A.07.24_SolicitationAmendment1_InspectionReport_16T0041.pdf

Inspection Report of Turbine Bay Crane at Ozark Powerhouse Rev 1

Specialists in hoists, cranes, and electrical service since 1913

1230 South Hannah Avenue

Forest Park, IL. 60130-2448

708-771-1600

FAX 708-771-3124

www.sievertelectric.com

INSPECTION REPORT OF TURBINE BAY CRANE

(150/15T) AT OZARK POWERHOUSE

PREPARED FOR

CONTRACTING DIVISION

USACE, LITTLE ROCK (W9127S)

700 W. CAPITOL AVE, RM 7315

LITTLE ROCK AR 72201-3225

PREPARED BY

SIEVERT CRANE AND HOIST,

DIVISION OF SIEVERT ELECTRIC

1230 S HANNAH AVE,

FOREST PARK, IL 60130

CONTRACT # W9127S-15-P-0139

NOVEMBER 05, 2015

Sievert Electric 1230 South Hannah Ave.

Forest Park, IL 60130

Phone: 708-771-1600

Fax: 708-771-3124 www.sievertelectric.com

INSPECTION REPORT

PAGE: ____ OF ____1 6

JOB NO:_________________41728

CUSTOMER:__________________________________OZARK POWERHOUSE

ADDRESS:___________________________________

1598 LOCK & DAM RD., RUSSELLVILLE,

AR 72802

LOCATION/DESC:_____________________________OZARK POWERHOUSE

SCHEDULED DATE:_________________10/19/15

DIVISION:__________________________________

PHONE:_____________________________________

OWNER ID:__________________________________26719

EQUIPMENT TYPE:____________________________________________________________________________TR-DG TOP RUNNING CRANE - CAB CONTROLLED MOTOR DRIVEN

MAKE/MODEL:________________________________

INSPECTED BY:______________________________JOSH GUYER

SYSTEM SERIAL #:___________________________6845

INSPECTED ON:______________________________10/19/15

BRIDGE

COMPONENT OK REPAIR REPLACE MONITOR COMMENTS

BRIDGE - INSPECTION

XMOTOR

XMOTOR BRAKE

XGEAR REDUCER

XEND TRUCKS

XWHEELS

XCATWALK ACCESS - GUARD RAIL

XBRIDGE GIRDERS -CRACKED WELD AT

END OF RAIL ON THE

DOWNSTREAM/RIVERSID

E OF RAIL.

XCONTROL PANELS

XLIGHTS -ONE LIGHT NEAR

OPERATORS CAB IS

UNPLUGGED

INTENTIONALLY DUE

TO IT BLINDING

OPERATOR DURING

OPERATION.

XWARNING DEVICES

XMAIN COLLECTORS / COLLECTOR POLE -ALL 6 COLLECTOR

INSERTS ARE WORN

AND SHOULD BE

REPLACED. (100 AMP

DUCTOBAR)

150/15 TONBRIDGE CAPACITY:

BROADLINE CORP.BRIDGE MANUFACTURER:

480 VACBRIDGE POWER SUPPLY:

115VACBRIDGE CONTROL:

VFDBRIDGE DRIVE:

SERIAL NUMBER: 6845

Printed Date: November 11, 2015 03:56 PM

Visual inspection only. Customer is ultimately reponsible for safety, safe use, and start of shift inspections.

PAGE: ____ OF ____2 6

CUSTOMER:__________________________________OZARK POWERHOUSE LOCATION/DESC:_____________________________Ozark Powerhouse

COMPONENT OK REPAIR REPLACE MONITOR COMMENTS

XBRIDGE CROSS CONDUCTORS

XCLEARANCES

XLOAD TEST

XDISCONNECT SWITCH

XBUMPERS

XCAPACITY MARKINGS

XMOUNTING BOLTS

SERIAL NUMBER:

HOIST - ELECTRIC WIRE ROPE

COMPONENT OK REPAIR REPLACE MONITOR COMMENTS

HOIST - ELEC WIRE ROPE

XLOWER BLOCK

XWIRE ROPE

XMOTOR

XMOTOR BRAKE

XGEARED LIMIT SWITCH

XBLOCK LIMIT SWITCH

XGEAR REDUCER -OIL IS LEAKING AT

VARIOUS SHAFT SEALS

ON SECONDARY DRUM

GEAR REDUCER. OIL

LEVEL IS EMPTY. AL

SEALS ON DRUM

REDUCER SHOULD BE

REPLACED AND NEW

OIL TO PROPER

LEVEL.

