IBM09B0019 A003.pdf

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

1. CONTRACT ID CODE RATING

2. AMENDMENT/MODIFICATION NO.

A003

3. EFFECTIVE DATE

09/10/2009

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 A003 referenced solicitation for retrofitting a 45/30 ton crane is as follows:

a. Contractors questions and answers are enclosed ((Note, Amendment A002, questions 1 through 30 are superceeded by this amendment questions 1-30; 31-64 stay the same. This amendment A003, questions 31- 64 are new). The answers to the questions are for information purpose only and do not change th 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 (replace revised scope from amendment A002)

c. The date for receipt of bids is extended to September 18, 2009, 3:00 p.m., local time from 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 Amend A003 Questions & Answers

C Descriptions/Specifications/Statement of Work Amend A003 Revised Scope for 45 ZTon Crane Amend A003-1 Revised Scope for 30 Ton Crane

Section 0 - Commercial Clauses

Amend A003 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 open-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 requirement 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: No, this could be AutoCAD 2003 or latest edition.

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 size is 1.5 inch.

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 SOW has been revised to include testing for the presents of asbestos. The Contractor shall be responsible for the testing. In the event that asbestos is discovered the Contractor shall immediately inform the Contracting Officer.

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 open loop system be installed.

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 QUESTIONS: Can we leave galvanized conduit unpainted?

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

15 QUESTIONS: 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 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 structural 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: The SOW of work has been change to include 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: The SOW of work has been change to include 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 loading 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: The conduit drawings are not available, a field study may be required.

31 QUESTION: Could you measure the conduit size running inside the dam?

ANSWER: The rigid conduit running from the switch disconnect inside the intake structure (bottom floor) is

1.5 inch.

32 QUESTION: Is replacement of the disconnect AFTER the DPDT switch part of the scope?

This would be in addition to the floor level disconnect that needs to be put on the crane itself.

ANSWER: The disconnect switch inside the intake structure (bottom floor) will not be replaced. The contractor will connect from the current switch (Square D manufacturer.) and run wires to the roadway crane. The contractor will be required to have a service disconnect outside the roadway crane.

33 QUESTION: A ground connection is at the connector box on the top of the dam. Is this sufficient or are you looking for additional? You are limited to # of wires in conduit.

ANSWER: The ground connector at the box on top of the dam will be sufficient.

34 QUESTION: Mechanical Load Brake

These are typically removed and gears/componens need to be replaced in the gear box. Replacing the gear boxes was not included in the original spec of the project.

Further, we have done a lot of work on these vintage and manufacturer of cranes and engineering studies have shown that the gears themselves usually do not meet current CMAA specs and typically have to be replaced.

Without drawings this will be extremely difficult.

I did not get any information regarding the gearbox. Could you provide any information on a nameplate on the gearbox regarding ratios, speeds etc?

45t Main Hoist

45t Aux Hoist

30t Main Hoist

30t Aux Hoist

Would replacement of gear boxes be part of additional scope?

ANSWER: First part of the Question - With regard to the gear box (es), the SOW does not require that the gears in the gear boxes be replaced; however, the SOW has been changed requiring the Contractor to conduct a through inspection of the crane as per OSHA 1910.179 at the beginning of this project in order to determine if there are any unforeseen concerns. Concerns shall be expressed in writing and brought to the attention of the Contracting Officer immediately.

Second part of the Question - 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.

35 QUESTION: Control Panel - Do you want the main panel to have a UL 508 Inspection and Sticker on it?

This is an additional cost. The components are UL listed.

ANSWER: A UL 508 compliance will be required.

36 QUESTION: Controls - Operator stations. In the Q&A there is mention of pendants (#36). Are the cranes to be changed to pendant back up? Or are existing operator controls to be replaced with like kind.

ANSWER: The SOW has been changed to require backup pendant controls. For the 45 Ton crane, the backup controls are to be located in the cab. For the 30 Ton crane the controls are to be located where the control platform is now located.

37 QUESTION: Should the “Closed loop” system should be reference to the hoisting motions only? There is no need to have closed loop on the trolley and gantry motions.

ANSWER: The SOW has been changed. The closed loop system will not be required; the open loop system shall be required for all motions.

38 QUESTION: Gantry drive on 45t - These are complete special gear motors and we have replaced with new motors and gear box sets. The gear mounted on the end of the existing gear motor will have to be removed and re used.

ANSWER: It is the intent of USIBWC that all the motors be replaced with new, any ancillary component required shall be provided with the ultimate aim of providing a fully functional crane with all the motions required.

39 QUESTION: I tried to get information on the gear box, but could you provide the data on the unit as this will need to be replaced.

ANSWER: The Information from the name plate for the gear motor, 45 Ton Crane Gantry Drive:

HP 10

Class 2

Output 45

Ratio 25.7

Unit ELB 320

Style SF 77731

Serial 124426

40 QUESTION: Load testing - We typically use water weights for the load testing. Is there access to the reservoir water via a connection inside the dam?

