3154_-_Revised_Section_C_-_Amendment_0001.pdf

The purpose of this amendment is to:

1. Revised Section C – Description and Specification

2. Include 52.212-5 in full text

3. Answer questions from offerors. Questions that may be of general interest of all

Bidders/Government will appear below. These questions may have been paraphrased or altered to represent several questions regarding the same subject and/or clarify and simplify the question(s). Questions and answers are issued to the Offerors for information purposes only.

All other terms and conditions shall remain unchanged.

Oferors must acknowledge receipt of this amendment by the date specified in the solicitation (or as amended). FAILURE TO ACKNOWLEDGE AMENDMENTS BY THE DATE AND TIME

SPECIFIED MAY RESULT IN REJECTION OF YOUR QUOTE.

Section C – Descriptions and Specifications

SCOPE OF WORK

C000 GENERAL

C001 PROJECT DESCRIPTION

The Marine Design Center (MDC) of the U.S. Army Corps of Engineers (USACE) has issued this solicitation, for the procurement, installation support, testing support, and commissioning of two (2) new swing winches for the Dredge GOETZ. The U.S. Army Corps of Engineers, Saint

Paul District, operates the Dredge Goetz in the northern sections of the Mississippi River.

The Contractor is not responsible for installing the winches on the Dredge. The Government will furnish all labor, material, tools, and test equipment to install the swing winches on the dredge and perform testing.

The Contractor shall have a representative present onsite to perform commissioning, and to provide oversight and guidance to the Government during the installation and testing. Bidders shall assume that installation and testing will be performed at Fountain City Service Base, Fountain City, Wisconsin. Any change in cost associated with a change in location will be modified after award.

The Contractor shall also provide the services of Avid Controls, Inc. to travel to the Dredge

Goetz to perform reprogramming and commissioning of the existing Variable Frequency Drives

(VFDs), to ensure that the VFDs are configured for operation with the new winches.

C002 OPERATIONAL BACKGROUND

The Dredge GOETZ is a hydraulic cutter suction dredge with a 22 inch suction and 20 inch discharge pipe. The dredge is 225 feet long by 39 feet wide with an operating draft of 5 feet.

The dredge is powered using diesel-electric generator engines that produce a total of 4,000 horsepower at 1,200 rpm. Each generator is capable of producing 1,300 KVA at an 80% continuous duty cycle.

The Dredge GOETZ currently has swing winches installed on the port and starboard sides. The winch motors are controlled by individual VFDs, manufactured by Alstom. The two winches are employed to swing the dredge back and forth across the river, allowing the cutterhead and main dredge pump suction to break up and clear away material from the river bottom. While in operation one winch is hauling and the opposite is paying out cable under variable hold-back tension, with both cables being connected to external anchors. The paying-out cable is kept taut by dynamic braking through the winch gearing and VFD programming, preventing a slack cable situation.

An operator controls the winches through console-mounted joystick controls which provide the means to regulate the speed at which the dredge swings back and forth and the degree of hold-back tension on the winch that is paying out. Once the dredge completes a swing from one side of the river to the other the swing process is reversed. The operator has the discretion to independently operate either the port and/or the starboard winch for other specific tasks. The dredge operates 24 hours per day 7 days per week for approximately 6 to 8 months out of the year. During a 24 hour period, the swing winches typically log between 16 and 20 hours of running time. The remainder of the period the dredge is not swinging. Swing rates vary depending on the amount and hardness of the material being dredged. In hard material with a digging depth of several feet the winch line speed may be as low as 5 feet per minute at the maximum torque available from the drive. In light material with shallow cuts the winch line speed will range up to 80 feet per minute.

C003 DESIGN STANDARDS

The winches, controls, and associated materials and equipment shall be designed and constructed in accordance with the latest edition and interpretations of the rules, regulations, requirements and standards of the Legislation, Regulatory Agencies and technical organizations listed below.

The Contractor is required to incorporate requirements included in any revisions to the rules and regulations listed below as well as those stipulated in the respective specification clauses.

U.S. Army Corps of Engineers, Publication No. EM 385-1-1; “Safety and Health

Requirements Manual.” May be viewed at internet web site:

http://publications.usace.army.mil/publications/eng-manuals/EM_385-1-

1_languages/EM_385-1-1_English_2008/toc.html

American Bureau of Shipping (ABS) "Rules for Building and Classing Steel

Vessels for Service on Rivers and Intracoastal Waterways."

U.S. Coast Guard Regulation 46 CFR, Subchapter S – “Subdivision and

Stability”.

