Statement_of_Work_for_Tensile_Test_Tower_Upgrade0901.pdf

SOW-Test Tower Upgrade 01 September 2017

Statement of Work for Tensile Test Tower Upgrade

1. Scope.

The Naval Surface Warfare Center, Indian Head Explosive Ordnance Disposal Technology Division, (NSWC IHEODTD) Picatinny Detachment (Code G1) requires the upgrade of an existing hydraulic 50,000 pound capacity Tensile Test Tower to a new capacity of 80,000 pounds (80K). A separate contract option will be added to upgrade the tower to a capacity of 100,000 pounds (100K). The government evaluators will determine the final capacity based on information received in the contractor bids. The existing tower is constructed from structural steel beams in an A- frame configuration. The base of the tower measures 15ft x 15ft and the peak of the tower is approximately 48ft from the floor. The tower is located completely within Building 458. The building roof above the tower is raised, as to accommodate the tower height. Access to the hydraulic cylinder and upper part of the tower is only from inside the building, via a ladder and a catwalk. No roof access is available and there are no means to access the tower with an overarching crane.

2. Task List.

Request that prospective contractors provide cost proposals for the Contract Line Item Numbers (CLINs) listed below. Government evaluation of the contractor proposals will select either CLIN 001 (80K upgrade) or CLIN 0002 (100K upgrade), but not both. Other CLINs, 0003 through 0005, may be selected for inclusion in the contract as required. Details regarding each CLIN are provided in the Performance Requirements of para 3.

CLIN 001 Tower Upgrade to 80K – Perform Tower Upgrade to 80K Capacity, including Structural, Hydraulic and Control System Design, Installation, Acceptance Testing and Certification, Training, and Clean-up (See para 3.1);

CLIN 002 Tower Upgrade to 100K – Perform Tower Upgrade up to 100K Capacity. Consists of additional costs and efforts above the 80K upgrade in the areas of Structural, Hydraulic and Control System Design, Installation, Acceptance Testing and Certification, Training, and Clean-up (see para 3.2);

CLIN 003 Test Pendants – Fabricate Six (6) Test Pendants (see para 3.3);

CLIN 004 Test Fixtures – Fabricate Three (3) Test Fixtures (see para 3.4);

CLIN 005 Rigging Gear – Fabricate Five (5) Rigging Gear Items (see para 3.5).

3. Performance Requirements.

The contractor shall implement best and safest industry practices during accomplishment of all contracted tasks and meet all applicable OSHA requirements. The contractor shall provide all necessary labor, tools, lifting equipment, materials and parts, unless otherwise stated. The following information is provided for clarification regarding each primary task.

3.1 CLIN 0001 - Perform Tower Upgrade to 80K. Upgrade the existing test tower capacity to provide a Safe Working Load (SWL) of 80,000 pounds. Details as follows:

3.1.1 Structural Design The contractor will conduct a formal analysis on both the existing tower structure and the concrete anchor pad to confirm they are capable of providing the contracted Safe Working Load (SWL) and a proof test load equal to 125% of the SWL. If existing structures are found to not be capable of the new SWL, the contractor shall determine where and what type of reinforcement is needed so the tower will support the new SWL with a 125% proof test. All final calculations created by the contractor during the structural analysis shall be certified by a PE and included with the data submitted (CDRL A001). All final drawings created by the contractor during the structural analysis shall be included with the data submitted (CDRL A002). Engineering drawings and analysis of the existing tower structure and concrete anchor pad were recently prepared by a contractor and are provided for reference in Attachment A.

3.1.2 Hydraulic System Design. The contractor will design, fabricate and install an integrated hydraulic system. The system shall include all new parts, including the cylinder(s), piping, valve(s), pump(s) and reservoir. The new hydraulic system shall allow the tower to have a minimum working test height of 24 feet and a maximum working test height of 33 feet, when the height is measured from the floor to the pendant attachment point of the crosshead. The current system includes a crosshead which supports a 1,000‐pound capacity electric chain hoist used for raising and lowering the pendant attachment block. This chain hoist shall be replaced by a model with the capability of safely lifting the heaviest pendant and a set of rigging gear as described in para 3.3 and 3.4. The contractor may modify or replace the crosshead in order for it to be compatible with the new equipment.

