IBM09B0019 A002.pdf

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

1. CONTRACT ID CODE RATING

2. AMENDMENT/MODIFICATION NO.

A002

3. EFFECTIVE DATE

08/25/2009

4. REQUISITION/PURCHASE REQ. NO. 5. PROJECT NO. (If applicable)

IBWC_CODE

International Boundary and Water Commission

(IBWC)

USIBWC - ACQUISITIONS DIV

4171 NORTH MESA, STE. C100

EL PASO, TX 79902-1441

Patricia Singer

NAME

TEL.

singerps@state.gov

EMAIL

6. ISSUED BY CODE7. ADMINISTERED BY (If other than Item 6)

9A. AMENDMENT OF SOLICITATION NO.

IBM09B0019

CONTACT DUNS

CODE FACILITY CODE

8. NAME AND ADDRESS OF CONTRACTOR (No., street, country, state and ZIP Code) (X)

X 9B. DATED (SEE ITEM 11)

07/21/2009

10A. MODIFICATION OF CONTRACT/ORDER NO.

10B. DATED (SEE ITEM 13)

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X XThe above numbered solicitation is amended as set forth in item 14. The hour and date specified for receipt of Offers is extended, is not extended, Offers must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended, by one of the following methods: (a) By completing items 8 and 15, and returning __1__copies of the amendment;(b)By acknowledging receipt of this amendment on each copy of the offer submitted; or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM ONLY APPLIES TO MODIFICATION OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

CHECK ONE A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(b).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.__1__X

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

Purpose of amendment A002 reference solicitation for retrofitting a 45/30 ton crane is as follows:

a. Contractors questions and answers are enclosed. The answers to the questions are for information purpose only and do not change the terms of the contract nor do they alter the specifications and plans. Any changes will be done by amendment addressing the specific changes in specifications/plans and/or terms of the solicitation.

b. Revised scope of work is attached.

c. The date for reciept of bids is extended to September 15, 2009, 3:00 P.M., local time.

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print) 16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

Patricia Singer

(Signature of person authorized to sign)

15B. CONTRACTOR/OFFEROR 15C. DATE SIGNED

By (Signature of Contracting Officer)

16B. UNITED STATES OF AMERICA 16C. DATE SIGNED

NSN 7540-01-152-8070

Previous edition unusable

STANDARD FORM 30 (REV. 10-83)

Prescribed by GSA FAR (48 CFR) 53.243

IBM09B0019

Summary Info Continuation Page Continuation Sheet

Table of Contents

Section Description Page Number

0 Commercial Clauses A002 Questions & Answers

C Descriptions/Specifications/Statement of Work

A002 REVISED SPECIFICATIONS FOR 45-TON GANTRY CRANE (ROADWAY)

A002-1 REVISED SPECIFICATION FOR 30-TON GANTRY CRANE (SPILLWAY)

F Deliveries or Performance 52.211-10 Commencement, Prosecution, and Completion of Work (Apr 1984)

Section 0 - Commercial Clauses

A002 Questions & Answers

1 QUESTION: Is the performance period firm? The lead time generally required for controls and motors such as these is between 80 & 100 days to ship after submittal approval. If it takes 3 weeks +- to create submittals and 2 weeks to approve them, we are already overdue. This assumes that there are no re-submittals necessary. In my experienced opinion, a more realistic period, that would allow for the submittal process, manufacturing of the equipment and installation, testing, etc, would be about 165-180days.

ANSWER: Change period of performance for 45 ton crane to 180 days and add additional 20 calendar days if 30 ton is added for a total of 200 days.

2 QUESTION: Are the existing hoist brakes to be re-used? Aren't they also 1955 vintage? It appears that only the trolley and bridge brakes are to be replaced.

ANSWER: The hoist brakes shall be replaced; both main and auxiliary brakes.

3 QUESTION: Are the new controls to be open or closed-loop design?

ANSWER: The controls shall be a closed-loop design.

4 QUESTION: Is a spare parts list going to be required as part of the project? Typically it is.

ANSWER: This is already a requirements under XIV. Close-Out Documentation

5 QUESTION: Is the requirement for AutoCAD 2009 a firm need? This would mean upgrading our existing version if so.

ANSWER: Yes, needs to be AutoCAD 2009.

6 QUESTION: For the load testing, will it be a requirement of the contractor to supply the weights? Are water weights acceptable?

ANSWER: The Contractor shall supply the weights. Yes, water weights are acceptable.

7 QUESTION: Can you tell us how long the runway travel is for these two gantry cranes for determining the cord reel needs?

ANSWER: The travel lengths are 245 ft for the 45 ton Roadway Crane, and 380 ft. for the 30 ton Spillway crane.

8 QUESTION: Some of the conduit for the cranes runs through the gantry legs. Can we leave the conduit in the gantry legs in place and just pull wire through these?

ANSWER: Yes, in this case where the conduits are in acceptable conditions with regard to corrosion and are not accessible, these conduits may be re-used.

9 QUESTION: Some of the conduit runs through concrete from the main power boxes to the cranes. Can we leave the conduit in the concrete in place and pull the wire through these? Can we possibly run power from the power plant (located below the dam) up to the 45 ton gantry crane?

ANSWER: This is a two part question; refer to the answer provided previously for the first part of the question. For the second part of the question a “run” from the Power Plant will not be allowed.

10 QUESTION: The conduit that runs through the concrete does not appear large enough for the required power lines and ground wire. Can you verify the size of the conduit that runs through the concrete?