XSHAFTS

XROPE DRUM

XUPPER BLOCK

XCONTROL PANELS

XCLEARANCES

XCAPACITY AND WARNING SIGNS

BROADLINE CORP.MANUFACTURER:

75 TONHOIST CAPACITY:

480 VACHOIST POWER SUPPLY:

115 VACHOIST CONTROL:

VARIABLEHOIST SPEED:

#1 MAINOWNER ID NUMBER:

MAIN HOIST #1

SERIAL NUMBER:

HOIST - ELECTRIC WIRE ROPE

BROADLINE CORP.MANUFACTURER:

15 TONHOIST CAPACITY:

480 VACHOIST POWER SUPPLY:

115 VACHOIST CONTROL:

VARIABLEHOIST SPEED:

#1 AUX.OWNER ID NUMBER:

AUX. #1

Printed Date: November 11, 2015 03:56 PM

Visual inspection only. Customer is ultimately

PAGE: ____ OF ____3 6

CUSTOMER:__________________________________OZARK POWERHOUSE LOCATION/DESC:_____________________________Ozark Powerhouse

COMPONENT OK REPAIR REPLACE MONITOR COMMENTS

HOIST - ELEC WIRE ROPE

XLOWER BLOCK

XWIRE ROPE

XMOTOR

XMOTOR BRAKE

XGEARED LIMIT SWITCH

XBLOCK LIMIT SWITCH

XGEAR REDUCER -OIL IS LEAKING

FROM OIL SEAL

BETWEEN PRIMARY

REDUCER AND DRUM

REDUCER. OIL LEVEL

IN DRUM REDUCER IS

EMPTY. SHOULD

REPLACE ALL SEALS

ON DRUM REDUCER AND

ADD NEW OIL TO

PROPER LEVEL.

XSHAFTS

XROPE DRUM

XUPPER BLOCK

XCONTROL PANELS

XCLEARANCES

XCAPACITY AND WARNING SIGNS

SERIAL NUMBER:

HOIST - ELECTRIC WIRE ROPE

COMPONENT OK REPAIR REPLACE MONITOR COMMENTS

HOIST - ELEC WIRE ROPE

LOWER BLOCK X -MONITOR: CABLE ON

CABLE REEL HAS A

BULGE IN ONE AREA,

BUT THE IS NO

BROKEN INSULATION

OR SIGNS OF BROKEN

WIRES.

XWIRE ROPE -WHEN HOOK IS

LOWERED, THE WIRE

ROPE TWISTS AND

CAUSES WIRE ROPE TO

RUB AGAINST ITSELF.

RECOMMEND REMOVING

WIRE ROPE AND RE-

REEVING TO REMOVE

TWIST.

XMOTOR

BROADLINE CORP.MANUFACTURER:

75 TONHOIST CAPACITY:

480 VACHOIST POWER SUPPLY:

115 VACHOIST CONTROL:

VARIABLEHOIST SPEED:

#2 MAINOWNER ID NUMBER:

MAIN HOIST #2

Printed Date: November 11, 2015 03:56 PM

Visual inspection only. Customer is ultimately

PAGE: ____ OF ____4 6

CUSTOMER:__________________________________OZARK POWERHOUSE LOCATION/DESC:_____________________________Ozark Powerhouse

COMPONENT OK REPAIR REPLACE MONITOR COMMENTS

XMOTOR BRAKE

XGEARED LIMIT SWITCH

XBLOCK LIMIT SWITCH

XGEAR REDUCER

XSHAFTS

XROPE DRUM

XUPPER BLOCK

XCONTROL PANELS

XCLEARANCES

SERIAL NUMBER:

