IBM09B0019.pdf

SOLICITATION, OFFER,

AND AWARD

(Construction, Alteration, or Repair)

1. SOLICITATION NO.

IBM09B0019 X SEALED BID (IFB)

NEGOTIATED (RFP)

2. TYPE OF SOLICITATION 3. DATE ISSUED

07/21/2009

RATING

IMPORTANT -The "offer" section on the reverse must be fully completed by offeror.

4. CONTRACT NO. 5. REQUISITION/PURCHASE REQUEST NO. 6. PROJECT NO.

CODE IBWC_

International Boundary and Water Commission (IBWC)

USIBWC - ACQUISITIONS DIV

4171 NORTH MESA, STE. C100

EL PASO, TX 79902-1441

7. ISSUED BY

International Boundary and Water Commission (IBWC)

USIBWC - ACQUISITIONS DIV

4171 NORTH MESA, STE. C100

EL PASO, TX 79902-1441

8. ADDRESS OFFER TO

9. FOR INFORMATION EMAIL: a. NAME

Patricia Singer

b. TELEPHONE NO. (Include area code) (NO COLLECT CALLS) c. EMAIL singerps@state.gov

SOLICITATION

NOTE: In sealed bid solicitations "offer" and "offeror" means "bid" and "bidder".

10. THE GOVERNMENT REQUIRES PERFORMANCE OF THE WORK DESCRIBED IN THESE DOCUMENTS (Title, identifying no., date)

Furnish all labor, materials, equipment, supplies, coordination to retrofit controls and electrical wiring for a 45 ton gantry roadway crane. Also included as an option item is a 30 ton gantry spillway crane.

The estimated cost range for this project is between $250,000 and $500,000. Or if option item is exercised between $500,000 and $1,000,000 Requirement is 100% set-aside for small business concern.

11. The Contractor shall begin performance within ___10___ calendar days and complete it within ___*___ calendar days after receiving award, X notice to proceed. This performance period is X mandatory negotiable. ( (See _*SEE SECTION F_.)

12a. THE CONTRACTOR MUST FURNISH ANY REQUIRED PERFORMANCE AND PAYMENT BONDS? (If "YES," indicate within how many calendar days after award in Item 12b).

X YES NO

12b. CALENDAR DAYS

Sealed offers in original and __1__ copies to perform the work required are due at the place specified in item 8 by __03:00:00__ (hour) local time __08/21/2009 __ (date). If this is a sealed bid solicitation, offers will be publicly opened at that time. Sealed envelopes containing offers shall be marked to show the offeror's name and address, the solicitation number, and the date and time offers are due.

a.

b. An offer guarantee is, X is not required.

All offers are subject to the (1) work requirements, and (2) other provisions and clauses incorporated in the solicitation in full text or by reference.c.

d.

Offers providing less than __60__ calendar days for Government acceptance after the date offers are due will not be considered and will be rejected.

13. ADDITIONAL SOLICITATION REQUIREMENTS

NSN 7540-01-155-3212 STANDARD FORM 1442 (REV. 4-85)

Prescribed by GSA - FAR (48 CFR) 53.236-1(e)

IBM09B0019

OFFER (Must be fully completed by offeror)

14. NAME AND ADDRESS OF OFFEROR (Include ZIP Code) 15. TELEPHONE NO. (Include area code)

16. REMITTANCE ADDRESS (Include only if different than Item 14.)

CONTACT: DUNS:

CODE FACILITY CODE

The offeror agrees to perform the work required at the prices specified below in strict accordance with the terms of this solicitation, if this offer is accepted by the Government in writing within ____ calendar days after the date offers are due. (Insert any number equal to or greater than the minimum requirement stated in Item 13d. Failure to insert any number means the offeror accepts the minimum in Item 13d.)

17.

AMOUNTS

18. The offeror agrees to furnish any required performance and payment bonds.

19. ACKNOWLEDGMENT OF AMENDMENTS

(The offeror acknowledges receipt of amendments to the solicitation -- give number and date of each)

AMENDMENT NO.

