Amendment_0003_-_Revised_PWS_Folsom_and_Nimbus_Crane_Testing_Rev._4 _R16PS00522.pdf

Performance Work Statement (PWS)

Crane and Hoist Load Testing, Wire Rope Replacement and Certification

Central California Area Office

Dated: May 12, 2016

1.0 BACKGROUND

The Reclamation Safety and Health Standard s require that all cranes and hoists greater than 5 tons be inspected and certified by a third party on an annual basis; they also need to be load tested every four years. The majority of the cranes at the Central California Area Office (CCAO) have lapsed on this requirement and 5 cranes need to be load tested and certified. Additionally, the condition of the wire ropes of both the 50 and 10-ton hoists on the Nimbus Powerplant crane are currently unknown. Due to the amount of grease on the Nimbus gantry crane wire ropes adequate inspection of the ropes is difficult; furthermore, the age of these wire ropes is unknown. For these reasons the wire ropes should be replaced in order to ensure reliable operation of the crane.

2.0 SCOPE

An equipment outage may be required for each crane, and coordination regarding access to begin work on the crane will be coordinated with the Contracting Officer Representative (COR)/ On-site

Government Representative (OGR).

Folsom Dam 140-Ton Gantry Crane

A. Perform periodic inspection (as defined by ASME B30.2) and full functional test of crane and all hoists with no load.

B. Proof/Load test to 100 – 125 % of rated capacity and perform all operational movements in accordance with ASME B30.2, Section 2-2.3.2 for the following:

a. 140-Ton hoist

b. 25-Ton hoist

c. 10-Ton hoist

C. Check and calibrate the load cell of each hoist concurrent with the load testing. Calibration shall be performed in accordance with manufacturer’s recommendations.

D. Provide test and certification report upon completion of all work.

Nimbus Dam 50-Ton Gantry Crane

A. Perform periodic inspection (as defined by ASME B30.2) and full functional test of crane with no load.

B. Replace the 1-in diameter wire rope of the 50-Ton hoist. Clean sheaves, block, drum, and all surfaces that come in contact with the rope. Inspect hook, block sheaves and bearings, and provide inspection report. Perform any necessary lubrication.

C. Replace the 5/8-in diameter wire rope of the 10-Ton hoist. Clean sheaves, block, drum, and all surfaces that come in contact with the rope. Inspect hook, block sheaves and bearings, and provide inspection report. Perform any necessary lubrication.

R16PS00522, Amendment 0003

D. Proof/Load test to 100 – 125 % of rated capacity and perform all operational movements in accordance with ASME B30.2, Section 2-2.3.2 for the following:

a. 50-Ton hoist

b. 10-Ton hoist

E. Recalibrate load cells for both the 50-ton and 10-ton hoists. Calibration shall be performed in accordance with manufacturer’s recommendations.

F. Provide test and certification report upon completion of all work.

Folsom Powerplant 275-Ton Bridge Crane

A. Perform periodic inspection (as defined by ASME B30.2) and perform a full functional test of crane with no load.

B. Proof/Load test to 100 – 125 % of rated capacity and perform all operational movements in accordance with ASME B30.2, Section 2-2.3.2 for the following (hoists may be tested individually):

a. 137.5-Ton Main Hoist A

b. 137.5 – Ton Main Hoist B

c. 30-Ton Auxiliary Hoist A

d. 30-Ton Auxiliary Hoist B

C. Provide test and certification report upon completion of all work.

Folsom Powerplant 10-Ton Underhung Monorail Hoist

A. Perform periodic inspection (as defined by ASME B30.11) and perform a full functional test of hoist with no load.

accordance with ASME B30.11, Section 11-2.2.2 for the following:

a. 10-Ton Hoist

Folsom Pumping Plant 7.5-Ton Bridge Crane

A. Perform periodic inspection (as defined by ASME B30.2) and perform a full functional test of crane with no load.

accordance with ASME B30.2, Section 2-2.3.2 for the following:

a. 7.5-Ton Hoist

3.0 OBJECTIVES

Perform a comprehensive inspection of CCAO cranes and hoists in accordance with ASME and

OSHA standards

Successfully load/proof test CCAO cranes, and provide test reports as evidence of successful load test.

Replace wire ropes on Nimbus Powerplant Gantry Crane and re-calibrate load cells.

Check and calibrate the load cell of each hoist on the Folsom Dam 140T crane, concurrent with the load testing.

Complete all on-site work and submit test and certification reports within 3 business days following successful load tests.

4.0 TYPE OF CONTRACT

The Government will award a firm fixed priced service contract.

5.0 PERIOD OF PERFORMANCE

All on-site work shall be complete within 60 days after award of the contract. Period of performance to include approval of submittals and all on-site work, which includes preparatory work by the contractor, replacement of wire ropes, load testing/certification, and receipt of the testing/certification report.

