FOUO C04.01 Attachment 1 SOW 10-30-2020.pdf

TWO OVERHEAD ELECTRIC TRAVELING

BRIDGE CRANES FOR

PUGET SOUND NAVAL SHIPYARD (PSNS)

Date of Revision: 10/30/2020

PREPARED BY:

Code 713

Bldg. 448, PSNS

Bremerton Washington 98314

SPECIFICATION PREPARED BY:

Project Engineer: Nathan Pervinich

Branch Head Supervisor: Bryce Perkins

Contract Representative: James Wright

Contract Number 2

TABLE OF CONTENTS

1 GENERAL

STANDARDS

DEFINITIONS

CONTRACTOR COMPLIANCE

SUBMITTALS

DRAWINGS

QUALITY ASSURANCE

2 PRODUCTS

SYSTEM DESCRIPTION

CRANE REQUIREMENTS

PAINTING

LETTERING, MARKINGS, AND LABEL PLATES

UNIQUE IDENTIFIER TAG

3 EXECUTION

SITE SPECIFIC REQUIREMENTS

CONSTRUCTION PREPARATION

CRANE REMOVAL/INSTALLATION

TRAINING

APPENDIX (A) CRANE ENVELOPE DRAWING

APPENDIX (B) SHOP TEST PROCEDURE

APPENDIX (C) ACCEPTANCE TEST PROCEDURE

APPENDIX (D) BRAKE DATA SHEET

APPENDIX (E) PSNS SITE SPECIFIC REQUIREMENTS

APPENDIX (F) CONTROL SYSTEM INVENTORY

Contract Number 3

1 GENERAL

STANDARDS

If standards other than those listed below are used, proof of equivalence shall be provided.

Submit a certificate of compliance stating that the crane complies with the standards called out in this specification. (SUBMITTAL REQUIRED)

AMERICAN GEAR MANUFACTURERS’ ASSOCIATION (AGMA)

2001 – Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth

6013 - Standard for Industrial Enclosed Gear Drives

6019 – Gearmotors Using Spur, Helical, Herringbone, Straight Bevel, or Spiral Bevel Gears

6034 - Practice for Enclosed Cylindrical Wormgear Speed Reducers and Gearmotors

6035 - Design, Rating and Application of Industrial Globoidal Wormgearing

ASSOCIATION FOR IRON & STEEL TECHNOLOGY (AIST)

TR-06 - Specification for Electric Overhead Traveling Cranes for Steel Mill Service

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

B4.1 – Preferred Limits and Fits for Cylindrical Parts

B17.1 - Keys and Keyseats

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

B30.2 - Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist)

B30.10 – Hooks

AMERICAN SOCIETY OF NONDESTRUCTIVE TESTING (ASNT)

SNT-TC-1A – Personnel Qualification and Certification in Nondestructive Testing

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

A275 – Standard Practice for Magnetic Particle Exam of Steel Forgings

A388 - Standard Practice for Ultrasonic Examination of Steel Forgings

A1023/A - Standard Specification for Stranded Carbon Steel Wire Ropes for General Purposes

E94 - Standard Guide for Radiographic Examination

E164 - Standard Practice for Contact Ultrasonic Examination of Weldments

Contract Number 4

E165 - Standard Practice for Liquid Penetrant Examination

E317 - Standard Practice for Evaluating Performance Characteristics of Ultrasonic Pulse-Echo Testing Instruments and Systems

E543 - Standard Specification for Agencies Performing Nondestructive Testing

E709 – Standard Guide for Magnetic Particle Testing

F3125 - Standard Specification for High Strength Structural Bolts, Steel and Alloy Steel, Heat Treated, 120 ksi (830 MPa) and 150 ksi (1040 MPa) Minimum Tensile Strength, Inch and Metric Dimensions

F436 – Standard Specification for Hardened Steel Washers

F593 - Stainless Steel Bolts, Hex Cap Screws, and Studs

F594 - Stainless Steel Nuts

AMERICAN WELDING SOCIETY (AWS)

A2.4 - Standard Symbols for Welding, Brazing, and Nondestructive Examination

D14.1 - Welding of Industrial and Mill Cranes and Other Material Handling Equipment

CRANE MANUFACTURERS' ASSOCIATION OF AMERICA, INC (CMAA)

70 - Specification for Top Running & Gantry Type Multiple Girder Electric Overhead Traveling Cranes

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

15408 – Common Criteria for Information Technology Security Evaluation

NATIONAL ELECTRIC CONTRACTORS ASSOCIATION (NECA)

NECA 1 – Good Workmanship in Electrical Construction

NECA 130 – Installing and Maintaining Wiring Devices

NECA 230 – Electric Motors and Motor Controllers (1000 Volts and Less)

NATIONAL ELECTRICAL MANUFACTURERS' ASSOCIATION (NEMA)

NEMA ICS 3 - Industrial Control and Systems: Medium Voltage Controllers Rated 2001 to 7200 Volts AC

NEMA ICS 8 - Industrial Control and Systems Crane and Hoist Controllers

NEMA MG 1 - Motors and Generators

NEMA 250 - Enclosures for Electrical Equipment (1000 Volts Maximum)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 - National Electric Code

Contract Number 5

NFPA 70E – Standard for Electrical Safety in the Workplace

NFPA 79 – Electrical Standard for Industrial Machinery

NAVAL SHIPS TECHNICAL MANUAL (NSTM)

NSTM - Chp 613, Wire and Fiber Rope and Rigging

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

Title 29 CFR, Part 1910 Subpart D, Walking-Working Surfaces

Title 29 CFR, Part 1910.140, Personal Fall Protection Systems

Title 29 CFR, Part 1910.147, The Control of Hazardous Energy (lockout/tagout)

Title 29 CFR, Part 1910.179, Overhead and Gantry Cranes

Title 29 CFR, Part 1910.306, Specific Purpose Equipment and Installations

Title 29 CFR Part 1926.62, Safety and Health Regulations for Construction (Lead)

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

Specification for Structural Joints Using High-Strength Bolts

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE J429 - Mechanical and Material Requirements for Externally Threaded Fasteners

SAE J995 – Mechanical and Material Requirements for Steel Nuts

SOCIETY OF PROTECTIVE COATINGS (SSPC)

SSPC - SP 10, Near-White Metal Blast Cleaning

UNDERWRITERS LABORATORIES

UL 60947-4 – Low Voltage Switchgear and Controlgear

DEFINITIONS

Words that are italicized throughout this specification are defined below:

Angularity: Angle of shaft centerline measured from other shaft centerline.

