50711008 DATA.pdf

SYNCHRONOUS LIFTING SYSTEM

DESCRIPTIONS/SPECIFICATIONS

1. GENERAL INFORMATION

Minimum technical information required for submittal shall specifically address all the requirements of section 3 through 5 of this specification. The vendor shall also provide a drawing of the synchronous lifting system showing all of the dimensional and tolerance information contained in section 4 of this specification. Signed documentation must be submitted for the requirements of section 4.1.5.

1.1 DESCRIPTION- This specification covers a synchronous lifting system with four (4ea) 10,000 psi pump per point units with a 40 gallon reservoir, stroke sensors, pressure sensors, control panel, and miscellaneous cables that are compatible to our existing 1000ton hydraulic jacks and 3/8 inch inner diameter hydraulic lines. This specification also covers initial proof testing requirements to ensure mandatory performance specifications can be met.

1.2 INTENDED APPLICATION- The synchronous lift system will be used to lift a large ship’s hull section at four jacking supports welded to the ship’s hull structure. Jacking supports are spaced out over 50 feet from each other and 100 feet from the control center. The hull sections will have an uneven weight distribution resulting in different loads at each jack location. This process requires the use of our existing 1000ton hydraulic jacks, Model CLR100012U100.

1.3 Each pump per point unit is used to supply one of the four hydraulic jacks in a system used to raise the hull section. The hull section is raised approximately 12 inches and then blocked with cribbing and the jacks are retracted. This process is repeated until the hull section is at its desired height. The synchronous lifting system will be capable of automatically lifting a structure with differing loads at four points while controlling the levelness of the lift +/- 1/8 inch.

4ea

10,000 psi, 460V/3ph/60Hz 20 hp motor electric-hydraulic pumping units with 40 gallon reservoirs. The electrical controls on the pump must include an on/off switch and pump mounted main breaker shut off for emergencies. One pump per point unit will be used per 1000ton hydraulic jack.

3ea

Control panels that provide controls for pump per point units and existing 1000ton jacks and hydraulic lines that can maintain synchronous lifting for up to 8 jacks within tolerances described in this specification. The pump controller must have an emergency stop that stops the operation of all lift points. A schematic must be provided that shows how the emergency stop interrupts the control circuit.

8ea

Stroke sensors and stroke sensor cables compatible with control panel and pumps.

4ea Spare parts kit for hydraulic pumps and miscellaneous equipment for yearly maintenance.

If no maintenance is required than parts kit can be omitted.

The pump shall be designed and built to be operated in an environment ranging from 0 to 150 degrees Fahrenheit. Each pump shall be in a water resistant enclosure and shall be designed and built to operate up to 12 hours continuously. The pumps shall be designed and built to be secured for a 2-hour period prior to starting another 12-hour cycle. This operation cycle will be continuous over a six week period. The maximum oil temperature shall be limited to 150 degrees Fahrenheit.

1.4 MANUFACTURER’S CERTIFICATION-Portions of this specification indicate that a manufacturer’s certificate of compliance is required stating that the specified requirements have been met. Failure to provide the required documentation shall be considered cause for rejection of the affected portions.

2. APPLICABLE DOCUMENTS

2.1 The following documents form a part of this specification to the extent specified herein. Use the newest revision as applicable.

SPECIFICATIONS

MILITARY

MIL-PRF-8625F - Anodic Coatings for Aluminum and Aluminum Alloys MIL-DTL-5541F - Chemical Conversion Coatings on Aluminum and Aluminum Alloys MIL-DTL-15024G - Plates, Tags and Bands for Identification of Equipment

STANDARDS

MILITARY

ASME Y14.100 – Engineering Drawing Practices ISO-17025 Second Edition- General requirements for competence of testing and calibration laboratories

PUBLICATIONS

2.2 OTHER PUBLICATIONS – the following documents form a part of this specifications to the extent specified herein. Unless otherwise indicated, the issue in effect on the date of invitation for bids or request for proposal shall apply.

