Grove_88_Major_Maintenance_-_SOW_4-20-17.docx

20 APR 2017

1. SCOPE

1.1 This Statement of Work (SOW) is for major maintenance of Norfolk Naval Shipyard (NNSY) Grove mobile crane (model number RT635C, serial number 87489), herein referred to as Grove 88. The crane is a 1998 rough terrain telescoping boom cruiser crane. The Grove 88 shall be restored to “like new” condition within all specifications of the Original Equipment Manufacturer (OEM) and this SOW.

2. APPLICABLE DOCUMENTS

2.1 Naval Facilities Engineering Command (NAVFAC) P-307

2.2 ASME B30.5, Mobile Cranes

2.3 Army Corps of Engineers EM 385-1-1

2.4 29 CFR 1910, 29 CFR 1915, and 29 CFR 1926, Personnel Safety

3. REQUIREMENTS

3.1 Personnel Safety

3.1.1 Contractor and Non-NNSY Government Agencies (NNGAs) are hereby informed that their employees or representatives present on property under Norfolk Naval Shipyard (NNSY) cognizance must adhere to Federal OSHA requirements for hazardous energy control IAW 29 CFR 1915.89 and must follow Hazardous Energy Control (HEC) procedures as identified in NAVSEA’s Occupational Safety, Health, and Environmental Corporate Manual (OSHECM) Chapter 250 (latest revision) and Chapter 230 (latest revision), when performing work under NNSY contract. All HEC work to be performed by Contractors and NNGAs requires that NNSY Technical Point of Contact (TPOCs) and/or Contracting Officer’s Representatives (CORs) be notified of the HEC scope of work prior to starting work. Any changes or deviations in the initial scope of the HEC work requires NNSY TPOCs and/or CORs be informed of the change/deviation. Appendix 250.B-1 through B-3 of OSHECM Chapter 250 for multiple employer work identifies when Contractors and NNGAs are required to assign their Lockout/Tags-Plus Coordinator (LOTC) to coordinate HEC work with the cognizant NNSY LOTC. HEC locks shall be provided by the contractor or NNGA for their employees use. The HEC locks shall have red bodies with name labels or name tags affixed, identifying who installed the HEC lock(s) and a point of contact telephone number. HEC lock name labels and tags must be made of materials that will hold up to the environment to which they are exposed. HEC tags used for Tags-Plus HEC work shall be provided by the cognizant NNSY LOTC to the contractor or NNGA for their use if machinery, equipment, or systems (MES) cannot be locked out. OSHECM Chapter 250 Tags-Plus procedures will be strictly followed. In accordance with OSCHECM Chapter 230, REV M, paragraph 230.4.B.7 work on energized equipment less than or equal to 30V, although energized, presents minimal risk to personnel. Therefore, only general safety practices apply to protect sensitive electrical equipment from damage and to protect personnel from hazards. The general safety practices will be decided by the contractor and NNSY assigned Subject Matter Expert (SME) during the job safety briefing. Contractors and NNGAs may obtain electronic copies of OSHECM Chapter 250 (latest revision) and access the OSHA 1915.89 web site by using the following link to NNSY’s public access web site:

Http://www.navsea.navy.mil/shipyards/norfolk/default.aspx

3.1.2 Personal Protective Equipment (PPE)

3.1.2.1 All personnel while in a posted area inside or outside the Controlled Industrial Area (CIA) will wear mandatory Personnel Protective Equipment (PPE) at all times. Mandatory PPE includes a hard hat that shall be identified with the name of the respective contractor, safety glasses with side shields, safety-toed shoes, and hearing protection on their person at all times in case they need it. In addition, all personnel shall wear any additional PPE as appropriate to control hazards of the work being performed. Personal Floatation Devices (PFDs) will be required for each person working on the deck of a YD crane.