ANSWER: Water is available at the complex operations and maintenance facility, however transporting the water to the site will be the responsibility of the Contractor. Water from the testing may be placed into the reservoir.

41 QUSTION: We need to locate a water pump in the vicinity of access to the water and there is usually a port somewhere nearby. Otherwise we will have to put the pump in close proximity to the water on the rocks.

ANSWER: Water is available at the complex operations and maintenance facility, however transporting the water to the site will be the responsibility of the Contractor. After testing the water may be placed into the reservoir.

42 QUESTION: During the duration of the project the cranes will be inoperable. Will this be acceptable?

ANSWER: For the duration the cranes can be inoperable.

43 QUESTION: Asbestos: There is no requirement for asbestos testing. Cranes of this vintage typically has asbestos on the crane. Who will do the testing? If an area is suspect, who will do the testing on the spot? What happens to the timeline of the project? Who would be responsible for removal? This is a fairly costly operation and it takes time to complete. The impact on the project could be quite large going into it unknown.

ANSWER: The SOW has been revised to include testing for the presents of asbestos. The Contractor shall be responsible for the testing. In the event that asbestos is discovered the Contractor shall immediately inform the Contracting Officer.

44 QUESTION: Is the VFD control to be an open-loop or closed-loop design? The closed-loop system uses encoders to send feedback to the drives providing very precise positioning control as well as 1000:1 speed variation. The open-loop design would seem to be adequate for the type of cranes being upgraded but the determination must be made ahead of time since there are significant cost differences between these two styles of control. The closed-loop design is significantly more costly.

ANSWER: The closed loop requirement will be changed in the SOW to reflect an open loop design.

45 QUESTION: On both crane system specifications, neither of the hoist brakes is specified for replacement. Is it the intention of the IBWC to have all brakes replaced on these projects?

ANSWER: The SOW has been changed to reflect in the 1st paragraph, Introduction, that the hoist brakes will require that the hoist brakes be replaced.

46 QUESTION: Section VIII. AC thruster brakes. Both the trolley and gantry motors of these two cranes lend themselves to the use of a motor mounted disc style brake due to their smaller horsepower ratings. This would provide a significant cost savings while providing the same efficient braking capability and the brakes would be come complete with the motors form the same supplier. I would leave the shoe brake requirement for all of the hoist motors and change the requirement for the traverse motions to allow a disc brake if this is acceptable.

ANSWER: The SOW has been changed to include disk brakes for transverse motions of the cranes.

47 QUESTION: Since both of these cranes are located outdoors, and the existing motor brakes are supplied with covers, would you like the new shoe brakes to also include covers to protect them from the elements?

ANSWER: The SOW now includes a requirement for exposed brakes to be covered and thus protected from the elements.

48 QUESTION: Section III details somewhat the requirement for electrical replacement of all elements including conduits from the load side of the crane power source. Approximately 95% of the conduit for either of these cranes is set in concrete and in the case of the 45-ton crane, this conduit passes below the roadway. Has it been determined that these conduits are faulty or otherwise failing or can this requirement be removed from the spec?

ANSWER: In this case where the conduits are in acceptable conditions with regard to corrosion and are not accessible, these conduits may be re-used, however, all exposed conduit is to be replaced as per the SOW.

49 QUESTION: IIIA-7 calls for the re-wiring of ancillary lighting. Is it also the intent of the customer to have new lighting provided on these cranes? If so, what type and wattage of lighting is preferred?

ANSWER: In kind lighting will be acceptable

50 QUESTION: There does not appear to be a specification calling for new operator controls other than the RF controls. Is it the intent of the customer to operate these cranes strictly from the radio control or do you wish to also include new fixed operator controls? If new fixed controls are a requirement, do you want them to be of similar type and location on the crane or in the case of the 45-ton, would you prefer a complete operator chair with joy-stick controls? The 30-ton crane does not lend itself to this option because of the existing crane layout.

ANSWER: The SOW will be changed to reflect the need for a backup pendant for each of the cranes. The pendant will provide for all the motions of the crane(s).

51 QUESTION: The radio control specification requests a 6-lever belly-box transmitter. Both of these two cranes have only 4 functions: main hoist, aux. hoist, gantry & trolley. 4-levers would be adequate.

ANSWER: The SOW will be changed to reflect the need for only the 4-lever motion of the belly-box transmitter.

52 QUESTION: Regarding the 45-ton crane, does a new AC unit need to be supplied for the cab with the controls or will the cab no longer be used to operate the crane?

ANSWER: The Contractor shall protect in place the existing AC unit, but shall replace the electrical components providing power to the unit.

53 QUESTION: Section III calls for the contractor to retain a licensed electrical PE to design the electrical system for these cranes. These crane controls are very commonplace to the industry and installed around the country every day. This requirement will be adding, in my opinion, unnecessary costs to the project. Would the IWBC consider removing this requirement?

ANSWER: Because of the critical nature of dam operation and the need for the cranes to operate reliably during critical operations the requirement shall remain in the SOW.