ANSWER: The conduit from the power source to the concrete is 1 ? inches; hence, the size of the conduit as it enters the concrete is 1 ? inches. Verification that the size of conduit in the concrete does not change cannot be provided.

11 QUESTION: Have there been any asbestos or lead paint surveys completed on the two cranes? If so, what were the results? If either is found during the project, then who is responsible for the cleanup?

ANSWER: The potential exists for paint on cranes to contain lead. Any construction activity that may disturb the surface must be completed in accordance with OSHA’s lead standard (29 CFR 1926.62). It is unknown if there are sources of asbestos, however, if asbestos is encountered during the project, the abatement will be treated as a differing site condition.

12 QUESTION: The hoist reducers have loadbrakes, these will have to be removed to use closed loop controls. They can be left-in if an open loop control is used. We would recommend completely removing the loadbrakes from the hoist reducers for a number of reasons:

- Removing the loadbrake will allow you to use a better grade of gear lube, improving the life of all the gearing and bearings.

- Removing the loadbrake wear pad will eliminate the possibility of contanimants from the loadbrake pad causing gearbox issues.

The best way to remove the loadbrake is to make new shafting and gearing as needed (not the entire drive-train, just those that cannot be re-used). I would not recommend removing the pawl and bolting the loadbrake together, this is an inferior solution.

ANSWER: It is the intent of USIBWC to completely renovate the all braking systems (hoist, trolley and bridge) for both the 45 ton Gantry Crane and the 30 ton Spillway crane, and it is the intent that a closed loop system be installed, therefore, any ancillary components needed to comply with the Scope of work will be required.

13 QUESTION: We are going to have to cut access holes in the top and bottom of the ganrty to allow removal of old equipment and installation of new.

ANSWER: Modifications to the Gantry for the installation of equipment shall be acceptable provided that the openings are repaired, are structurally and mechanically sound, and painted. Of course all changes shall be documented on drawings and stamped by a Registered Professional Engineer.

14 QUESTION: Can we leave galvanized conduit unpainted?

ANSWER: Yes, painting of galvanized conduit will not be required.

15 QUESTION: Can we use a cable reel that can handle the entire travel length instead of having to change the plug locations (applies to both cranes)?

ANSWER: Yes, this approach is preferred.

16 QUESTION: There are a number of travel drive gearmotors that appear to have an integral motor / reducer input shafts.

Many also have gears mounted on the output shaft of the reducer. We need some drawings to determine how these motors are to be changed. We may have to either make a special motor, change out the entire motor and gearbox, or look at some other type of solution. It is difficult to say what the best approach will be until we can get an idea of the gearmotor configuration.

ANSWER: Unfortunately the mechanical drawings are not available in USIBWC records, however, there is a possibility that the information can be obtained from the manufacturer of the cranes, if not; a field study may be required.

17 QUESTION: On the 30 Ton Gantry crane, the trolley drive brake on the hoist is going to be difficult to replace with a thruster type. Can we use a motor mounted disc brake?

ANSWER: Yes, provided that the ability to manipulate the design load is not compromised, and no diminished service is demonstrated during testing.

18 QUESTION: I would recommend changing the couplings connecting the hoist motors to the hoist reducers on all hoists with gear couplings.

ANSWER: The recommendation will be acceptable provided that the ability to manipulate the design load is not compromised and no diminished service is demonstrated during testing.

19 QUESTION: It was mentioned during the meeting that the hoist brakes are also to be changed out. Can this be verified?

ANSWER: Yes it is the intent of USIBWC to improve the hoist braking system.

20 QUESTION: We may have to add some gusset supports to the decking below the hoist motors and brakes, depending on the final location and configuration of the equipment. The new motors and brakes may not fall close enough to the existing gussets to fully support the weight of the new motors and brakes. Is this acceptable?

ANSWER: Modifications to the cranes are acceptable for the installation of equipment provided that the modifications are structurally and mechanically sound, and painted. Of course all changes shall be documented on drawings and stamped by a Registered Professional Engineer.

21 QUESTION: The cranes are going to need audible signals of some type. These need to be specified.

ANSWER: A gong or other effective audible warning signal shall be provided for each crane in accordance with. Title 29 Chapter XVII-Occupational Safety and Health Administration, Department Labor.

22 QUESTION: Do you want a backup pendant(s) for any of the motions?

ANSWER: Yes, provide backup pendant(s) for all motions.

23 QUESTION: None of the cable reels on the aux hoist on the 30 ton gantry are working. These need to be changed out. Is this clearly defined in the specification?

ANSWER: The intent of the USIBWC is to replace all the Reels, Festoons and or Loops on both the 45 ton Gantry Crane and the 30 ton Spillway crane with new Reels and Festoons, reference item XI, Reels/Festoons, A.

24 QUESTION: Do you want cable reels on the aux hoist on the 45 ton gantry similar to the 30 ton or do you want to keep using a loop?

ANSWER: The intent of the USIBWC is to replace all the Reels and Festoons on both the 45 ton Gantry Crane and the 30 ton Spillway crane with new Reels and Festoons, reference item XI, Reels/Festoons, A.

25 QUESTION: The 30 ton enclosures should be NEMA-4 rated and not NEMA-12 as stated in the specification. They are exposed to the elements.

ANSWER: Correct – for the 45 ton Gantry crane and the 30 ton Spillway crane, change Item V. Electrical Re-wiring, F, to read “All enclosures shall be dust tight enclosures designed to house electronics and electrical control (NEMA 4) equipment, wiring, etc.”

