N0025320Q0113 Attachment 1_SOW.pdf

ELECTRO-HYDRAULIC DRIVE WINCH (Revision A, 29 APR 2020)

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STATEMENT OF WORK

1. SCOPE

1.1. The Naval Undersea Warfare Center (NUWC) Division Keyport has a requirement for one

(1) new steel marine‐grade electro-hydraulic drive winch. The winch shall be designed using modern and best marine industry practices and standards for strength; reliability; adaptability to various operating conditions; simplicity of operation and maintenance; precision control;

and corrosion resistance. The winch shall conform to the characteristics and specifications outlined in this requirements document.

1.2. All materials and parts comprising the marine‐grade electro-hydraulic drive winch shall be new, of current industry design and manufacture, and shall not have been in prior service except as required for factory testing. Products such as a prototype unit, pre-production model, or experimental unit DO NOT qualify as meeting this requirement. The equipment shall be complete, so that when connected to the utilities identified herein, it can be used for the function for which it is designed and constructed.

1.3. Marine‐grade electro-hydraulic drive winch shall conform to the characteristics and specifications outlined in this Statement of Work (SOW).

1.4. Contractor shall have International Standards Organization (ISO) 9001:2015 Quality Management Systems certification.

2. SALIENT PHYSICAL, FUNCTIONAL, AND PERFORMANCE REQUIREMENTS

2.1. A Marine‐grade electro-hydraulic drive winch that meets the government minimum SALIENT PHYSICAL, FUNCTIONAL, AND PERFORMANCE CHARACTERISTICS is the manufacturer Appleton Marine, Inc., Part Number BMD-0701 Revision 4 or EQUAL.

2.1.1. The winch shall support the electrical‐marine (E‐M) cable with the following characteristics.

2.1.1.1. Maximum payout Cable Length of 1800 feet.

2.1.1.2. Nominal Cable Outside Diameter is 0.760 inches.

2.1.1.3. Cable Weight in Air is 310 lbs. /1,000 feet.

2.1.1.4. Cable Weight in Seawater is 110 lbs. /1,000 feet.

2.1.1.5. Cable minimum tensile Breaking Strength is 8,000 lbs.

2.1.1.6. Maximum operational tensile working Load through cable is 1,200 lbs.

2.1.1.7. Cable Minimum Bend Diameter is 20 inches.

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2.1.1.8. Cable Outer Jacket is Polyurethane.

2.2. Cable payout Length projected for use with the winch during its Service Life is 1800 feet in length.

2.3. The winch shall support a Planned Payload with the following characteristics.

2.3.1. Maximum dry payload weight in Air is 500 lbs.

2.3.2. Payload weight fully submerged in seawater will be no more than 454 lbs.

2.3.3. Payload volume Dimensions are approximately 48 inches (Height) x 24 inches (Diameter).

2.4. The winch shall support the following in relationship to cable speed.

2.4.1. The cable hoisting and heaving drum shall provide infinitely variable winch drum speed control.

2.4.1.1. Hoisting and Lowering Rates shall be controllable between 0‐240 feet per minute

(FPM).

2.4.2. The winch Pulling Force at the Drum Core shall be 1100 lbs. minimum.

2.4.3. The winch Pulling Force with Full Drum shall be 1000 lbs. minimum.

2.5. The winch Drum shall support the following features.

2.5.1. Core outside diameter shall meet the proposed cable requirements in accordance with 2.1.1.7.

2.5.2. Drum Capacity shall support a minimum of 1800 feet of 0.76-inch nominal diameter cable in accordance with 2.1.1.

2.5.3. Flange Outside Diameter shall exceed the diameter of a fully spooled drum of cable, assuming maximum cable length and diameter to retain the cable.

2.5.4. The winch shall possess a Drum Flange Cable Feed‐through and Cable Clamp meeting the following description.

2.5.4.1. A cutout shall be provided for the winch cable assembly to exit the drum with the cable connector intact. The cutout shall be tangential to the first cable wrap as to not exceed the Cable Minimum Bend Diameter (2.1.1.7). The cutout shall accommodate free passage of support a Government owned connector of size 3.5 inches in diameter 8 inches long.

