Statement of Work.pdf

Statement of Work

Crane #169 Wire Rope Replacement 1300865517

1.0 BACKGROUND

1.1. The Seneca Lake Sonar Test Facility is a field station of the Naval Sea Systems

Command (NAVSEA) located in the Finger Lakes region if Dresden, NY. Seneca Lake is the Navy’s primary underwater test facility established for evaluating active and passive acoustic devices from single element to full sonar systems. Seneca Lake is a government controlled and operated facility and is a world-class acoustic test bed for the Navy capable of supporting all developmental work, element and system evaluations and acceptance testing for active and passive underwater acoustics

1.2. Seneca Lake is particularly well-known for its massive lift capabilities, capabilities provided by the Macgregor crane as well as other smaller articulating boom cranes mounted on the platform. The MacGregor crane, designated crane # 169, was built in 1975 by the MacGregor-Comarain company, and is a 200 Short Ton “Stülcken Mast” derrick of the double pendulum block type. It consists of one boom (derrick) and a boom gooseneck with support tube, a set of two unstayed Kingposts fitted with swivel heads, cargo and span tackle blocks, double barbed hook, two (2) span winches (60 HP each) operating on a 413.6:1 reduction, one (1) cargo winch (60 HP), complete with motors and gearboxes also operating on a 413,6:1 reduction.

1.3. Original manuals and General Arrangement drawings are available for review upon award.

2.0 SCOPE

The contractor shall remove the existing wire rope in crane #169 and replace with a new wire rope, provided as Government Furnished Material. All work shall be done at the Seneca Lake Sonar Test Facility.

Prior to removing the existing wire rope, the contractor shall submit a plan identifying how they will place the removed wire rope in a safe condition, how much space is required for storing the wire rope (it cannot remain on the System Measurement Platform (SMP) after removal) and estimated time for completion. Following approval of the plan, the Government will transport the wire rope to a temporary location. The contractor is responsible for removal and disposal of the wire rope by the contract completion date.

The contractor shall perform the following:

Unpin and remove the existing speltered socket at the main hoist dead-end point that is located on the boom. If possible, this socket shall be re-used on the new wire rope. When the wire rope is removed in its entirety, the disconnected wire rope must be placed in a safe condition on site at the Seneca Lake Facility. The wire rope cannot stay on the SMP after removal due to space constraints and safety concerns. The plan (including the estimated time and required laydown space) for placing the wire rope in a safe condition shall be submitted to the government for approval, so as to assure that the wire rope will not impact any other adjacent work on site at Seneca Lake. The government shall provide a crane operator and water transportation to support this task. The contractor is responsible for any cutting of the existing rope to facilitate transportation as well as disposal of the existing wire rope, as well as a new socket if needed (OPTION, CLIN 0002).

Test the new wire rope and end connections per NAVFAC P-307. Government inspection personnel shall inspect the wire rope and end connections before the wire rope is installed. The contractor shall provide 5 days notice prior to installation to allow for Government inspection.

Remove and dispose of the existing main, auxiliary and whip hoist wire ropes from Crane #169. The government shall provide a crane operator and water transportation as necessary to support this task.

Install the new wire rope on the main, auxiliary and whip hoists of Crane #169. The government shall provide a crane operator as necessary to support this task. The installation of the new wire ropes shall not proceed until all submittals have been received and approved by the government.

Exercise and load test the new main, auxiliary and whip hoist wire ropes for Crane #169.

The government shall provide test weights/rigging gear (we can identify specifically as GFE) and a crane operator to support this task. The wire ropes shall not be accepted by the government until satisfactory completion of the acceptance criteria included in this document and IAW

NAVFAC P-307.