26 QUESTION: The Inverter supplied has the capability of transferring data via laptop computer with additional software. Is the software all that is required here or does a computer need to be supplied as well?

ANSWER: Provide a laptop with the capabilities listed in the Scope of Work, VII Controls, A, Adjustable Frequency Drive, 6.

27 QUESTION: The diagnostic capability listed on page 13 (bullet 23) is available. Does this need to be supplied on this project?

ANSWER: Yes, in addition to providing diagnostic capability, change the 8th word in the 2nd line of bullet 23 to “remote” instead of “remove”.

28 QUESTION: I am a little concerned about space limitations and using water bags for load testing. There may not be enough room to use these. Is it possible for us to use the stop-logs and lifting beam as part of the load test? If so, can you give us some idea regarding the weight of the stop logs and lifting beam?

ANSWER: This information is not available. The Contractor shall provide all means for load testing.

29 QUESTION: If possible, could we get drawings for the following:

45 Ton Gantry

Main Hoist reducer assembly

Main Hoist reducer input coupling bore size with tolerance

Aux Hoist reducer assembly

Aux Hoist reducer input coupling bore size with tolerance

Trolley drive/reducer assembly drawing

Gantry drive/reducer assembly drawing

30 Ton Gantry

Main Hoist reducer assembly

Main Hoist reducer input coupling bore size with tolerance

Aux Hoist reducer assembly

Aux Hoist reducer input coupling bore size with tolerance

Trolley drive/reducer assembly drawing

ANSWER: Unfortunately the mechanical drawings are not available in USIBWC records, however, there is a possibility that the information can be obtained from the manufacturer of the cranes, if not; a field study may be required.

30 QUESTION: Other drawings showing path of conduit from main panel to crane

ANSWER: There are no drawings available or found at this time.

31 QUESTION: Does the contractor need to replace the main feed breaker in the dam to the cranes cable reel? If the panel itself is to be replaced, there are several other breakers in the panel that are not associated with the crane, what is to be done with them?

ANSWER: The panel is to remain in place, replace the breaker the conduit and conductors that provide power to the respective crane.

32 QUESTION: Does the Contractor need to replace the conduit embedded in the concrete and wiring between the breaker and the cable reel, or just the wiring?

ANSWER: The Contractor does not have to replace the conduit in the concrete; however, exposed conduits, all conductors and reels will have to be replaced.

33 QUESTION: Are there complete drawing available showing the crane structure, motor mounting details etc.?

ANSWER: Unfortunately the mechanical and structure drawings are not available in USIBWC records, however, there is a possibility that the information can be obtained from the manufacturer of the cranes, if not; a field study may be required.

34 QUESTION: Par. X Radio, sub. Par. A.1 indicates the radio transmitter shall have 6 paddles, but the crane only has four motions. Is this a typo, if not what are the other functions?

ANSWER: Provide a four function radio transmitter.

35 QUESTION: Who provides the test weights, contractor or IBWC?

ANSWER: The Contractor shall be responsible for provide the means for testing the crane capabilities.

36 QUESTION: There is no mention of replacing the existing operator’s station. Is this to be abandon in place and the crane controlled by radio only? There is also mention of a pendant. Will a control pendant need to be provided in addition to a radio control?

ANSWER: The intent is to remove all the old controls in the operator’s station and replace with new. Provide backup pendant controls which can be housed in the operator’s room for the 45 ton Roadway Crane and pendant control for the 30 ton Spillway crane.

37 QUESTION: Par. IBWC 236-80 (pg. 46 of 69) indicates the IBWC will not provide water or electricity to the Contractor. Will we have to supply a generator to power tools and equipment” or is there a 480 outlet that can be used near the area of work?

ANSWER: There is power available; the Contractor shall make arrangements for temporary power from Government sources. The government will not be responsible any temporary power supply i.e. temporary conduits, extension cords, etc., any temporary power installed shall comply with NEC.

38 QUESTION: Is there a drawing showing the location of the feed to the cable reel in relation to the crane runway, and the total travel of the cranes to be able to determine how much cable and the size of the reel to be supplied?

ANSWER: Drawings are not available. However, the travel lengths are 245 ft for the 45 ton Roadway Crane, and 380 ft. for the 30 ton Spillway crane.

39 QUESTION: Are the existing lighting fixtures reused or all new?

ANSWER: The fixtures, conductors, conduits are to be all new.

40 QUESTION: Section V. G. (pg10) Fuses required to have a spare set of fuses for all fused devices?

ANSWER: If fused devices are part of the improvements, the Contractor is to provide a spare set.

41 QUESTION: Are E-Stops at ground level required?

ANSWER: An emergency stop will be required at ground level.

42 QUESTION: Are any warning devices(s) (lights, horn, bell) required?

ANSWER: A gong or other effective audible warning signal shall be provided for each crane in accordance with. Title 29 Chapter XVII-Occupational Safety and Health Administration, Department Labor.

43 QUESTION: What is the extent of lighting control required? (Manual switches(s), lights controlled from radio)

ANSWER: Manual switches will be the minimum required.

44 QUESTION: Please provide the speeds required for the hoist and travel functions of each motion on the each crane.

ANSWER: 30 / 7 ? TON Spillway Crane (No information available for the 45-ton, roadway)

Motion HP RPM MFG. Type Frame Brake Speed F.P.M.

Main Hoist

20 900 GE MR 404Z CR9516-464S

Thrustor

8.13

Aux Hoist 10 900 GE MR 364Z CR9516-463A Solen.