TITLE 29 OF THE CODE OF FEDERAL REGULATIONS, CHAPTER XVII, PART 1910 – Occupational Safety and

Health Standards

AMERICAN NATIONAL STANDARDS INSITITUTE, INC (ANSI)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS, (ASME)

AMERICAN GEAR MANUFACTURES’ ASSOCIATION AGMA 360 – Manual for Machine Tool Gearing

NATIONAL ELECTRICAL MANUFACTURERS’ ASSOCIATION (NEMA)

NATIONAL FIRE PROTECTION ASSOCIATION

3. GENERAL REQUIREMENTS

3.1 DESIGN-The equipment shall be new and unused, capable of performing its intended function in accordance with the operation and performance requirements specified herein. The equipment shall be complete so that when connected to the utilities identified herein it will perform as specified herein. ISO 4413 shall be used for guidance where applicable. The system must be compatible with off the shelf parts that are readily available from either the manufacturer of the equipment or parts suppliers to the manufacturer (not custom built on demand). If parts suppliers are used to satisfy this requirement then the parts supplier shall be identified in provided parts list. The systems design should not be considered novel (one of a kind) and should be consistent with existing well established designs used in industry.

3.2 HYDRAULIC OIL REQUIREMETS- All hydraulic seals and components shall be compatible with DTE 24 (MIL-

PRF-17672E) hydraulic oils and or equivalent hydraulic oils

3.3 ENVIRONMENTAL PROTECTION- The equipment shall be designed and constructed such that, under the operating, services, transportation and storage conditions described herein, the equipment shall not emit materials hazardous to the ecological system as prescribed by federal, state or local statutes in effect Bremerton, Washington.

3.4 INTERCHANGEABILITY – All replaceable parts shall be manufactured to definite standards, tolerances and clearances in order that any such parts of a particular type or model can be replaced or adjusted without modification of the contract.

3.5 MAINTAINABILITY – The equipment shall be designed and constructed to permit maintenance personnel to easily and effectively service the equipment using standard tools and with minimal disturbance or removal of adjacent components or parts. Consistent with required maintenance and design of the equipment, the manufacturer shall provide any special tools required to service the unit. The equipment shall be equipped with access covers to facilitate inspection, cleaning and repair or replacement of parts. Replacement parts shall be available for a minimum of ten years after this contract is awarded.

3.6 CONSTRUCTION – The equipment shall be constructed of parts, which are new, without defects and free of repair.

3.7 SAFETY – The equipment shall be provided with the requisite safety features necessary to render it in full compliance with the latest approved requirements of NAVSEA.

OSHA Requirements – The equipment installation and its component parts shall be in compliance with the applicable OSHA regulations in accordance with CFR Title 29, Chapter XVII, Part 1910 and installed in accordance with NEC/NFPA requirements. Approval shall be as specified under the “Approval” and “Acceptance” criteria in the OSHA regulations Subpart “O”, Machinery and Machine Guarding paragraph

1910.212 and Subpart “S” Electrical, paragraph 1910.303 and paragraph 1910.399. After equipment delivery and installation, and prior to testing, the contractor shall provide an OSHA Compliance Report.

Failure to provide this compliance report will delay acceptance of the equipment and could result in rejection for failure to comply with the terms of the contract. This report documents the results of all tests performed, provides an assessment of the equipment performance for compliance with the contract requirements, and forms a basis for recommending a safety certification. The report, test and evaluation shall be a composite of those inspection requirements specified in the contract. The report shall be prepared in an orderly manner to clearly and accurately set forth the collected data and conclusion resulting from these inspection requirements, opinions and subjective conclusions shall be clearly identified. The report shall include, but is not limited to, the following:

1. List of all tests performed and by who witnessed.

2. List of data used for evaluation.

3. Tabulation of all discrepancies related to specification performance requirements.

4. Description of limitations revealed by data utilized.

5. Actions taken to mitigate each discrepancy and limitation.

6. Recommendations for subsequent actions.

7. Summary conclusions.

8. Manufacturer Certification that equipment has been manufactured and installed in compliance with OSHA CFR 1910.399 (per definition of “acceptable”).

3.8 PAINTING – The equipment shall be properly painted; painting may be the manufacturer’s standard practice provided it results in a highly wear-resistant finish, which guarantees continued protection to the surfaces covered against corrosion in a salt-laden, moist, variable temperature atmosphere under all services conditions. Prior to painting, surfaces shall be properly prepared and primed. The manufacturer’s standard color shall be provided with MSDS.

3.9 FERROUS PARTS – All exposed ferrous parts such as screws, bolts, nuts, washers, etc…, shall be chromed plated, galvanized or otherwise surface protected by an electrical/chemical process or with stainless steel to resist corrosion in a salt-laden, moist, variable temperature atmosphere.

3.10 DISSIMILAR METALS – Dissimilar metals shall not be used in direct contact with each other without suitable means for preventing electrolytic corrosion.