2.5.4.2. A contoured cable retainer(s) and/or clamp(s) shall be placed on the outer drum flange to secure both the winch cable assembly and the pig‐tail cable assembly that will be connected to each other by government owned Pyle National connectors (Part Numbers ZPEMJ-1416- 321PN and ZREM-1416-321SN. Commercial specification are available at http://www.steinerpylenational.com/

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2.5.4.3. The winch shall support affixing/mounting one and a half (1 1/2) complete service loops (wraps) of the winch cable assembly and pig‐tail cable assembly to the outer flange without interfering with winch operation and any of the drum drive hardware.

2.5.5. The outer drum flange (the opposite side of the internal slip ring) shall provide an exit with an IP64 packing gland assembly for the (pig‐tail) cable assembly from the internal slip ring.

The exit opening shall be positioned pointing towards the level wind. Three (3) L‐bracket assemblies with two holes in the assembly shall be placed inside the drum to secure the routing of the cable from the internal slip ring to the exit. The exit and routing of the cable shall not exceed the Cable Minimum Bend Diameter (2.1.1.7).

2.5.6. Drum access shall be provided with no less than two (2) access ports on each side of drum.

Access ports shall allow for expected cable management and slip ring maintenance to be performed by maintenance personnel.

2.6. The winch shall be designed and constructed to support the following Environmental Conditions.

2.6.1. Components and subsystems shall be designed and constructed to withstand a marine environment and operating temperatures minimum 0°F to maximum 145°F (with 100% relative humidity (condensing). All components and subsystems shall be rated for direct salt water spray and ultraviolet (UV) resistance or be enclosed in IP64 rated casings.

2.6.2. All tubing, tube fittings and hose fittings shall be 316 corrosion resistant/stainless steel.

All fasteners shall be 316 corrosion resistant/stainless steel where practicable, and the remaining tubing, tube fittings and hose fittings shall be zinc coated.

2.6.3. A Hydraulic Power Unit (HPU) shall be integrated in the winch chassis. The HPU tank shall be designed large enough to prevent the oil from overheating when operated at full power in 145°F ambient air for 8 continuous hours.

2.6.3.1. The valve used to drain hydraulic oil from the HPU tank shall be positioned outward towards the edge of the HPU tank for “ease access” when draining the tank. The valve position shall NOT extend beyond the footprint of the HPU tank.

2.6.3.2. Hydraulic oil used in HPU tank shall be Panolin HLP Synth 46. Panolin HLP Synth 46 is ISO 46 weight biodegradable synthetic hydraulic oil.

2.6.3.3. All piping valves shall be labeled with the industry standard valve nomenclature and a reference to the piping assembly drawing number.

2.6.4. All electrical enclosures shall have adequate heating and cooling capacity to prevent condensation and overheating of components in conditions spanning 0°F to 145°F with 100% relative humidity (condensing).

3. MECHANICAL AND CONSTRUCTION CHARACTERISTICS AND FEATURES

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3.1. The winch type shall be electro‐hydraulic with variable speed operation from 2% to 100% of maximum rated revolutions per minute (RPM) and full torque at any RPM.

3.2. The winch chassis frame shall fit completely within, at maximum, a 8 ft. wide x 8 ft. deep x 7 ft. high perimeter. All winch components shall be contained within the dimensions of the chassis frame (AKA, winch assembly footprint).

3.2.1. Steel marine‐grade electro‐hydraulic drive winch without E‐M cable assemblies and slip ring shall not exceed 5100 lbs total weight.

3.3. The winch shall support the following handling/transport requirements.

3.3.1. The winch chassis base shall have two (2) SAE AS5389 standard fork truck lifting pockets, equally spaced horizontally from the winch’s center of gravity (drum full of cable included), no more than 48 inches center-to-center apart. The pockets shall receive and accept a 6-foot-long fork truck tine with a 3-inch x 8-inch cross section.

3.3.2. The winch chassis shall have four (4) integrated lifting point lugs with design factor of 5:1 for lifting the unit with a crane. Lift points shall be located on the top of the winch and be designed to support a four-legged sling with a single lift point (master link).