17.71

Trolley 2 900 GE MR 254 CR9516-460H Solen.

Gantry 10 900 GE MR 364Z CR9516-462L Solen.

68.6

Fed Spec’s RR-R 571a

Type XXXIII Uncoated 6 X 37, High Grade Plow Stl. Fiber Core

Main Hoist – 1 1/8 inch diameter rope – LIFT 392 feet

IDLE 140 feet

TOTAL 532 feet Furnished 540 feet

Aux Hoist – 9/16 inch diameter rope – LIFT 224 feet

IDLE 40 feet

TOTAL 264 feet Furnished 270 feet

Motion HP RPM MFG. Type Frame Brake Speed F.P.M.

Main Hoist

20 900 GE MR 404Z CR9516-464S

Thrustor

8.13

Aux Hoist 10 900 GE MR 364Z CR9516-463A Solen.

17.71

Trolley 2 900 GE MR 254 CR9516-460H Solen.

Gantry 10 900 GE MR 364Z CR9516-462L Solen.

68.6

Fed Spec’s RR-R 571a

Type XXXIII Uncoated 6 X 37, High Grade Plow Stl. Fiber Core

Main Hoist – 1 1/8 inch diameter rope – LIFT 392 feet

IDLE 140 feet

TOTAL 532 feet Furnished 540 feet

Aux Hoist – 9/16 inch diameter rope – LIFT 224 feet

IDLE 40 feet

TOTAL 264 feet Furnished 270 feet

45 QUESTION: Are NEMA12 enclosures acceptable on the 30 ton crane? Are they going to be exposed to the weather?

ANSWER: Change Item V. Electrical Re-wiring, F, to read “All enclosures shall be dust tight enclosures designed to house electronics and electrical control (NEMA 4) equipment, wiring, etc.”

46 QUESTION: The 120 day performance period is extremely tight considering the new motors can take 12 to 16 weeks to get from approval drawings. Can the IBWC extend the performance period to 180 days?

ANSWER: Peformance period to be extended 180 days.

47 QUESTION: Is there any lead based paint, PCB’S or Asbestos (brake shoes, cab floor, wiring insulation) that the Contractor must deal with?

ANSWER: The potential exists for paint on crane to contain lead. Any construction activity that may disturb the surface must be completed in accordance with OSHA’s lead standard (29 CFR 1926.62).

48 QUESTION: Are the existing convenience outlets to be replaced or re-used?

ANSWER: Existing convenience outlets are to be replaced with new conduit, outlet and conductors. There are 4-110 volt outside, 2–110 volt outlets outside and, 3-220 volt outlets inside.

49 QUESTION: Is the existing AC unit in the 45 ton gantry crane cab to be reused?

ANSWER: Protect in place the existing AC unit; however replace the conduit, outlet and conductors feeding the unit.

50 QUESTION: It is unclear if the government requires the hoist drives to be “closed loop” flux vector type controls(with encoder feedback and no load brake) or variable frequency type “open loop” and retain the existing mechanical load brakes. Please clarify?

ANSWER: It is the intent of USIBWC to completely renovate the all braking systems (hoist, trolley and bridge) for both the 45 ton Gantry Crane and the 30 ton Spillway crane, and it is the intent that a closed loop system be installed, therefore, any ancillary components needed to comply with the Scope of work will be required.

51 QUESTION: The hoist gearboxes have mechanical load brakes, the load brakes, and the load brakes will need to be disabled to work with the new flux vector controls. Will this work be performed by the Government or the Contractor? (ref. question #20)

ANSWER: The work is to be performed by the Contractor, ref. answer to question #20.

52. QUESTION: Can the existing conduit that is in good condition be re-used or must it all be replaced? If so can it be abandoned in place?

ANSWER: In the case where the conduits are in acceptable conditions with regard to corrosion and are not accessible, these conduits may be re-used, otherwise, old conduits are to be removed and disposed of off of government property and replaced with new.

53 QUESTION: Are the motor couplings to be re-used or replaced?

ANSWER: The motor couplings are to be replaced.

54 QUESTION: If water bags are used to load test the crane can water from the reservoir be pumped out and returned to the reservoir?

ANSWER: The Contractor will be allowed to use the water from the reservoir and then returning to the reservoir; however, prior to this, the Contractor must submit a certified letter to the Texas Water Master’s office stating that the containers are not contaminated. The Contractor must provide verification to the COR that this has been accomplished prior to performing this activity.

55 QUESTION: What is the height of the building at the 30 ton crane?

ANSWER: The height of the spillway crane is 50 feet above the roadway surface.

56 QUESTION: What are the traffic control / road closing restrictions for working on the cranes?

ANSWER: The Contractor shall be required to furnish traffic control in accordance with part VI of the “Texas Manual on Uniform Traffic Control Devices for Streets and Highways,” and in accordance with TXDOT traffic standard plan sheets TCP (2)-03.

57 QUESTION: Does the government require a CCO certified crane operator for the mobile crane?

ANSWER: The Contractor shall provide a crane operator that complies with ASME B30.5, Federal/State OSHA regulations, specifically 29CFR Part 1926.550, Cranes and Derricks. OSHA 1926.550 incorporates by reference, the national standard ASME B30.5 for operating the crane during the refurbishment, and testing process.

58 QUESTION: Are all control panel components required to be NEMA rated? (contactors, etc.)

ANSWER: Yes all components shall be required to be NEMA rated.

59 QUSTION: Is it acceptable to use all UL listed components in the control panels, or is a UL 508 listing on the entire control panel required?