3.1.3 Personal Fall Arrest Systems (Fall Protection)

3.1.3.1 The contractor shall provide all employees, while on NNSY property, and utilize proper guarding around every open-sided platform and work surface edge or shall use other means of fall protection to include a fall protection safety harness and lanyard, fall restraint system, safety nets, or other appropriate protection against fall hazards meeting the requirements of 29 CFR 1910, 29 CFR 1915, and 29 CFR 1926. Personnel fall arrest systems are required whenever working on an unguarded surface 5 feet or more above the next level.

3.2 Contractor Shipyard Entry

3.2.1 Contractor is responsible for obtaining RAPID GATE ACCESS into NNSY for work that is expected to exceed one (1) normal business day. RAPID GATE ACCESS into NNSY shall be obtained via the RAPID GATE ACCESS Kiosk at the NNSY security office, building 1502 (outside gate 15 (main gate) off George Washington Highway, Portsmouth, VA 23709). EACH employee entering NNSY for work must obtain RAPID GATE ACCESS. In addition, COMPANY vehicles must also be registered and pass through the contractor inspection station each day work is to be performed on NNSY property. RAPID GATE ACCESS can take up to thirty (30) days to process. CIA access for each contractor employee who obtains the RAPID GATE ACCESS must also complete a CIA access form for work that will be performed inside the CIA area. The CIA access form will be provided to the awarded contractor ten days prior to NNSY entry. The point of contact for the CIA access form is:

James Nguyen Norfolk Naval Shipyard Lifting & Handling Department Office: 757.396.1575 Email: james.c.nguyen@navy.mil

3.2.2 Contractors entering NNSY property for work outside the CIA area are responsible for completing an NNSY contractor access form for entry. EACH employee entering NNSY shall be included on the form. The contractor access form will be provided to the awarded contractor ten days prior to NNSY entry. The point of contact for the contractor access form is:

James Nguyen Norfolk Naval Shipyard Lifting & Handling Department Office: 757.396.1575 Email: james.c.nguyen@navy.mil

3.3 General

3.3.1 Grove 88 Transportation

3.3.1.1 The contractor shall be responsible for transporting the Grove 88 from NNSY to their facility and transportation from their facility back to NNSY. The contractor shall provide the truck, trailer, driver, escorts, and permits for transportation of the Grove 88. The contractor shall also provide any hardware to secure the crane to the trailer for transportation. The awarded contractor shall contact the government personnel listed in section 6.4 to schedule loading of the Grove 88. The designated loading area will be disseminated to the awarded contractor at the time of the loading schedule. The government will provide crane operator rigger support for loading the Grove 88 at NNSY. The contractor is responsible for off-load of the Grove 88 at their facility. The government assumes no responsibility for damage to the Grove 88 during transportation.

3.3.1.2 Crane Transportation Data – Weight: 73,000 pounds, Dimensions: (L x W x H) 12’-6” x 11’ x 12’-8”.

3.3.2 Grove 88 Work Specifications

3.3.2.1 Contractor workmanship shall provide a standard of quality consistent with that of OEM specifications and Government high quality expectations. Contractor shall ensure that all personnel assigned to this contract possess suitable professional skills, qualifications, and certifications to accomplish the maintenance of the Grove 88 mobile crane to this standard of quality.

3.3.2.2 The Grove 88 contractor maintenance shall restore the crane within OEM specifications using OEM bulletins, recall notices and OEM upgrades for existing components and parts, and this SOW. The contractor shall be responsible for following all OEM specifications using OEM drawings, documents, bulletins and publications during the performance of the Grove 88 maintenance period.

NOTE: Upgrade includes the repair of existing components and parts due to OEM no longer using the components or parts. Replacement of these components and parts (as deemed by the OEM) shall be included in the estimate.