3.3.2.1. Any two (2) lift-points shall without permanent deformation carry the full weight of the winch, drum full of cable included.

3.3.2.2. Swivel hoist rings shall be compatible with the integrated lifting points. Swivel hoist rings shall be Crosby brand HR‐125 series Brand Name or EQUAL and the Contractor shall provide with the winch. The swivel salient characteristics are Working Load Limit (WLL) and Recommended Torque value that shall be permanently stamped into each washer.

Washer color code shall be red for Unified National Coarse Thread (UNC) thread.

3.3.2.2.1. Any two (2) swivel hoist rings shall without permanent deformation carry the full weight of the winch, drum full of cable included.

3.3.2.2.2. Each swivel hoist ring shall Proof Tested to 2 ½ times WLL.

3.3.2.2.3. Swivel hoist-ring bolts shall be SAE J429 Grade 8 medium carbon steel socket head cap screws conforming to American Society for Testing and Materials (ASTM) A-574.

3.3.3. Contractor shall provide a 5:1 rated-and-certified four-legged sling with a single lift point.

3.3.3.1. Contractor shall design integrated lifting points and four-legged sling to safely lift winch assembly and additional components (3.3.5.1) in a horizontal and parallel plane relative to the surface the winch is resting on.

3.3.3.2. Spreader bars, if needed, shall be 5:1 rated-and-certified and must be integrated with the four-legged sling identified above.

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3.3.4. All components (integrated lifting points, spreader bar, slings and shackles) of the lifting assembly shall comply with American Society of Mechanical Engineers (ASME) B30.9- 2014, ASME B30.20.2015 and ASME B30.26-2015; and Federal Specification RR-C-271F.

A letter of compliance or proof certificate shall be provided for each component.

3.3.5. The contractor shall perform a proof load test for the final lifting assembly.

3.3.5.1. The proof load weight shall include the weights of an operational winch including all fluids, E-M cable assemblies (Winch cable, Deck Cable, and Pig-tail), slip ring, electrical cable (winch to ship), winch shipping pallet assembly, and test ship’s deck frame (890 lbs.).

3.3.5.2. The Contractor shall analyze and document proof load test results. The analysis shall include a setup diagram with dimensions, calibrated load cell data, test method description (test method load duration shall be a minimum of twenty (20) minutes), and photographs of the tested structure being supported by the final lifting assembly, and the display on the calibrated load cell.

(A001, DI-NDTI-80809B)

3.3.6. The winch chassis shall have provisions to allow for the chaining of the winch to the deck of an offshore craft while allowing for the operation of the winch system.

3.3.6.1. At least four locations for chaining shall be provided on the winch. The chain attachment points (four locations) shall sustain all winch reactionary loading during operation plus loading due to heave (vertical movement), sway (transverse movement), and surge (longitudinal movement) of an offshore craft. As a minimum, added loads resulting from simultaneous accelerations of one (1) gravity (g) (in addition to static gravitational acceleration – a total of 2 g) vertical, 1 g transverse, and 1 g longitudinal shall be used for design.

3.3.6.2. Chain preload rating shall be determined by the Contractor based on best commercial practices.

3.4. The winch shall use a dedicated drive with remote handheld electrical control of drum rotation direction and speed via a hydraulic directional control valve (DCV). The remote handheld electrical control device shall allow operator at least 10 feet of distance between herself and the winch.

3.5. The winch Brake(s) shall conform to the following requirements:

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3.5.1. Independent brake(s) shall be provided for load holding; this is required as a safety feature for vertical lifting.

3.5.2. The winch shall be designed and constructed with heavy-duty electrical/mechanical or hydraulic fail‐safe brakes for the drum with precise timing control of the brake’s set and release action. The full load capacity and timing control of the brake shall be defined as calculated pounds of line pull and support the physical characteristics outlined in Section 2 above. The brake shall be sized to hold the full load capacity at any drum layer. The winch assembly shall include spring‐set automatic “parking” brake.

3.6. Contractor shall design and construct the winch employing the use of anti‐friction bearings where practicable based on best commercial practices.