3.1.3 Control System Design. The contractor will design, fabricate and install a dedicated digital control system that allows the operator to select, create, and store test profiles. If the controller is PC based, the latest Windows operating system shall be provided. The controller programs shall be a user friendly graphical interface. The user shall have control over graphical presentation and results. The test result plots shall allow the user to include organizational logos on the printouts. All units shall be in USA system (foot, pound, second, etc.) units but metric units shall also be available. The control system shall come with a surge protector with battery backup. The system shall have an emergency stop button located next to the Digital Control System that will shut down the hydraulics. The following additional control system features will be provided, as a minimum:

a) The application program will allow the user to specify a test load and test time. The program will apply the specified load in tension and hold for the specified time. The application program will reverse the load back to zero.

b) The application program will allow the user to specify a multi‐step test. The user will specify up to ten different test loads and test times. The application program will then apply the 1st specified load in tension and hold this load for the specified time. After this time, the load will be increased or decreased to the next test specified test load and then held for the specified time. This process should be available for up to 10 different test loads and different time periods. All of these test parameters shall be defined prior to the testing and the test should be run without further input from the user.

c) The application program will allow full manual control of the tensile tower.

d) The application program will allow the user to stop the test at any time during its operation and control the tensile tower manually.

e) Test setups should be capable of being saved so they can be recalled and used at a later date.

f) Data shall be captured by the control system and be capable of being plotted in numerous plotting formats (within the supplied controller program). Also, the data files need to be capable of being saved and an export utility should be provided to export data into ASCII and or Common Separated Value (CSV) formats.

g) A user friendly extensive help section shall be included within the controller. It shall allow a search on select topics and also word search to find help topics.

h) During testing and as the test is progressing a digital numeric display shall show relevant test data. This shall include but not be limited to force, time and displacement of crosshead.

i) The system shall be equipped with a removable standalone load sensing device installed in the load path. Also, the crosshead shall be equipped with a displacement measuring device. These devices must be able to be calibrated in accordance with applicable National Institute of Standards and Technology

(NIST) standards.

j) The hydraulic control system will be remotely located on the opposite side of a protective wall. Conduit is already in place to allow the passage of piping and wires through the protective wall. Any additional piping and work will be done by the contractor.

k) Controls for the new pendant locking pin and chain hoist controls must remain on the tower itself. A new control pendant for the chain hoist shall be installed and secured to the pendant locking pin bar. These controls cannot be remotely located.

3.1.4 System Installation. The contractor will perform the tower upgrade, on‐site at

Picatinny Arsenal, Building 458. All integral components shall be installed, including the structural, hydraulic, and control systems. The purchase or modification of all components required to produce a fully operational final product, consistent with the design analysis, are the responsibility of the contractor. Any required structural reinforcements and/or improvements shall be conducted during this installation. Due to the limited cylinder access at the top of the test tower, the contractor’s removal and reinstallation methods will require equipment such as temporary scaffolding and special handling equipment supplied by the contractor. All equipment and methods must meet or exceed all current Occupational Safety and Health Association (OSHA) requirements.

There is no means to access the tower using an overarching crane.

3.1.5 Acceptance Testing and Certification. Prior to government acceptance, the contractor shall demonstrate acceptable operations by applying Proof and

Operational test loads. Pendants/fixtures supplied under the contract may be used. All other fixtures required for these tests shall be provided by the contractor.

a) Proof Test. The structural capacity of the finished tower will be demonstrated by applying a vertical proof test load of 125% of the contracted

SWL (+1000/‐0 pounds) and holding the load for a period of 5 minutes. The contractor will supply all pendants, swivel hoist rings, and rigging gear as needed to perform the proof test.

b) Operational Test. Acceptable operation of the finished tower will be demonstrated by performing two load tests. The first test will be for the tower to apply and hold a vertical test load of 1000 (+50/‐0) pounds for a period of

5 minutes. The second test will be for the tower to apply and hold a test load up to the contracted SWL amount (+1000/‐0 pounds) for a period of 5 minutes.