3.3.2.3 All components and parts to be replaced shall be sourced from the crane’s OEM. Where the OEM has substituted parts or components with a newer model or identification number, a record of superseded model numbers and designations shall be provided to the government for its records. For OEM components or parts not available, an OEM approved equivalent component or part shall be provided. Components or parts not sourced through the crane OEM require submittal of documentation to the government to include the following:

3.3.2.3.1 Manufacturer’s part name and full part number

3.3.2.3.2 Confirmation of compatibility to OEM component specifications and/or system design parameters

3.3.2.3.3 Location of the component or part on the crane, including reference in the crane parts manual bill of material for the subject assembly or system, and on the parts manual drawing or system schematic as applicable

3.3.2.4 Maintenance of the Grove 88 shall include all work elements necessary to access, and evaluate the condition of all systems and subsystems of the machine. Evaluated wear elements shall be reported to the Government if not within OEM criteria for acceptable tolerance of fit, function, and finish. Components subject to environmental degradation (UV sunlight, moisture, corrosion, rust) shall be replaced, or cleaned and refinished as applicable. Load-bearing structural and mechanical components shall be checked for deformation, cracks, and loss of material from wear or damage and repaired if minor in nature or reported if not within OEM criteria.

3.3.2.5 Surface preparation shall include media blast of painted steel surface areas and cosmetic repairs to metal surfaces as needed.

3.3.2.6 OEM required Non-Destructive Testing (NDT) such as dye penetrant or x-ray inspection to structural members such as load bearing components shall have documentation of NDT inspections and shall be provided to the government. All structural deficiencies shall be corrected In Accordance With (IAW) OEM specifications. Primer and paint specifications and colors shall be IAW OEM specifications.

NOTE: material restrictions: Lead paint and asbestos (in any form) shall not be installed on the Grove 88.

3.3.3 Grove 88 Work Description

3.3.3.1 Drain all fluids (fuel, hydraulic oil, engine oil, antifreeze coolant, auxiliary fluids, and gear oils) and filters. Replace all fluids and filters with new during reassembly.

3.3.3.2 Dismantle Grove 88 down to foundational structure. All components and parts shall be removed for separate cleaning and evaluation by OEM and Government personnel. Wire rope shall be spooled for reuse during reassembly. When the contractor is ready for Government personnel to evaluate the crane components and parts the Government personnel in section 6.4 shall be notified of the scheduled inspection date(s). Contractor shall provide the government a minimum of 15 working days’ notice prior to the scheduled inspection date to allow travel arrangements of Government personnel. Contractor’s personal protective equipment requirements for his site shall be conveyed during the notification.

NOTE: For sections 3.3.4 through 3.3.6, items that are “test and inspect” only may be reused unless deficiencies are noted. Deficiencies shall be reported to the Government personnel listed in section 6.4 for resolution.

3.3.4 Grove 88 Mechanical Work Description

3.3.4.1 Reconditioned Parts – The following parts shall be reconditioned to “like new” condition for reinstallation or replaced with reconditioned parts.

· Fuel lines

· Radiator resealing

· Winch assembly soft goods

· Slewing bearing soft goods

· Cummins engine

· Transmission (inspected and resealed only)

3.3.4.2 New parts – The following parts shall be replaced with new OEM parts.

· Boom extend cable

· Boom retract cable

· Boom wear pads

· Boom sheave bearings

· Slewing bearing bolts

3.3.5 Grove 88 Hydraulics Work Description

3.3.5.1 Reconditioned Parts – The following parts shall be reconditioned to “like new” condition for reinstallation or replaced with reconditioned parts.

· Hydraulic pumps

· Boom tele-cylinder assemblies

3.3.5.2 New parts – The following parts shall be replaced with new OEM parts.

Component / Parts Identification Part Number (As Applicable)

· Hydraulic oil

· Hydraulic oil filters

· Hydraulic fittings

3.3.6 Grove 88 Electrical Work Description

NOTE: All wiring, wire harnesses, wire connectors, wire plugs, and wire terminations will be 100% cleaned and inspected for degraded insulation, cracks, nicks, kinks, frays, discoloration, burns, corrosion, or other damage that may render a wired system in jeopardy of failure.