ANSWER: The Contractor shall install UL 508 components in the control panels.

60 QUESTION: Is the power supply to the crane provided by a Delta or “Y” type secondary on the transformer? Grounded system? Nominal system voltage is 440 or 480?

ANSWER: Both cranes are 480 “Y” and are grounded.

61 QUESTION: Please clarify the HP ratings on the 45 ton crane. The gantry motor HP and RPM are not visible on the nameplates.

ANSWER: This information was included in the SOW drawings.

This is a Firm Fixed Price Contruction Requirement for Falcon Height, Falcon, Texas Lump Sum bid set forth herein shall include any applicable taxes, see FAR clause 52.229-3, Federal, State, and Local Taxes, listed by reference in this requirement.

IBM09B0019

Line Item Summary

Solicitation Number:

IBM09B0019

Contract Number: Title: answer questions & revised sow

Date of Solicitation:

08/25/2009

Line Item No. Description Quantity Unit Unit Price Total Cost

Section C - Descriptions/Specifications/Statement of Work

A002 REVISED SPECIFICATIONS FOR 45-TON GANTRY CRANE (ROADWAY)

45-Ton Gantry Crane (Roadway Crane)

I. Introduction

The United States Section of the International Boundary and Water Commission (USIBWC) wishes to conduct a retrofit of controls and electrical wiring for a 45- ton gantry crane. The crane is part of the Falcon Dam and Reservoir project. Falcon Dam is located on the Rio Grande in Starr County in Texas. The dam straddles the international boundary with part of the dam in the Republic of Mexico; however, all work will be conducted in the United States. The crane is to be retrofitted with new motors, new controls, new gantry and trolley brakes, new cable reels and new power supply wiring including variable frequency drives, trolley festooning and all limit switches. The Contractor shall have been engaged in the manufacturer of major components for cranes of the type specified for this project for a period of no less than ten (10) years and shall provide a letter certifying the aforementioned. The crane is located wholly in the United States. The crane is 55 years old. The physical address of the dam is: P.O. Box 1, FM 2098, Reservoir Road Falcon Heights, Texas 78545. The dam can also be located on Google Earth, coordinates 26 degrees 33 minutes 28 seconds North and 99 degrees 09 minutes 42 seconds west.

II. Description of Crane

A. 45 Ton Gantry Crane - The crane straddles the dam roadway and travels on rails the longitude of the dam. Its primary use is to set and remove stop logs and service gate actuators. There are two lifting implements on the crane, a 45-ton eye, and a 10-ton hook. The 45-ton eye is situated at the end of a short-cantilevered beam. The 10-ton hook is on a traveling trolley. The crane is illustrated on exhibit 1.

1. Power Supply – 440 volts, 3 phase, 60 Hertz

2. Motors

a. Hoist Motor – 40 H.P

b. Trolley Motor – 1-1/2 H.P.

c. Bridge Motor – 1-1/2 H.P.

d. Gantry

(1) Motor 1

(2) Motor 2

3. Brakes

a. Hoist Motor - Brake Rectox

b. Aux Hoist – Brake Rectox

c. Trolley Motor – Solenoid

d. Gantry– Brake Rectox

(1) Motor 1 - Solenoid

(2) Motor 2 - Solenoid

B. Index of plans for the 45 Ton Gantry Crane (Roadway):

1. Exhibit 1 – International Boundary and Water Commission, United States, and Mexico, Rio Grande International Storage Dams Project, Falcon Dam and Power Plant, United States Abutment, Intake Structure, 45-Ton Gantry Crane.

2. Exhibit 2 - Pacific Coast Engineering Company, Alameda, California

45 Ton Gantry – Falcon Dam

May 1952

3. Exhibit 3 - Westinghouse Electric Corporation

Drawing No. - SV- 12A 135

Special Class 13-630A Hoist Controller, 30 to 75 H.P. 440V, 60 Cycle

With Dynamic Breaking, Wiring Diagram

4 Exhibit 4 – Westinghouse Electric Corporation

Drawing No. SV-12A136

Crane Overall Diagram.

5. Exhibit 5 – Westinghouse Electric Corporation

Drawing No. SV-11A939

Class 13-600 Hoist Controller

440V-3 Phase-60 Hertz

Schematic and Connection Diagram

6. Exhibit 6 – Westinghouse Electric Corporation

Drawing No. SV-11A940

Gantry Crane – Falcon Dam

45-Ton Roadway Crane

Overall Diagram

7. Exhibit 7 – Westinghouse Electric Corporation

Drawing No. SV-11A942

Class 13-600 Gantry Controller

440 V, 3 Phase, 60 Hertz

Schematic and Connection Diagram

III. Electrical Re-wiring

A. The roadway crane will require that the electrical wiring be replaced. The Contractor shall retain an electrical engineer who shall be responsible for designing a new electrification system for the crane. The design shall include the sizing of conduits, panels, motor starters, conductors, and all other elements required to supply electrical power to the cranes to new elements i.e. motors, control panels, transformers, switches, motor controllers and all other crane elements requiring electrical power.

B. The 45-Ton Gantry Crane – From the crane’s power feed, the Contractor shall replace all elements from the load side to include but not limited to the 100 amp 3 phase, 3 pole, 600 v panel located in the dam’s tower and all conduits, conductors, reels, and boxes that are part of the crane electrical power supply and controls. The new panel shall have a 3-pole breaker with 3 pole switch, lock to de-energize the entire electrical feed to the crane. The breaker trip shall be lockable for “lock out tag out” operations. The electrical retrofit shall include but not limited to all ancillary panels, transformers, conduits, conductors, junction boxes, and switches, that provide 1 phase, 240/120-volt power for general lighting. All elements shall be firmly attached to the dams’ structure with straps, framing members (unistrut or an approved equal), clamps, pipe hangers, beam clamps, concrete anchors, and all elements in accordance to the National Electrical Code (NEC).