3.0 Wire Rope Specifications:

3.1 Wire ropes for Crane #169 shall be provided by the Government to the contractor. The ropes shall be extra improved plow steel (EIPS), preformed (P), uncoated, right regular lay (RRL), with independent wire rope core (IWRC). The wire rope shall be 1 ¾” diameter and 4,660’ (-0’ / +132’) in length at zero load. The wire rope shall have a minimum breaking strength of 304,000 lbs. The wire rope shall be in one continuous spool, all taken from the same reel; the use of splices to permanently connect different reels of wire rope is prohibited. The wire rope shall be lubricated exclusively with LPS-3 per OEM requirements prior to powered movement of the wire rope using Crane 169’s main hoist. The wire rope shall be subjected to the inspections/tests outlined below, and the installed rope shall only be accepted by the government if results meet the required specification in 4.0.

3.2 There shall be two distinct types of end connection, one at each end of this wire rope assembly. The first end shall be speltered, either poured (i.e. molten zinc) or with resin, into a steel socket. This steel socket shall be the socket that is currently installed on the existing wire rope. This socket will need to be removed from Crane #169 in order to be re-utilized on the new wire rope. Poured spelter socket end connections shall be fabricated in accordance with Naval Ships’ Technical Manual (NSTM) S9086-UUSTM-010. Resin socketing material must meet NSTM S9086-UU-STM-010 Chapter 613, and resin end connections shall be fabricated in accordance with the resin OEM’s instructions. This end shall be connected by re-using existing hardware at the main hoist’s dead-end point that is located on the boom. The other end connection shall be plain cut and double-seized per the Wire Rope Users’ Manual. This end shall be routed through a pocket in the wire rope drum, and clipped to the wire rope drum flange.

The existing wire rope clips currently on the main hoist of Crane #169 shall be re-utilized for the new wire rope. The wires at the cut end of the rope shall be welded together. A weld less link shall also be welded to this end, sized sufficiently to provide the ability to tug/pull the wire rope.

The Contractor shall ensure that the wire rope end connections are properly attached, and this shall be subject to inspection and approval by the government. The end connections shall be subjected to the inspections/tests outlined below, and the end connections shall only be accepted by the government if results meet specifications as detailed in section 4.0.

4.0 Inspection:

The two areas that require inspection are the wire rope and the end connections. The inspection criteria for these two areas are included below:

4.1 Wire Rope:

The wire ropes shall be inspected by government personnel twice: (1) during the installation process and (2) after the wire rope load testing evolution. The wire rope will need to satisfactorily pass both inspections in order to be accepted by the government. Both inspections shall be performed to the following criteria:

(a) The entire length of the wire rope shall be inspected using additional equipment as necessary for access. Dimensional checks should be performed at several places over the length of the wire rope. In all cases, the depth and detail of the inspection shall be that necessary to ensure that the entire rope is acceptable with special attention paid to areas of expected wear or damage. During the inspection, the wire rope shall be paid out as far as possible. For sections that cannot be spooled off the drum, inspection of the wire rope on the drum is sufficient. Excess wire rope lubricant shall be removed from areas where it prevents the rope from being properly inspected. Wire rope end fittings will not be disassembled for inspection. The wire rope shall be re-lubricated by the Contractor with LPS-3 per OEM requirements as necessary after inspection.

(b) Wire rope shall be rejected if any of the following conditions exist:

(1) One completely broken or torn strand in any rope

(2) Six randomly distributed broken wires in one lay length

(3) Three broken wires in one strand in one lay length

(4) One outer wire broken at the point of contact with the core of the rope that has worked its way out of the rope structure and protrudes or loops out from the rope structure.

(5) Two broken wires within one lay length of the end connection.

(6) Wear exceeding 1 /3 of the original diameter of outside individual wires.

(7) Loss in diameter greater than five percent. New wire rope diameter is to be obtained from the reel certification documentation or by direct measurement.

(8) Flattened Sections where the diameter across the flat is less than 5/6 of the nominal diameter.

(9) Kinked, bird-caged, dog-legged, or crushed Sections of rope where the core is missing or protrudes through or between strands.

(10) High Strand where the height exceeds 10 percent of the nominal diameter.

(11) Corrosion such that significant pitting occurs on the surfaces of outside wires.

Minor surface roughness on outside wires is acceptable provided no significant pitting occurs and the rope is not corroded internally. Significant pitting is defined as pitting that cannot be removed by abrasive removal of less than 1 /3 of the diameter of individual outside wires.