3.7. The winch housing shall be made of appropriately coated steel and contain SAE 316 corrosion resistant/stainless steel and other corrosive resistant/stainless fasteners; winch surfaces shall be sandblasted and shall have inorganic zinc coating, barrier coating, and a topcoat Sherwin Williams Acrolon 218 HS Acrylic Polyurethane, Part A (B65-650 semi-gloss) and Part B (B65V600 hardener) Brand Name or EQUAL. Protective and marine coating shall conform to the following minimum salient characteristics fast drying, urethane that provides color and gloss retention for exterior exposure; and compliant with ASTM D4541 and ASTM B117. The color shall be international orange, FED STD 595 #12197.

3.7.1. The topcoat shall be completely dry prior to any assembly of any components and/or covers to reduce the risk of components and/or covers causing degradation issues with the topcoat during future removal of those items.

3.8. The winch Level Wind shall conform to the following requirements.

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3.8.1. Contractor shall incorporate a complete direct drive corrosion resistant/stainless steel diamond level wind lead screw assembly with corrosion resistant/stainless steel rollers.

3.8.2. Level wind shall be powered and properly timed for the cable diameter (2.1.1.2) planned for use with the winch. Level wind shall support manually advancing or retarding without disassembly of the drive mechanism. The level wind shall support fleeting the cable to an over board sheave that is positioned between 0 and 35 degrees of elevation above the fairlead assembly’s exit.

3.8.3. All external drive components, such as gears, sprockets, chain, etc., shall be fitted with a protective shroud to promote safe operation and to prevent entanglement(s).

3.8.4. The level wind and fairlead assembly shall be attached to the winch main frame. Fairleads that contact the cable shall have rolling elements constructed of a polymer compatible with the polyurethane outer jacket of the cable to minimize the possibility of cable chafing.

3.8.5. The fairlead assembly shall allow disconnection to provide access for the government owned cable connector (TE Connectivity SEACON MSSO31CCPSC-001) to pass through.

The connector is nominally 3.25-inch diameter.

3.9. Slip Ring

3.9.1. The contractor shall design and construct into the winch the government furnished property, Focal Technologies Corporation, Model 180 Slip Ring, Drawing Number 180- 2661-00 REV A, ESR INSTALLATION FOR NUWC dated 06 OCT 2014; and the PIG- TAIL CABLE ASSY 10FT. See contract clause 252.211-7002 for contact information to obtain drawing.

3.9.1.1. The slip ring shall fit in the hollow shaft of the winch drum. The slip ring shall mount on the taps on the exterior of the hollow shaft, no portion of the slip ring shall touch the interior of the drum or drum shaft. The slip ring torque arm shall have side play.

3.9.1.2. The slip ring shall have a protective cover that will allow the Deck Cable to be connected without removal of the protective cover.

3.10. All winch hydraulic hose ends and adapters shall be constructed of marine grade corrosion resistant/stainless steel. Joint Industry Council (JIC), defined by Society of Automotive Engineers (SAE) J514, 37° flared and O-ring bossed (ORB), fittings shall be used in as many hydraulic connections as possible.

3.11. All lubricants, oils and greases used in the winch assembly shall carry a designation indicating they are safe for marine use.

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3.11.1. The Contractor shall collect and make available Safety Data Sheets (SDS) information for all lubricants, oils and greases prior to contractor design finalization and no later than one

(1) month after contract. Government will review each SDS for the marine safe characteristics. Government will provide the contractor a products list outlining what is acceptable for use in the winch assembly. The Contractor shall provide SDS, OSHA Form 174 or equivalent, containing data items communicating to users the chemical, physical, and hazardous properties of their product. SDSs are not required for all products used in the manufacture of the final winch assembly. SDSs are required for any item contained in the final product, which requires special disposal, or handling during operational use or de‐mil operations. SDS forms shall comply with the OSHA Hazard Communication Standard, Title

29 CFR 1910.1200.

(A002, DI-TMSS-80527C)

3.12. The winch shall contain instrumentation and controls meeting the following.

3.12.1. The winch assembly shall include a marine grade corrosion resistant/stainless steel Control Panel Cabinet (operator console) with retractable cover that can be secured in place during an operation. The operator console shall be located on the left side of the winch drum (when viewed from the winch’s rear) to meet shipboard deployment. All operating levers (joysticks), buttons, switches, indicators, and display shall be inset and inside the winch assembly footprint (3.2) to prevent damage during operations and/or shipment.