Collision forces (CF): Defined per CMAA No. 70.

Control Circuit Type (Limit Switch): When activated this type of limit switch restricts the control operations of the crane.

End gap: Distance between the ends of two shafts after a coupling is installed.

Flex-Rigid Coupling: A coupling that allows for angularity but does not allow for offset.

Contract Number 6

Holding Brake: A brake that does not set on a moving shaft during normal operations, not including testing operations.

Joint Class I: Defined per section 6.9.1 of AWS D14.1.

Joint Class II: Defined per section 6.9.2 of AWS D14.1.

Load Bearing: Components are considered load bearing if they contribute to holding up a portion or all of the lifted load or dead weight of the crane.

Loss of Power Test: A test where the crane is lifting 100% load, and the power is removed from the hoist, bridge, or trolley when in operation, simulating a loss of power.

Offset: Vertical and horizontal distance between the center line of two shafts

Primary Hoist Brake: Hoist brake closest to hoist motor that is located on high speed shaft.

Primary Welds: Defined per section 3 of AWS D14.1.

Rigid-rigid Coupling: A coupling that does not allow for any angularity or offset misalignment.

Flange-to-flange shaft connections are examples of rigid-rigid couplings.

Secondary Hoist Brake: Hoist brake that is furthest from motor located on the high speed shaft.

Secondary Welds: Defined per section 3 of AWS D14.1.

Spliced Connection: Is a connection of two structural members where the two members are treated as one continuous member.

CONTRACTOR COMPLIANCE

The Contractor is required to read, understand, and comply with this entire specification.

The Government will determine compliance with the requirements of this specification by reviewing and accepting the submittals shown in section 1.4.4, attending an on-site shop test (Appendix B), performing crane inspections, and witnessing the Contractor complete the acceptance test (Appendix C).

SUBMITTALS

The Contractor is required, per this specification, to provide a submittal to the Government anytime there is a SUBMITTAL REQUIRED designation after a sentence. The Government will review each submittal within the time period stated in the Submittal Summary Table (section 1.4.4), and either provide comments or accept the submittal. For convenience each occurrence is listed in the Submittal Summary Table (section 1.4.4) along with the file format, location, due dates, and number of copies. The Contractor shall ensure that all submittals are entirely legible and suitable for reproduction.

A separate submittal for each crane is required. The submittals shall identify which crane they apply to by labeling with the crane number.

Design submittals for each crane (e.g. catalog cuts, calculations, drawings/schematics and technical/operation manual) shall be staggered by 10 days to allow adequate time for Government review.

Contract Number 7

The Government reserves the right to require changes to submittals, which may change the design, if the requirements of this specification are not met. Any fabrication work performed prior to obtaining design approval is at the Contractor’s risk.

SUBMITTAL SUMMARY TABLE:

Contract Number 8

SUBMITTAL FILE

FORMAT

SPECIFICATION

SECTION

CONTRACTOR DUE

DATE

GOVERNMENT

DUE DATE COPIES

TECHNICAL FORMS

Certificate of Compliance for Standards Listed in this Specification

.pdf 1.1.2 Prior to shop test

Review, comment, and submit within ten (10) business days after date received

Catalog Cuts (Structural, Mechanical, Electrical and Control System/Networking)

.pdf 1.4.5.2 Prior to manufacturing of crane

Review, comment, and submit within ten (10) business days after date received

Preliminary Drawings (Structural, Mechanical, Electrical, and Control System/Network)

.pdf and .dxf or .dwg 1.5.1 Prior to manufacturing of crane

Review, comment, and submit within ten (10) business days after date received

Final As-Built Drawings (Structural, Mechanical, Electrical, and Control System/Network)

.pdf and .dxf or .dwg 1.5.1 Ten (10) business days after crane acceptance

Review, comment, and submit within twenty (20) business days after date received

Preliminary Maintenance, Technical, and Operations Manual

.pdf 1.5.11.1 Ten (10) business days prior to crane delivery

Review, comment, and submit within ten (10) business days after date received

Final Maintenance, Technical, and Operations Manuals

Hard copy and .pdf 1.5.11.1 Ten (10) business days after crane acceptance

Review, comment, and submit within twenty (20) business days after date received

2 Hard Copies, 1 pdf

Contractor Schedule .pdf 1.6.1.1

First submittal prior to post-award meeting (after first submission an updated schedule shall be submitted monthly at a minimum)

Continual Feedback and Communication Regarding Schedule 1

Crane Envelope Drawing

.pdf, .dxf or

.dwg

1.6.3.1

Prior to manufacturing of crane

Review, comment, and submit within five (5) business

Final Parameter Record .pdf & CD/DVD 1.6.8.3 After field acceptance test

Review, comment, and submit within three (3) business days after date received

1 pdf &

1 CD/

DVD

Contract Number 9

FORMAT

SPECIFICATION

SECTION

CONTRACTOR DUE

DATE

GOVERNMENT

DUE DATE COPIES

Preliminary Calculations (Structural, Mechanical, and Electrical)

.pdf 1.6.13.1 Prior to manufacturing of crane

Review, comment, and submit within ten (10) business

Final Calculations (Structural, Mechanical, and Electrical)

.pdf 1.6.13.1 Prior to crane delivery

Review, comment, and submit within ten (10) business days after date received

Welder Certifications .pdf 1.6.14.1 Prior to performing welding

Review, comment and submit with two

(2) business days after date received

NDT Qualification Report .pdf 1.6.15.1 Prior to performing any

NDT

Review, comment, and submit within two (2) business days after date received

Weld NDT Reports .pdf 1.6.15.2 Prior to shop test meeting

Review, comment, and submit within five (5) business days after date received

Cybersecurity Certificate – Public Domain Software .pdf 1.6.16.1 Prior to manufacturing of crane