American Society of Mechanical Engineers (ASME) “Base-Mounted Drum

Hoists”, ASME B30.7-2011

Institute of Electrical and Electronic Engineers Standards, Publication No. IEEE-

45 “Recommended Practice for Electrical Installations on Shipboard”

National Electrical Code (NEC) http://publications.usace.army.mil/publications/eng-manuals/EM_385-1-1_languages/EM_385-1-1_English_2008/toc.html http://publications.usace.army.mil/publications/eng-manuals/EM_385-1-1_languages/EM_385-1-1_English_2008/toc.html

C004 PRE-PREPOSAL INSPECTION

Pre-proposal inspections may be held to allow all prospective Offerors to inspect the vessel, existing winches, motors, and VFDs prior to submission of a proposal. Inspections shall be at the

Offeror’s expense and can be scheduled for any weekday, excluding Federal holidays, between the hours of 7 AM and 3:30 PM. Representatives of prospective Offerors interested in attending should contact Jake Bernhardt at (651) 249-6068 to make an appointment.

During the pre-proposal inspections, representatives of the Government will be available, but only to the extent necessary to escort Offerors and assist with access. Government

Representatives on the vessel will not discuss the scope of the work or make any technical clarifications or interpretations.

After each inspection, a meeting will be held with all participants to allow for the presentation of any questions. This meeting is not for the purpose of educating Offerors that have not carefully reviewed the plans and specifications and have come unprepared. Questions will not be answered at that time, but will be acknowledged and recorded. The Government will prepare answers to all questions and forward a copy of both the questions and answers to all prospective

Offerors through form Solicitation Amendment.

C006 SCOPE OF WORK

The Contractor assumes complete responsibility for providing the new swing winches, performing commissioning, and providing oversight and guidance to the Government during installation and testing in accordance with the requirements of the contract. Should the

Contractor determine at any time that he is unable to fulfill those responsibilities, he shall notify the COR immediately of the problem experienced and his proposed manner of correction.

The Contractor is also responsible for reprogramming and commissioning of the existing

Variable Frequency Drives (VFDs), to ensure that the VFDs are configured for operation with the new winches, as previously mentioned in Section C001.

The Contractor is not responsible for performing installation or testing work for the winches. The

Government will install the winches on the dredge and perform testing. The Contractor shall have a representative on site during installation and for testing of the winches.

C010 DEFINITIONS

The following definitions are applicable to phrases and acronyms used throughout this contract:

COR - Contracting Officer’s Representative - a member of the contract management and quality assurance team authorized by the Contracting Officer to perform certain administrative and managerial duties. A copy of the COR’s authority letter is furnished to the Contractor.

K.O. - Contracting Officer - A person with the authority to enter into, administer and/or terminate contracts and make related determinations and findings.

MDC – Acronym for the Marine Design Center.

QC - Quality Control - Quality Control is a function of the Contractor. Quality

Assurance (QA) is a function of the Government.

USACE – Acronym for United States Army Corps of Engineers.

VFD – Variable Frequency Drive

C025 CONTRACTOR QUALITY STANDARDS

The Contractor shall utilize the specified components so as to meet specification requirements utilizing construction and testing methods to ensure that the completed winches conform to the intended design.

Inspection by the Government is for the purpose of verifying the proper function of the

Contractor’s quality control measures and is not to be used as a substitute for control of quality by the Contractor.

A. STANDARD PARTS & MATERIALS

All articles, fittings, equipment, machinery, supplies, and materials used in the construction and outfitting of the winches shall be the highest grade, free from defects and imperfections, unused and, be the standard product of reputable manufacturers, to the maximum extent practicable.

Any material not specified shall be the best of their kind for the purpose intended.

Materials specified herein to meet the requirements of standard specifications published by national authorities shall conform to the respective editions, including amendments, specified.

No salvage materials shall be used in the work.

B. CONSTRUCTION STANDARDS

All material, machinery and equipment shall be new, of current manufacture and suitable for the marine service intended. Spare parts and service shall be readily obtainable.

All material, unless otherwise specified in these specifications or in the drawings, shall be of commercial quality to ASTM, ANSI, or SAE specifications.

All materials shall be free of imperfections due to manufacturing processes and from defects which adversely affect appearance or serviceability.

All sharp edges or projections which constitute a personnel hazard shall be removed or ground smooth. All notches shall have a radius to prevent stress concentrations.

C400 OUTFIT

C456 SWING WINCHES

A. EXISTING SWING WINCHES

The existing winches are IHC winches with the following specifications. Note that English units are provided in parenthesis.