3.12.1.1. The contractor shall provide a retractable step to allow the operator to see over the operator console for the operating the winch; and to operate / view the warning indicator lights, the electronic displays, button/switches.

3.12.1.2. The step shall extend forty-six (46) inches from the left most edge of the operator console to the right such that operator can see over the cable drum. Step shall be folded up when not in use and shall be within the winch chassis frame, see 3.2. Step shall have a feature to secure the step from moving in the down or up position.

3.12.1.3. The operator console shall have handles inside on both the left and right sides to aid in stepping up on step and maintaining balance in various sea states.

3.12.1.4. The operator console shall have protective storage for the winch operation manual.

3.12.1.5. All cabling inside the operator console shall be secured via cable ties.

3.12.2. The operator console shall have the following WARNING indicator lights:

3.12.2.1. System Power ON

3.12.2.2. Ship Power Available

3.12.2.3. Motor: Incorrect Phase Order

3.12.2.4. Low Hydraulic Oil

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3.12.2.5. High Oil Temperature

3.12.3. The operator console shall have the following electronic numeric displays:

3.12.3.1. The winch Line Speed (feet/Minute)

3.12.3.2. Length of Cable Payed out (feet)

3.12.3.3. The winch Drum Speed (FPM)

3.12.3.4. Drive Motor Amperage (Amps)

3.12.3.5. The winch Cable Tension (Load) (Lbs)

3.12.3.6. Hydraulic Oil Pressure (PSIG)

3.12.4. The operator console shall have the following functional switches:

3.12.4.1. Power ON / OFF Switch

3.12.4.2. Emergency Stop (E-stop). Emergency Stop Switch shall be red colored mushroom resettable style.

3.12.4.3. Warning Alarm with Switch

3.12.4.4. Single Axis (horizontal plane) Joystick/Level

3.12.5. The operator console shall have a separate and independent display for “Length of Cable Payed Out” with a manual reset mounted inside the operator console.

3.12.5.1. The numbers on the display shall be minimum be minimum one (1) inch and maximum two (2) inches high. The display shall be labeled.

3.12.5.2. The display shall be readable in direct sunlight.

3.12.6. The operator console shall have additional WARNING indicator lights for “System Power ON” and “Incorrect Phase Order” mounted outside the operator console for shipboard deployment. The indicator lights shall be mounted on the right side of the operator console viewable from the main power receptacle for shipboard deployment. All indicator lights shall be labeled.

3.12.6.1. System Power ON shall display a green light. Light shall be viewable in direct sun light.

3.12.6.2. Incorrect Phase Order shall have display a red light. Light shall be viewable in direct sun light.

3.12.7. The winch assembly shall be designed and constructed with a Rotating Amber LED Beacon, manufacturer Ionnic, Part Number 107002 Brand Name or EQUAL. The rotating amber LED beacon shall conform to the minimum salient characteristics noted below.

3.12.7.1. The beacon shall be 24 inches above the winch assembly footprint (3.2) for safety purposes. The beacon shall be mounted on a collapsible pole assembly. The pole assembly

N0025320Q0113 P a g e 10 | 17 Attachment 1 shall be collapsible to at least 6 inches inside the winch assembly footprint (3.2) when not use for transit to and from ship.

3.12.7.2. Color: Amber

3.12.7.3. Line of sight: Viewable from 360 degrees

3.12.7.4. Physical location: Mounted above operator’s console

3.12.7.5. Operation: Energized whenever the main winch power is ON

3.12.7.6. Operating Temperature: ‐22°F to 122°F

3.12.7.7. Environmentally protected: sealed – IP64 rated

3.12.8. The winch assembly shall be designed and constructed with an Audible Alarm, manufacturer Mallory Sonalert, Part Number A028SDC Brand Name or EQUAL. Alarm shall conform to the following minimum salient characteristics.