5.1 Recognized Holidays

No work shall occur during Federal holidays.

5.2 Hours of Operations

The contractor is responsible for conducting business, between the hours of 0700 – 1700 Monday through Friday except Federal holidays or when the Government facility is closed due to local or national emergencies, administrative closings, or similar Government directed facility closings. The

Contractor shall at all times maintain an adequate workforce for the uninterrupted performance of all tasks defined within this PWS when the Government facility is not closed for the above reasons.

When hiring personnel, the Contractor shall keep in mind that the stability and continuity of the workforce are essential.

5.3 Place of Performance

The work under this contract will be performed at two locations. The Folsom Dam Gantry Crane, Powerplant Crane, Pumping Plant Crane and Powerplant Draft Tube Hoist are located at 7794 Folsom

Dam Road, Folsom, CA 95630; the Nimbus Powerplant Gantry Crane is located next to the CSUS

Aquatic Center, 1901 Hazel Ave, Golden River, CA

5.4 Security

Contractor Security Requirements:

The contract solicitation may delineate any applicable specific contractor security requirements. As such, contractor personnel performing work under this contract shall meet the security requirements at the time of award, and must maintain the level of security required for the life of the contract. The contractor shall coordinate access for personnel, materials, and equipment with the COR/OGR prior to mobilization on site. The COR/OGR will escort contractor personnel as necessary and will be at the work site any time the contractor is on site. The COR/OGR will need the names, company names, position of each individual and dates and times each individual is expected on site at least five business days prior to any work conducted onsite.

Site Security:

The Government anticipates about 10-14 business days on site to complete the work. Because of this short duration, contractor storage areas should not be required. Any material stored onsite shall be done so at the risk of the Contractor.

The contractor shall be responsible for safeguarding all government equipment, information and property provided for contractor use. At the close of each work period, government facilities, equipment, and materials shall be secured.

6.0 DELIVERABLES

The contractor shall provide all labor, materials, equipment and permits necessary to complete the requirements outlined in this PWS. The items/deliverables that follow are effectively submittal/technical requirements to be provided/complied by the contractor, and will require approval by the COR prior to any work starting on site.

6.1 Site Specific Safety Plan and JHA

The contractor shall submit a written safety plan covering all aspects of the onsite activities associated with the proposed work/contract. See Section 3 and Appendix B of Reclamation Safety and Health

Standards (RSHS), October 2009, (http:://www.usbr.gov/ssle/safety/RSHS/rshs.html) for detailed requirements. In addition, the contractor shall submit Job Hazard Analyses (JHAs), and the contractor shall participate in joint JHA field meetings with Reclamation prior to the start of any onsite activities.

See Sections 3 and 4 of the RSHS for specific requirements. No work shall proceed without an approved safety plan and JHA.

6.2 Product and Technical Data on New Wire Rope

The hoisting rope shall be of proper design and construction for crane service. The rated capacity load plus the load block weight divided by the number of parts of rope shall not exceed 20 percent of the published breaking strength of the rope. Provide length of rope sufficient to permit the required lift, plus two dead wraps at the drum, plus length for anchoring to drum. Match existing rope diameter, strands, number of wires per strand, and lay. The rope shall have an independent wire rope core and shall be pre-lubricated using the manufacturer’s recommended lubricant and lubrication process for wire ropes on outdoor CMAA 70 Class A gantry cranes. Pending confirmation of the existing rope by the contractor, the new rope should be:

i. Nimbus 50-Ton Hoist: 1-in diameter, 6x37 classification, right regular lay, approximately

660-ft long. Provide submittal on the above requirements and include a rope certificate.

ii. Nimbus 10-Ton Hoist: 5/8-in diameter, 6x37 classification, right regular lay, approximately

440-ft long. Provide submittal on the above requirements and include a rope certificate.

6.3 Wire Rope Installation and Hook Inspection

The Contractor shall:

A. Remove the existing ropes, and prior to installation of new ropes, clean drums, blocks, hooks, etc. to remove grease, dirt, and debris. Inspect all sheaves and bearings for damage and proper operation.

B. Inspect crane hooks in accordance with ASME B30.10. Inspect block sheaves and bearings. Measure hook throat opening, and other key parameters to establish baseline data for future inspections. Compare with manufacture data if available. Provide submittal of findings for this item (6.3.B), and provide baseline measurements on a manufacture drawing if available, or sketch indicating the key baseline dimensions for future reference.

C. Re-lubricate hook(s) and block(s) as required, and then reuse them to retain existing configurations.

D. Reeve and terminate rope(s) in a manner identical to existing installations.

E. Hang a light weight (10% of rated load) on the rope to allow proper set-in of the rope and associated equipment.

6.4 Load Test Plan

See Scope section of PWS for applicable requirements.