Type: KA-15-E-TR

Power: 74 kW (100 hp)

Line Pull (1st Layer): 14.5 MT (31,970 lbs) / 24 MT (52,910 lbs)

Line Speed (1st Layer): 24 meter/min (79 ft/min) / 16 meter/min (52.5 ft/min)

Speed: 1800 rpm

Voltage: 3 phase 480 V

Frequency: 60 Hz

Drum Capacity: 366 meters (1200 ft) of 32 mm (1.25 inch) diameter wire rope over 6 layers

B. GENERAL

The Contractor shall furnish two (2) new swing winches in accordance with the technical requirements detailed in this section.

Each winch shall be capable of developing first layer line pull of 35,000 pounds with a line speed of 80 feet per minute. The line pull shall increase to a minimum 60,000 pounds with a line speed of 50 feet per minute.

Each winch shall be supplied with a foundation that supports the winch assembly and provides points for mounting the assembly via bolts to the structural members of the dredge. Reference

Drawing Goetz Winch Foundations has been provided to show the existing foundations on the

Goetz. For reference, the distance from the center of the existing winch drum to the fleeting sheave is 27 inches. The winches shall be sized so that they do not exceed the following dimensions by greater than 1.5 feet in any direction when fully assembled on the foundation:

Width………………….8.5 feet

Length…………………8.0 feet

Height…………………5.5 feet

Each winch shall be designed for a continuous duty rating based on design, materials, and construction techniques. All bearings in the assemblies, to include the bearings in the gear reducer, shall have a minimum B10 bearing life of 40,000 hours.

The recommended lubricant and lubricating method shall be suitable for this range of speed and torque.

C. WINCH DRUMS

Each swing winch drum shall be designed with grooves suitable for 1200 feet of 1-1/4 inch diameter Independent Wire Rope Core (IWRC), Extra Improved Plow Steel (EIPS) steel wire rope. The lay of the wire shall be right hand lay. The Contractor is not responsible for providing wire rope for the winch drums.

D. WINCH BRAKES

Each winch shall be furnished with a dynamic brake and a holding brake. At least one brake shall be located on the winch drum, and the brakes shall be separate systems with the following rated capacities and specifications.

The holding brake capacities shall be greater than or equal to 125% of the highest rated line pull of the winches. The holding brake shall not be designed to be used as a dynamic brake. The winch drum holding brake shall be spring applied, and either electromagnetically or pneumatically released.

The holding brake shall automatically set when:

There is any failure in the electrical system powering the winch and

The control lever is in the center position. Unless moved by the operator, the winch control handles shall always be in the center position.

The dynamic braking torque capacity shall be greater than or equal to 100% of the torque at full

HP and rated line speed. Dynamic brake thermal capacity shall not be less than 15 minutes.

The winch drum brake shall have “anti-backlash” or “anti-slack” provisions. These provisions at a minimum shall stop the drum within 1 turn if a wire rope loop exits the area between the drum flanges.

E. GEAR REDUCERS

The Contractor shall provide documentation that shows that the gear reducers for the swing winches are be rated in accordance with AGMA standards. The gears shall be planetary gears or parallel shaft arrangements. The gear reducers shall have a minimum service factor (KSF) of 1.5.

The gear reducers shall be designed with consideration to carburized hardened gearing, or other hardening methods in order to combat the effects of shock loading and to provide better wear properties at slower speeds. The gear reducers shall be capable of enduring the high speed vibration of a VFD that is adjusting speed and torque many times per second. The gear reducers shall be capable of operating under these conditions without damage to gear teeth. Each gear reducer shall be separable from the rest of the winch assembly without removal of the winch drum.

The gear reducers shall be a standard product of a gear reducer manufacturer. All gear reducers shall be from the same manufacturer.

F. ELECTRIC DRIVE MOTORS

1. GENERAL REQUIREMENTS

The swing winches shall be powered electrically with 480 VAC 3-phase motors. The motors shall be Totally Enclosed, Fan-Cooled (TEFC) Inverter Duty electric motors. The motors shall be able to operate with the existing VFDs, which are rated at 100 horsepower each. The VFDs are manufactured by Alstom, Model Number

MV3302A5A1. The port swing winch VFD has a serial number 2265155, and the starboard swing winch VFD has a serial number 2265152.

The Government will perform all work required in order to connect the new winches and their components to the existing electrical system. The Contractor shall be present during installation and connection of electrical components.

2. ELECTRICAL REQUIREMENTS

Both winches shall be in accordance with applicable ABS, IEEE, NEMA, ANSI, and

NEC standards and codes. All electrical equipment furnished shall bear the approval of the Underwriters Laboratories or other recognized independent laboratory, where applicable.

