A04.01_SOW.pdf

Bridge Crane - Wireless Control System

STATEMENT OF WORK (SOW)

WORKSHEET

JML #:

DD2276 #:

Crane: H50950 & H51951 Title: House Crane Primary Wireless Control System Place of Performance: Puget Sound Naval Shipyard, DD5, West Side, Enclosures 50 and 51 Period of Performance:

1. BACKGROUND

1.1. The current primary control systems for cranes H50950 and H51951 is a pendant style wireless control that has been determined to not meet the prior wireless standard (EN 954) or the new wireless standard (ISO 13849). A change is required as the wireless system is the primary control system for these cranes.

2. REFERENCES

2.1. Electrical Drawings:

2.1.1. Heco 2509-37658 (Magnetek #604519)

2.2. Wireless Drawings:

2.2.1. Magnetek 175-12344

2.3. Section H: Requirements for onsite work at the PSNS & IMF.

2.4. Environmental Compliance P5090

2.5. Allowable Ground Loading Drawing

2.6. 29 CFR 1915, Occupational Safety and Health Standards for Shipyard Employment

2.7. PSNS & IMF Memorandum, Environment, Safety, and Health Requirements for Code 1202

2.8. PSNS & IMF Publication, NAVSHIPYDPUGET P5100 Handbook for Contractors and Visitors

2.9. ISO 13849

2.10.ECMA 15

2.11.NEMA ICS8 Part 9

2.12.Navy. P-307 125% load test

3. WORK REQUIREMENTS – The contractor shall provide all required design (via Magnetek), material, labor, supervision, testing, transportation required by this contract. The contractor is required to be an authorized Magnetek Dealer and a Magnetek qualified/certified service field installer. The contractor shall design (via Magnetek), install and test a belly box style wireless system to replace the existing pendant wireless system. The new system shall meet ISO 13849 PL d or higher and be integrated into the existing Magnetek designed crane control system.

3.1. Design

3.1.1. The contractor shall design (via Magnetek) a belly box style wireless system that fully integrates with the existing Magnetek electrical system (ref. 2.1 and 2.2) and maintains all existing functions and features of the crane.

3.1.2. The system design shall be submitted to the Contracting Officer Representative for approval prior to manufacture and installation.

3.1.3. The new system shall have the following characteristics:

Flex M receivers designed with electrical voltage, current and phase needs compatible with the existing cranes electrical system (480VAC 3 phase, 45 amps, 60 hertz at mainline.)

New system frequency must match the existing wireless system frequency

(unlicensed frequency which has already been allocated/approved). Contractor shall confirm that 436.60 MHz is the existing frequency.

Fully comply with ISO 13849 Stop Function PL d

Fully comply with ECMA 15

Fully comply with NEMA ICS8 Part 9

Provide primary and backup controllers for each crane (4 total)

XLTX controllers shall have; three speed detent spring return joysticks for each motion, on/off/start switch, all controllers shall have a prominent e-stop which will be depressed if the controller is pushed upside down onto a flat surface, physical

“inadvertent operation guarding” of all crane functions (crane motions and all other functions except e-stop), micro speed switch, e-stop, horn, with labels for all functions.

The second XLTX controller shall not be able to control the crane if a controller is already communicating with the crane.

System shall utilize new material

Shall utilize only UL or third party NRTL tested components

Provide three rechargeable batteries and one charger for each crane

System shall require continuous communication in order to maintain functions

Wireless battery level indication shall be provided to the operator.

A contact monitoring board shall be provided on the receiver.

The belly box fasteners and components shall be designed to allow captivation.

Captivation shall be performed with Loctite, lockwire or equal on all components.

3.2. Removal of current system

3.2.1. The contractor shall fully remove the currently installed pendant style wireless control system, including transmitters, receivers, batteries and chargers.

3.2.2. All material remains the property of the Government and must be submitted to the

Contracting Officer Representative after removal.

3.3. New system install

3.3.1. Fully install the new wireless system.

3.3.2. Provide / modify any crane wiring necessary to install the new equipment. All wiring shall match existing wiring and meet NEC.

3.3.3. Provide for captivation of all belly box fasteners and components. Captivation shall be performed with Loctite, lock-wire or equal.

3.4. Test

3.4.1. The contractor shall be present during all the following phases of testing. Government shall provide test director, test weights, rigging and rigging personnel.

3.4.2. Punch-list Inspection Prior to Testing – Allowed duration of eight hours. Government shall document non-compliant items on a punch-list. Contractor shall repair all items not meeting the contract requirements prior to further testing.

3.4.3. No Load Function Test – Allowed duration of four hours. Test each function of each controller. Ensure that when one controller is in use another cannot be used to operate the crane. Test and record the distance the controller is from the crane at which point the crane stops safely due to lack of communication.

3.4.4. Endurance Test – Perform a two-hour operation of the crane at rated service class (CMAA

70, class D) for each crane (with one controller per crane). No wireless/control system faults are allowed. If a fault/stop of operation occurs the testing shall stop. The contractor shall document the problem and the Government shall update the punch-list. The contractor shall correct the situation prior to restarting testing. Retesting shall be for a full two hours.