DATE

20a. NAME AND TITLE OF PERSON AUTHORIZED TO SIGN OFFER (Type or print)

20b. SIGNATURE 20c. OFFER DATE

AWARD (To be completed by Government)

21. ITEMS ACCEPTED

22. AMOUNT 23. ACCOUNTING AND APPROPRIATION DATA

24. SUBMIT INVOICES TO ADDRESS SHOWN IN

(4 copies unless otherwise specified)

ITEM

10 U.S.C. 2304(c) ( ) 41 U.S.C. 253(c) ( )

25. OTHER THAN FULL AND OPEN COMPETITION PURSUANT TO

26. ADMINISTERED BY CODE

International Boundary and Water Commission (IBWC)

USIBWC - FINANCIAL SERVICES DIV

4171 NORTH MESA, STE. C100

EL PASO, TX 79902-1441

27. PAYMENT WILL BE MADE BY

CONTRACTING OFFICER WILL COMPLETE ITEM 28 OR 29 AS APPLICABLE

28. NEGOTIATED AGREEMENT (Contractor is required to sign this document and return ____ copies to issuing office) Contractor agrees to furnish and deliver all items or perform all work requirements identified on this form and any continuation sheets for the consideration stated in this contract. The rights and obligations of the parties to this contract shall be governed by (a) this contract award, (b) the solicitation, and (c) the clauses, representations, certifications, and specifications incorporated by reference in or attached to this contract.

29. AWARD (Contractor is not required to sign this document.) Your offer on this solicitation is hereby accepted as to the items listed. This award consummates the contract, which consists of (a) the Government solicitation and your offer, and (b) this contract award. No further contractual document is necessary.

30a.NAME AND TITLE OF CONTRACTOR OR PERSON AUTHORIZED TO SIGN (Type or print)

Patricia Singer 31a. NAME OF CONTRACTING OFFICER (Type or print)

30b. SIGNATURE 30c. DATE 31b. UNITED STATES OF AMERICA

BY

31c. DATE

STANDARD FORM 1442 (REV. 4-85) BACK

Table of Contents

Section Description Page Number

B Supplies or Services and Prices/Costs C Descriptions/Specifications/Statement of Work c.1 RETROFIT/UPGRADE A 45 TON ROADWAY CRANE c.1a OPTIONAL REQUIREMENT: RETROFIT/UPGRADE A 30 TON SPILLWAY CRANE

D Packaging and Marking d.1 THIS SECTION IS NOT USED

E Inspection and Acceptance 52.246-12 Inspection of Construction (Aug 1996)

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

G Contract Administration Data IBWC 242-70 Designation of Contracting Officer IBWC 242-71 Contractor's Officer Representative

H Special Contract Requirements 52.236-4 Physical Data (Apr 1984) IBWC 228-71 Performance and Payment Bonds IBWC 228-72 Compensation and Liability Insurance IBWC 236-72 Brand Name or Equal IBWC 236-73 Technical Data Submittal Requirements IBWC 236-74 Accident Prevention Pre-Planning IBWC 236-75 Construction Program IBWC 236-76 Construction Safety Standards IBWC 236-77 Equipment and Ownership and Operating Expense Schedule IBWC 236-78 Cultural Resources IBWC 236-79 Work Schedule IBWC 236-80 Utility and Telephone Services IBWC 249-70 Administration of Default (Fixed-Price Construction) IBWC 249-71 Time Extensions for Unusually Severe Weather

I Contract Clauses 52.202-1 Definitions (July 2004) 52.203-3 Gratuities (Apr 1984) 52.203-5 Covenant Against Contingent Fees (Apr 1984) 52.203-6 Restrictions On Subcontractor Sales To The Government (Sept 2006) 52.203-7 Anti-Kickback Procedures (Jul 1995) 52.203-8 Cancellation, Rescission, and Recovery of Funds for Illegal or Improper Activity (Jan 1997) 52.203-10 Price Or Fee Adjustment For Illegal Or Improper Activity (Jan 1997) 52.203-12 Limitation On Payments To Influence Certain Federal Transactions (Sept 2007) 52.204-4 Printed or Copied Double-Sided on Recycled Paper (Aug 2000) 52.204-7 Central Contractor Registration (Apr 2008) 52.209-6 Protecting the Government's Interest When Subcontracting With Contractors Debarred, Suspended, or Proposed for Debarment (Sept 2006) 52.214-26 Audit and Records--Sealed Bidding (Mar 2009) 52.214-27 Price Reduction for Defective Cost or Pricing Data - Modifications - Sealed Bidding (Oct 1997) 52.214-28 Subcontracting Cost or Pricing Data--Modifications--Sealed Bidding (Oct 1997) 52.214-29 Order of Precedence--Sealed Bidding (Jan 1986) 52.219-6 Notice of Total Small Business Set-Aside (June 2003) 52.219-8 Utilization of Small Business Concerns (May 2004) 52.219-14 Limitations on Subcontracting (Dec 1996) 52.222-3 Convict Labor (June 2003) 52.222-4 Contract Work Hours and Safety Standards Act - Overtime Compensation (July 2005) 52.222-6 Davis Bacon Act (July 2005) 52.222-7 Withholding of Funds (Feb 1988) 52.222-8 Payrolls and Basic Records (Feb 1988) 52.222-9 Apprentices and Trainees (July 2005) 52.222-10 Compliance with Copeland Act Requirements (Feb 1988) 52.222-11 Subcontracts (Labor Standards) (July 2005)