Provide detailed, step-by-step plan for performing Contractor field quality testing. Include rigging details, crane operator certifications or training, equipment required, 3rd party certifier as applicable, and any other pertinent details of the test procedures. Load test will not be conducted until after repairs are complete, as applicable, and the crane is determined safe to load test. Method of load testing shall be proposed by the contractor, e.g. utilization of water bags, steel/concrete weights, etc. If water weights are to be used the water bags must be certified mussel free before discharge will be allowed back into either reservoir or river.

Water, if required for testing, is available on site, either from hydrants or adjacent bodies of water.

The crane deck at Folsom Dam is located at El. 480.5; the lake surface constantly fluctuates, but could be as low as El. 350. The crane deck at Nimbus Dam is located at El. 132. Lake Natoma is normally allowed to fluctuate between El. 120–125. Water can be drained back into adjacent bodies of water

(i.e reservoirs/tail races) only if the bags have been certified mussel free.

A. Contractor Field Quality Testing

1. Testing of cranes shall be performed by Contractor and witnessed by the COR/OGR.

Notify the COR, in writing, of date and time of test at least 5 days before beginning test.

2. Comply with requirements of ASME B30.2, ASME B30.11 and 29 CFR 1910

3. Prior to starting tests, briefly operate the hoists and drives under no loading to confirm proper operation.

4. Ensure crane equipment operates without abnormal noise, vibration, binding, or overheating. Verify any new and refurbished equipment is functional

5. Inspect crane to verify correct alignment, no excessive wear has occurred, and all components are functioning properly. Perform adjustments as required.

6. Contractor is responsible for providing:

i. All safety barricades and maintaining a safe area during testing.

ii. All test weights, slings, shackles, rigging, and the means of transportation thereof .

iii. Any measurement gauges required.

iv. Crane operator and communication devices during testing.

B. Required Testing

All inspections and testing shall be in accordance with ASME B30.2, or ASME B30.11

6.5 Test and Certification Report

Provide Plate V (DOSH Form – CCAU 55) or equivalent report. Provide certified weight data or water weights calculations and data as applicable. Provide documentation demonstrating the crane has passed inspection/certification.

6.6 Documentation

Clause or

Section

Title

Submittals required Due date or delivery time

Number of

Copies

Required

6.1 Safety Plan and JHA Must be approved prior to

mobilization

6.2 Wire Rope Technical

Data

At least 14 days prior to ordering wire rope

6.3 Hook/Block Inspection

Report

Within 7 days of evaluation of each hook/block

6.4 Load Test Plan At least 14 days prior to

testing

6.4 Mussel Free Certification At least 14 days before

bringing water bags onsite

6.5 Test and Certification

Report

Within 14 days of each crane certification

2.0 Calibration

documentation

Within 14 days of calibration of each load cell

7.0 GOVERNMENT FURNISHED PROPERTY

See applicable information under 5.4 Security above. The contractor shall be given an adequate work area, and parking shall be allowed on site as coordinated through the COR/OGR and upon approval of all key submittals. CCAO cranes and hoists will be turned over to the contractor for repair and load testing as coordinated and approved by the Government.

7.1 Services

The Government may provide brief instructions and orientation on operation and use of the cranes.

The contractor shall provide qualified crane operators and certifications to the COR/OGR at least five days before any planned and approved repairs or load test operations. Reclamation personnel may observe rigging and similar operations to ensure safety, and protection of equipment. The contractor shall be expected to provide all qualified personnel, ladders, equipment, materials, etc. to facilitate completion of the work.

7.2 Facilities

The Government will provide an accommodating work area as indicated in 7.0 above. Note that due to ongoing work at Nimbus Dam the available storage area may be in use, and access over the top of the dam may be limited. Access will be provided from Main St. to the North side of Nimbus Dam via the

American River Bike Trail as needed.

7.3 Utilities

Nearby rest room facilities are available for the contractor’s use at Nimbus Dam. There will be no rest room facilities available at Folsom Dam. Assume that no potable water is available. Available

120VAC power should be available, but may not be at a location convenient to the contractor.

Extension cords and alike shall be provided by the contractor. Water will be available as stated in 6.4 for the sole purpose of load testing.

7.4 Equipment

The Government will hand over the cranes as stipulated in 7.0 above, and will provide a testing beam capable of supporting 140T and the attachment of water bags for the Folsom Dam Gantry, see

Attachment 5.

The Government will also make available a mobile crane (45T Grove TM500E-2) and operator to use for the staging of any test weights.