Review, comment, and submit within ten (10) business days after date received

Cybersecurity Certificate – Software and Services .pdf 1.6.16.2 Prior to manufacturing of crane

Review, comment, and submit within ten (10) business days after date received

Cybersecurity Closeout Submittals

.pdf and CD/DVD 1.6.17 Forty (40) business days prior to crane delivery

Review, comment, and submit within twenty (20) business days after date received

1 pdf &

1CD/

DVD

Overload Test Certificate .pdf 2.2.1 Prior to crane delivery

Review, comment, and submit within two (2) business days after date received

Loss of Power Test Certificate .pdf 2.2.4 Prior to crane delivery

Review, comment, and submit within two (2) business days after date

Contract Number 10

FORMAT

SPECIFICATION

SECTION

CONTRACTOR DUE

DATE

GOVERNMENT

DUE DATE COPIES

Hazardous Material Certificate

.pdf

2.2.6.4.1

Prior to shop test meeting and submit within one (1) business

Trolley and Bridge Wheel Specification Sheet .pdf 2.2.8.5.3

Provide report after completion of wheel sample

Review, comment, and submit within five (5) business days after date received

Coupling Alignment Certificate .pdf 2.2.9.3.4 Prior to acceptance of crane

Review, comment, and submit within five (5) business days after date

Wire Rope Braking Strength and Specification Certificate

.pdf

2.2.9.8.3

Prior to crane delivery and submit within two (2) business

Wire Rope End Connection Proof Test Certificate .pdf 2.2.9.8.5 Prior to crane delivery

Review, comment, and submit within two (2) business days after date received

Brake Setting Certificate .pdf 2.2.9.16.4 Prior to shop test

Review, comment, and submit within two (2) business days after date received

Lubrication SDS .pdf 2.2.9.19.1 Prior to applying lubrication or filling gearbox

Review, comment, and submit within five (5) business days after date received

Lifting & Handling Certificate of Compliance (NAVFAC P- 307, P1 form)

.pdf 3.2.2 Prior to use of crane/lifting and handling equipment at PSNS

Reviewed on site during equipment inspection (prior to PSNS entry)

Removal and Installation Lifting Plans .pdf 3.2.4.1 Forty (40) business days prior to crane delivery

Review, comment, and submit within twenty (20) business days after date

Contract Number 11

FORMAT

SPECIFICATION

SECTION

CONTRACTOR DUE

DATE

GOVERNMENT

DUE DATE COPIES

Lead Work Plan .pdf 3.3.4 Ten (10) business days prior to crane delivery (if applicable)

Review, comment, and submit within two (2) business days after date received

Training Syllabus .pdf 3.4.4 Prior to crane delivery

Review, comment, and submit within ten (10) business days after date received

APPENDIX (E) FORMS

Contractor Hazardous Material Inventory (CHMI) (Attachment 1)

Hard Copy or .pdf 3.1.2.1 Ten (10) business days prior to crane delivery

NA

TBD

Solid Waste Tracking Sheet (SWTS) (Attachment 3)

Hard Copy or .pdf 3.1.2.2

Filled out when disposing of waste at Contractor determined disposal facility

NA

TBD

Contractor’s Monthly Project Waste Summary Report (CMPWSR) (Attachment 4)

Hard Copy or .pdf 3.1.2.3 Monthly during on-site work

NA

TBD

Personal Information for Visitor Request (Attachment 6)

Hard Copy or .pdf 3.1.2.4 Ten (10) business days prior to coming to PSNS

NA TBD

AIS Survey (Attachment 7) Hard Copy or .pdf 3.1.2.5

Twenty (20) business days prior to bringing a laptop into the CIA

NA

TBD

Radio Operations Request (Attachment 8)

Hard Copy or .pdf 3.1.2.6

Ten (10) business days prior to coming to PSNS with a radio

NA

TBD

Vehicle Pass Request for Access to the Controlled Industrial Area (CIA) (Attachment 12)

Hard Copy or .pdf 3.1.2.7

Twenty (20) business days prior to bringing a vehicle into the CIA at

PSNS

NA TBD

Foreign Interest Determination (Attachment 13)

Hard Copy or .pdf 3.1.2.8 Twenty business days prior to coming to PSNS

NA

TBD

Certificate of Compliance Form (Attachment 16)

Hard Copy or .pdf 3.1.2.9

Prior to use of crane/lifting and handling equipment at PSNS

Government will fill out form on-site with Contractor

TBD

Contractor Operator License Hard Copy or .pdf 9.6, Appendix E

Submit License(s) prior to operating equipment such as fork lift, ariel work platform, crane, and other types of equipment

NA

TBD

Contract Number 12

FORMAT

SPECIFICATION

SECTION

CONTRACTOR DUE

DATE

GOVERNMENT

DUE DATE COPIES

Waste Information Sheet

(WIS)

Hard Copy or .pdf 3.1.2.10 Ongoing as waste is generated

NA TBD

CATALOG CUTS:

Catalog cuts for all commercially available components shall be provided as a submittal to the Government. The catalog cuts shall be marked to clearly display what component and component options are used on the crane, e.g., part number, model, and load rating.

The Contractor shall submit for approval all applicable component catalog cuts listed below and any other commercially available components not listed. If components below are fabricated by the Contractor then design drawings will need to be submitted in place of catalog cuts.