3.12.8.1. Control: controllable via a switch mounted on console

3.12.8.2. Mode of Operation: Continuous

3.12.8.3. Loudness @ 2 ft.: 65 to 75 dB (A)

3.12.8.4. Operating Temperature: ‐22°F to 122° F

3.12.8.5. The annunciator shall be mounted on the outside of the operator console in the front of operator console when viewed from the winch’s rear for safety purposes. Annunciator shall be adjustable and shall be audible above winch noise level.

3.12.8.6. Annunciator shall be environmentally protected: sealed – IP64 rated.

3.12.8.7. Connections shall be NEMA 4X compliance.

3.13. The operator console shall be designed and constructed of marine grade corrosion resistant/stainless steel; the corners/edges shall be reinforced inside the operator console with marine grade corrosion resistant/stainless steel to reduce the risk of any seams splitting.

3.14. The winch shall be designed and constructed using fully waterproofed boxes for hydraulic gauges as well as hose, power and data breakouts if routed outside the winch housing. ALL hoses, cabling and connectors will be IP64 rated or enclosed in IP64 rated conduit(s) and/or housing(s).

3.15. Contractor shall design and construct the winch to accommodate the future installation of winch radio control system which, when installed, shall be completely within the winch assembly footprint (3.2).

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3.15.1. The operator console shall be designed and constructed considering the space and installation needs for an optional winch radio control system.

3.16. The winch design and construction shall NOT incorporate the use of any davit(s).

4. ELECTRICAL CHARACTERISTICS AND FEATURES

4.1. The winch shall be designed and constructed to support Ship’s Power of 480 VAC, 3 Phase, 60 AMP maximum.

4.2. The winch Power shall be 480/440 VAC, 24 HP minimum, 35 or 36 AMP, 3‐Phase.

4.3. With the exception of the main power supply cable, all electrical components, electrical distribution components, and enclosures shall be wired and mounted within the winch assembly footprint (3.2).

4.4. The winch assembly design and construction shall support internal power distribution beyond the main power receptacle. This shall include internal overcurrent fault protection.

4.5. Contractor shall provide one (1) minimum 100‐foot power cord for the winch assembly. A IP67 marine grade locking type receptacle on the winch shall be integrated in the design so the main power cable can be fully removed for shipping.

4.5.1. The other end of the power cord shall plug into the ship’s Hubbell receptacle (60AMP 3Phase 480VAC 3P 4W IP67 Watertight) Part Number 460R7W.

4.6. All external cabling and connectors shall be IP64 rated or housed in marine grade IP64 conduit(s) and/or housing(s).

5. SUSTAINABILITY

5.1. The winch design and construction shall support a fifteen (15) year life cycle at a projected 10% duty cycle.

5.2. Storage

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5.2.1. The winch shall support outdoor covered storage for up to six (6) months with no service or power available. If special layup or startup procedures are required to support a six (6) month storage period, detailed procedures shall be included in the winch operations and maintenance manual(s).

5.2.2. A protective storage and transportation canvas cover shall be provided with the winch. The protective storage and transportation canvas cover shall be a water‐proof rain cover for the entire winch and securable in a way that will withstand 70 miles per hour highway transportation air speeds. The protective storage and transportation canvas cover shall be UV‐resistant.

5.3. Spare Parts Inventory

5.3.1. The winch design and construction shall optimize in‐field replaceable modularity and component level replacements including, at a minimum, the following:

5.3.1.1. Power transmission chain and master links

5.3.1.2. Hydraulic hoses and field serviceable fittings

5.3.1.3. Level wind wear items including bushings or diamond screw shuttles

5.3.1.4. Any special tools for winch disassembly or maintenance shall be included with the winch at time of delivery. Detailed special tool use shall be included in the winch operations and maintenance manual(s).

5.3.2. Recommended quantities for spare components shall be included with the winch operations and maintenance manual(s).

5.4. Design and Approval

5.4.1. The Contractor shall develop and document a proposed ELECTRO-HYDRAULIC DRIVE WINCH design (high-level documents and drawings) for government approval.

(A003, DI-CMAN-80883)

5.5. Manuals

(A004, DI-TMSS-81675A & DI-TMSS-81678A)

5.5.1. The Contractor shall develop and document winch installation, operation, and maintenance manual(s).

5.5.1.1. Operational procedures outlining all controls, indicators, and external features of the winch along with operating instructions shall be included in the manual(s).