3.11 CONTROL PANELS, INSTRUMENTS AND PLATES – Wording and numbers on control panels, instruments and plates shall be in the English language, permanently displayed in easily legible characters on a contrasting background.

3.12 HYDRAULIC PRESSURE COMPONENT SAFETY FACTORS – Unless otherwise specified herein all hydraulic fittings and components shall have a minimum safety factor of 2 to 1 based on the burst pressure, documentation shall be provided when requested. When possible, a minimum safety factor of 4 to 1 based on burst pressure is recommended.

4. MAJOR COMPONENT REQUIREMENTS

4.1 SYNCHRONOUS LIFTING SYSTEM – System will use a control panel, stroke sensors, hydraulic pump per point units, and miscellaneous cables to be capable of automatically lifting a structure with differing loads at four points while controlling the levelness of the lift +/- 1/8 inch.

4.1.2 Pump per point units shall meet the performance requirements of this specification and shall be designed

(or modified if a current production model) for operation with the jacking cylinders specified herein.

Hydraulic pumping units shall also provide for emergency direct manual operation of the jacking cylinders with the synchronous control system components removed from the system. Each pump shall deliver hydraulic oil volume required to operate a 1000short ton jacks.

4.1.3 The pump mounted Directional Control valves shall designed and built capable of being isolated

(unplugged) from the synchronous system, and a hand remote installed for single pump operation or for pump testing/certification.

4.1.4 Pump(s), electric motor(s), oil reservoir, valves, filters, electrical panels, etc… shall be mounted onto a protective structural frame.

4.1.5 Vendor shall provide evidence of the synchronous lift systems compatibility with the existing Enerpac 1000ton hydraulic jacks and 3/8 inch inner diameter hoses with burst pressure of 40,000 psi. A signed letter from ENERPAC stating the synchronous lifting system is compatible will be considered acceptable.

Alternately, the vendor can provide documentation signed by a qualified licensed practicing engineer, which addresses how the synchronous system is interchangeable with Enerpac 1000ton jacks.

4.1.6 Control panel shall be compatible with up to 8 jacks and pump per point units and corresponding sensors and cables. System shall be closed circuit controls to meet IT requirements. The pump control system shall have its own standalone operating system. Bluetooth and other wireless communications shall not be installed. As part of the submittal, all software requiring periodic updates will be identified and must meet cyber security evaluation, failure to meet security evaluation is cause for rejection of submittal. Any peripherals required for hard wired communications shall be provided by manufacturer.

4.1.7 Cables and sensor wires are required to be long enough to reach from the control center to the hydraulic jacks and pump per point units. Pump per point units to hydraulic jacks are up to 80 feet apart and pump per point units are up to 30 feet from the control center.

4.2. PUMP ELECTRICAL DESIGN

4.2.1. ELECTRICAL EQUIPMENT – All electrical components shall meet National Electrical Manufacturer’s Association (NEMA) and National Electrical Code (NEC) standards and be approved by Underwriters Laboratories (UL), and section 3.7 of this specification

4.2.2. ELECTRICAL POWER PANELS – Electric power panels shall be provided for 460 VAC 3 phase loads. Main breaker and branch breaker amperage ratings shall be adequate to provide power for all synchronous lift system components.

4.2.3. ELECTRIC POWER DISCONNECTS – A main supply circuit disconnect device or circuit breaker shall be provided and installed on the power panel to de-energize in case of emergency. All disconnect devices shall be ‘lockable’ in the ‘off’ position.

4.2.4. OVERCURRENT PROTECTION – All electrical components shall be fuse or circuit breaker protected in each phase conductor for AC circuits and both DC circuit conductors. Overload fuse and circuit breakers shall be coordinated for maximum component protection and minimum circuit disruption.

4.2.5 MOTOR – Motors shall be of adequate horsepower and duty rating to operate the jacking system under normal conditions without overheating, etc... Motors shall be provided complete with starter (on/off switch) and any other required accessories required for operation.

4.2.6 Proper identification of wiring, bussing, terminals and circuits for function, polarity, phasing, etc..., shall be adhered to throughout the equipment. Identification shall be in the form of wire markers, color-coding, permanently engraved plates, and permanent markings on the devices. Alternatively, if wiring connections are minimal, and terminal blocks are labeled, identification shall be deemed adequate.

4.2.7 Adequate spacing shall be maintained throughout to avoid excessive bending of cabling and wiring, to maintain adequate separation and creep age distance between electrical potentials and between these potentials and ground, and to permit ease in connecting and disconnecting wiring and cabling during trouble-shooting and repair.

