 512 ME receiver.

12 Relays.

Operating voltage 42-240V AC.

FSS micron 5i transmitter.

6 two-stage pushbuttons.

1 spare pushbutton.

1 power buttons and horn.

1 memory key.

1 emergency stop pushbutton.

Charger.

NiMH batteries (2 units).

Belt clip.

Documentation binder.

HAN16 connector mounting with 3m of cable.

4 holding magnets.

1.2. Final Cleaning.

Final cleaning of installations affected by this contract.

The items mentioned and the list of main tasks do not limit in any way the responsibility of the contractor to perform all work required by the contract to provide a complete and operational installation.

1.3. Special Requirements.

Prior to accomplish any activities the contractor shall submit shop drawings of any specific site plan showing final dimensions, supports, connection of the input/output lines to the electric hoist. The contractor shall not accomplish any work up to this drawings will be approved by the Contracting Officer.

1.4. Brand Names.

Names indicated for materials are for the purpose of establish a standard selection only. Other manufacturers' materials are acceptable provided they conform to all the requirements. Names indicated for quality of model, gives the quality standard to be achieved. Other manufacturer's materials are acceptable only if they are identical or superior in quality to suggested model and subject to approval of Contracting Officer.

1.5. Period of Performance. The period of performance for this contract is one hundred and twenty (120) days. The contractor shall provide its execution time with your proposal.

2. SERVICES SUMMARY.

Performance Objective SOW Performance Threshold

Activities. Par 1.1 100%

3. GOVERNMENT FURNISHED PROPERTY AND SERVICES.

3.1. Use of Base Utilities: Base utilities are available to the Contactor at no additional expense to the Contractor. The following utilities shall be available from the existing Base utility connections in reasonable quantities:

a. Electricity 120/208 volts, 60 Hz or 250/440 volts, 60 Hz.

b. Water.

All of the equipment, materials and labor required to accomplish the aforementioned items stipulated shall be supplied by the Contractor, as part of this contract.

4. GENERAL INFORMATION.

4.1. Security Requirements. The contractor will request installation access through 496

ABS/CE

4.2. Physical Security. The contractor shall be responsible for safeguarding all government property provided for contractor use. At the close of each work period, government facilities, property, and materials shall be secured.

4.3. Hours of Operation.

4.3.1. Normal Hours of Operation. The contractor shall perform the services required under this contract during the following hours: Monday to Friday, 08:00-17:00. The contractor may work, with prior approval of the Contracting Officer, extended hours to ensure timely completion of work at no additional cost to the Government.

4.3.2. Recognized Holidays. The contractor is not required to provide service on the following days: New Year’s Day, Martin Luther King Day, Presidents Day, Memorial

Day, Independence Day, Labor Day, Columbus Day, Veterans Days, Thanksgiving

Day and Christmas Day. If the holiday falls on Saturday, it is observed on Friday. If the holiday falls on a Sunday, it is observed on Monday.

4.4. Conservation of Utilities. The contractor shall instruct employees in utilities conservation practices. The contractor shall be responsible for operating under conditions which prevent the waste of utilities which include the following:

4.4.1. Lights shall be used only in areas where and when work is actually being performed.

4.4.2. Mechanical equipment controls for heating, ventilation, and air conditioning systems shall not be adjusted by the contractor or by contractor employees unless authorized.

4.4.3. Water faucets or valves shall be turned off after the required use has been accomplished.

4.4.4. Government telephones shall be used only for official government business.

4.5. Records. The contractor shall be responsible for creating, maintaining, and disposing of only those government required records that are specifically cited in this SOW.

4.6. Environmental Controls:

4.6.1. Compliance with Laws and Regulations. The contractor shall be knowledgeable of and comply with all applicable Interstate, Federal, State, and Local laws, regulations, and requirements regarding environmental protection. In the event environmental laws/regulations change during the term of this contract, the contractor is required to comply as such laws come into effect. If there is an increase or decrease in cost as a result of the change, the contractor shall inform the Contracting Officer pursuant to notice requirements and negotiate a modification to the contract.

4.6.2. Notification of Environmental Spills. If the contractor spills or releases any substance contained in 40 CFR 302 into the environment, the contractor or its agent shall immediately report the incident to Moron AB Fire Dept at 117. The liability for the spill or release of such substances rests solely with the contractor and its agent.

4.6.3. Material Storage and Use. The contractor shall follow manufacturer’s guidelines and professional recommendations for control of humidity, temperature, cleanliness, and materials handling. This includes hazardous materials.

4.7. Government Observations. Government personnel, other than contracting officers (COs) and quality assurance personnel (QAPs), may from time-to-time, with CO coordination, observe contractor operations. However, these personnel may not interfere with contractor performance or make any changes to the contract.

4.8. Safety Requirements. In performing work under this contract, the contractor shall:

4.8.1. Conform to the safety requirements contained in the contract for all activities related to the accomplishment of the work.

4.8.2. Take such additional immediate precautions as the contracting officer may reasonably require for safety and mishap prevention purposes.

4.8.3. Develop and provide at the start of the orientation period or the start of the first operational performance period (if there is no orientation period) a safety plan for the protection of government facilities and property and to provide a safe work environment for contractor personnel.

4.8.4. Provide protection to government property to prevent damage during the period of time the property is under the control or in possession of the contractor.

4.8.5. Include a clause in all subcontracts to require subcontractors to comply with the safety provisions of this contract as applicable.

4.8.6. Record and report promptly (within one hour) to the contracting officer or designated government representative (GR), all available facts relating to each instance of damage to government property or injury to either contractor or government personnel.

4.8.7. In the event of an accident/mishap, take reasonable and prudent action to establish control of the accident/mishap scene, prevent further damage to persons or property, and preserve evidence until released by the accident/mishap investigative authority through the contracting officer.

4.8.8. If the government elects to conduct an investigation of the accident/mishap, the contractor shall cooperate fully and assist government personnel in the conduct of investigation until the investigation is completed.

4.8.9. Include a clause in each applicable subcontract requiring the subcontractor's cooperation and assistance in accident reporting and investigation.

4.9. Special Qualifications. The Contractor shall submit any commercial certifications and a reference of past performance on similar works performance to the existing as a means to verify experience in this field of work.

4.10. Continuation of Essential DOD Contractor Services During Crisis IAW DoDI 3020.37.

IAW AFI 63-124, para 2.7.1, and DODI 3020.37 this requirement is not considered mission essential.

4.11. Contract Restriction: In accordance with the Agreement of Defense and Cooperation between the Kingdom of Spain and the United States of America, any contract resulting from this notice/solicitation can only be entered into with companies authorized to carry out these activities in Spain under Spanish law. Companies must meet the requirements established by

Spanish legislation for execution of Government works. In addition, in accordance with the

Office of Defense Cooperation Policy Directive 400- 5 "(4) Spanish material, labor, and equipment must be used if permitted by the requirements of the contract specifications."

APPENDICES

A. Existing Hoist Sketch

B. Existing Beam Channel Sketch

C. Pictures.

APPENDIX A

EXISTING HOIST SKETCH

APPENDIX B

EXISTING BEAM CHANNEL SKETCH

APPENDIX C

PICTURES