N6247019R1005_Specification_-_Pearl_City_100T_MBH_Amendment_0002.pdf

Work Order No. 1630180 Page 1 of 12

N62470-19-R-1005

Work Order Number: 1630180

ONE (1) 100 METRIC TON MOBILE BOAT HOIST

FOR

NAVAL SPECIAL WARFARE GROUP 3

PEARL CITY, HAWAII

PREPARED BY:

Navy Crane Center

Bldg. 491, Norfolk Naval Shipyard

Portsmouth Virginia 23709-5000

Work Order No. 1630180 Page 2 of 12

1. REFERENCED DOCUMENTS

The following documents of the issue in effect on the date of the invitation for bids or request for proposal form a part of this specification to the extent specified herein. In case of difference between the following documents and this specification, this specification shall govern to the extent of such difference.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

BTH-1 Design of Below-the-Hook Lifting Devices

B30.20 Below-the-Hook Lifting Devices

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

A314 Standard Specification for Stainless Steel Billets and Bars for Forging

A1023/A Standard Specification for Carbon Steel Wire Ropes for General Purposes

FEDERAL SPECIFICATION

RR-C-271 Chains and Attachments, Welded and Weldless

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

Title 29 CFR, Part 1910.27, Fixed Ladders

U.S. ENVIRONMENTAL PROTECTION AGENCY (EPA)

Title 40 CFR, Part 89 Control of Emissions from New and In-Use Non-Road Compression-Ignition Engines at or Above 37 KW.

WIRE ROPE TECHNICAL BOARD

Wire Rope Users Manual

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2. GENERAL PARAGRAPHS

2.1 INTENTION

The intention of this specification is to procure a straddle type self-propelled 100 metric ton mobile boat hoist (MBH) for the Naval Special Warfare Group 3 at Pearl City, Hawaii. For the purposes of this contract, a metric ton shall be taken as 2,200 pounds, making the rated lifting capacity of the MBH equal to 220,000 pounds. The MBH shall be designed, fabricated, tested (pre-shipment), shipped, reassembled, tested (post-delivery) and made ready for use at Pearl City, Hawaii.

For the purposes of this specification, the Contractor shall design, fabricate, proof test and provide a custom spreader assembly to be used on the boat hoist.

2.2 EQUIPMENT DESCRIPTION

The MBH and the custom spreaders shall be designed and fabricated in accordance with industry standard design codes as applicable. The MBH shall be of the open-end design (one top cross beam) with a pivot trunnion structural frame (gantry), operator's cab, hydraulic drive, diesel engine, and independently reeved hoist blocks. Estimated usage for the 100 metric ton MBH is 2 to 4 hours per day, 7 days per week.

2.3 DELIVERY

The Contractor shall be responsible for transport and delivery of the MBH and the custom spreader assembly to the Naval Special Warfare Group 3 in Pearl City, Hawaii.

2.4 MAIN CHARACTERISTICS

The MBH shall include, but is not limited to the following features: independent and independently reeved hoists/block systems, three-point spreader beams, and a center of gravity (CG) compensating system.

The MBH dimensional sketch, building clearance sketch and the sketch of the existing spreader assembly are shown in Appendix A.

100 Metric Ton MBH

Minimum Inside Clear Height (Loaded): --------------------------------------- 25′-6″

Maximum Overall Height (Light) ------------------------------------------------- 29′-6″

Minimum Inside Clear Width: ---------------------------------------------------- 24'-6"

Maximum Overall Width: -------------------------- (see note at end of this section)

Hoist Blocks per Side: -------------------------------------------------------------------- 2

Minimum Hoist Block Reach Below Grade: ------------------------------------- 5'-0″

Minimum Hoisting Low Speed with Rated Load: -------------------------- 7.0 fpm

Minimum Hoisting High Speed with Reduced or No Load: ------------ 16.0 fpm

Minimum Low Travel Speed with Rated Load: ------------------------------ 80 fpm

Minimum High Travel Speed with Reduced or No Load: ---------------- 150 fpm

Minimum Gradeability with Rated Load: ---------------------------------------- 5.0%

Maximum Wheel Load at any Corner: ------------------------------------- 90,100 lbs

Amendment 0002

Work Order No. 1630180 Page 4 of 12

The MBH shall have at least half of the wheels driven and capable of turning a minimum of 90 degrees in either direction.

