PWS_Folsom_and_Nimbus_Crane_Testing_R16PS00522-0002.pdf

Attachment - 1

R16PS00522/0002

Performance Work Statement (PWS)

Folsom Dam and Nimbus Powerplant Gantry Cranes, Load Testing, Wire Rope Replacement and

Certification

Central California Area Office

February, 2015

1.0 BACKGROUND

The Folsom Dam gantry crane and the Nimbus Powerplant gantry crane are due for their periodic load testing as per the Reclamation Safety and Health Standards (RSHS). Additionally, the condition of the wire ropes of the 140-ton hoist on the Folsom Dam crane and both the 50 and 10-ton hoists on the

Nimbus Powerplant crane are currently unknown. The wire rope on the 140-ton hoist was replaced around 2005 and is expected to be in satisfactory condition but will require an inspection as part of the certification. 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 cranes.

The Folsom Dam gantry crane was fabricated by Judson Pacific Murphy Corp. and is equipped with a

140-ton, a 25-ton and a 10-ton hoist. All three hoists were last load tested in 2011. The center to center span of the runway rails is 27-ft. The upper hook limit is roughly 44-ft above the top of the dam at El. 524.5.

The Nimbus Dam gantry crane was also fabricated by Judson Pacific Murphy Corp. and is equipped with a 50-ton and 10-ton hoist. Both hoists were last load tested in 2011 and the gantry has a span of

60-ft. The upper hook limit on the main hoist is 30.5-ft above the deck at El. 162.5, and the lower hook limit is at El. 87. The upper hook limit on the auxiliary hook is 32-ft above the deck at El. 164, and the lower hook limit is at El. 67.

2.0 SCOPE

Folsom Dam 140-Ton Gantry Crane

A. Inspect and perform a full functional test of crane and all hoists with no load.

B. Inspect the 140-Ton hoist’s 1 ¼-in diameter wire rope in place, and provide a report.

C. Inspect hook, block sheaves and bearings, and provide inspection report. Perform any necessary lubrication.

D. Proof/Load test to 120 – 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

E. Verify accuracy of the load cell of each hoist. If, during the load test, it is observed that the load cell is providing inaccurate readings, recalibrate the load cell.

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

Government Representative (OGR). All submittals must be approved prior to any work starting on site.

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

Nimbus Dam 50-Ton Gantry Crane

A. Inspect and perform a 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.

D. Proof/Load test to 120 – 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

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

3.0 OBJECTIVES

Perform a comprehensive OSHA inspection of the Nimbus Powerplant Gantry Crane

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

Perform a comprehensive OSHA inspection of Folsom Dam Gantry Crane, calibrate load cells if necessary

Successfully load/proof test both cranes, and provide test report as evidence of successful load test.

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 service contract.

5.0 PERIOD OF PERFORMANCE

All on-site work must be complete by within 45 days of the notice to proceed. 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. For other than firm fixed price contracts, the contractor will not be reimbursed when the Government facility is closed for the above reasons. The Contractor must 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 is 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 must meet the security requirements at the time of the proposal submission, 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 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.

5.5 Contractor Key Personnel and Qualifications

The work shall be accomplished by a firm and personnel with a minimum of five years of direct experience in providing the services described herein. At the Government’s discretion, the contractor may be asked to provide evidence of the previous and personnel qualifications necessary to perform the work. The contractor will comply if requested. Evidence may include, but is not limited to personnel resumes and certifications.

5.6 Site Visit(s)

Any site visits as applicable will be indicated in the solicitation.

5.7 Protection of Existing Facilities and Environment

The contractor shall be responsible to protect all work areas under their purview and surrounding areas from any harm or damage. The contractor shall repair, clean, or remediate any damages caused at their expense.

6.0 DELIVERABLES

The contractor shall provide all labor, materials, equipment and permits necessary to complete the requirements outlined in this PWS and in Reclamation approved submittals. 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, 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, and right regular lay. Provide submittal on the above requirements and include a rope certificate.

ii. Nimbus 10-Ton Hoist: 5/8-in diameter, 6x37 classification, and right regular lay. 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 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 from both Folsom Lake and Lake Natoma. The crane deck at Folsom Dam is located at El. 480.5; the lake surface consistently fluctuates, but could be as low as

El. 400. 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 both Folsom Lake and Lake Natoma 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 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 all 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 testing shall be in accordance with ASME B30.2

1. Trolley, gantry or bridge travel as applicable; perform the following at 25%, 100% and

125% rated load:

i. Travel full distance of rails, both directions.

ii. Verify brake operation in each direction.

iii. Verify proper operation (brakes set) upon loss of power.

2. Hoists; perform the following at 25%, 100%, and 125% of rated load

i. Test motions of crane

ii. Verify that the overload device operates properly, then temporarily override device so overload tests can be performed

iii. Verify that full range of hoisting is achieved, to the extent possible.

iv. With trolley(s) or hoist at mid-span, raise test load 1 foot and hold for 10 minutes.

Verify that load does not move.

v. Verify crane hoist ropes are correctly and securely connected to their respective drums and blocks.

3. Verify all limit switches

i. Both limits of trolley

ii. Both limits of gantry

iii. Upper and lower limits of both hoists

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

7.0 GOVERNMENT FURNISHED PROPERTY

See applicable information under 5.4 Security above. The contractor will be given an adequate work area, and parking will be allowed on site as coordinated through the COR/OGR and upon approval of all key submittals. Therefore, the Folsom Dam 140-ton gantry crane and Nimbus Dam 50-ton gantry cranes 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 is 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.

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 crane as stipulated in 7.0 above, and will provide a testing beam capable of supporting 140T and the attachment of water bags, see Attachment 5.

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

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