3.3.6.1 New parts – The following parts shall be replaced with new OEM parts.

Component / Parts Identification Part Number (As Applicable)

3.3.7 Reassembly

3.3.7.1 The Grove 88 shall be reassembled with the components and parts listed in section 3.3.4 through 3.3.6 in accordance with OEM specifications.

3.3.7.2 Reinstall wire rope.

3.3.7.3 Replace all filters and fluids with new.

3.3.7.4 Prime and paint complete, install safety OEM safety decals.

3.3.7.5 Set up and function test the completed Grove 88 crane. Troubleshoot and repair and discrepancies. Load test and certify the crane in accordance with OEM specification and to the OEM load chart for the crane. Load test shall also incorporate the applicable requirements of section 2.1, Appendix E. Excerpts of appendix E can be found in section 6.6.

4. QUALITY ASSURANCE

Major Maintenance of Grove 88 Mobile Crane

4.1 The Government reserves the right to perform quality inspections (visual and operational) of the work being performed, the work process, and the work progress. The contractor performing the work on the Grove 88 shall make available their work site for Government personnel to perform visual and/or operational inspections of the Grove 88 components and parts during the disassembly stage, component rebuild stage, and crane reassembly stage for adherence to OEM and section 2.1 specifications. Scheduled visits shall be coordinated by Government personnel listed in section 6.4 and shall be directly with the contractor performing the work on the Grove 88.

4.2 The following quality assurance task elements shall be performed by the Government:

5. SCHEDULE

5.1 Within 15 business days after award, the contractor shall notify the Government representatives in section 6.4 of a proposed loading date for transportation of the Grove 88 to the contractor facility. The load date shall allow the Government 15 business days to process contractor personnel entry into the Shipyard if required. The designated loading area will be disseminated to the awarded contractor at the time of the loading schedule. Contractors entering the Shipyard shall adhere to section 3.22. Contractor entry shall include the truck driver and all contractor personnel who assist with the loading. Normal Shipyard business hours are 7:30am to 4:00pm Monday through Friday excluding federal holidays.

5.2 Upon completion of maintenance, and PRIOR to load test, the contractor shall notify the government representatives in section 6.4 of the scheduled load test date and allow the government representative(s) site access to witness the load test. Contractor shall provide the government 15 working days’ notice prior to the scheduled load test to allow travel arrangements of Government personnel. Contractor’s personal protective equipment requirements for his site shall be conveyed during the notification. The contractor is responsible for fully load testing the crane. Certified load test documentation shall be provided to the government representatives. The Grove 88 is to be delivered complete within 180 days from contract award.

6. NOTES

6.1 Transportation

Major Maintenance of Grove 88 Mobile Crane

6.1.1 The contractor shall be responsible for transporting the Grove 88 from NNSY to their facility and transportation from their facility back to NNSY. The contractor shall provide the truck, trailer, driver, escorts, and permits for transportation of the Grove 88. The contractor shall also provide any hardware to secure the crane to the trailer for transportation. The awarded contractor shall contact the government personnel listed in section 6.4 to schedule loading of the Grove 88. The government will provide crane operator support for loading and off-loading the Grove 88 at NNSY. The contractor is responsible for off-load of the Grove 88 at their facility. The government assumes no responsibility for damage to the Grove 88 during transportation.

6.2 The Government reserves the right to perform quality inspections of the contractor’s workmanship and parts selection via visual inspections any time during the maintenance period at government expense. The Government representatives in sections 6.4 shall coordinate and schedule these inspections with the contractor directly performing the maintenance work.

6.3 The contractor shall deliver the Grove 88 full maintenance complete, tested and operational, including all operating fluids to:

Norfolk Naval Shipyard Bldg. 276 – Receiving, 757/396-7703/5815 Beatty Street Portsmouth, VA 23709 Attn: Will Hebert, (Office) 757/396-1314, (Cell) 757/944-0077

6.3 The contractor shall provide to the government representative certified documentation of the crane weight after remanufacturing.