NOTE: One side of the MBH shall travel into and out of a building through the space labeled “G” between a pool and the door protection bollards as shown in Appendix A sheet 2. The Contractor shall verify dimensions “F” and “G” in Appendix A and recommend for approval the optimal dimensions for the “Maximum Overall Width” and the “Inside Clear Width” based on the OEM’s standard dimensions and operating characteristics of the boat hoist for the specific obstruction in the building.

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3. DESIGN REQUIREMENTS

3.1 STRUCTURAL

3.1.1 SITE INTERFACE

The 100 metric ton MBH shall be capable of traversing a minimum grade of 5% for travel over concrete and asphalt surfaces while operating within the clearances shown in Appendix A and technical parameters outlined in Section 2.4.

3.1.2 GENERAL REQUIREMENTS

The MBH shall be a straddle type crane with an open-end design (one top cross beam), which will straddle boats and other loads. The rated capacity of the MBH shall be distributed between the pairs of hoists. The gantry structure shall be of steel box girder construction with continuous flange to web welds or shall be of formed hollow structural steel sections.

The MBH shall be designed with means for jacking each corner of the unit for tire/wheel replacement. Jacking means may be removable so that they will not increase the overall width or decrease the minimum inside clear width.

3.1.3 MATERIALS

Material shall be free from all defects and imperfections that might affect the serviceability or appearance of the finished product. All material shall be new and unused. All structural steel shall conform to ASTM standards.

3.1.4 GANTRY PIVOT TRUNNIONS

The main crossbeam to gantry shall articulate on a trunnion in composite bearings to allow for travel over uneven surfaces.

3.1.5 CORROSION PROTECTION AND PAINT SYSTEM

All parts of the MBH shall be protected against corrosion and pockets where water could collect shall be avoided or drained to prevent standing water. All exposed surfaces shall be free of grease, oil, and other surface contaminants prior to abrasive blasting. The steel surface shall be abrasively blasted to a near-white metal condition before coating.

The MBH shall be protected by a zinc-rich primer and finish coats, formulated for a marine environment, and applied in accordance with the paint manufacturer’s recommendations.

Primer and paint shall not contain any lead or chromates.

The finish coat shall be blue and gray.

Hoist wire ropes, lubrication fittings, and sheave and wire rope drum grooves shall not be painted.

3.1.6 CAPACITY PLATES

Provide two capacity plates with permanent lettering, one for each side of the MBH. Each plate shall indicate the rated hoisting capacity of the MBH in both metric tons and pounds, and shall be securely attached to the gantry. Beneath the rated capacity the following information shall be included:

Naval Facilities Engineering Command Contract Number xxxxxx-xx-x-xxxx Manufacturer’s name and MBH serial number

The Crane shall be equipped with signage located on the outside of the upper support beams displaying the direction of travel (e.g. FWD-REV-PORT-STARBOARD).

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The travel direction signage shall be visible from all sides of the crane for reference when operating the crane via remote control. The travel direction signage shall match labels for the remote control and cab control station.

3.1.7 MAINTENANCE WALKWAY

Not applicable to this specification.

3.1.8 CUSTOM SPREADER ASSEMBLY

The Contractor shall design and provide a custom spreader assembly which has identical capacity, shape, function and dimensions of the spreader shown in Appendix A. The capacity of the sliding spreader shall be 24,000 pounds.

The overall dimensions of the spreader are approximately 19’ x 41'. The Contractor shall verify design concept and measurements from the existing spreader assembly for the overall dimensions and the locations of attachment points for designing of the new custom spreader.

The custom spreader assembly design shall meet the requirements of ASME BTH-1 and

ASME B30.20.

The Contractor shall load (proof) test the custom spreader assembly with a load no less than 125% of the assembly capacity for a minimum of two minutes with no permanent deformation.

3.2 MECHANICAL

3.2.1 HYDRAULIC SYSTEMS

All hydraulic tubing, fittings, hose ends, and steering cylinder rods shall be stainless steel.

Hoses shall be protected from the elements, damaging UV rays and abrasions. The fittings shall be flat-face O-ring type.

3.2.2 HOISTS

The hoists shall be driven by hydraulic motors with planetary gearing to provide independent or simultaneous motion of the wire rope drums for precise handling. Each hoist motor shall be equipped with a spring-applied, hydraulically released disc brake rated at not less than 125% of the hoist motor rated torque.