5.5.1.2. Detailed troubleshooting, fault isolation, and corrective maintenance procedures shall be provided for all field replaceable components and subassemblies.

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5.5.1.3. Maintenance information shall also include preventative maintenance schedules and procedures.

5.5.1.4. Maintenance details supporting electro‐hydraulic systems shall include a hose list citing all hose lengths and corresponding fitting types.

5.5.1.5. All operational configuration settings, default factory settings, dip switch positions, and other key variable settings, as appropriate, shall be outlined in the documentation set.

5.5.1.6. Maintenance details shall include illustrated parts lists and suggested sources of support for all field replaceable parts as well as recommended quantities for spares. The illustrated parts breakdown of all serviceable components shall include a component list containing part numbers and quantities required per winch assembly.

5.5.1.7. Installation details shall include a discussion outlining cable spooling, associated parameters, and a diagram depicting “how the cable looks as spooled on the drum”.

5.5.1.8. Installation, Operation, and Maintenance details shall include final assembly drawings, hydraulic schematics, and electrical schematics for winch system and winch subsystem, including any Original Equipment Manufacturer (OEM) used subcomponents.

5.5.1.9. Operational details shall include the list of supporting compliances, standards, specifications (salient characteristics), registrations and certifications for final as‐delivered winch.

5.5.1.10. Operational and maintenance procedures shall include appropriate cautions and warning to minimize equipment damage and address hazards to personnel. A safety summary outlining the potential operational and maintenance hazards shall be included in the documentation set.

6. TEST AND ACCEPTANCE

6.1. The Contractor shall develop and document a winch test plan to demonstrate that the winch meets or exceeds the winch characteristics, functions, capabilities and performance of this winch design specification document. This will include an electrical test (continuity) for the installed government furnished property (SLIP RING WITH BULKHEAD CONNECTORS, PIG-TAIL CABLE ASSY 10FT and TEST CABLE WITH CONNECTORS) per MATS CABLE ASSEMBLIES Wiring Diagram REV C dated 20 SEP 2018.

6.1.1. All general and special purpose test equipment utilized in testing winch and components shall be calibrated in accordance with the Navy METCAL program. Test records shall include a list of all utilized test equipment, by manufacturer, model, serial number and last calibrated date.

(A005, DI-QCIC-80553A)

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6.2. Upon the government’s acceptance of the winch acceptance test plan, the Contractor shall perform and document the winch acceptance test. The Contractor shall notify the government four (4) weeks prior to winch acceptance test plan execution at the contractor’s facility. The government reserves the right to witness this factory acceptance testing.

6.3. The Contractor shall analyze and document the test results of the winch acceptance testing that demonstrates the winch’s ability to meet all design requirements outlined in this design specification.

(A006, DI-NDTI-80809B)

6.4. Certificate of Conformance

6.4.1. The Contractor shall provide a Certificate of Conformance specifying the winch meets all requirements denoted in this specification.

6.4.2. The Contractor shall also provide a certification/compliance statement that all materials used in the construction of the winch assembly meet the FAR/DFAR sources and usage requirements.

7. GOVERNMENT-FURNISHED PROPERTY

7.1. 10FT Pig‐tail cable assembly with Pyle National connectors (Part Numbers ZPEMJ-1416- 321PN and ZREM-1416-321SN)

7.2. Focal Technologies Corporation, Model 180 SLIP RING WITH BULKHEAD CONNECTORS, and Drawing Number 180-2661-00 REV A, ESR INSTALLATION FOR NUWC dated 06 OCT 2014. The drawing is propriety refer to Focal Technologies Corporation. See contract clause 252.211-7002 for contact information to obtain drawing.

7.3. Test cable for testing Model 180 Slip Ring, quantity 2 each.

8. PACKAGING & MARKING

PACKAGING ‐ All wood products used in crate and pallet assemblies shall be compliant with DoD 4140.xM, and contractor shall mark wood assemblies with ISPM #15.

Packaging for Electro‐Hydraulic Drive Winch: the contractor shall use industry best practices for the shipping of the Electro‐Hydraulic Drive Winch. The winch shall be crated and palletized, and fully covered with no exposure to weather.