Crane elements requiring new AC (alternating current) wiring from the main electrical panel include but are not limited to:

1. Trolley Controller

2. Main Hoist Controller

3. Gantry Controller

4. Bridge Controller

5. Brakes

6. Limit Switches

7. Ancillary Lighting

IV. Demolition

A. All elements of the crane’s electrical power feed and or controls rendered obsolete including but not limited to wiring, transformers, controls, panels, fuse boxes, conduits, shall be removed and disposed of off of Government Property in accordance with all local, State and Federal laws and ordinances.

B. The Contractor shall identify elements in the field to be removed and disposed of. The

Contractor shall use surveyors orange paint to identify the elements to be removed by spraying the element. The Contractor shall provide the Government with a list of the elements to be removed. In tandem with the Government, the Contractor shall conduct a walk through, identifying and agreeing on the elements to be removed and/or demolished. The Contractor shall begin demolition after all obsolete elements have been identified.

V. Electrical Re-wiring

A. Electrical Work: The installation shall comply with all mandatory, advisory and recommended applicable rules of the National Electrical Code (NFPA 70) and all state and municipal codes, where applicable. All electrical materials shall be new and as approved by Underwriter’s Laboratories, Inc.

(UL) for the application. New equipment that is found to be defective or damaged in the course of installation or during testing shall be replaced or repaired in an approved manner at the Contractor’s expense. Existing equipment that to remain in place that is damaged by the Contractor shall be repaired at the Contractor’s expense. Equipment that has been scratched and/or marred shall be repainted. The standard manufacturer’s color and finish shall be used. Equipment shall not be stored outdoors unless properly covered as approved by the Government. The final approved drawings shall indicate the extent and general arrangement of the conduit and wiring systems.

B. Conduit: Conduits shall be Electrical Rigid Metallic Tubing throughout. Conduits shall be securely fastened to all junction boxes and control cabinets. Conduits shall be of adequate size to carry required conductors. Final connections to motors and other non-stationary devices shall be made with galvanized steel core liquid tight flexible conduit.

C. Wiring: Power wiring shall consist of stranded conductors and shall not be smaller than No. 12 AWG. Control and pendant cable wiring shall be stranded type No. 16 of larger. Wire with white colored insulation shall be used throughout the system for the neutral conductor. Green colored insulation shall be used for the ground wire only. No splices shall be allowed in control wiring. All wiring shall be enclosed in conduit. All cables in stress, such as the pendant cable, shall have insulation of the load. Unless otherwise noted, all conductors shall be annealed copper with minimum 93% conductivity and shall conform to the applicable standards of Underwriter’s Laboratories (U.L.), American National Standards Institute (A.N.S.I.) and Insulated Power Cable Engineers Association (I.P.C.E.A.).

D. Labeling: The Contractor shall furnish and install wraparound, stick-on labels covered with clear plastic, heat shrinkable tubing of the proper size to fit the conductors. These labels shall identify each wire as to panel and circuit number or terminal numbers. Neutrals shall be similarly tagged as to all the circuits they serve in each box.

E. Grounding and Bonding: An independent grounding conductor shall be supplied throughout. The power and control system (conduit, rails, etc.) shall not serve as the sole grounding means. All equipment shall be grounded.

F. Enclosure: All enclosures shall be dust tight enclosures designed to house electronics and electrical control (NEMA 12) equipment, wiring, etc.

G. Fuses: The Contractor shall furnish a complete set of fuses for all switches where fuses are specified. Fuses shall be time-delay type.

H. Safety Switches: All safety switches shall be of heavy duty type and shall comply with the requirements of the Underwriter’s laboratories, Inc. (UL) Standards for Service Equipment. They must be NEMA (National Electrical Manufacturers Association, Type HD (heavy duty), and must be horsepower rated.

They shall not be used as pullboxes or junction boxes. Switch terminals shall be approved for use with copper or aluminum conductors. All switches shall have engraved nameplate labels affixed to the cover designating the equipment controlled and actual voltage, fuse type, and fuse amperage rating utilized. Furnish and install a main disconnect for the cranes at ground level.

VI. Electrical and Crane Control Drawings

A. The Contractor shall produce drawings of the proposed electrical replacement and proposed crane controls identifying all elements to be removed and replaced. The drawings shall include, but not limited to motors, panel boards, conductors, conduit sizes, circuit breakers, transformers, motor starters, switches, crane controls, trolley controls, auxiliary controls, limit switches and all other elements associated with a complete working crane. The drawings shall be submitted to the USIBWC for review and approval before any work is commenced. The drawings shall be stamped by a professional engineer with a current registration. An engineer with registration from any of the 50 States will be accepted. The drawings shall contain the following characteristics:

1. Drawings shall be produced in AutoCAD 2009 and plotted on 36”x24” paper. The Contractor shall also produce the drawings in electronic format saved on a CD-media (Autocad, with no xreferences and no layers) and in PDF format. The drawing will have the USIBWC title page and with lettering in Romand script.

2. A general plan view drawing(s) illustrating the Dam, the location of the crane, location of all major elements i.e. main panels, main feed from the panel to the crane, and conduit runs.