A test fixture for this demonstration shall be provided by the contractor.

c) Certification. The contractor must include a written certification of SWL for the Completed Test Tower in the as‐built condition (CDRL A003).

3.1.6 Operational/Maintenance Training and Manuals

a) Training. Training on the completed system shall be provided by the contractor at Picatinny Arsenal, Building 458. Operational and system maintenance training shall support up to ten US Navy employees.

b) Manuals. The contractor shall provide two copies of all comprehensive operation and maintenance manuals (CDRL A004) including available sub‐ manuals with the system. These manuals shall include:

A comprehensive technical overview of the systems capabilities.

Step by step instructions for setting up, conducting, and post‐test data reduction and plotting

Comprehensive drawings and wiring diagrams of the “as built” configuration, sufficient for understanding the functions of the component parts, and performing basic trouble shooting.

Complete instructions for utilizing all features of the software provided with the systems

All safety features and safety precautions relevant to maintaining and operating the systems safely.

Complete parts list.

3.1.7 Clean-up. The contractor will be responsible for clean‐up of the tower and surrounding area after completion of the tower upgrade. Tools, equipment, cleaning materials, fluids, old hydraulic oil, old and discarded material, and any other materials brought in by the contractor shall be removed from government property. All chemicals or supplies must be housed in contractor supplied enclosures that meet OSHA requirements during the work on site.

3.2 CLIN 0002 - Perform Tower Upgrade to 100K. Upgrade the existing test tower capacity to provide a Safe Working Load (SWL) of 100K pounds. Details as follows:

3.2.1 Structural Design. See para. 3.1.1

3.2.2 Hydraulic System Design. See para. 3.1.2

3.2.3 Control System Design. See para.3.1.3

3.2.4 System Installation. See para. 3.1.4

3.2.5 Acceptance Testing and Certification. See para. 3.1.5

3.2.6 Operation and Maintenance Instruction. See para. 3.1.6

3.2.7 Clean-up. See para.3.1.7

3.3 CLIN 003 – Fabricate Test Pendants. New extension pendants for use as reach connectors, extending vertically to the tower’s load-transfer device (crosshead) shall be fabricated and delivered to the site by the contractor. Each pendant must have a minimum SWL of 100,000 pounds.. Pendants shall be constructed of stranded carbon steel wire rope, with a nominal diameter between 1-1/4” and 1-3/8”, and rotation resistant properties in accordance with ASTM A1023.

The pendants shall be suitable for use with a swivel fitting and have poured socket terminations on either end. One end shall have a Closed Spelter Socket with a corresponding Open Spelter Socket on the opposite end. All pendants must have a certificate of proof test, showing that they have been tested to 200% of SWL, and held for 2 minutes (CRDL A003). Pendants shall be supplied in the following lengths and quantities:

Test Pendants for use with Upgraded Test Tower Qty Length

(in)

1 36 ± 1 2 60 ± 1 1 90 ± 1 2 120 ± 1

3.4 CLIN 0004 – Fabricate Test Fixtures. New test fixtures shall be fabricated by the contractor in a similar method to the test fixture shown in NAVSEA drawing 53711-8410907 (see Appendix A) and delivered to the site. The diameter and SWL shall be as shown in the table below. Each test fixtures will be required to sustain a proof load test of 150% SWL for a period of 2 minutes (CDRL A003).

Test Fixtures for Use with Upgraded Test Tower

Qty Diameter (in)

Safe Working Load (lbs)

Proof Test Load (lbs)

1 6.00 25,000 37,500 1 12.75 25,000 37,500 1 13.50 25,000 37,500

3.5 CLIN 0004 – Fabricate Rigging Gear. New rigging gear shall be fabricated by the contractor as described below and delivered to the site. Each piece of gear must have a minimum SWL of 100,000 pounds. Each item shall come with a certificate of proof test showing the item was tested to 200% of its SWL and held for 2 minutes (CDRL A003).