TROLLEY - ELECTRIC

COMPONENT OK REPAIR REPLACE MONITOR COMMENTS

TROLLEY - ELECTRIC

XMOTOR

XMOTOR BRAKE

XTRAVERSE REDUCER

XEND TRUCK

XWHEELS

XBUMPERS

XDROP LUGS / SWEEPS

XCONTROL PANELS

XEND STOPS

XCAPACITY AND WARNING SIGNS

XCLEARANCES -A MID RAIL SHOULD

BE ADDED TO

EXISTING RAIL ON

DOWNSTREAM SIDE OF

TROLLEY. 2"X2"X117

1/4" SQUARE TUBING.

90 TONTROLLEY CAPACITY:

BROADLINE CORP.MANUFACTURER:

115 VACTROLLEY CONTROL:

#1 MAINOWNER ID NUMBER:

VARIABLETROLLEY SPEED:

480 VACTROLLEY POWER SUPPLY:

#1 MAIN TROLLEY

SERIAL NUMBER:

TROLLEY - ELECTRIC

COMPONENT OK REPAIR REPLACE MONITOR COMMENTS

TROLLEY - ELECTRIC

XMOTOR

XMOTOR BRAKE

75 TONTROLLEY CAPACITY:

BROADLINE CORP.MANUFACTURER:

115 VACTROLLEY CONTROL:

#2 MAINOWNER ID NUMBER:

VARIABLETROLLEY SPEED:

480 VACTROLLEY POWER SUPPLY:

DOWNSTREAM MAIN TROLLEY #2

Printed Date: November 11, 2015 03:56 PM

Visual inspection only. Customer is ultimately

PAGE: ____ OF ____5 6

CUSTOMER:__________________________________OZARK POWERHOUSE LOCATION/DESC:_____________________________Ozark Powerhouse

COMPONENT OK REPAIR REPLACE MONITOR COMMENTS

XTRAVERSE REDUCER

XEND TRUCK

XWHEELS

XBUMPERS -UPSTREAM/LAND SIDE

BUMPER SPRING IS

BROKEN. SPRING

NEEDS TO BE

REPLACED.

XDROP LUGS / SWEEPS

XCONTROL PANELS

XEND STOPS

XCAPACITY AND WARNING SIGNS

XCLEARANCES

SERIAL NUMBER:

RUNWAY

COMPONENT OK REPAIR REPLACE MONITOR COMMENTS

RUNWAY - INSPECTION

XRAILS / BEAMS - WEAR

XSPLICE PLATES -SECOND AND SECOND

TO LAST SPLICE

PLATE FROM LAND

SIDE ON UPSTREAM

SIDE OF RUNWAY HAS

A LOOSE BOLT ON

EACH. ON DOWNSTREAM

SIDE OF RUNWAY,

THIRD SPLICE PLATE

FROM LAND SIDE, HAS

LOOSE BOLTS. ALL

LOOSE BOLTS SHOULD

BE TIGHTENED.

XJ-BOLTS / CLIPS / HANGERS -ON UPSTREAM SIDE,

THERE IS A LOOSE

RAIL CLAMP NUT NEXT

THE SECOND TO LAST

SPLICE PLATE FROM

LAND SIDE. ON

DOWNSTREAM SIDE

THERE ARE A FEW

LOOSE RAIL CLAMP

NUTS NEAR THIRD

SPLICE PLATE FROM

LAND SIDE.

XEND STOPS -THERE ARE NO END

STOP PLATES MOUNTED

TO WALL ON

RIVERSIDE OF RUNWAY

LIKE THERE IS ON

THE LAND SIDE. A

12"X12"X1" SHOULD

ASCE RAILBEAM TYPE:

135#BEAM SIZE:

DUCTOBAR DUAL 100ACOLLECTORS:

INSUL8POWER BAR:

NSA15-1019000038

Printed Date: November 11, 2015 03:56 PM

Visual inspection only. Customer is ultimately

PAGE: ____ OF ____6 6

CUSTOMER:__________________________________OZARK POWERHOUSE LOCATION/DESC:_____________________________Ozark Powerhouse

COMPONENT OK REPAIR REPLACE MONITOR COMMENTS

BE ANCHORED TO THE

WALL ON BOTH SIDES

OF RIVERSIDE.