(12) Heat damage evidence from any cause.

(13) Wavy rope (where the longitudinal axis of the wire rope takes the shape of a helix instead of a line when the diameter of the envelope of the wave is greater than 110% of the diameter of the normal diameter of the wire rope.

(14) Accumulation of defects which, in the judgment of the government inspector, creates an unsafe condition.

4.2 End Connections:

The government shall be on-site to witness the removal and re-installation of the existing speltered socket. The socket shall be inspected for excessive wear. Sockets showing a wear reduction due to use that reduces any cross-sectional dimension of the jaw by more than 10 percent or the pin diameter by more than five percent below the nominal dimension shall be rejected. Additionally, the end connections shall be inspected for excessive wear, broken wires, stretching, kinking, twisting, or undue looseness of, at, or in end connections. Undue looseness is defined as abnormal looseness due to wear, distortion, slippage, etc., of individual components of end fittings or between end fittings and other mating components. Undue looseness in poured sockets is defined as looseness or evidence of slippage of wires in the potting material, evidence of deterioration (crushing or other significant deformation) of the potting material, looseness of wire rope strands or wires adjacent to the poured socket, or any looseness resulting from cracks or other defects in the socket.

4.3 Testing:

There shall be testing evolutions that occur both prior to delivery and post-delivery; they are listed below, and their results shall be submitted to the government for approval.

Pre-Delivery:

- The actual breaking strength shall be determined using the methodology in ASTM A931, based on a sample taken from the same reel of wire rope. The actual breaking strength shall exceed the specified minimum breaking strength of 304,000 lbs.

- The wire rope socket end connection shall be submitted to a pull-test of (TBD) lbs., which is 200% of the maximum line pull of the wire rope.

Post-Delivery:

- The wire rope shall be exercised per the Wire Rope Users’ Manual. The exercising shall include the incremental application of weight, up to the nominal test load for Crane #169 (125% (+0% / -5%) of rated capacity). Accordingly, this test shall serve as the load test for the new wire rope and the proof test for the seized end connection.

4.4 Acceptance:

NAVFAC MIDLANT Weight Handling Equipment Program Office Northeast shall provide inspection personnel to accomplish the wire rope inspection. Following completion of government inspection, final government acceptance of the wire rope shall take place only after the following conditions are met:

4.4.1 Contractor receives Government approval for all data items and submittals.

4.4.2 The wire rope passes a final inspection by the Government, per the previously listed inspection criteria.

4.4.3 All deficient items have been corrected or methods of resolution have been determined.

Deficient items not corrected shall be carried as warranty items, which shall be corrected by the Contractor prior to the Government’s final acceptance and payment.

5.0 Submittals:

5.1 The contractor shall submit to the Contracting Officer all items of technical documentation listed hereinafter. The contractor shall ensure that all submittals are entirely legible and suitable for reproduction. Compliance with the requirements of this specification will be determined by a review of the submittals by the government and acceptance inspection/testing.

5.2 The contractor shall submit certification, with positive traceability to the wire rope manufacturer and wire rope reel, that the wire rope has been manufactured in accordance with Federal Specification RR-W-410 (L/R).

5.3 The Government shall submit to the contractor documentation, with positive traceability to the wire rope manufacturer and wire rope reel, of the actual breaking strength of the wire rope to be installed on Crane #169.

5.4 The contractor shall submit documentation that the wire rope’s socket end connection has been satisfactorily pull-tested.

5.5 The contractor shall submit a document outlining the planned procedure for wire rope exercising, which shall be in accordance with the Wire Rope Users’ Manual. This plan shall include weight increments up to the maximum test load of Crane #169, so this plan shall serve as the load test for the wire rope, and the proof test for the seized end connection. The wire rope exercising shall not commence until the wire rope exercising plan has been approved by the government.

5.6 The contractor shall submit the MSDS sheet for the LPS-3 wire rope lubrication to be used on the wire rope upon installation at the Seneca Lake Facility.

6.0 Security:

Crane #169 is located on the SMP at the Seneca Lake Sonar Test Facility is a field station of the Naval Sea Systems Command (NAVSEA) located in the Finger Lakes region if Dresden, NY. .