Rigging Gear Required for Test Tower

Qty Item SWL (minimum)

Description

2 Shackle 85 Ton Bolt Type Alloy Shackle, 2.75” pin diameter, Master Link

19 Ton Alloy Master Link, 1.25” nominal diameter, Swivel Hook

30-ton Alloy Swivel Hook, ball bearing, minimum throat opening of 5”

Swivel Hook

30-ton Alloy Swivel Hook, ball bearing, minimum throat opening of 5”

4. Schedule and Performance Test Requirements. The contractor shall provide a defined work schedule (CDRL A005) within 14 days of contract award. Work will commence within 14 days after receipt of schedule by the government. The actual window between taking the tower out of service and returning to it back to service shall be minimized, not exceed to three months.

a) Installation Availability. The work site where the existing tensile test tower is located will be made available to the contractor after 14 days of contract award, and upon notification of work commencement from the contractor. The tower is located inside Building 458 at Picatinny Arsenal, NJ.

b) Performance Tests. After all tasks are completed, the contractor shall demonstrate that the newly upgraded test tower can apply test loads the required

Proof and Performance Test loads. All fixtures required for these tests shall be provided by the contractor. The pendants supplied by the contractor shall be used to connect the test tower to the test fixture(s). The contractor shall operate the control system which is used to control the hydraulic cylinder. The load shall be held stable for a period of 5 minutes. No leakage of hydraulic oil from any part of the system will be permitted.

5. Safety Plan. The contractor will be required to obtain a work permit from the Picatinny Arsenal Garrison Safety Office prior to beginning work at Building 458. To obtain a permit, the following items must be supplied to the Safety Office for review:

Site Specific Health and Safety Plan (HASP) – This plan will document the contractor’s health and safety plan for work conducted on the Picatinny Arsenal Garrison. Sub‐contractors will be permitted to work under the prime contractors Health and Safety Plan as long as the sub‐contractor agrees to follow the prime contractor's safety rules. The name and contact information for the Onsite Supervisor and Jobsite Safety Supervisor (if different then Onsite Supervisor) shall also be included in the document.

Activity Hazard Analysis (AHA) – An Activity Hazard Analysis is required for the work that will be done. This form will document each expected hazard that will be encountered and what steps will be taken to mitigate the risks. The Activity Hazard Analysis is required to use DD Form 2977.

Contractor’s Scope of Work – The contractor must supply a scope of work describing the onsite work to be performed.

Applicable Certifications – The contractor must provide evidence of valid training certifications for each employee that will be working onsite. Contractor employees shall be trained in general OSHA requirements such as Lockout/Tagout and Fall Protection. If required, the employees shall also be trained in specific areas such as, but not limited to, fork‐truck operator, crane operator, and aerial work platform operation.

All documents must be submitted a minimum of two weeks prior to the start of onsite work.

(CDRL A006) The complete document package shall be submitted to:

Picatinny Garrison Safety Office Building 351 South, Room 2 Picatinny Arsenal, NJ 07806

Once a permit is issued by the Picatinny Safety Office, all contractor and sub‐contractor employees working onsite will be required to attend a safety briefing given by the Picatinny Arsenal Garrison Safety Office. This brief will be held on the first day the contractor is working in Building 458 and before any actual work is performed.

6. Warranty/Calibration. A one year warranty, including all parts and labor, shall be included and shall start after final acceptance of the system. A one year calibration service shall be provided by the contractor.

7. Deliverable Documents. The following is a compiled list of deliverable documentation, identified in the contract as CDRLs (Contract Data Requirements Lists) to be provided by the contractor upon completion of contract tasks.

CDRL A001. All final calculations generated during the Structural, Hydraulic

System, and Control System analyses, including PE review and signature (see para

3.1);

CDRL A002. All final drawings generated during the design, covering Structural

Design, Hydraulic System, and Control System (see para 3.2);

CDRL A003. A written PE certification of the tower SWL upon completion of the

Test Tower Construction and Acceptance Tests (see paras. 3.1.1, 3.3, 3.4, and 3.5);

CDRL A004. Operating and Maintenance Manuals, 2 copies (see para. 4);

CDRL A005. Contractor’s Complete Planned Schedule of Work (see para. 4);

CDRL A006. Safety Plan, certifications and other documentation required for meeting Army site‐specific safety requirements and obtaining an on‐site work permit from Picatinny Arsenal. (see para. 5).