6.4 Government Representatives – The government representatives are:

Contracting Officer Representative (COR) Will Hebert, Office: 757/396-1314, Cell: 757/944-0077 Contracting Officer Representative Supervisor Robert Steiner, Office: 757/396-1316, Cell: 757/636-5737

6.5 Contractor Submittals – The contractor shall submit the following documents to the government representatives listed in section 6.4:

6.5.1 Documentation of All NDT reports, results and corrective actions.

6.5.2 Documentation of components or parts in accordance with section 3.3.2.3.

6.5.3 Certified load test documentation.

6.5.4 Certified documentation of the crane weight after remanufacturing

6.5.6 Certified documentation that load bearing bolts have been torqued in accordance with OEM requirements. Documentation at minimum is to include both the OEM torque value that was used, and the sequence the bolts were torqued in.

6.5.7 Certified documentation of hydraulic pressure readings.

6.5.8 Documentation of specification and quantity of new hydraulic oil installed in the crane. Additionally, certified documentation of hydraulic oil testing results if required must be submitted.

6.5.9 Certified documentation that all parts/components have been reworked or replaced in accordance with this SOW. (see section 6.5.2)

NOTE: Certified documentation shall be initiated and signed by a qualified quality assurance inspector. Shop shift reports, daily task reports, etc. will not meet the requirement of “Certified Documentation.”

NOTE: The following excerpt is selected pages from the NNSY Crane Work Package. These pages are included as examples denoting the level of expected workmanship and criteria for information required in the contractor’s certified documentation.

Major Maintenance of Grove 88 Mobile Crane

[Begin Excerpts]

TURNTABLE BEARING BOLTS

Purpose: The purpose of this element is to provide instructions to verify that the turntable bearing bolts are secure.

Precautions: Assure that all personnel are clear of moving parts before rotating / repositioning the crane and perform Lockout / Tags-plus in accordance with LHAP 002 prior to bolt verification.

Procedure:

C-721 is to review the history file and determine if the tension in the turntable bearing bolts needs to be verified at this PM. Cranes that have had a minimum of three consecutive satisfactory bolt tension inspections may have the inspection performed during “C” PMs in lieu of “B” PMs. A satisfactory inspection is defined as no more than 1 (one) loose fastener in any ring. If the tension does not need to be verified the remaining steps in this element may be lined through and N/A’d.

Bolts tension verification required at this PM: YES _____ NO _____ (Check One)

*INSP ___________________________________ Date __________ Step 1 Complete SAT

If “YES” was checked in Step 1 above, the shop is to notify C-721 to be present for the tensioning of bolts. C-721 is to perform a 10% random verification of rotate bearing bolt tension. Verify that the Turntable Bearing Bolts have not loosened by accomplishing the following Steps.

Verify that the Turntable Bearing Bolts do not turn when 853 + 40 -0 FT/LBS is applied.

To maintain accountability mark each bolt head with an "X" when satisfactory torque verification of each bolt is achieved. Also, place an “X” on the corresponding bolt location on the applicable bolt configuration diagram, Figures 1 and 2, included in this element.

Use of a dial or click-type torque wrench is authorized for the work of this element. NA any non-applicable items below.

NOTE: Ensure the values to be recorded fall within the mid-range of the torque wrench selected.

Torque Wrench Serial # ______________________ Calibration Date _______________________

Torque Meter Serial # ______________________ Calibration Date _______________________

User Shop 98 __________________________ Badge # _______________ Date _______________

Upon completion of checkout of the torque wrench, verify the tolerance utilizing the torque tester available at the tool room of checkout.

Torque Wrench Reading ___________ FT/LBS Torque Tester Reading ___________ FT/LBS

*SM

Torque Wrench & Torque Tester Readings Recorded

DATE

NOTE: Torque wrench is only approved for the work of this element and shall be returned to the tool room upon completion of torque evolution, not to exceed a one month period. The readings above are for tool room information. Torque wrench tolerance will be verified before and after performance of work on the crane as identified below.