52.222-12 Contract Termination-Debarment (Feb 1988) 52.222-13 Compliance with Davis-Bacon and Related Act Regulations (Feb 1988) 52.222-14 Disputes Concerning Labor Standards (Feb 1988) 52.222-15 Certification of Eligibility (Feb 1988) 52.222-21 Prohibition of Segregated Facilities (Feb 1999) 52.222-26 Equal Opportunity (Mar 2007) 52.222-27 Affirmative Action Compliance Requirements for Construction (Feb 1999) 52.222-35 Equal Opportunity for Special Disabled Veterans, Veterans of the Vietnam Era and Other Eligible Veterans (Sept 2006) 52.222-36 Affirmative Action for Workers with Disabilities (June 1998) 52.222-37 Employment Reports on Special Disabled Veterans, Veterans of the Vietnam Era, and Other Eligible Veterans (Sept 2006) 52.223-3 Alt I Hazardous Material Identification and Material Safety Data (Jan 1997)- Alternate I (July 1995) 52.223-5 Pollution Prevention and Right-to-Know Information (Aug 2003) 52.223-6 Drug Free Workplace (May 2001) 52.223-14 Toxic Chemical Release Reporting 52.225-13 Restrictions on Certain Foreign Purchases (June 2008) 52.227-1 Authorization and Consent (Dec 2007) 52.227-2 Notice and Assistance Regarding Patent and Copyright Infringement (Dec 2007) 52.227-4 Patent Indemnity--Construction Contracts (Dec 2007) 52.228-2 Additional Bond Security (Oct 1997) 52.228-5 Insurance - Work on a Government Installation (Jan 1997) 52.228-11 Pledges of Assets (Feb 1992) 52.228-12 Prospective Subcontractor Requests for Bonds (Oct 1995) 52.228-14 Irrevocable Letter of Credit (Dec 1999) 52.229-3 Federal, State and Local Taxes (Apr 2003) 52.232-5 Payments under Fixed-Price Construction Contracts (Sept 2002) 52.232-17 Interest (Oct 2008) 52.232-23 Assignment Of Claims (Jan 1986) 52.232-27 Prompt Payment for Construction Contracts (Oct 2008) 52.232-33 Payment by Electronic Funds Transfer--Central Contractor Registration (Oct 2003) 52.233-1 Disputes (July 2002) 52.233-3 Protest after Award (Aug 1996) 52.233-4 Applicable Law for Breach of Contract Claim (Oct 2004) 52.236-2 Differing Site Conditions (Apr 1984) 52.236-3 Site Investigation and Conditions Affecting the Work (Apr 1984) 52.236-5 Material and Workmanship (Apr 1984) 52.236-6 Superintendence by the Contractor (Apr 1984) 52.236-7 Permits and Responsibilities (Nov 1991) 52.236-8 Other Contracts (Apr 1984) 52.236-9 Protection of Existing Vegetation, Structures, Equipment, Utilities, and Improvements (Apr 1984) 52.236-10 Operations and Storage Areas (Apr 1984) 52.236-11 Use and Possession Prior to Completion (Apr 1984) 52.236-12 Cleaning Up (Apr 1984) 52.236-13 Alt I Accident Prevention (Nov 1991)- Alternate I (Nov 1991) 52.236-17 Layout of Work (Apr 1984) 52.236-21 Alt I Specifications and Drawings for Construction (Feb 1997)- Alternate I (Apr 1984) 52.236-26 Preconstruction Conference (Feb 1995) 52.242-13 Bankruptcy (July 1995) 52.242-14 Suspension of Work (Apr 1984) 52.243-4 Changes (June 2007) 52.244-6 Subcontracts for Commercial Items (Mar 2009) 52.246-21 Warranty of Construction (Mar 1994) 52.248-3 Value Engineering--Construction (Sept 2006) 52.249-2 Alt I Termination for Convenience of the Government (Fixed-Price) (May 2004)- Alternate I (Sept 1996) 52.249-10 Default (Fixed-Price Construction) (Apr 1984) 52.253-1 Computer Generated Forms (Jan 1991) 52.222-39 Notification of Employee Rights Concerning Payment of Union Dues or Fees (Dec 2004) 52.223-9 Estimate of Percentage of Recovered Material Content for EPA-Designated Items (May