(SUBMITTALS REQUIRED)

STRUCTURAL CATALOG CUTS

1.4.5.3.1 End trucks (including drive units)

1.4.5.3.2 Product information for all paint used on the crane

1.4.5.3.3 Trolley end stops

1.4.5.3.4 Trolley rails

1.4.5.3.5 Commercial lifting attachment points

1.4.5.3.6 Manufacture’s installation instructions for swing gates

MECHANICAL CATALOG CUTS

1.4.5.4.1 Speed reducers (including gear ratio, HP rating, speed ratings, service factors)

1.4.5.4.2 Brakes (including electrical information, installation, servicing and adjusting)

1.4.5.4.3 Bearings (including lubrication instructions, load ratings)

1.4.5.4.4 Couplings (including acceptable offset, angularity, and end gap values as applicable)

1.4.5.4.5 Load blocks and hooks

1.4.5.4.6 Wheels

1.4.5.4.7 Sheaves

1.4.5.4.8 Bumpers (including bumper compression and the resulting force based on the total kinetic energy absorbed)

1.4.5.4.9 Wire rope and end fittings

ELECTRICAL CATALOG CUTS

Contract Number 13

1.4.5.5.1 Variable Frequency Drive Controllers (including dynamic braking resistors and line reactor selection/isolation transformers)

1.4.5.5.2 Motors

1.4.5.5.3 Encoders

1.4.5.5.4 Electrical Enclosures

1.4.5.5.5 Runway Electrification and Collectors

1.4.5.5.6 Limit Switches

1.4.5.5.7 Bridge-to-Trolley Electrification

1.4.5.5.8 Warning Devices

1.4.5.5.9 Disconnect Switches

1.4.5.5.10 Contactors and Relays

1.4.5.5.11 Pendant Controls

1.4.5.5.12 Auxiliary Devices (Floodlight, Horn, etc.)

1.4.5.5.13 Circuit Breakers

1.4.5.5.14 Fuses

NETWORKED CONTROL SYSTEM AND NETWORK PRODUCT DATA

1.4.5.6.1 To include, but not limited to the following devices: Crane Supervisory Controller, Programmable Logic Controller/Relay (PLC/PLR), Remote Terminal Unit (RTU), Human Machine Interface (HMI), Motor Drive Interface Terminal, Network Communication Module, Network Router, Network Switch/Hub, or other network-capable (whether networked or not upon delivery) device as applicable).

1.4.5.6.2 Provide the each of the following pieces of data for each applicable device:

1.4.5.6.2.1 Device Manufacturer

1.4.5.6.2.2 Device Model

1.4.5.6.2.3 Device (relative) Location

1.4.5.6.2.4 Key Technical Ratings (e.g. memory, capacity, format, compatibility, etc.)

1.4.5.6.2.5 Serial Number

1.4.5.6.2.6 Unique Network Identifier/Address

1.4.5.6.3 Provide each of the following pieces of data for software:

1.4.5.6.3.1 Manufacturer

1.4.5.6.3.2 Version/Sub-Version

Contract Number 14

1.4.5.6.3.3 Associated device (relative) location

1.4.5.6.3.4 Used network ports/protocols/services

1.4.5.6.4 Descriptions of all security features associated to vendor hardware and software.

Contract Number 15

DRAWINGS

Provide a preliminary drawing package to the Government for review (SUBMITTAL REQUIRED). Provide a final design drawing package that complies with all requirements listed in section 1.5 (SUBMITTAL REQUIRED). The preliminary and final design drawing packages shall include all general arrangement drawings, structural/mechanical drawings, electrical drawings.

Drawings that use foreign language and nomenclature shall include corresponding English equivalents. Metric units may be used for drawings, but they shall include conversions to English units on the drawings.

All drawings shall have a complete title block that includes the crane number, and the signature and seal of a registered Professional Engineer that directly oversees the work. There shall be no proprietary notes on any of the drawings.

All drawings shall have a comprehensive and complete bill of materials for the given drawing.

Each revision shall be tracked and marked on the drawing. An index of drawings shall be included that tracks current revisions of drawings.

All drawings must be provided in PDF format during the design review phase and in PDF and DWG or DXF for final submitted drawings.

GENERAL ARRANGEMENT DRAWINGS

Provide general arrangement drawings that show all assemblies in plan, elevation, and side views. These drawings shall show all mechanical components and assemblies, e.g., hoist assembly, trolley and bridge drivetrains, building clearances, and principal dimensions that include tolerances.

Provide general arrangement drawings that show major components in plan, elevation, and end views. All major features of the crane shall be shown including: clearances, lifts, spans, wheel spacing, rated speeds, trolley gage, hook approaches on all sides, maximum wheel loads, electrical power supply, and general locations of components, e.g., brakes, motors, speed reducers, electrical enclosures (including size).

Include weights of all components and maximum bridge wheel loads (without impact), wheel spacing, and show the location of the center of gravity of the trolley and bridge assemblies.

STRUCTURAL/MECHANICAL DRAWINGS

Provide a complete drawing package detailing all fabricated components and structural assemblies/weldments, include tolerances, camber requirements, weld call outs per AWS A2.4, material type and the standard associated with the material type, e.g., ASTM A36. For structural fasteners, include size and type of fastener and associated hardware.

Wheels and shafts (excluding motor and gearbox) machining detail including material type, hardness and ultimate and yield strength. Gearbox assembly/setup drawings including any backlash limits and shim stacks or preload requirements.

Reeving diagram including wire rope specification. Sheave assemblies including machining details, dimensions, material type and hardness.

Contract Number 16

Component bolt torque values shall be provided for installed fasteners with consideration for any lubrication and washers type. A general table may be used however, any special torques shall be called out on the applicable drawing.

Coupling & brake installation drawings including: locations, applicable shaft engagement, allowable misalignment, and bore and key details.

Hook block assembly drawing with bearing size, load ratings, part numbers and material type.

ELECTRICAL DRAWINGS

Provide electrical schematics and wiring diagrams for all electrical components and drives.

The schematics and wiring diagrams shall have sufficient detail that show; wire sizes, types and sizes of protective devices, all installed electrical components and connections, settings and application appropriate adjustment ranges for tunable/adjustable devices as determined by the crane designer, motor rated current motor horsepower, and a detailed bill of materials associated to all electrical components. The wiring diagram shall include all system and equipment grounding conductors.