All new electrical equipment shall be provided with at least the minimum degree of protection specified by ABS "Rules for Building and Classing Steel Vessels for Service on Rivers and Intracoastal Waterways."

Electrical equipment and machinery shall have suitable barriers or screens wherever required to protect personnel from contacting energized, moving or rotating parts.

All controllers and equipment indicators shall be installed in weather tight enclosures, unless otherwise required in the specification.

All winch components shall be treated to provide protection against corrosion, moisture, mold, and other destructive agents to which the equipment may be exposed.

The conductivity of connections shall not be less than the conductivity of the connected cable. All bolts, screws, nuts, and washers shall be made of corrosion-resistant metal of adequate size for their functions. Lock washers or equivalent shall be used to prevent loosening of bolted connections throughout the electrical system.

3. MOTORS AND CONTROLLERS

The Contractor shall furnish and install an AC electric motor for each winch. Each motor shall be drip-proof protected. Each motor shall be NEMA type, and shall be sized and designed for continuous operation of the winch at rated capacity.

Each motor shall be designed for a minimum ambient temperature of 50 degrees C.

Each motor shall be equipped with anti-friction bearings. All grease-lubricated bearings shall be provided with grease fittings and shall have positive means for preventing grease from being forced out upon the motor windings.

Each motors shall be designed for operation with the existing VFDs.

In addition to the requirements above, the motors shall be suitable for operation of the winches as identified in contract Clause C456. For additional requirements on winches, see contract Clause C456.

G. EMERGENCY SHUTDOWN DEVICES

The winches shall be equipped with emergency shutdown devices. The emergency shutdowns shall be located on each winch in an easily noticeable and accessible location. The switches shall be suitable for marine outdoor use.

H. DOCUMENTATION

The Contractor shall provide two (2) hard copies and one (1) digital copy of the owner’s manual and the parts manual for the winches.

I. WARRANTY

The Contractor shall provide a minimum of a two year warranty from the date of delivery. The warranty shall cover all components of the delivered systems, to include mechanical, structural, and vendor-supplied electrical and pneumatic components. The warranty shall also cover parts, labor, and transportation costs.

C800 TESTING, COMMISSIONING, AND ONSITE SUPPORT

A. GENERAL

The Contractor shall perform tests on the winches and associated equipment. The tests shall be performed as necessary to demonstrate satisfactory compliance with the Contract requirements.

The testing shall consist of two (2) levels of testing to include Factory Acceptance Testing (FAT) and Onsite Testing. The Contractor’s responsibility for each level of testing is defined in the paragraphs below.

B. FACTORY ACCEPTANCE TESTING

The Contractor shall perform factory acceptance testing at the manufacturer’s facility. The

Contractor shall develop a FAT testing plan and submit it to the COR for review sixty (60) days prior to the scheduled testing date. The testing shall include the following, at a minimum:

Demonstrate the operation of each swing winch in forward, reverse and stop.

Perform pull tests to demonstrate rated load capability for each winch.

Demonstrate that each winch will operate at the rated speeds.

Demonstrate the operation of all controls for each winch.

Demonstrate the operation of all brakes for each winch.

Perform pull tests to demonstrate rated load capabilities for all brakes.

Demonstrate that all brakes will operate at their rated loads.

Demonstrate the operation of all brake switches for each winch.

The COR shall have the option of witnessing the testing. The COR shall be notified at least 10 working days prior to the scheduled test date.

Factory acceptance testing is not to be used as a substitute for control of quality by the

Contractor. Upon successful completion of factory acceptance testing, the Contractor shall package the winches and deliver them to the Government as specified in Section F of this solicitation.

C. INSTALLATION OVERSIGHT AND COMMISSIONING

Bidders shall assume that installation and testing will be performed at Fountain City Service

Base, Fountain City, Wisconsin during a single shipyard repair period. Any change in cost associated with a change in location will be modified after award.

The Contractor shall have a representative present onsite to provide oversight and guidance to the Government during the installation of the winches. Additionally, the Contractor shall perform commissioning of the winches after the Government has correctly installed the winches on their foundations and completed all cable terminations. The Government will furnish all labor, material, tools, and equipment to perform the installation.

For bidding purposes, the Contractor shall assume that they will send a representative to the

GOETZ for two (2) separate trips for installation oversight and commissioning. Each trip is assumed to include five (5) days onsite (excluding travel time). Bidders shall assume that the

GOETZ will be located at Fountain City Service Base, Fountain City, Wisconsin. Any change in cost associated with a change in location will be modified after award.