4.3 HYDRAULIC PUMP

4.3.1 Hydraulic pump per point unit as required in this specification includes reservoir, filters, piping/hoses, fittings, gauges, etc.

4.3.2 RESERVOIR – Each pump per point unit shall have a hydraulic oil reservoir (40 gallons) designed in accordance with good engineering practices and shall include the following:

a. The reservoir shall be equipped with an oil level gauge (sight glass) and temperature gauge to give external visual indication of the oil level and temperature.

b. The filler opening(s) shall be equipped with a strainer(s) and shall be adequately sized to allow filling the reservoir in a reasonable time (approx. 45 minutes or less).

c. A large, easily removable, clean-out opening(s) shall be provided on the reservoir to allow access to all the reservoir internals.

d. The reservoir shall have adequate capacity to operate the jacking system as specified herein and provide reserve fluid in accordance with established industry design standards.

e. The reservoir shall have sufficient volume to allow time for dirt and cuttings to settle and for air to vent.

f. Magnets shall be included in the reservoir near the return outlet for collection of ferrous metals.

g. A drain plug shall be provided at the reservoir low point to allow complete draining of the reservoir.

4.3.3 FILTERS- The hydraulic pump per point unit shall be equipped with all filters necessary to remove any foreign material from the oil that may cause damage to the pump or other system components.

4.3.4 Filter assemblies shall be equipped with by-pass valves and filter condition indicators to protect the system components.

4.3.5 Return line filter(s) shall be installed and shall: 1) be of the spin-on canister type. 2) Be readily accessible and 3) have a maximum nominal retention of 5 micron (less if required to meet pump and component manufacturer’s warranties). Additional filtration such as suction strainers shall be provided if required to achieve component manufacturer’s cleanliness requirements.

4.3.6 Air breather filter(s) shall be installed to remove airborne contaminants, moisture and maintain atmospheric pressure in the reservoir.

4.3.7 Replacement filter ordering information, instructions and service interval recommendations shall be included in the maintenance manual.

4.3.8 Sufficient replacement filters for one servicing shall be included with the unit.

4.3.9 Adequate magnetic filtration shall be installed.

5 MISCELLANEOUS COMPONET REQUIREMENTS

5.1 COMPONENTS (VALVES, FITTING QUICK-COUPLERS, GAUGES, ETC.)

5.2 All components shall have a minimum safety factor of 2 to 1 based on burst pressure. Where possible, a minimum safety factor of 4 to 1 based on burst pressure shall be provided.

5.3 All hydraulic pressure components shall have a rated working pressure, which is equal to or greater than 10,000 psi.

5.4 Advance and retract ports shall be clearly labeled.

5.5 QUICK COUPLERS- Quick couplers shall be Parker #372 (male) and Parker #371 (female), 3/8” NPTF threads, 10,000 psi operating pressure.

5.6 Gauges shall be rated for 0 to 10,000 psi, be accurate to +/- 1% of full scale, provide a means of recalibration.

5.7 Gauges shall be sealed and protected to maintain reliable operation in inclement weather and rugged operating conditions.

6 TECHNICAL DATA- Detailed operation, maintenance, and troubleshooting instructions, written in the English language, shall be furnished with the equipment. Four copies of each instruction shall be provided to PSNS & IMF C/250.5, Bremerton, Washington 98314, via the designated Contract Administration Office.

6.1 ENGINEERING DRAWINGS- Engineering drawings may be provided separately or may be incorporated into the maintenance manuals.

6.2 Drawings shall list all components and provide a parts breakdown of all components.

6.3 Components parts breakdown shall provide the components manufacturer, component part replacement number, individual part replacement numbers, and industry standards part numbers for seals, couplers, fittings etc.

6.4 Drawings shall provide all material specifications, dimensions, and tolerances for those parts that are not standard components produced by well-established companies.

6.5 Drawings shall include all necessary requirements for assembly of the pieces, including torque values and other special requirements.

6.6 Repair and/or replacement instructions for all components parts shall be specified.

6.7 The manual shall specify service intervals for all periodic maintenance including filter, oil, and component replacement. Replacement parts shall be available ten years after purchase.

6.7.1 The manual shall include an Energy Control Procedure (ECP), in accordance with 29 CFR 1910.147, OSHA Energy Control Standard to bring equipment to a zero energy state for maintenance.

7 TESTING REQUIREMENTS

7.1 HYDROSTATIC TEST: Pumps and hydraulic pressure components as assembled shall be hydrostatically tested for a minimum of 10 minutes to a test pressure of 10,000 +/-100 psi.