Provide crane electrification detail drawings that include the runway conductor installation including method of attachment to building and spacing, the electrical supply circuit (conduit) routing path between existing circuit breaker and the connection point to the overhead runway conductor system and conductor size and approximate length of supply feeder conductors.

Provide motor nameplate data and overcurrent device ratings including all information called for in NFPA 70 Section 430.7.

Provide a comprehensive and complete drive parameter listing and all custom programming associated with the crane.

CONTROL SYSTEM AND NETWORK DRAWINGS

Network diagram must show interconnecting cabling, equipment locations, names, models, and unique network identification on network communications schematic for all network-capable devices.

Software logic graphical diagram (e.g. flow or block diagram, ladder-logic diagram, etc.)

1.5.10.2.1 Ladder logic and/or software flow/block diagrams shall include comments explaining the function of each unique software task or operation.

Network variable cross-reference list (or table) for all variables spanning multiple network protocols shall be provided in a drawing format. This list or table shall provide variable names and register addresses used in each communication protocol and each variable shall be correlated to the hardware/device served.

OPERATIONS AND MAINTENANCE/TECHNICAL DATA

The Contractor shall submit a preliminary copy of the crane’s operations and maintenance/technical manuals to the Government for review. The Contractor shall submit final copies of the operations and maintenance/technical manuals once all Government comments have been addressed. (SUBMITTAL REQUIRED)

Contract Number 17

The operations and maintenance/technical manual may be combined into one manual or may be separated out into multiple manuals. A detailed table of contents is required and all pages shall be individually numbered in a manner that corresponds to the table of contents.

OPERATIONS MANUAL

1.5.11.3.1 The body of the operations manual shall include detailed crane operating and safety instructions including specific starting/stopping instructions.

MAINTENANCE/TECHNICAL MANUAL

1.5.11.4.1 The maintenance/technical manual shall include detailed written procedures necessary to maintain the crane, all catalog cuts, a recommended spare parts list, and the final as-built crane drawing package.

1.5.11.4.2 The maintenance/technical manual shall include detailed maintenance procedures, and manufacturer’s installation and maintenance manuals for commercial components. If applicable, the manuals shall include alignment, adjustment, and calibration instructions.

1.5.11.4.3 Provide preventative maintenance instructions including location of lubrication points, type of lubricant used, and the frequency of lubrication.

1.5.11.4.4 Provide part numbers and all available information for all Contractor-designed parts, purchased sub-assemblies and components. The information shall be broken down to the smallest replacement part.

1.5.11.4.5 The maintenance/technical manual shall include all of the crane’s final as-built programming, i.e., ladder logic diagrams, software flow diagrams, parameter listings, or any other type of machine controlling software code that is used in the Contractor’s design.

Ladder logic and software flow diagrams shall include comments explaining the function of each unique software task/operation. The maintenance/technical manual shall include the Contractor’s recommended methods for tuning the motion controlling electronics to achieve various levels of performance, while staying within crane design allowances and/or limitations; and include a functional description of each subsystem and how each subsystem interfaces to the rest of the crane.

QUALITY ASSURANCE

CONTRACTOR SCHEDULE

The Contractor shall submit a preliminary schedule that details key events in the design, fabrication, and installation of the crane. The schedule shall be updated and submitted, at a minimum, monthly throughout the duration of the contract (SUBMITTAL REQUIRED). At a minimum the schedule shall include the information below (the order of events shown below is not fixed):

1.6.1.1.1 Post-Award Meeting

1.6.1.1.2 Crane Envelope and Dimension Verification

1.6.1.1.3 Preliminary Drawings and Calculation Submittals

1.6.1.1.4 Government Review of Initial Design

Contract Number 18

1.6.1.1.5 Final Drawings and Calculation Submittals

1.6.1.1.6 Government Review of Final Design

1.6.1.1.7 Start of Fabrication

1.6.1.1.8 Shop Test Meeting

1.6.1.1.9 Completion of Fabrication

1.6.1.1.10 Pre-Installation Meeting

1.6.1.1.11 Crane Delivery

1.6.1.1.12 Existing Crane Removal

1.6.1.1.13 New Crane Installation

1.6.1.1.14 Acceptance Test

1.6.1.1.15 Crane Acceptance

1.6.1.1.16 Completion of Warranty

CONTRACTOR VERIFICATION AND POST-AWARD MEETING (CONTRACTOR AT PSNS)

The Contractor shall meet with the Government at PSNS after the contract has been awarded.

This meeting will be used to discuss the contract and any other questions that arise.

The Contractor shall verify, on-site all electrification information necessary to install new runway conductors/grounding, conduit, and wiring from the crane to the building control panel (see section 2.2.10.6 for requirements).

CRANE ENVELOPE SURVEY

The Contractor shall verify all crane envelope clearances, hook approaches, hook heights, spans and other building/runway features, prior to designing the crane and shall submit a crane envelope drawing similar to the one shown in Appendix (A). The location and dimensions of the boarding platform shall also be included in this survey, see section 2.2.6.2.1. The purpose of Appendix (A) is to provide an example crane envelope and should not be used to design the crane. (SUBMITTAL REQUIRED)

CONTRACTOR TESTING

Prior to the Shop Test Meeting (see section 1.6.5), the Contractor shall test the operations of the crane under a no load condition. The Contractor shall perform a detailed inspection of the crane and its components and test all possible functions of the assembled crane. Once the Contractor successfully tests and inspects the crane, the Contractor shall notify the Government to schedule the Shop Test Meeting.

SHOP TEST MEETING (GOVERNMENT AT CONTRACTOR’S FACILITY)

Contract Number 19

The Contractor shall allow the Government to come to the Contractor’s facility and participate in a Shop Test Meeting and crane inspection. This meeting will cover the submittals that the Contractor is responsible for providing to the Government, shop testing, shipping, site mobilization, erection dates, crane installation plan, roles and responsibilities of the entities involved, and the overall schedule.