The Contractor shall also provide the services of Avid Controls, Inc. to travel to the Dredge

Goetz to perform reprogramming and commissioning of the existing Variable Frequency Drives

(VFDs), to ensure that the VFDs are configured for operation with the new winches. The Point of Contact for the VFD manufacturer is Mr. Kevin Williams, who can be reached by phone or email at: (281)-640-8600 or KRW@avidcontrolsinc.com.

For bidding purposes, the Contractor shall assume that Avid Controls, Inc. will require one trip for five (5) days onsite (excluding travel time) for the purpose of commissioning the winch drives.

D. ONSITE TESTING

Following completion of the winch and drive commissioning, the Government will perform testing of both swing winches to ensure proper operations. The Contractor shall send a representative to the GOETZ to provide technical support with testing. Bidders shall assume that the GOETZ will be located at Fountain City Service Base, Fountain City, Wisconsin. Any change in cost associated with a change in location will be modified after award. The testing will include the following, at a minimum:

Demonstrate the operation of each swing winch in forward, reverse and stop.

Demonstrate the operation of each winch in dredging operations, including having one winch pay in while the other winch pays out.

Demonstrate that each winch will operate at the rated speed.

mailto:KRW@avidcontrolsinc.com

Demonstrate the operation of the controls for each winch from all control stations and locally at each winch.

Demonstrate the operation of the brakes for each winch.

Perform pull tests to demonstrate rated load capability for the brakes.

Demonstrate that the brakes will operate at their rated loads.

Demonstrate the operation of the brake switches and operation from the control panel and locally at the winch.

The Contractor shall provide onsite support for testing on each swing winch in order to demonstrate satisfactory compliance with the specification requirement. The Government will furnish all labor, material, tools, and test equipment to perform the testing.

RFI Responses

Question 1. Does reducer have to be a planetary or can it be a parallel shaft arrangement? Using a planetary will make the unit much wider and if an in-drum is used then the drum must be removed with the planetary so it does not meet the drum-in-place criteria for replacement.

Response 1. In response to this question, Paragraph E of Section C456 has been revised.

Question 2. Can the drum size be increased if desired or will it adversely affect the rope access window?

Question 3. Are there height, width and offlead issues with drum size. What is the distance to the first sheave to determine proper spooling/offlead.

Response 2 and Response 3. In response to these questions, Paragraph B of Section C456 has been revised.

Question 4. Does the Factory Acceptance Test need to include full load and full load with speed?

If so, how long does it have to operate at speed?

Response 4. Factory Acceptance Tests shall be at both loads with their rated speeds. Testing shall be long enough to ensure operability of the winch at required loads without overheating.

Question 5. Performance implies a 1.6: 1 speed increase at constant HP. This indicates that with an 1800 rpm motor the maximum speed will be 2900 rpm. May be too fast for a planetary reducer. Recommend using a 1200 rpm base speed motor for lower high-end speed of 1920 rpm.

Response 5. The solicitation does not specify motor RPM speeds, and the requirements for the winches is for a line pull of 35,000 lbs at max speed of 80 fpm, and for a max line pull of 60,000 lbs at a min speed of 50 fpm.

Question 6. Do winches need to meet ‘Buy American’ or have a minimum USA content requirement?

Response 6. Yes they do. Please see FAR 25.101(a)(2)

Question 7. Are winches over or underwound?

Response 7. The winches are overwound.

Question 8. Are band and electric brakes acceptable?

Response 8. Either band or electric brakes are acceptable per solicitation Section C456 Paragraph

D.

Question 9. Can you provide any additional details or specifications of the existing electric motors?

Response 9. All information on the motors is included in Section C456 Paragraph A.

Question 10. Does the existing motor have an encoder? Does the new motor require an encoder?

Can the existing VFD accommodate an encoder?

Response 10. The existing motor has an encoder, and will be required for the new motor.

Question 11. Can the “winch drum holding brake” be on the gearbox input, or does it need to be physically mounted on the “winch drum?”

Response 11. In response to these questions, Paragraph D of Section C456 has been revised.

Question 12. What is a “wire rope loop” mentioned in the anti-slack device section?

Response 12. MDC provides clarification that a “wire rope loop” is when the wire becomes loose from the drum and causes issues with the operation of the winch.

Question 13. Will we need to procure and program a 100HP VFD for FAT testing at our facility, or will the Avid Controls MV3302A5A1 VFD be shipped here?

Response 13. MDC provides clarification that the existing VFDs will not be shipped to manufacturer’s facility. If required, the Government can provide a CD with the VFD programing.

Question 14. Will an Avid Controls representative need to be present at PDI for FAT testing?

Response 14. MDC provides clarification that an Avid Controls representative is not required to be present during FAT testing.

(End of amendment)