XCONDUCTORS -ONE SPLICE CAP IS

BROKEN IN HALF

BETWEEN THE THIRD

AND FOURTH TURBINE.

NEEDS TO BE

REPLACED TO PREVENT

COLLECTOR SHOE FROM

COMING OUT OF

CONDUCTOR BAR

INSULATION GROOVE.

SERIAL NUMBER:

TOP RUNNING CRANE - CAB CONTROLLED

TR-DGTYPE:

MOTOR DRIVENDRIVE TYPE:

150/15 TONCAPACITY:

BROADLINE CORP.MANUFACTURER:

SERIAL NUMBER:

CAB

COMPONENT OK REPAIR REPLACE MONITOR COMMENTS

CAB - INSPECTION

XOPERATOR'S CAB

XCONTROLS

XLIGHTING

XFIRE EXTINGUISHER

XLADDERS

STARFLITE SYSTEMS INC.MANUFACTURER:

JOYSTICKCONTROL TYPE:

115 VACCONTROL VOLTAGE:

05-934

SERIAL NUMBER:

RADIO

COMPONENT OK REPAIR REPLACE MONITOR COMMENTS

RADIO - INSPECTION

XHOUSING

XRADIO CONTROL

XBUTTONS

MAGNETEKMANUFACTURER:

SLTXMODEL NUMBER:

175-01618ID NUMBER:

273507-TX1

Printed Date: November 11, 2015 03:56 PM

Visual inspection only. Customer is ultimately

Inspection Report of Turbine Bay Crane at Ozark Powerhouse 1 Rev 1

Specialists in hoists, cranes, and electrical service since 1913

1230 South Hannah Avenue

Forest Park, IL. 60130-2448

708-771-1600

FAX 708-771-3124

www.sievertelectric.com

CONTENTS

Inspection Report Summary

1.1 Project Information

1.2 Procedure

1.3 Results

1.3.1 Bridge

1.3.2 Main Hoist #1

1.3.3 Aux Hoist #1

1.3.4 Main Hoist #2

1.3.5 Trolley #1

1.3.6 Trolley #2

1.3.7 Runway

1.4 Conclusion

1.5 Closing

Appendix A: Pictures

Appendix B: Estimated Cost for the Repairs

Inspection Report of Turbine Bay Crane at Ozark Powerhouse 2

Specialists in hoists, cranes, and electrical service since 1913

1230 South Hannah Avenue

Forest Park, IL. 60130-2448

708-771-1600

FAX 708-771-3124

www.sievertelectric.com

INSPECTION REPORT SUMMARY

November 11, 2015

Contracting Division

USACE, Little Rock (W9127S)

700 W. Capitol Ave, RM 7315

Little Rock AR 72201-3225

Subject: Inspection Report for Turbine Bay Crane, Ozark Powerhouse, Russellville Project Office.

Sievert Job No.: 41728

Mr. David Glorit, In general accordance with our Contract No.: W9127S-15-P-0139 with the Contracting

Division of the United States Army Corps of Engineers (USACE), Sievert Crane and Hoist, a division of Sievert Electric, has completed engineering services associated with the Turbine

Bay Crane located at Ozark Powerhouse, 1204 Aux Arc Road Ozark, Arkansas 72949. This report describes our understanding of the project information; the service performed, and presents the findings along with our conclusions and recommendations.

1.1 Project Information

The crane is a double girder crane with a capacity of 150 Ton and has two hoist trolleys.

Figure 1, shows the layout of the crane and shows the terminology used to identify the directions used in this report.