Packaging for Four Legged Sling Assemblies: the Contractor shall pack four legged sling assemblies in 275 lbs. Test Double Wall Box with filler using industry best practices that will ensure safe and undamaged delivery to final destination.

N0025320Q0113 P a g e 16 | 17 Attachment 1

The vinyl film to be used for “all” labels shall be 3M Controltac Graphic Film Brand Name or EQUAL. Vinyl film shall be for watercraft use, 2-mil thickness, 7-year durability, service temperature -60°F to 107°F, bondable to the winch topcoat (3.7).

The height of letters and numbers on the marine grade labels shall be no less than 3 inches and no more than 4 inches. The letters and numbers shall be black.

The nomenclature for the winch shall be FORACS MATS ELECTRO-HYDRAULIC WINCH.

The winch shall be serialized by contract year, manufacturer, and unit number. The serial number shall be unique for the winch delivered under this contract. The nomenclature, manufacturer, part number, serial number, gross weight (including all operating fluids, E-M cable assemblies (Winch cable, Deck Cable, and Pig-tail), slip ring, electrical cable (winch to ship), and test ship’s deck frame (approximately 890 lbs.), dimension and cubic feet, input power, and operating hydraulic fluid in gallons on will be a placards.

Minimum two (2) placards shall be attached to left outside of the corrosion resistant/stainless steel Control Panel Cabinet; and the right outside of the HPU tank. An example is

FORACS MATS ELECTRO-HYDRAULIC WINCH

CONTRACT:

MANUFACTURER/MANUFACTURED DATE:

MODEL NUMBER

SERIAL NUMBER

GROSS WEIGHT:

DIMENSIONS

INPUT POWER

The winch shall be labeled on two sides (length‐wise) with Gross Weight (including winch; all cable assemblies (winch, desk and pigtail), hydraulic fluid, and power cable) in lbs., dimensions including Length (L) x Width (W) x Height (H) in Feet, and total Cubic Feet.

Marking for Four Legged Sling Assemblies: The Four Legged Sling Assembly shall have all cabling tagged and marked, and all hardware shall be stamped (or tagged) with rating. The Four Legged Sling Assembly shall be serialized, with the serial number consisting of contract year, manufacturer, and unit number. The serial number shall be unique.

N0025320Q0113 P a g e 17 | 17 Attachment 1

Marking for Marine Grade Power Cord: the Marine Grade Power Cord shall be serialized, with the serial number consisting of contract year, manufacturer, and unit number. The Marine Grade Power Cord shall have voltage and amp mark on each end. Marking shall be on white with black lettering, and shall be 100% water proof for marine use.

Marking for Protective Storage and Transportation Cover: Protective Storage and Transportation Canvas Cover shall be marked with FORACS MATS ELECTRO-HYDRAULIC WINCH. The cover shall be serialized, with the serial number consisting of contract year, manufacturer, and unit number. The serial number shall be unique for the cover. Nomenclature, part number and serial number shall be stenciled on two sides (width‐wise).

Marking for Winch Documentation and Media: The Binder and Media shall be marked with the title FORACS MATS ELECTRO-HYDRAULIC WINCH followed by the subtitle. The binder and Media shall be serialized, with the serial number consisting of contract year, manufacturer, and unit number.

10. INSPECTION AND ACCEPTANCE

Inspection and acceptance will be made at destination by a representative of the Government. A detailed list of items being delivered, including documentation, shall be provided with each shipment to the government to facilitate receipt inspection. Government will verify all required items, including test documentation and certificate of conformance, are present before acceptance.

11. DELIVERIES OR PERFORMANCE

The Contractor, or its representatives, shall require access for the delivery of material under Section 8. to the activity's Operations Area (OA) and shall be admitted to the work site only after they have been issued a Security Pass/ID Badge at the NUWC Division Keyport Pass/ID. The Contractor, or its representatives, shall provide Proof of Citizenship (Passport, or Enhanced Driver’s License, or Birth Certificate (with normal Driver’s License)). RapidGate is another option for contractor access provided access had been granted to NUWC Division Keyport.