52.225-9 Buy American Act--Construction Materials (Feb 2009) 52.252-2 Clauses Incorporated by Reference (Feb 1998)

J List of Attachments J.1 Davis Bacon Wage Decision TX20080287

K Representations, Certifications, and Other Statements of Offerors or Respondents k.1 Instruction for this requirement 52.204-8 Annual Representations and Certifications (Feb 2009)

L Instructions, Conditions, and Notices to Offerors and Respondents 52.214-3 Amendments to Invitations for Bids (Dec 1989) 52.214-4 False Statements in Bids (Apr 1984) 52.214-5 Submission of Bids (Mar 1997) 52.214-6 Explanation to Prospective Bidders (Apr 1984) 52.214-7 Late Submissions, Modifications, and Withdrawals of Bids (Nov 1999) 52.214-18 Preparation of Bids-Construction (Apr 1984) 52.214-19 Contract Award-Sealed Bidding-Construction (Aug 1996) 52.214-34 Submission of Offers in the English Language (Apr 1991) 52.214-35 Submission of Offers in U.S. Currency (Apr 1991) 52.222-23 Notice of Requirement for Affirmative Action to Ensure Equal Employment Opportunity for Construction (Feb 1999) 52.211-1 Availability of Specifications Listed in the GSA Index of Federal Specifications, Standards and Commercial Item Descriptions, FPMR Part 101-29 (Aug 1998) 52.211-3 Availability of Specifications Not Listed in the GSA Index of Federal Specifications, Standards, and Commercial Item Descriptions (June 1988) 52.216-1 Type of Contract (Apr 1984) 52.225-10 Notice of Buy American Act Requirement--Construction Materials (Feb 2009) 52.233-2 Service of Protest (Sept 2006) 52.236-27 Alt I Site Visit (Construction) (Feb 1995)- Alternate I (Feb 1995) IBWC 209-70 Qualification of Bidders IBWC 236-71 Site Visit

M Evaluation Factors for Award m.1 Award will be made in accordance with FAR 52.214-19, Contract Award-Sealed Bidding-Contruction (referene provision in the solicitation)

This is a Firm Fixed Price Contruction Requirement for Falcon Height, Falcon, Texas

001 All work to rerofit controls and electrical wiring for a 45 Ton Gantry Roadway Crane in accordance with Scope of Work and Drawings incorporated herein.

1.00 LS

Doc Ref No:

Delivery Date FOB:

Destination

002 OPTIONAL ITEM for all work to rerofit controls and electrical wiring for a 30 Ton Gantry Spillway Crane in accordance with Scope of Work and Drawings incorporated herein.

1.00 LS

This item is subject to availability of funds. This item may be exercised with award of item 001, but no later then 30 days from award of item 001.

Doc Ref No:

Delivery Date FOB:

Destination

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: Crane Upgrade-Falcon Date of Solicitation:

07/21/2009

Line Item No. Description Quantity Unit Unit Price Total Cost

Section C - Descriptions/Specifications/Statement of Work c.1 RETROFIT/UPGRADE A 45 TON 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 manufacturer of major components for cranes shall have been engaged in 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 phase small (fractional) and medium (integral) horsepower AC squirrel-cage induction motors rated 500 horse power and less.

B. Main Auxiliary Hoist Motor

Hoist motor shall be ac squirrel cage type for use in ac adjustable frequency control systems.

C. Bridge and Trolley Drive Motors

Bridge and Trolley Drive motors shall be ac type for use in ac adjustable frequency control systems.

D. Motor Enclosures

Motor enclosures shall be totally enclosed, non-ventilated (TENV) or totally enclosed, fan cooled (TEFC.)