The Contractor shall be available to operate the crane, participate in the shop test, complete the shop test shown in Appendix (B), and answer any questions that arise. All contract violations found during the shop test will be recorded by the Government on a punch list. The Government will conduct an out-brief with the Contractor and will go over every punch list item with the Contractor before leaving the Contractor’s facility. All punch list items shall be resolved by the Contractor prior to shipping the crane to PSNS. The crane shall not be shipped to PSNS until the Government accepts the Contractor’s request to ship.

PRE-INSTALLATION MEETING (CONTRACTOR AT PSNS)

The Contractor shall attend a Government conducted pre-installation conference that will be held at the installation site. This conference will provide the Contractor/Sub-Contractors, and the Government the ability to review all aspects of the crane installation to ensure accuracy and safety.

GOVERNMENT INSPECTION

Once the Contractor has installed, tuned, tested and is ready for acceptance testing, the Contractor shall allow the Government to conduct a 3-5 day inspection (per crane) prior to field acceptance testing. The Contractor shall be available to operate the crane at the request of the inspectors during this 3-5 day period. The government shall be given a 2 day notice that the crane is ready for inspection before the 3-5 day period begins. All references to “days” in this section are considered working days (M-F).

All items that are found during the Government inspection that do not meet the requirements of this contract shall be written on the punch list and corrected by the Contractor prior to acceptance testing. After the corrections have been made, the Government has one day (per crane) to re-inspect the crane to ensure all the corrections have been made.

FIELD ACCEPTANCE TEST

The Acceptance Test, shown in Appendix (C), shall be satisfactorily completed after each crane is installed inside building 455 at PSNS by the Contractor. The Government will provide all test weights and rigging gear. If the crane fails to complete an item listed in Appendix (C) the test shall be repeated after repairs/adjustments have been made until the test is passed. Any repairs that would affect an already tested component will require retesting of the previously tested component. The Government may, if necessary, request additional tests to determine that the crane meets the requirements of this specification.

The Government shall have one regular work day to conduct a final inspection after the Field Acceptance Testing is completed.

Contract Number 20

After the crane has passed the field acceptance test, the contractor shall complete a control system parameter record for the crane and provide the crane parameter file downloaded from the crane at a 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. A copy of the parameter file records shall be provided to the Government on CD. (SUBMITTAL REQUIRED)

ACCEPTANCE

Final Government acceptance of the cranes shall take place only after the following conditions are met:

1.6.9.1.1 Contractor receives Government approval for all tests, inspections, and verification that all submittals have been received and acceptable.

1.6.9.1.2 The cranes meet all contract requirements.

1.6.9.1.3 The cranes pass a final inspection by the Government.

1.6.9.1.4 All punch list items have been corrected or a method of resolution has been determined.

Outstanding punch list items not corrected prior to the Government's acceptance shall be carried as warranty items, which shall be corrected by the Contractor.

CONFERENCE CALLS

The Contractor shall support 30 minute weekly teleconferences at the Government’s request including the Contractor project manager and lead engineer.

GOVERNMENT INSPECTIONS

The Government may perform scheduled inspections of material, workmanship, and documentation throughout the life of the contract. If the Government determines there is a problem with quality, then they will submit a written notification to the Contractor and they shall respond to each identified problem within ten day(s) of receiving the notification.

MANUFACTURER QUALIFICATIONS

The overhead electric crane system, including sub-system components manufactured by vendors, shall be designed and manufactured by a company with experience in designing this type of crane or system and can meet the requirements of this specification.

CALCULATIONS

The Contractor shall provide preliminary and final structural, mechanical, and electrical calculations to the Government that validate that the design complies with the requirements in section 1.6.13, CMAA No. 70, and all other applicable requirements in this specification (SUBMITTAL REQUIRED). Design calculations shall be provided for custom items, and sizing calculations shall be provided for commercial items.

Design calculations that use foreign language and nomenclature shall include English equivalent nomenclature. Metric units may be used for calculations, but they shall include conversions to English units. In the case of calculations, only the initial inputs and final results need to be converted.

Contract Number 21

All calculation submittals shall be labeled with the crane number.

Any Finite Element Analysis (FEA) that is provided as a submittal shall come with hand calculations that verify the FEA model and a write-up that details the designer’s assumptions and explains the thought process behind the model.

STRUCTURAL CALCULATIONS

1.6.13.5.1 Operating Wind loads and Stored Wind Loads (WLO and WLS) shall be neglected since the crane will be indoors. Collision forces (CF) due to the crane impacting the bridge and trolley end stops shall be accounted for; however, calculations from two cranes colliding may be neglected since there are no other cranes on the rail.

1.6.13.5.2 Calculations verifying the maximum wheel loading are required.

1.6.13.5.3 Calculations are required for sizing of the girders, end trucks, welds and bolt sizes.

1.6.13.5.4 Calculations verifying the design of trolley frame including its end stops shall be provided.

1.6.13.5.5 Calculations shall be provided that verify all lifting attachment points.

1.6.13.5.6 Perform a seismic analysis per the requirements of section 2.2.8.6.

1.6.13.5.7 Calculations shall be provided to verify the sizing of new runway end stops.

MECHANICAL CALCULATIONS

1.6.13.6.1 Calculations are required for sizing of couplings, brakes, sheaves, wheels, bumpers, gear reducers, drum, wire rope and bearing life.

1.6.13.6.2 Fatigue calculations shall be provided for any custom design shafts. The calculations shall address the stresses and fatigue induced by the OEM allowed misalignment of couplings in addition to other applied forces.

1.6.13.6.3 The calculations shall address overstressing the drivetrain and reducers during a situation where both the primary and secondary brakes set at the same time without the drive controls stopping the test load. The calculations shall address the worst case scenarios regarding hoist up/down, no load/max load, and slow speed/rated speed. This load case is considered a momentary peak load. The stress due to this load case shall not exceed the component OEM’s peak load rating or for custom designed components, 75% of the yield strength of the material.

1.6.13.6.4 Any non-commercial mechanical components shall be analyzed to show compliance with CMAA No. 70.

ELECTRICAL CALCULATIONS

1.6.13.7.1 Conduit fill calculations (using tables from NFPA 70 or manufacturer’s data sheets).

Grounding conductors shall be included in the calculations.