3. An overall drawing(s) illustrating the crane in three views (top, front and right side) each view illustrating the old components in dashed lines and the proposed location of the new electrical components in solid lines.

4. An overall schematic diagram for the roadway crane, illustrating the electrical wiring from the main panel feed through all intermediary components to the main hoist motor and brake, auxiliary hoist motor and brake, trolley motor and brake and gantry motors and brakes.

5. An overall schematic diagram for the roadway cranes illustrating the proposed controls, their location and their salient features.

VII. Controls

A. Adjustable Frequency Drive

1. The drive supplier shall have a minimum of ten (10) years experience in the application of AC

Adjustable Frequency Drives on cranes and hoist.

2. The drive supplier shall be able to provide 24 hour service, repair, and testing capabilities including telephone availability of a technical and/or service assistance 365 days a year.

3. The drive supplier shall provide complete instructions, service, maintenance, and operations manuals.

4. The drive supplier shall provide complete instructions, service maintenance, and in-house maintenance instructions for specific crane and hoist applications.

5. The drive shall be sized for the application and the motor data. The drive shall consist of, but not be limited to, the following hardware features:

a. All digital design

b. IGBT type power output transistors

c. 32-bit microprocessor

d. High Speed digital signal processor (DSP)

e. Keypad display capable of performing the following functions using a standard language format:

i. Parameter entry

ii. Fault message displays for diagnostics, fifty (50) fault diagnostic displays, upper and lower display and brake fault displays

iii. Status of all terminals (digital and analog inputs)

iv. Drive/Motor operating displays i.e. output torque, output current, motor slip, output voltage, DC (direct current) bus voltage, motor RPM, and I/O terminal status.

6. The drive parameters must be transferable via a laptop or similar handheld device, for subsequent data printout, data transfer, or data storage by maintenance personnel. The laptop or handheld device shall use English for interfacing with maintenance personnel or an operator. Binary, octal, etc codes for programming or monitoring the drive are not acceptable.

7. The drive keypad must be capable of copying, storing, and writing parameters from the VFD (variable frequency drive). The key pad shall be capable of being moved among drives and uploading stored parameters. The keypad must be capable of being easily removed from the drive without the use of hand tools.

8. All drive input terminals with the exception of analog reference signals shall be capable of directly receiving 120 VAC (volts alternating current) signals without damage to the drive.

The use of a separate programmable logic controller (PLC) or PC is not acceptable.

9. Control interface cards shall be mounted on the drive. Interface cards panel mounted external to the drive are not acceptable.

10. The drive control devices shall operate at 120 volt AC and be isolated from power wiring.

11. The system shall operate with a line voltage variation of plus or minus 10 percent.

12. Drives shall be protected so that no damage occurs to the drive in the event of an emergency shutdown which may de-energize the main AC power lines coming into the drive while the drive is in any mode of operation.

13. The control shall have a minimum speed range of 1000:1 for hoist applications and 100:1 for transverse applications.

14. The speed regulation between no-load and full load speeds shall not be greater than 0.1% for analog reference signals and 0.01% for digital references signals.

15. The drive shall have programmable torque limits (motoring and regenerative)

16. The drive shall have a programmable alternate deceleration rate that provides for faster stopping when the drive receives a stop command from the operator. This deceleration rate differs from the “normal” deceleration rate that is followed when decelerating from a higher to a lower commanded speed.

17. The drive shall be able to simulate the reverse plugging of a motor by automatically switching to an alternate deceleration or acceleration ramp. This will give the operator the “feel” that a reverse plug operation is occurring, because the load will decelerate faster than normal before it changes direction.

18. Firmware shall be available from the drive manufacturer to allow the drive to be used with a foot pedal brake on cab operated transverse applications.

19. The drive shall have a built-in Auto Tune function. The drive shall also be capable of performing a static Auto Tune without the need for uncoupling the drive motor from the drive machinery.

20. The drive shall be capable of electronically reversing the motor leads through a parameter change.

21. The drive shall be capable of load sharing that will allow the operation of two or more motors on the same drive shaft.

22. When operating with an encoder, the drive shall continuously monitor the encoder for signal loss.

23. A fully developed wireless diagnostic system shall be available from the drive manufacturer that will allow real time remove drive output status and fault history monitoring, drive resettling, and parameter viewing and editing. The diagnostic system shall link directly to the drive(s) without the need for a PLC. The diagnostic system shall also be “internet Ready” to allow off site drive access.

24. On multiple drive applications the VFD firmware shall be capable of synchronizing up to eight motors.

25. When operating in closed loop vector mode the drive shall be capable of performing a “Brake Test” function that will allow testing of available brake torque.

26. The drive shall incorporate a maintenance function that will automatically limit the maximum drive speed.

B. Hoist Drive Specification – For hoist drives the above adjustable frequency drive specifications shall apply as well as the additional hoist drive specifications listed below.

1. The hoist drive shall ensure that sufficient torque is produced in the motor to suspend a load before a brake release command is issued. In the event that sufficient torque to suspend the load is not produced, the drive shall have the ability to maintain or set the brake to control the load, and also to issue an alarm signal to notify the maintenance personnel and operator of an unsafe condition.

2. The hoist motion control shall be capable of maintaining zero speed within the set torque limits.

3. To allow for safe operation of the hoist, when the operator commands the drive to stop, the drive shall check the ability of a brake to suspend a load before it removes power from the motor. If it is determined that the brake has not set or is unable to safely hold the load, the drive shall simultaneously float the load at the zero speed and issue an alarm signal for maintenance personnel. The operator shall have the ability to raise the load at reduced speed or lower the load as needed to place the load in a safe location.