E. Hoist Motor Insulation and Time Rating

Hoist motors shall be provided with insulation which has a Class F rating based on an 105 degree C motor temperature rise above 40 degrees C ambient, with frame size selection based on continuous ratings.

F. Bridge and Trolley Motor Insulation and Time Rating

Bridge and trolley drive motors shall be provided with an insulation which has a Class F rating based on 105 degrees C motor temperature rise above 40 degree C ambient with frame size selection based on continuous rating.

X. Radio Controls

A. General

1. Transmitter- 4 motion transmitter with gantry, trolley, main hoist and auxiliary hoist controls, belly-box with 6 fully proportional paddle levers.

2. Receiver – 5 step output for all functions.

3. Accessories – Caring Belt, 2 rechargeable batteries, and a 120 VAC battery charger.

4. 120V AC, License-Free – System approved for operation under FCC Part 15 rules – no user license required.

XI. Reels/Festoons

The Contactor shall be responsible for identifying the cable size (AWG-American Wire Gauge) and the number of conductors required to power the gantry crane and all its components. The Contractor shall supply reels that account for active travel, total travel, payout and cable length. Provide oversized re-greasable bearings on both sides of the load-bearing spool. Provide electric gear drive. The unit shall be sized by the Engineer to provide the correct amperage to the cane and work in concert with the electrical upgrade.

XII. Submittals

A. Prior to replacement of existing crane components, the Contractor shall submit manufacturer’s product specifications, as applicable, for all the new components and equipments that will be provided by the Contractor. Each submittal shall be consecutively numbered and shall include the following:

1. Submittal date, revision dates, and transmilttal number

2. Project Name and USIBWC contract number and Project title

3. Name of Contractor and Subcontractor, if applicable

4. Name of supplier and manufacturer

5. Standard code, test, or contact document reference

6. Identification of deviation from the contract documents

7. Contractor’s stamp, initialed or signed, dated and certifying the review of submittal and compliance with contract documents.

8. Physical location at which the equipment/part is to be installed.

9. Manufacturer’s warranty of product

B. The Contractor shall submit four (4) complete sets of each submittal.

C. The Contractor shall allow for a fourteen (14) calendar day review time for the USIBWC for each submittal. The Contractor shall include this review time in their schedule.

XIII. Inspection and Testing

A. Notify USIBWC COR within 14 calendar days prior to beginning any testing. USIBWC shall be present.

B. Field Test - Conduct testing under the supervision of the Contractor’s representative and conduct the following test:

1. Operational Tests:

Test crane systems, following installation but prior to acceptance, to ensure compliance with the contract documents. Test the crane functions of hoisting and lowering, operation of brakes, travel limit switches, and all safety devices. Trip setting of limit switches and safety devices at no-load conditions initially.

Conduct test at first by hand, if practical, and then under the lowest speed obtainable. Continue testing until all systems are tested under no-load conditions through the full range of motion and speed attainable by the crane.

Test crane to determine that the hoists, including pendants are electrically grounded during all phases of operation.

2. Overload Test:

tem will be operated through its complete range of movements at this overloaded condition. Adjust the hoist overload cutoff to 125 percent of the rated load during the overload test and reset to 105 percent after the overload testing is complete.

3. Adjustment and Repairs

Correct any unsafe conditions disclosed by the inspection and retest until crane systems are approved by USIBWC.

4. Training

Supply USIBWC with 8 hours of training, four in classroom and 4 in the field. Cover operations and maintenance requirements.

XIV. Close-Out Documentation

A. Contractor shall provide warranties within seven (7) calendar days after completion of project and acceptance by Government. Effective date for these warranties shall be the day project is completed by the Contractor and accepted by the Contracting Officer. Contractor shall provide a minimum one (1) year labor and parts/equipment warranty.. When repairs due to defective workmanship and/or equipment are required during the Contractor’s warranty period, the Contractor shall make such repairs within 72 hours of notification. When repairs are not performed within the specified time, emergency repairs performed by others shall not void the warranty.

B. Contractor shall provide operation and maintenance data on each part/equipment to include the following:

a. Name, address and telephone number of nearest authorized service facilities and parts distributor

b. Equipment manuals or cut sheets.

c. Parts list

d. Recommended spare parts

e. Maintenance requirements and schedules for all equipment.

f. Lubrication requirements and list of lubricants

g. Safety procedures

h. Routine maintenance procedures

i. Wiring Schematics

XV. Safety The Contractor shall comply with all applicable provisions of the “U.S. Army Corps of Engineers Safety and Health Requirements Manual”, EM385-1-1, 2008 edition, and the Federal Occupations Safety and Health Administration, 29 CFR 1926 – Construction Standards.