INSPECTION: During the test, inspect all mechanical joints, connections, piping and fasteners for damage and deformation.

ACCEPTANCE CRITERIA: The hydraulic pump per point unit and pressure components shall successfully supply test pressure, operate without leakage (except minor weeping at mechanical joints), and operate without abnormal vibration or excessive noise. The pump and pump components shall not show deformation to any valves, fittings, gauges, manifolds, internal and external piping. The hydraulic fluid temperature shall not exceed 150 degrees maximum during testing. Documentation of testing/inspection shall be provided to include the following: test pressure, time, inspection results, fluid temperature, and a certifying signature for each assembly tested.

7.2 OPERATIONAL TEST: After Hydrostatic test, cycle two of the 40-gallon pump per point unit and two jacks through a full range of advance and retract cycles three times. Complete a second Hydrostatic test by pressurizing the pump to 4,000 psi. Hold pressure for two minutes, if the pump and pump components show no deformation to any valves, fittings, gauges, manifolds, internal and external piping, continue the test. Increase the pressure by 2,000 psi until full test pressure has been reached, and then hold the fully pressurized pump (10,000 +100 /-0 psi) for 10 minutes. Set a base line zero point to test synchronous lifting using the control panel and stroke sensor cables. Have the panel extend the jack in synchronous lifting mode three times by increments of 3 inches from the zero to 9 inches. During operation, use emergency stop button to shut down jacking operation before it completes its full stroke, inspect and then resume lifting to the targeted length. Once at target height have the system synchronously lower back to the base line in three steps of 3 inch increments. During lowering, use emergency stop button to shut down jacking operation before it completes retraction, inspect and then resume retracting until completion. Test every outlet and plug for functionality.

INSPECTION: During test, inspect all visible mechanical joints for deformation to any valves, fittings, gauges, manifolds, internal and external piping interface for leakage. Listen/feel for abnormal sounds or vibrations. Measure the stroke length after the emergency stop and then again after the target length to check if they are equal, repeat for synchronous lowering.

ACCEPTANCE CRITERIA: Have no leakage that would allow a drop to form, run or fall away within the duration of the test. The pump shall have no visual deformation of any valves or components. No sound or vibration was detected that would lead to a reasonable person to assume that the pump is damaged or not operating properly. The emergency stop is functioning properly and ceases jacking operation. The synchronous system properly operates the jack within required leveling tolerances.

7.3 All vendor tests and inspections shall be documented. Documentation shall include the following:

Test figure drawing including operational specification for hydraulic pump Test gauge calibration dates and gauge range and accuracy Actual test pressure where applicable Measurements taken during lifting operation An itemized list of inspected joints and components with the inspection criteria and inspection results for each item Signature date and contact information of the inspector

7.4 The vendor shall coordinate with PSNS & IMF so that PSNS & IMF may send a designated representative(s) to witness the testing /certifying process of paragraph 7.1. The vendor can use their own jacks for testing or they can request government furnished equipment (GFE) be provided. Sufficient notice shall be provided (2 weeks minimum) to allow travel arrangements for personnel and (1 month minimum) If GFE is to be used. PSNS may provide a written waiver to allow the vendor to test/certify without a designated representative present. This waiver will be at the discretion of PSNS & IMF and shall not be provided to accommodate insufficient notification time by the vendor

8 PROCUREMENT QUALITY ASSURANCE, INSPECTION AND ACCEPTANCE

8.1 ACCEPTANCE AT DESTINATION- Final acceptance of the equipment furnish per this specification shall be made at destination by the PSNS & IMF designated cognizant engineer for the equipment. Acceptance shall be based upon satisfactory completion of operational testing at destination, acceptability of the drawings and manuals required.

9 TRAINING

9.1 Vendor shall provide training on the operation of the equipment.

10 CONTRACT OPTIONS (if required)

10.1 This contract provides for an option year with the potential to purchase, on an as needed bases, new hydraulic pumps and sensor cables. Included in the table below is the quantity to purchase, the price including inflation and the approximate total cost per option year.

OPTION

YEAR

DESCRIPTION

QTY TO

ORDER

PRICE/EA WITH

% INFLATION

TOTAL COST

1-(FY26) PUMPS AS DESCRIBED IN SECTION

1.1 6 Quote request Quote request

1-(FY26) SENSOR CABLES AS DESCRIBED IN

SECTION 1.1 5 Quote request Quote request