Hoist Trolley #1 : Located at Upstream Side of the Crane

Main Hoist #1 : 75 Ton

Aux Hoist #1 : 15 Ton

Hoist Trolley #2 : Located at Downstream Side of the Crane

Main Hoist #2 : 75 Ton

Inspection Report of Turbine Bay Crane at Ozark Powerhouse 3

Specialists in hoists, cranes, and electrical service since 1913

1230 South Hannah Avenue

Forest Park, IL. 60130-2448

708-771-1600

FAX 708-771-3124

www.sievertelectric.com

Figure 1: Layout of the crane

1.2 Procedure

The project commenced with the assessment and preparation of Accident prevention plan and activity hazard analysis. Once complete the plans were submitted to the Contracting office and subsequently approved.

The inspection was performed from October 19, 2015 to October 22, 2015. The inspection generally consisted of performing visual observations and obtaining measurement of selected components of crane using Vernier Calliper. The observations included:

Inspection Report of Turbine Bay Crane at Ozark Powerhouse 4

Specialists in hoists, cranes, and electrical service since 1913

1230 South Hannah Avenue

Forest Park, IL. 60130-2448

708-771-1600

FAX 708-771-3124

www.sievertelectric.com

Visually scanning the accessible portion of each of the individual components and the associated connections in the structural framing.

Checking for metal shavings in the gear reducers using magnets.

Checking the general operations/functioning of the crane (bridge, hoists and trolleys).

Inspecting the rope for broken wires by spooling the wire rope

Measuring the diameter of the wire rope at various locations of the wire rope.

Measuring the tread width of the runway at various random locations.

1.3 Results

This section provides a general summary of the typical issues noted during the inspection.

Appendix A shows the photographic documentation of these issues.

1.3.1 Bridge

There is a crack in the weld between the trolley rail (for cross travel of the hoist trolley) and the Girder.

Figure 2: Location of the damaged weld on crane

One of the crane lights is unplugged intentionally; because the light falls directly on the operators eyes causing lack of visibility to the operator during operation.

All the 6 main collector inserts (100 Amp Ductobar) are worn and need to be replaced.

Inspection Report of Turbine Bay Crane at Ozark Powerhouse 5

Specialists in hoists, cranes, and electrical service since 1913

1230 South Hannah Avenue

Forest Park, IL. 60130-2448

708-771-1600

FAX 708-771-3124

www.sievertelectric.com

1.3.2 Main Hoist #1

Oil level in the Gear Reducer/ Gearbox was empty. There is oil leakage at various shaft seals on secondary drum gear reducer. The oil seals need to be replaced and the gear reducer needs to be filled with oil to proper level

1.3.3 Aux Hoist #1

Oil level in the Gear Reducer/ Gearbox was empty. There is oil leakage between the primary and the secondary gear reducer. Seals on drum gear reducer are worn and need to be replaced and the gear reducer needs to be filled with oil to proper level.

1.3.4 Main Hoist #2

Cable Reel: There is a bulge on the cable in the cable reel. There is no sign of broken insulation or wires. This needs to be monitored periodically.

Wire Rope: When the hook is lowered the wire rope rubs against itself, this is mainly due to the twist in the wire rope. We recommend removing the wire rope and performing re-reeving to remove the twist.

1.3.5 Trolley #1

There is an unsafe opening on the trolley on the downstream side; we recommend adding a mid-section guard rail to the existing hand rail to reduce the opening.

1.3.6 Trolley #2

The bumper spring (Upstream and Land side) on the trolley is broken and needs to be replaced.

1.3.7 Runway

Upstream Side Runway

There are loose bolts on splice plates at couple of locations. One of these splice plates is second from the land side and the other is second from riverside.

There is a loose rail clamp nut near second to last splice plate from land side.

Downstream Side Runway

There is a loose bolt connection on the third splice plate from the land side.

There are a few loose rail clamp nuts near third splice plate from land side.

Inspection Report of Turbine Bay Crane at Ozark Powerhouse 6

Specialists in hoists, cranes, and electrical service since 1913

1230 South Hannah Avenue

Forest Park, IL. 60130-2448

708-771-1600

FAX 708-771-3124

www.sievertelectric.com

All the loose connections must be tightened.