54 QUESTION: Same general question for section VI. This section requires a rather extensive list of drawings to be produced by a licensed PE. The drawings would definitely be a good addition to the documentation for future reference but a costly one. Typical drawings for a project such as this would be complete as-built electrical drawings for all crane wiring, including panel layouts, etc. Are the drawings of the dam and cranes in 3 views necessary for this project? Is the licensed PE a requirement? Can the drawings be provided in AutoCad 2003?

ANSWER: The drawing(s) requirement will remain as part of the SOW to illustrate installation of new conduits and equipment for proper documentation, however, drawings detailing crane views, conduit runs and general power circuitry do not have to be completed by a PE. The USIBWC will require that an engineer be responsible for electrical power requirements i.e. conduit, conductor, breakers sizes to assure proper crane operation and will place his seal on the drawing(s) attesting to the cranes ability to function properly for power supply.

55 QUESTION: Can existing conduits on these cranes be re-used rather than replaced if it is still in good condition?

ANSWER: In this case where the conduits are in acceptable conditions with regard to corrosion and are not accessible, these conduits may be re-used, however, all exposed conduit is to be replaced as per the SOW.

56 QUESTION: Section V – D calls for wrap-around and heat shrink style wire labels. Can the spec be changed to only heat shrink type? These are a much better and longer lasting label and provide for a more professional installation.

ANSWER: The SOW will be changed to reflect that only the heat shrink style wire labels be used.

57 QUESTION: Section XI Reels/Festoons. Currently the 45-ton has two plug-in locations for the power pickup to the existing cord reel. Does the customer want a cord reel capable of handling the entire range of gantry travel or to keep the requirement of having to move the plug to reach the extents of the runway? Not having to relocate the plug to move the crane seems like the better choice.

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. The new reels or festoons shall be replaced such that there will be no need to relocate the plug to move the cranes, reference item XI Reels/Festoons, A.

58 QUESTION: The 30/7.5-ton crane currently uses an electric cord dragging along the floor to provide power to the crane. The spec calls for a cord reel. This would be a much cleaner application. My question simply is to clarify whether or not in fact the cord reel is wanted for this option since one currently does not exist.

ANSWER: See the response to question No. 26.

59 QUESTION: Trolley festooning. Currently the 45-ton crane use cords suspended between the gantry and the trolley to provide the power and control to the hoist and trolley. Would a flat cable festoon system or a segmented, moving cable carrier be preferred for this area?

ANSWER: See the response to question No. 26.

60 QUESTION: Section XIII – 2 requires setting hoist overload cut-offs at 105% of capacity. Are these devices currently installed on these cranes?

ANSWER: It is unknown if this capability is in place, however, Provide hoist load limiting function in the raise direction utilizing the drives of all hoists, based on a known load being applied in order to properly program the drives. Limit load to less than 110% of capacity.

61 QUESTION: Do you have a specification for the painting that will be necessary for the modifications to install the new equipment?

ANSWER: All surfaces to be painted shall receive proper metal preparation and cleaning prior to application of the paint coating system to insure good adhesion. Rust inhibiting prime coat shall be applied followed by a finish coat of lead free industrial enamel. Finish color to match existing.

62 QUESTION: Runway end-stops? The 45-ton roadway crane has no runway end-stops on one end of the runway and only a single stop on the other end. According to ANSI B30.2 which is incorporated by reference in OSHA 1910.179, these are required. Would the customer wish to include this upgrade or address this issue at a later date?

ANSWER: The SOW will be changed to provide bumpers capable of stopping the crane (not including the lifted load) at a rate of deceleration not to exceed 3 fps squared when traveling in either direction at 20 percent of rated speed.

63 QUESTION: Cab and radio frequency controlled cranes are required to have a travel warning device incorporated into the design. This can be mechanical or electric and can be automatically sounded when there is crane movement or manually actuated by the operator. Does the customer want to include this feature in the system?

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.

64 QUESTION: Do the cranes have evidence of recent inspection so as to determine that all of the mechanical components (especially the wire ropes) are safe to perform a 125% load test as required by OSHA 1910.179?

Should it be a part of the spec. to have the contactor perform their own thorough crane inspections at the beginning of this project in order to determine if there are any unforeseen concerns before the cranes are due to be load tested?

ANSWER: The SOW will be changed to reflect that the Contractor shall be required to conduct His/Her own inspection prior to beginning work. Any deficiencies discovered in the structural or mechanical components of the cranes shall be addressed as a “differing site condition”

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:

09/10/2009

Line Item No. Description Quantity Unit Unit Price Total Cost

Section C - Descriptions/Specifications/Statement of Work

Amend A003 Revised Scope for 45 ZTon Crane

Scope of Work Crane Controls

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 Variable Frequency Drive (VFD) control open-loop design, new motors, new controls, new gantry, hoist and trolley brakes, new cable reels and new power supply wiring, 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. Lighting shall be replaced in kind. 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. Existing conduits in concrete or in inaccessible areas (i.e. within the legs of the gantry) may be reused provided that they are in good condition. 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 heat shrinkable wire labels 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 2003 or later version 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 open loop 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.