No person not known to be an American citizen of good standing and repute shall be eligible for access to the Seneca Lake Facility. Proof of citizenship will be required. All Contractor personnel will be required to register in DBiDS and a local visit request form will need to completed and submitted for all work being performed on the SMP. Two forms of ID required, one must prove Citizenship i.e. passport or birth certificate.

6.1 SITE ACCESS REQUIREMENTS

6.1 A Visit Request is MANDATORY for contractors, their employees, and agents to the Seneca Lake Facility.

6.2 Site visit requests for bidding purposes and for work if selected should be submitted 2 weeks in advance to ensure processing. The Government accepts no liability for lack of access and potential loss of work time.

6.3 All persons working at the site shall check in at the Main Office during every visit, prior to proceeding to work and will checkout when leaving.

6.4 No Photographic equipment is allowed in the facility. This includes cell phones.

7.0 Project Constraints and Logistics:

7.1 The repairs, modifications and alterations performed on Weight Handling Equipment

(WHE) fall under the guidance of the Navy Crane Center of which approval needs to be obtained prior to beginning any work. Once approval is granted, no deviation from the approved means, methods or plans may take place without first obtaining their approval.

The Government will assist with NCC approval, but the responsibility ultimately lies with the contractor.

7.2 The successful bidder must be familiar with and conform to the requirements of

NAVFAC P-307.

7.3 The location of the SMP is near the center of the lake, approximately 1.5 miles from shore. Facility staff transport personnel and equipment using the facilities vessels.

Transportation of equipment may also be facilitated through Seneca Lake Staff, but this must be discussed and agreed upon in advance. Loading and unloading of equipment from the pier to the vessel, and from the vessel to the SMP will be performed by Site personnel; no contractor may use Seneca Lake vessels or equipment.

7.4 Normal working hours are 0730 – 1600, Monday through Friday. Any weekend, overtime or holiday work is on a requested basis and is not to be assumed when scheduling. There are limited messing facilities on the SMP. Contractors should plan accordingly for lunches and snacks.

7.5 Subject Matter Experts (SME) will be available by NUWC and NAVFAC MIDLANT WHE, to answer any questions from the contractor while on-site performing the modernization.

7.6 Materials

7.6.1 The contractor will provide the necessary labor, equipment and materials (except as noted below) to replace all three (3) wire ropes on Crane #169.

7.6.2 The wire new wire ropes will receive welded pulling eyes prior to installation and the work will be performed by the contractor and is part of this proposal.

7.6.3 The drum grooves will also be cleaned to the extent possible during the wire rope replacement.

7.6.4 The contractor will also assist with replacing of the gear oils in each of the three

(3) gear reducers as time permits, providing this has no impact on the wire rope replacement work.

7.6.5 The contractor shall conduct a “breaking-in” of the new wire ropes at increasing weight intervals from unloaded to fully-loaded using the 20,000 Lb. test weights stored on-site.

7.6.6 The wire rope clamps will be re-checked for proper torque once the “break-in” procedure has been completed.

7.6.7 Contractor Provided Materials:

7.6.7.1 Six (6) Crosby S-264 Pad-Eyes.

7.6.7.2 Ten (10) Crosby G-450 Clips

7.6.7.3 Miscellaneous tooling, cleaning supplies, and all other material to complete the requirements of all three wire rope replacements.

7.6.7.4 All equipment required including lifts, scaffolding, tools, ladders and any other required equipment to complete all aspects of the SOW.

7.7 GOVERNMENT FURNISHED INFORMATION AND SERVICES

7.7.1 Operations Manual for Crane #169

7.7.2 General Arrangement Drawings

7.7.3 Transportation to and from the SMP.

7.7.4 Crane and Forklift operation for moving materials from shore to the barge.(Limited to currently available equipment)

7.7.5 Replacement wire ropes (3)

8.0 APPLICABLE DOCUMENTS

8.1 NAVFAC p-307 Management of Weight Handling Equipment

8.2 Crane 169 OEM Manual