3.4.5. Load Test – Allowed duration of 8 hours. Pretest inspection by the Navy. P-307 125% load test. Post-test inspection by the Navy.

4. DELIVERABLES

4.1. Schedule. Design work of this contract shall be performed prior to scheduling on-site work. The cranes are in service and being used to perform Navy work. On-site performance dates of this contract work will need to be reviewed and adjusted to fit ongoing work in the complex.

Contractor on-site work schedule shall be submitted with duration and desired time. PSNS shall evaluate duration and desired on-site work times and determine the final allowable work time.

4.2. Wireless system design (via Magnetek) schematics and wireless drawings showing full compatibility with the currently installed Magnatek electrical system. The modified drawings shall be stamped by a Professional Engineer (PE).

4.3. Belly box style wireless control system preserving full functionality of all crane components and abilities.

4.4. All associated certifications showing compliance with contract requirements, catalog cuts, technical manuals and instruction manuals.

4.5. Existing wireless components removed from crane.

5. DELIVERY OBJECTIVES

SOW

Paragraph

Performance

Objectives

Standards /AQL Performance

Assessment Method

3.1 Design Submittal

Approved by

Government

100% Compliance Government Design

Review

3.2 – 3.4 Installation and

Testing Acceptable

100% Compliance Government

Observing Sat

Completion of All

Testing

4.0 Deliverables 100% Compliance Government

Acceptance of All

Submittals

7.0 Contractor maintain

close liaison and good communication with

Government

Any problems or questions encountered by either party are addressed within 24 hours (1 business day)

Provide COR with written report of discrepancies

Final condition report of assessment

100% compliance Provide COR final assessment condition report

6. TRAVEL REQUIREMENTS

6.1. The location of the required service is PSNS, Bremerton, WA. The contractor will be responsible for their own travel expenses, including scheduling transportation, food, per-diem and lodging.

7. GOVERNMENT REPRESENTATIVE

7.1. Contracting Officer’s Representative (COR):

Murry Rexin, Code 713, Puget Sound Naval Shipyard

Stacy Impey, Code 713, Puget Sound Naval Shipyard

7.2. WAWF Acceptor:

Tami Murphy, C/702

8. ENVIRONMENTAL AND SAFETY

8.1. The Contractor shall comply with current applicable federal, state, and local laws, codes, ordinances, and regulations in their entirety. Any reference to a specific portion of a federal, state, or local law, code, ordinance, or regulation in this SOW shall not be construed to mean that relief is provided from any other sections of the law, code, ordinance, or regulation. The Contractor shall comply with all current environmental, health, safety, and hazardous waste requirements/regulations including, but not limited to the following:

29 CFR 1915, Occupational Safety and Health Standards for Shipyard Employment;

PSNS & IMF Memorandum, Environment, Safety, and Health Requirements for Code 1202 Contractors at the Bremerton Naval Complex; Serial Number 430/431, dated 20 Sept 10, PSNS & IMF Publication, NAVSHIPYDPUGET P5100 Handbook for Contractors and Visitors

8.2. Hazmat Material: If the contract brings Hazmat Materials into the Shipyard (via a service truck) all materials must be reported and processed per PSNS & IMF requirements.

8.3. Accident/Injury/Environmental Mishap Report: Reports of accidents, injuries, and environmental mishap incidents/events (actual and potential) involving Contractor personnel and equipment shall immediately be reported by verbal means to the designated Project POC and the QA/ESH Director. Verbal reports shall be followed within 24 hours by a written report after each occurrence.

8.4. The accident/injury/environmental mishap report, as a minimum, shall contain the following:

Identity of Contractor/subcontractor witnesses;

Descriptive location of incident/mishap (e.g. ship name and hull number, space, compartment name, compartment location, frame number, etc.);

The type of incident/mishap (e.g. accident, collision, fire, fall, environmental spill, etc.);

The name and PSNS & IMF badge number of each injured or affected person;

Date and time of the accident, injury, and mishap;

A brief description of the incident/mishap including occurrences and conditions leading up to the incident/mishap;

Extent of each personal injury or property damage sustained;

Whether personal injuries required medical treatment or property damage required immediate repair to prevent further damage or injury to personnel or property

9. ADDITIONAL CONSIDERATIONS

9.1. Government supported work hours: 0720-1602 M-F, excluding Federal holidays

9.2. All technical clarifications / deviations will be coordinated through the government representative.

9.3. Laydown and utilities requirements: The Government will provide the necessary work area and utilities to complete the work.

9.4. Upon award, the contractor shall contact the appropriate POC to clarify exact requirements and start date of work.

10. Contractor Work Performed in PSNS & IMF

10.1. Contractor shall follow the PSNS & IMF requirements of Section H (reference 2.3 of this

Statement of Work) governing work performed in the Shipyard.