Hoist wire ropes shall have an independent wire rope core conforming to ASTM A1023/A and thoroughly lubricated. The wire rope drums shall be designed with Lebus type grooves to evenly distribute the load between the individual layers of the wire rope and reduce wire rope wear.

Drum design shall allow for a minimum of 2 wraps of wire rope remaining on the drum when the hoist blocks are at their lower limit. Spreaders shall be pin-connected to the load blocks.

The load blocks shall have a powered position adjustment feature. The blocks shall be capable of being positioned at locations that allow for proper attaching to the attachment points on the custom spreader assembly.

Hoist load block locations shall not be adjustable.

3.2.2.1 SHEAVES

Sheaves shall be machined in accordance with Table 12 of the Wire Rope Users Manual.

3.2.2.2 SHACKLES

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Shackles shall conform to Federal Specification RR-C-271 for material composition. Stainless steel shackles, if provided, shall be forged from austenitic stainless steel meeting ASTM A314 for material composition.

3.2.2.3 SLINGS

Not applicable for this specification.

3.2.3 GANTRY

At least half the wheels shall be driven. The articulating steering wheels shall be capable of a minimum of 90 degrees of rotation. The hydraulic drive system shall be closed loop type.

The driven wheels shall be equipped with spring-applied, hydraulically released disc brakes, rated at not less than 100% of the motor rated torque available.

3.2.4 ENGINE

The MBH shall be self-powered by a heavy-duty diesel engine that is liquid-cooled and mounted inside a weather resistant enclosure that minimizes penetrations/openings through the enclosure. The engine shall comply with the Environmental Protection Agency regulation Title 40 CFR part 89 and all applicable state and local environmental regulations.

The engine shall be an EPA certified tier 4, non-road mobile engine. The engine shall be equipped with a low-noise exhaust system, a screw-on type oil filter, and a replaceable air filter.

An onboard fuel tank shall be provided with the engine having a minimum capacity of 30 gallons or industry standard size, whichever is greater.

Engine instrumentation shall include, but is not limited to the following: ammeter or voltmeter, hour meter, engine tachometer, coolant temperature gauge, lubricating oil pressure gauge, and fuel gauge or fuel site gauge.

3.2.5 ALARM AND SHUTDOWN SYSTEMS

Audible and visual alarms shall be provided in the operator's cab to signal when the coolant temperature or lubricating oil pressure approach the limit of the safe operating range, as specified by the engine manufacturer.

If the limit of any of these safe operating ranges is exceeded, then the engine controls shall automatically shut the engine down.

3.2.6 SOUND SUPRESSION SYSTEM

The MBH engine compartment shall include sound suppressing insulation that will effectively prevent the personnel working around the unit from raising their voice for verbal communication.

3.3 ELECTRICAL

3.3.1 CONTROLS

All motions shall be controlled either electrically, electro-hydraulically, or by hydraulic valves from the operator's cab with additional control via a wireless remote control.

The hoist control system shall be designed to operate each hoist independently and all hoists simultaneously. The hoist speeds shall be infinitely variable in both directions, and there shall be no roll-back at any load.

The wireless remote control system shall include a belly box type portable transmitter unit and an identical back-up transmitter unit. Each transmitter shall be provided with an adjustable

Work Order No. 1630180 Page 8 of 12 belt or harness to support it when worn by the operator. Only one transmitter at a time shall be able to control the crane and there shall be no interference from this crane’s controller affecting operation of other cranes in the area. Each transmitter shall include at a minimum:

individual spring return joystick motion control levers for each function with variable speed control; a maintained contact, keyed switch, marked ON-OFF, for portable transmitter unit power; indication of Battery Power, and indication of Transmitting Status; a red emergency STOP mushroom pushbutton; and headlight/floodlight on/off pushbuttons. The transmitters and all controls shall each be clearly and permanently labeled with functionality and direction.

The remote radio control system shall be designed to meet the requirements of NEMA ICS 8, Part 9 and ECMA 15.

Each radio remote control lever shall be in the OFF position before the associated crane function can begin. The system frequency shall be within the unlicensed FCC Part 15 range.

Each control unit shall maintain a continuous status signal to the associated receiver during operation.