Contract Number 22

1.6.13.7.2 Protective device coordination study showing proper coordination for any overcurrent devices that have the same rating as another overcurrent device upstream. This study shall include all devices from the line side of the primary facility overcurrent device. 5.685kA of fault current is available at each existing crane primary facility overcurrent device.

1.6.13.7.3 Provide arc flash energy calculations for each electrical enclosure showing proper data necessary for appropriate arc flash labels per NFPA 70E Flash Calculations.

1.6.13.7.4 Provide wire sizing calculations for all power circuit conductors.

1.6.13.7.5 Provide component and device sizing calculations for transformers, reactors, resistors and control panel environmental controls.

1.6.13.7.6 An analysis of the temperature inside the electrical enclosures shall be conducted to ensure that the OEM recommended climate of the components inside is being maintained.

WELDING

Welders shall be qualified per AWS D14.1 section 9. (SUBMITTAL REQUIRED)

Welded or fabricated items (not including commercially purchased components) shall be per

AWS D14.1.

Workmanship regarding welds shall be performed per Section 7 of AWS D14.1.

All weld repairs for primary and secondary welds shall be per section 12 of AWS D14.1.

NON-DESTRUCTIVE TESTING (NDT)

The Contractor shall provide a certificate with qualification data showing that the inspector performing NDT on the crane is qualified as a level 2 examiner per ASNT-SNT-TC-1A

(SUBMITTAL REQUIRED).

All NDT performed per the NDT Table section 1.6.15.3, including visual inspection, shall be fully documented, and submitted to the Government. (SUBMITTAL REQUIRED). At a minimum, the test document shall provide the acceptance criteria used, identification of the weld or component that was tested, test results, and the individual who performed the test/inspection.

NDT TABLE

DESCRIPTION EXAMINATION METHOD

*Primary Welds V, MT

*All Joint Class I and II welds that are considered Primary Welds (Section 10.8.1 of AWS D14.1)

V, MT, UT

All Lifting Attachment Welds V, MT

*All Secondary Welds (Section 10.6 of AWS D14.1) V

Hook and Eye Pin or Swivel Eye Bar V, (MT performed by Government)

Contract Number 23

*See section 1.2 for definitions regarding joint class, primary welds, and secondary welds

Radiographic examination can be used in place of ultrasonic examination.

VISUAL EXAMINATION (V):

1.6.15.2.1 All welds shall have a visual examination. Acceptance criteria for a Visual Examination shall be per section 7, 10.6, and 10.7 of AWS D14.1 and any other applicable standards included in these sections.

MAGNETIC PARTICLE TESTING (MT):

1.6.15.3.1 All magnetic particle testing shall be performed per ASTM E709.

1.6.15.3.2 Acceptance criteria shall be per section 10.16.4 of AWS D14.1. A minimum length of 20% of the primary welds shall be randomly selected for MT; if a sample shows defects, two adjacent locations shall be inspected. The entire length of weld is required to be inspected if either of the sample locations show defects.

1.6.15.3.3 The entire weld of a lift attachment point shall be magnetic particle tested.

RADIOGRAPHY EXAMINATIONS (R):

1.6.15.4.1 Welds that are subjected to radiography examination shall first undergo a visual examination per sections 7, 10.6, and 10.7 of AWS D14.1.

1.6.15.4.2 All radiography examinations shall be conducted per ASTM E94.

1.6.15.4.3 Acceptance criteria for Radiographed welds shall be per section 10.11 of AWS D14.1 and any applicable standards included in this section.

ULTRASONIC EXAMINATIONS (UT):

1.6.15.5.1 Welds that are subjected to ultrasonic examination shall first undergo a visual examination per sections 7, 10.6, and 10.7 of AWS D14.1.

1.6.15.5.2 All ultrasonic examinations shall be conducted per section 10.13 and 10.14 of AWS D14.1 and ASTM E164/E317.

1.6.15.5.3 Acceptance criteria for ultrasonic examinations shall be per section 10.15 of AWS D14.1 and any applicable standards included in this section. A minimum length of 20% of joint class I and II primary welds shall be randomly selected for UT; if a spot shows defects, two adjacent locations shall be inspected. The entire length of weld is required to be inspected if either of the spot locations show defects.

CYBERSECURITY CERTIFICATES

The Contractor shall provide a declaration that public domain software (e.g., freeware, shareware) is not used in the system (SUBMITTAL REQUIRED).

Contract Number 24

The Contractor shall provide a certificate stating that all software and services that are not required for operation and/or maintenance of the product have been removed (SUBMITTAL REQUIRED). If removal is not technically feasible, then the contractor shall take action to disable software not required for the operation and/or maintenance of the product, and shall note this on the submitted certificate. Configure the product to allow the ability to re-enable ports and/or services if they are disabled by software. The removal of software or services shall not impede the primary function of the product. If software that is not required cannot be removed or disabled, document a specific explanation and provide risk mitigating recommendations and/or specific technical justification. The software/service to be removed and/or disabled shall include, but not be limited to:

1.6.16.2.1 Cameras

1.6.16.2.2 Games

1.6.16.2.3 Device drives or product components not procured/delivered

1.6.16.2.4 Messaging services (e.g. Email, instant messenger, peer-to-peer file sharing, etc.)

1.6.16.2.5 Source code

1.6.16.2.6 Software compilers in workstations

1.6.16.2.7 Software compilers for programming languages that are not used in the control system

1.6.16.2.8 Unused networking and communications protocols

1.6.16.2.9 Unused administrative utilities, diagnostics, network management, and system management functions

1.6.16.2.10 Backups of files, databases, and programs used only during system development

1.6.16.2.11 All unused data and configuration files

1.6.16.2.12 Remove and/or disable, through software, physical disconnection, or engineered barriers, all services and/or ports in the procured product not required for normal operation, emergency operations, or troubleshooting. This shall include communication ports and physical input/output ports (e.g., USB docking ports, video ports, and serial ports).