A. The 2008 edition of “U.S. Army Corps of Engineers Safety and Health Requirements Manual” may be downloaded by visiting the following site:

http://www.usace.army.mil/CESO/Documents/EM385-1-1Final.pdf

B. The Federal OSHA Safety Manuals can be procured from the following source:

Superintendent of Documents

U.S. Government Printing Office

P.O. Box 371954

Pittsburgh, PA 15250-7954

Or may be downloaded by visiting the following site:

http://www.osha.gov/pls/oshaweb/owasrch.search_form?p_doc_type=STANDARDS&p_toc_level=1&p_keyvalue=1926

XVI. Performance Period

The Contractor shall complete all work and deliver the crane retrofitted with new motors, new radio controls, new gantry and trolley brakes, new cable reels and new power supply wiring including variable frequency drives, trolley festooning and all limit switches within the time frame(s) stated in Sectio F of this requirement.

XVII. References

A. In the event of a conflict between the referenced standard and these Contract Documents, the provisions of the Contract Documents shall apply. When a reference standard is specified, comply with the requirements and recommendations stated in the standard, except when they are modified by the Contract Documents, or when applicable laws, ordinances, rules, regulations or codes establish stricter standards. The latest provisions of applicable standards shall apply to the work, unless otherwise specified.

B. Reference publications are cited in other sections of the specifications along with identification of their sponsoring organizations. The addresses of the sponsoring organizations are listed below, and if the source of the publications is different from the address of the sponsoring organization, that information is also provided.

C. The publications listed below form a part of this specification to the extent referenced.

National Fire Protection Association

1 Batterymarch ParkQuincy, Massachusetts 02169-7471Tel: +1 617 770-3000Fax: +1 617 770- 0700 http://www.nfpa.org/aboutthecodes/list_of_codes_and_standards.asp

NFPA 70 National Electrical Code

Underwriter’s Laboratories, Inc.

333 Pfingsten Road Northbrook, IL 60062-2096 Telephone: +1-847-272-8800 Customer Service:

+1-877-854-3577Fax: +1-847-272-8129www.ULStandards.com

UL 1004 Electric Motors

American National Standard Institutes

Washington D.C. Headquarters

1819 L Street, NW

6th floorWashington, DC 20036Tel: 1.202.293.8020Fax: 1.202.293.9287

Customer Service: 1.212.642.4980 http://www.ansi.org/

Insulated Power Cable Engineers Association http://www.icea.net/

National Electrical Manufacturers Association

National Electrical Manufacturers Association1300 North 17th StreetSuite 1752Rosslyn, Virginia 22209

Phone: (703) 841-3200Fax: (703) 841-5900 http://www.nema.org/

NEMA MG 1 2006, Revision 1 – 2007 Motors and Generators

NEMA 12 Enclosures Rating

IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)

American Iron and Steel Institute

680 Andersen DrivePittsburgh, PA 15220

412.922.2772 http://www.steel.org/AM/Template.cfm?Section=Construction

International Electrotechnical Commission http://www.iec.ch

IP 65 IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)

Crane Manufacturers Association of America http://www.mhia.org/industrygroups/cmaa

CMAA Specification No. 70 - 2004 - Multiple Girder Cranes

Federal Communications Commission http://www.fcc.gov/

END SOW

c.1a OPTIONAL REQUIREMENT: RETROFIT/UPGRADE A 30 TON SPILLWAY

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 30- 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 manufacturer of major components for cranes shall have been engaged 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. 30 Ton Gantry Crane (Spillway) – The crane is on the platform of the dam situated over the gate actuators (gate motors), it travels on rails the length of the platform. Its primary use is to service the gate actuators and set and remove stop logs. There is one lifting implement on the crane, a 30-ton eye. The eye reel is on a trolley. The crane is illustrated on exhibit 8.

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

2. Brakes - Solenoid Brakes

3. Motors

a. Gantry Motor – 10 HP

b. Auxiliary Trolley Motor – 2 HP

c. Auxiliary Moist Motor – 10 HP

d. Main Hoist Motor – 20 HP

B. Index…