The transmitter batteries shall be rechargeable type. A minimum of three sets of batteries shall be provided (one for each transmitter plus one on recharge). There shall be no significant loss in systems efficiency and function at the end of eight hours of continuous battery use. A battery charger shall be provided.

The MBH shall be equipped with ground lugs.

3.3.2 ANTI-TWO BLOCK SYSTEM

An anti-two block system shall be provided to prevent damage to the hoisting machinery if the lower and upper block contact each other.

3.3.3 LOAD INDICATORS

Load sensors shall be provided to measure the total load being supported by the MBH. A digital load readout display shall be provided in the operator’s cab and also on the remote control. The load indicator shall display a continues readout of the lifted load in metric tons.

3.3.4 LIGHTING

A minimum of two travel lights shall be provided for each direction of travel, and four lights shall be provided for illuminating the work area. The interior of the operator's cab shall include lighting of instrumentation to permit MBH operation in the dark.

3.3.5 BATTERY AND CHARGER

Battery voltage shall be 12 or 24 volts. An engine-driven alternator shall be provided to maintain the charge on the battery and supply power for ancillary equipment.

3.4 OPERATOR'S CAB

The operator's cab shall be of enclosed design with a roof to provide protection for the operator and the controls when it is used outdoors. Steel bars for protection shall be provided outside of the operator’s cab inner side window. All controls, switches, and gauges shall be designed for an outdoor marine environment and shall be located within easy reach and have function labels readable from the operator's standing position. Labels shall be provided for all MBH controls. A portable ABC type dry chemical fire extinguisher shall be mounted in a suitable bracket in the cab. Access provisions to the cab including fixed ladders shall comply with OSHA 1910.27.

3.4.1 OPERATOR’S CAB CAPACITY PLATE

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A capacity plate shall be installed inside the operator’s cab such that it is visible to the operator when operating the MBH. The plate shall be sized to contain the following information:

Rated capacity of the blocks (in pounds and metric tons) Maximum vertical corner load of the MBH with rated load (in pounds and metric tons) Naval Facilities Engineering Command Contract Number xxxxxx-xx-x-xxxx Manufacturer’s name and MBH serial number

3.5 SAFETY FEATURES

A travel audible warning alarm, with adjustable volume, and amber strobe lights shall be provided and shall activate when the MBH travels in either direction.

3.6 SPARE PARTS AND CONSUMABLE ITEMS

The contractor shall provide a spare tire and wheel, and a Society of Automotive Engineers (SAE) tool kit for use on the MBH as part of this contract. Also, as part of this contract, the contractor shall provide all manufacturer recommended consumable items (including but not limited to filters, cleaners, belts) required during the first two years of operation (using the operational schedule of 2-4 hours per day, 7 days per week).

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4. TECHNICAL DOCUMENTATION

4.1 GENERAL REQUIREMENTS

The contractor shall submit to the Contracting Officer all items of technical documentation listed herein. The content, number of copies, time of submission, and distribution shall be in accordance with Exhibit A of this specification and as specified below.

4.2 DRAWINGS

All drawings submitted shall include a descriptive title block with a unique drawing number, and bear a registered professional engineer's original seal and dated signature. The following drawings shall be included:

a. General arrangement - showing side and end views of the MBH and all major dimensions, clearances, lift heights, hoist and travel speeds, estimated assembled weight, and maximum corner wheel load under rated load.

b. Hydraulic circuits - including Bill of Materials.

c. Electrical schematic diagrams - including Bill of Materials.

d. Custom spreader assembly - including Bill of Materials.

4.3 MANUFACTURERS' PRODUCT DATA

Original manufacturers' product data (catalog cuts) shall be provided, listing the original part numbers. The catalog cuts shall be marked-up or supplemented with additional sheets to clearly identify the model or size, selected options, features, and/or modifications to demonstrate compliance with specification requirements. Product data that show any modifications beyond the standard options and all supplemental pages shall bear original signatures and dates of the equipment manufacturer's authorized representative. Each product data and each supplemental sheet shall clearly identify the drive or system to which it applies.