CYBERSECURITY CLOSEOUT SUBMITTALS

Disabled Ports, Connections, and Interfaces (SUBMITTALS REQUIRED)

1.6.17.1.1 Provide list of disabled ports, connectors, and interfaces associated to all network-capable devices including the engineering workstation.

1.6.17.1.2 Provide disclosure of any known methods for bypassing computer authentication in the product, often referred to as backdoors, and provide written documentation that all such backdoors created have been permanently deleted from the system.

1.6.17.1.3 Provide summary documentation of the procured product's security features and security-focused instructions on product maintenance, support, and reconfiguration of default settings.

Contract Number 25

Network Capable Devices (SUBMITTALS REQUIRED)

1.6.17.2.1 For every network-capable control device (whether networked or not upon delivery), provide the following on CD/DVD:

1.6.17.2.1.1 Original firmware

1.6.17.2.1.2 Original Firmware hash

1.6.17.2.1.3 Standard Operating Procedure (SOP) for application of firmware update/patches

1.6.17.2.1.4 Point of contact (POC) or web-address for firmware updates/patches

1.6.17.2.1.5 Number of interfaces and types

1.6.17.2.1.6 Protocols in use, per interface

1.6.17.2.1.7 Configuration file

1.6.17.2.1.8 SOP for configuration

Engineering Workstation (SUBMITTALS REQUIRED)

1.6.17.3.1 Provide the following on CD/DVD

1.6.17.3.1.1 SOP for application of software updates/patches

1.6.17.3.1.2 POC or web-address for software updates/patches including vendor provided software

1.6.17.3.1.3 Protocols in use, per interface

1.6.17.3.1.4 SOP for configuration

1.6.17.3.1.5 PLC programming interface software and licensing

1.6.17.3.1.6 Any other compatible software and licenses to allow the crane software or firmware to be troubleshot, checked, and upgraded.

Control System Access Control

1.6.17.4.1 The Contractor shall document options for defining access and security permissions, user accounts, and applications with associated roles.

Control System Account Management

1.6.17.5.1 The Contractor shall document all accounts (including, but not limited to, generic and/or default) that need to be active for proper operation of the procured product.

Patch Management and Updates

1.6.17.6.1 The Contractor shall provide documentation of its security patch management program and update process (including third-party hardware, software, and firmware). This documentation shall include resources and technical capabilities to sustain this program and process.

Contract Number 26

1.6.17.6.2 The Contractor shall provide recommended of how security patch integrity can be validated by the Acquirer. This documentation shall also include the Supplier’s approach and capability to remediate newly reported zero-day vulnerabilities.

Malware Detection and Protection

1.6.17.7.1 The Contractor shall provide, or specify how to implement, the capability to automatically scan any removable media that is introduced to the product being acquired.

Wireless Technology Provisions

1.6.17.8.1 The Contractor shall document the following.

1.6.17.8.1.1 Specific protocols and other detailed information required for wireless devices to communicate with the control network, including other wireless equipment that can communicate with the Contractor-supplied devices.

1.6.17.8.1.2 Use, capabilities, and limits for the wireless devices.

1.6.17.8.1.3 Power and frequency requirements of the wireless devices (e.g., microwave devices meet the frequency requirements of Generic Requirements [GR]-63 Network Equipment Building System [NEBS] and GR-1089).

1.6.17.8.1.4 Range of the wireless devices and verify that the range of communications is minimized to both meet the needs of the Acquirer’s proposed deployment and reduce the possibility of signal interception from outside the designated security perimeter.

1.6.17.8.1.5 Wireless technology and associated devices compliance with standard operational and security requirements specified in applicable wireless standard(s) or specification(s) (e.g., applicable IEEE standards, such as 802.11).

1.6.17.8.1.6 Configuration control options that enable varying of the security level of the devices.

Control System Inventory (SUBMITTAL REQUIRED)

1.6.17.9.1 The Contractor shall provide the complete control system inventory in accordance with Appendix F. All microprocessor controlled devices provided as part of the cranes and/or Engineering Workstations shall be documented using Appendix F.

Evaluation Status of Hardware and Software (SUBMITTAL REQUIRED)

1.6.17.10.1 As applicable, the Contractor shall provide information in Common Criteria or National Information Assurance Partnership (NIAP) or Federal Information Processing Standards (FIPS) evaluation status of hardware and software.

Contract Number 27

2 PRODUCTS

SYSTEM DESCRIPTION

The intent of this specification is to procure two double girder, pendant controlled, top running, overhead electric traveling cranes, each with a single hoist. The cranes will replace existing cranes (USN# 103005 (5-ton) & 103006 (15-ton)). The cranes shall be installed in Building 455 at Puget Sound Naval Shipyard (PSNS) in Bremerton Washington. The cranes shall be built to the design drawings of a registered Professional Engineer. The cranes shall be designed, fabricated, assembled, shop tested, delivered, installed, inspected, field tested, and made ready for use per this specification.

The crane’s characteristics shall be as follows:

Location New Crane Number

Minimum Capacity (lbs.)

Span (ft-in)

Minimum End Truck Wheel Spacing (ft-in)

Runway Length (ft)

Runway Height (ft-in)

Rail Size

(ASCE)

Maximum Allowable Wheel Load (lbs.)

Building 455 455-B-

10,000 lbs. *37’-3” 7’-3” 160’ 28’-2” 50# 14,000 lbs

Building 455 455-B-

30,000 lbs. *37’-1” 11’-0” 160’ 28’-2” 50# 25,000 lbs

*Span dimensions are approximate. Final values shall be verified by the Contractor per section 1.6.3.1

CRANE REQUIREMENTS

The bridge wheel spacing (center to center distance) shall meet the minimum given in Table 2.1.2.

The wheel loading shall be minimized to the maximum extent. The cranes shall be designed for periodic load testing of (125% -5%/+0%) of rated capacity. The Contractor shall provide an overload test certificate stating that the cranes can be periodically load tested to (125% -5%/+0%) of rated load. (SUBMITTAL REQUIRED)

The cranes shall be designed as Class C service cranes per…