8.0 APPLICABLE PUBLICATIONS/STANDARDS

Reclamation Safety and Health Standards (RSHS), October, 2009:

http://www.usbr.gov/ssle/safety/RSHS/rshs.html

American Society of Mechanical Engineers (ASME)

ASME B30.2 – Overhead and Gantry Cranes

ASME B30.10 – Hooks

ASME B30.11 – Monorails and Underhung Cranes

29 CFR 1910 – Occupational Safety and Health Standards

Crane Manufacturer’s Association of America (CMAA)

CMAA 70 - 2010

9.0 TASKS

The various tasks and technical requirements are outlined above and include, but are not limited to the

Scope and Deliverables sections of this PWS. The contractor shall provide all labor, materials, equipment and permits necessary to complete the requirements outlined herein and in Reclamation http://www.usbr.gov/ssle/safety/RSHS/rshs.html approved submittals. The contractor shall be responsible to field verify measurements and any data, reports or reference drawings provided by Reclamation in completing all submittals requirements and achieving the objectives of this project. The contractor shall comply with all applicable Federal, State and Local laws and regulations.

10.0 CONTRACTOR PERFORMANCE ASSESSMENT

The COR will be the primary individual to monitor and/or assess the contractor’s work, and will report any deficiencies to the CO as appropriate. The COR is responsible to ensure that all technical requirements of the contract and this PWS are met. As such, the COR may be asked to provide input to the CO regarding the contractor’s performance during the course of the contract, and during the close-out phase in which the contractor may receive a final evaluation of their work.

11.0 ATTACHMENTS

PWS Attachment 1 – Drawing No. 485-D-51 Folsom Dam 140 – Ton Gantry Crane

PWS Attachment 2 – Drawing No. 485-D-449 Nimbus Powerplant 50 Ton Gantry Crane

PWS Attachment 3 – Folsom 140T Digital Load Indicator Manual

PWS Attachment 4 – Nimbus 50T Remote Display Manual

PWS Attachment 5 – Photo: Folsom 140T Lifting Beam

12.0 PERFORMANCE BASED PLAN:

a. Monitoring Performance: During the course of the evaluation period, the COR will track

Contractor performance. Interim (mid-term) evaluations may be provided to identify strengths and weaknesses in the Contractor's performance during the period being evaluated. At the end of the period, the COR will assess the Contractor's performance in accordance with the Quality Assurance

Surveillance Plan (QASP) and report to the Contracting Officer.

b. Contractor Self-Assessment: Following each evaluation period, the Contractor may provide a written self-assessment of its performance to the COR to be considered in its report to the Contracting

Officer. The self-assessment shall be submitted not later than 5 working days after the end of each evaluation period. The self-evaluation shall not exceed 1 page per PRS element. The self-assessment shall address both the strengths and weaknesses of the Contractor's performance during the evaluation period. Where deficiencies in performance are noted, the Contractor shall describe the actions planned or taken to correct such deficiencies and avoid their recurrence. The self-assessment itself will NOT be the basis for the payment determination.

c. Government Representative Recommendation: The COR will consider all evaluations and any other pertinent information, including Contractor self-assessment, and will prepare a report to the

Contracting Officer with findings and recommendations. The Contractor will be provided a copy of the draft findings and recommendations of the COR and will be afforded the opportunity to identify factual errors. The COR’s draft recommendation is not subject to negotiation and the COR will not engage in discussions with the Contractor. Any errors identified by the Contractor will be addressed by the COR in its final report. The Contractor will be provided a copy of the final COR report at the same time the report is submitted to the Contracting Officer.

d. Payment Determination: The Contracting Officer may meet with the COR to discuss the COR’s report. The Contracting Officer will make a final determination in writing as to the percentage of work successfully completed, and the resulting payment to be made. A copy of the determination will be provided to the Contractor no later than 45 calendar days after the end of the period being evaluated. All Contracting Officer decisions regarding payment calculations are unilateral decisions made solely at the discretion of the Government.

e. Deduction: Notwithstanding any other clause of this contract, payment calculations will be made within the later of 60 days after the end of the evaluation period or 30 days after receipt of an approved invoice.

f. The Quality Assurance Surveillance Plan is one evaluation method the government uses to perform surveillance to determine whether the Contractor meets the standards of performance as defined in the PWS. The absence of a QASP for any contract requirement, however, shall not detract from its enforceability or limit the rights or remedies of the government under any other provision of the contract in determining the quality of the Contractor performance.

QUALITY ASSURANCE SURVEILLANCE PLAN

Performance Requirement

Summary (PRS) Acceptable Quality

Level Means of Measurement

Contractor shall comply with the Performance Work

Statement

a. Timeliness - Required turnaround time met 95% of the time.

b. Quality - Analyses are within required tolerances 98% of time.

COR Surveillance (100% review or periodic depending on tasks.)