Major Maintenance of Grove 88 Mobile Crane Only perform this step and sub-steps if a 4:1 multiplier will be used. If a 1000 ft-lb torque wrench is used, N/A the blanks and signoffs of this step. The torque wrench may be used in conjunction with a 4 to 1 multiplier on all rotate bolts. Prior to torquing any bolts, with the 4:1 multiplier the torque wrench must be “Qualified” in the following manner:

NOTE: Exercise the torque wrench 4 to 5 times prior to “Qualifying.”

Install the correct sized socket on a bolt to be torqued. Install a torque meter on the socket and then the multiplier. Install the torque wrench on the multiplier and, reading from the torque meter, apply 853 FT/LBS, +40 -0, and record the reading of the meter and torque wrench:

Torque Meter Reading ___________ FT/LBS Torque Wrench Reading ___________ FT/LBS

*SM

Torque Meter & Torque Wrench Readings Recorded

DATE

Torque the remaining bolts to the torque wrench value entered above.

Identify any bolt that turns during this process on the inner and outer bolt configuration diagrams, Figures 1 and 2 of this element, with an “ * “.

Only perform the step if a 4:1 multiplier was used. If a 1000 ft-lb torque wrench was used, N/A the blanks and signoffs of this step. After completion of inspection and torquing of rotate bolts, perform another crosscheck of the torque wrench to the torque meter as described in step 5, above.

Torque Meter Reading ___________ FT/LBS Torque Wrench Reading ___________ FT/LBS

*SM

Final Cross-Check of Torque Meter & Torque Wrench Satisfactory

DATE

Note: Notify Code 710 if any loose bolts are found or crosscheck is unsatisfactory. C-710 is to notify NCC, Code 03 of any loose bolts in accordance with P-307 MISR item 49a.

Supplemental Documentation:

List additional LHWIs written during performance of this element. Shop supervisor is to "NA" if not applicable.

Certification

*SM

Bolt Torque Verified In Accordance With This Element

DATE

*INSP

10% Random Verification of Bolt Tension Complete.

DATE

**SS

All work is complete and satisfactory for this element. Additional LHWIs and CWPCs written on this element are complete and recorded in the Supplemental Documentation section.

DATE

**INSP

All work is complete and satisfactory for this element.

DATE

* The person designated to sign for an action verifies, based on personal observation, and certifies by their signature that the action has actually been performed in accordance with the specified requirements.

** The person designated to sign for an action verifies, based on personal observation, certified records, or direct reports from watch standers, and certifies, by their signature that the action has been performed in accordance with the specified requirements.

FIGURE 1

OUTER RACE

FIGURE 2

INNER RACE

HYDRAULIC OIL PRESSURE CHECKS

Purpose:

The purpose of this element is to verify that hydraulic pressures are in accordance with manufacturer's specifications.

Precautions

Assure that all personnel are clear of moving parts before rotating the crane.

Procedure

1. The shop is to verify the hydraulic system main and circuit relief valve settings in accordance with LHEI S-132 Attachment 389. The shop is to record the initial and final pressure readings in the space provided.

2. If system(s) pressures are not within specifications make the necessary adjustments and record the final PSI reading. If the reading is SAT, the final pressure reading can be NA'd.

OUTRIGGER / REAR STEER MAIN RELIEF

LIFT / TELESCOPE

MAIN RELIEF

MAIN / AUX HOIST

OUTRIGGER

CIRCUIT RELIEF

TELESCOPE EXTEND

LIFT RETRACT (DOWN) CIRCUIT RELIEF

SWING BRAKE & SWING DRIVE

SWING BRAKE VALVE BANK P1

CONTROLLERS VALVE BANK

* The person designated to sign for an action verifies, based on personal observation, and certifies by their signature that the action has actually been performed in accordance with the specified requirements.

** The person designated to sign for an action verifies, based on personal observation, certified records, or direct reports from watch standers, and certifies, by their signature that the action has been performed in accordance with the specified requirements.

[END EXCERPTS]

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