End Stops: There are no End Stop plates mounted on the wall on the riverside of the runway. A 12” x 12” x 1” plate should be anchored to the wall on both the runways at riverside.

Conductors: One of the slice caps located between the third and fourth turbine is broken in half and needs to be replaced to prevent collector shoe from coming out of the conductor bar insulation.

Paint flakes: Both the runways have chipped off paint flakes, but there is no wear of the runways.

1.4 Conclusion

The results of the inspection conducted by Sievert Crane and Hoist indicate that a major problem with the crane is the “rubbing of ropes” for Hoist #2 and we highly recommend removing the wire rope and performing “re-reeving” in order to remove the twist in the rope. The crane is functionally in good condition1, we advise to take into consideration the recommendations presented in this report, which will improve the life of the crane and safety for the crane operators.

Note 1: Visual inspection only, Customer is ultimately responsible for safety, safe use, and start of shift inspections

1.5 Closing

We appreciate the opportunity to Sievert Crane and Hoist for these services and would be glad to discuss any of the results contained in this report. If we can be of any further assistance, please do not hesitate to contact our office.

Sincerely, Scott Sievert

Project Manager

Sievert Crane and Hoist

1230 S Hannah Ave, Forest Park, IL. 60130

708-771-1600

Inspection Report of Turbine Bay Crane at Ozark Powerhouse 7

Specialists in hoists, cranes, and electrical service since 1913

1230 South Hannah Avenue

Forest Park, IL. 60130-2448

708-771-1600

FAX 708-771-3124

APPENDIX A: PICTURES

Picture 1: Damaged weld between the girder and rail

Picture 2: Unplugged Light under the bridge

Inspection Report of Turbine Bay Crane at Ozark Powerhouse 8

Specialists in hoists, cranes, and electrical service since 1913

1230 South Hannah Avenue

Forest Park, IL. 60130-2448

708-771-1600

Picture 3: Worn out collector inserts

Picture 4: Main Hoist #1 Oil Seals damaged and low oil level in the Secondary Gear Reducer

Inspection Report of Turbine Bay Crane at Ozark Powerhouse 9

Specialists in hoists, cranes, and electrical service since 1913

1230 South Hannah Avenue

Forest Park, IL. 60130-2448

708-771-1600

Picture 5: Aux Hoist #1, oil seals broken, oil need to be filled in the Secondary Gear Reducer

Picture 6: Main Hoist #2, Cable reel, Bulge on the cable

Inspection Report of Turbine Bay Crane at Ozark Powerhouse 10

Specialists in hoists, cranes, and electrical service since 1913

1230 South Hannah Avenue

Forest Park, IL. 60130-2448

708-771-1600

Picture 7: Main Hoist #2, Rope rubbing against each other at lower hook position

Inspection Report of Turbine Bay Crane at Ozark Powerhouse 11

Specialists in hoists, cranes, and electrical service since 1913

1230 South Hannah Avenue

Forest Park, IL. 60130-2448

708-771-1600

Picture 8: Trolley #1, recommended additional mid rail

Picture 9: Trolley #2, Location of broken bumper

Inspection Report of Turbine Bay Crane at Ozark Powerhouse 12

Specialists in hoists, cranes, and electrical service since 1913

1230 South Hannah Avenue

Forest Park, IL. 60130-2448

708-771-1600

Picture 10: Trolley #2, View of the broken bumper

Picture 11: Runway Upstream side, loose bolt connection on the splice plate

Inspection Report of Turbine Bay Crane at Ozark Powerhouse 13

Specialists in hoists, cranes, and electrical service since 1913

1230 South Hannah Avenue

Forest Park, IL. 60130-2448

708-771-1600

Picture 12: Runway, Recommended end stops on the riverside end

Picture 13: Broken conductor splice plate

Inspection Report of Turbine Bay Crane at Ozark Powerhouse 14

Specialists in hoists, cranes, and electrical service since 1913

1230 South Hannah Avenue

Forest Park, IL. 60130-2448

708-771-1600

Picture 14: Paint Flakes on the runway