As a minimum, the following product data is required:

a. Mobile Boat Hoist

b. Diesel Engine

4.4 TECHNICAL MANUAL

An operation and maintenance manual, containing the following items (as a minimum), shall be provided:

a. Contractor information

b. Reduced size drawings listed in paragraph 4.2

c. Manufacturers' catalog data described in paragraph 4.3

d. MBH operation and safety precautions

e. Troubleshooting guide

f. Preventive maintenance plan and schedule

g. Lubrication data/schedule

h. Complete parts list with identification of the original manufacturers and their part numbers, or machine OEM part numbers

i. Recommended spare parts list

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j. Warranty information

4.5 CERTIFICATIONS

All certifications shall be dated and shall bear the original signature (above the printed name) of the authorized representative of the manufacturer of the items equipment being certified.

Each certification shall clearly identify the drive, component, or location (as applicable) to which it relates.

4.5.1 PERIODIC OVERLOAD TESTING

The contractor shall certify that the MBH can be subjected to periodic (semi-annual) load testing at up to 110% (-5%, +0%) of the rated capacity without any detrimental effects.

4.5.2 HOISTING ROPES

The contractor shall provide the hoisting wire rope manufacturer's certification that the wire ropes meet the published breaking strength of the wire rope. The certification shall be marked in a manner that ensures positive traceability to the manufacturer.

4.5.3 SHACKLES

All shackles shall be marked with the manufacturer’s name or logo and tagged with a unique serial number traceable to the proof test. The contractor shall provide the shackle manufacturer’s certification that the shackles have been proof tested to 150% of the rated capacity without any detrimental effects. The certification shall contain the name of the manufacturer, the capacity or size of the shackles being tested, and the shackle’s unique serial number.

4.5.4 CUSTOM SPREADER ASSEMBLY

The Contractor shall certify that the spreader assembly has been load (proof) tested with a load no less than 125% of the assembly capacity for a minimum of two minutes with no permanent deformation. Certification shall include the date of test, the actual test load and test duration.

4.5.5 EMISSIONS CERTIFICATION

The contractor or engine manufacturer shall certify that the diesel engine does not exceed the emission limits established by EPA, state, and local regulations.

4.6 ACCIDENT PREVENTION PLAN (APP)

The APP shall be prepared in accordance with Appendix E (Safety), and Exhibit A and B and shall be submitted for review and comment by the Contracting Officer. Mobilization cannot proceed prior to the review and acceptance of the APP by the Contracting Officer.

4.7 FREQUENCY ALLOCATION APPLICATION

The technical section of the frequency allocation application attached as Appendix G, addressing the Contractor’s equipment, shall be completed by the manufacturer of the radio control equipment being furnished under this contract. Frequency availability at this activity shall be verified prior to design approval.

4.8 TRAINING COURSES

The contractor shall provide one-week (five working days) of operational and maintenance training for operators, mechanics, and electricians as listed below. The course and training materials shall be presented in English. The training course will commence immediately after post delivery testing. The Government will provide a classroom for the indoor portion of the training and a test weight/craft, if available, for demonstration.

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a. The contractor shall conduct a class that will provide a general review of the MBH capabilities, limitations, operational characteristics, maintenance, safety considerations, and troubleshooting.

b Upon completion of the course, the students shall be competent to troubleshoot and repair the mechanical, hydraulic, and electrical systems of the MBH.

4.8.1 COURSE OUTLINE

The contractor shall prepare and submit to the Contracting Officer for approval the course outline. The outline should contain sufficient detail for the Contracting Officer to confirm that all required topics are properly covered.

4.9 TECHNICAL MANUAL ON CD ROM

The contractor shall provide the technical manual on CD ROM disc(s) following final Government acceptance of the technical manual. The files format shall be Adobe Acrobat

(PDF).

4.10 DRAWINGS ON CD ROM

The contractor shall provide three copies of the "as-built" drawings listed in paragraph 4.2 on CD ROM disc(s) following final Government approval of the drawings. The drawings shall be provided in Adobe Acrobat (PDF) format.

4.11 STATUS REPORTS

The contractor shall submit monthly status reports as described in Exhibits A and B.

4.12 PRE-SHIPMENT AND POST SHIPMENT TEST PROCEDURES

Minimal Pre-shipment and Post-shipment test requirements are identified in Appendix “B” and Appendix “C”.

4.13 MBH SHIPPING PLAN

Not Applicable to this specification.

4.14 MBH RE-ASSEMBLY PLAN

Not Applicable to this specification.

100 Metric Ton MBH