4. The hoist drive shall be capable of permitting the motor over speeding (i.e., field weakening) to a maximum of 200% of rated motor speed. The drive shall automatically determine (via ultra lift or the like) a maximum speed that is safest and most appropriate for a given load.

5. The hoist drive shall be capable, through a programmable input terminal, of providing a precision control method by which the speed range produced by the speed reference signal is automatically rescaled at the operators command from a 0 to 100% speed range to a programmable minimum of 0 to 0.1% on closed loop vectors drives, and to 10% speed range on open loop drives, to obtain micro speed control.

6. The hoist drive shall be capable of detecting a broken coupling or shaft without the need of a PLC.

7. On closed loop vector hoist systems, the VFD shall be capable through drive firmware of using hoist motor encoder feedback to measure hook height. The height thus measured shall be capable of being scaled to an accessible analog output. Monitoring encoder feedback or producing an analog output through the use of PLC is not acceptable.

8. Frequency drives used on hoist shall be capable through drive firmware of providing hoist overload protection.

9. Frequency drives shall be capable of providing an indexing function based off of encoder feedback. Upon receiving a run command, the drive shall” index”, or turn the motor a set number of encoder pulses and then stop; additional index moves shall require that the run command be removed and re-applied. The drive shall be programmable to allow an “index repeating” function for as long as a run command is present at the drive.

VIII. AC Thruster Shoe Brake Specifications

A. Brakes shall be of the shoe type. The brakes shall be furnished complete with an electrically driven AC thruster type actuator. Brakes shall be manufactured and conform to AIST-NEMA (American Iron and Steel Institute-National Electrical Manufacturers Association) torque and dimensional standards and be of mill duty quality.

1. All brakes shall be from the same manufacturer and must have a minimum of 10 years supplying brakes to the crane and hoist industry.

2. Brakes shall be an AC thruster type shoe brake, spring set and electrically released.

3. Brakes shall be AIST torque rated for the 45 ton Roadway Gantry Crane.

4. Brakes shall be furnished with an auto adjust assembly designed to automatically compensate for lining wear.

5. Brakes shall be furnished with an auto equalization assembly designed to ensure that the shoes maintain equal alignment, positive and equal braking action and equal lining wear.

6. Brakes shall be furnished with non latching manual release lever.

7. Brakes shall be furnished with corrosion resistant hardware.

8. Brakes shoes shall consist of a molded, non-asbestos type brake shoe lining that is bonded to the shoe holder.

9. All main pivots points on the brake shall be equipped with a bolted type anti-friction composite bushing assembly. This assembly is to be comprised of an outer race component made from a composite material containing a self lubricating surface coating on the bore and a precision machined nitrided steel inner race. Spherical needle type bearings are not acceptable. Pin and clip type connections are not acceptable.

10. The brakes shall be furnished completely assembled and must be furnished with the Eldro type thruster model “Ed” actuator.

11. The Eldro actuators shall be supplied with a 460 volt, 3 phase, 60 HZ, totally enclosed, squirrel cage ball bearing motors with moisture proof windings and conduit box. The thruster motor shall be of ample capacity for the intended application. The rated stalled thrust of each thruster shall be not less than 135 percent of the thrust actually required to release the brake with the torque adjusted to the continuous rated value. Brakes are to set automatically when for any reason power is removed from the thruster motor.

12. The oil used in the thruster-opening chamber of the brakes shall be hydraulic oil specifically recommended by the thruster manufacturer for low temperature operation. It shall have a free operating temperature range between 13 degrees below zero and 122 degrees above zero Fahrenheit. Throughout this temperature range there shall not be any material change of operating characteristics.

13. All thrusters shipped, either mounted or as a spare, must be filled with hydraulic fluid at the factory prior to shipment. All thrusters must meet IP65 standards. External thruster material shall be aluminum for light weight and corrosion protection. Thruster motors shall be rated for inverter duty operation.

14. Each Eldro type “Ed” thruster shall have the capability of being supplied with an independent time delay valve adjustable between 0 and 5 seconds for both setting and releasing the brake. Only an internal time delay constructed of stainless steel is acceptable, and must be infinitely adjustable between the minimum and maximum settings. These adjustments must be allowable with the brake in full service. A single time delay for both setting and releasing is not acceptable.

15. Brake shoes must me easily replaced from either side of the brake without dissembling the brake. All torque adjustments should not have to be reconfigured after replacing shoes.

16. The Contractor shall provide Brake Enclosures suitable for operation in moist or dusty applications.

IX. General Purpose Induction Motors

A. General

1. Motors shall be designed specifically for crane and hoist duty. CMAA Class “C”. Drain holes shall be provided at low points at each end. Inspection service covers shall be provided with gaskets. Hardware shall be corrosion-resistant. Motors shall conform to the requirements of NFPA 70, CMAA 70, NEMA MG 1, and UL 1004. One thermal sensitive device embedded in hoist motor windings shall be provided. Device and associated circuitry shall serve as an alarm activating a common fault at the Belly Box

Controller when motor temperatures become excessive. Set point shall be set below the Class B insulation t temperature limit. Thermal-sensitive device and associated circuits shall be self-restoring (automatic reset.)

a. The Contractor shall provide electric motors, accessories, and appurtenances complete and operable, in conformance with individual driven equipment.

b. The provisions of this specification apply to all low voltage, single-phase and three…