REVISED Attachment 2 - Inspection and Testing 3451 Hayward.pdf

E01 INSPECTION

The Contract will be managed by the Marine Design Center (MDC) of the U.S. Army Corps of Engineers (USACE) and is subject to inspection by its appointed representatives to ensure strict compliance with the terms of the contract.

No Government Representative, except the Contracting Officer, is authorized to change any provision of the specifications, nor shall the presence or absence of a Government Representative relieve the Contractor from any requirements of the contract.

The Contractor shall provide “Safe for Workers” labels in accordance with the OSHA regulations stated in 29 CFR 1915.11-12 for all confined and enclosed spaces prior to permitting entrance for work or inspection. This procedure shall be reflected in the Contractor’s Safety Plan. See Section C028.

Entry shall not be permitted to any confined or enclosed space that does not have a current “Safe for Workers” label.

E02 DETAILED INSPECTIONS AND CONDITION REPORTS

Many items in the technical specifications call for a detailed inspection and a written report to be submitted to the Contracting Officer Representative. Each item will specify which areas are to be inspected. Every report shall include, but is not limited to, what was inspected, condition of item inspected, and recommendation of repairs and/or replacement. All costs incurred for these services shall be reflected in each bid item.

Unless otherwise specified herein, the items that require inspection by the Contractor with written report to be furnished to the Contracting Officer Representative must be completed within fourteen (14) days after vessel enters shipyard or within fourteen (14) days after drydocking if an underwater item. The Contractor shall furnish the written reports for these items within 48 hours after each inspection.

E03 NOT USED

E04 NOT USED

E05 TRIALS, TESTS, AND DEMONSTRATIONS

A. GENERAL REQUIREMENTS

1. LEVELS OF TESTING

The Contractor shall perform tests on all equipment, machinery, and systems, individually and integrated as a whole.

The tests shall be performed as necessary to demonstrate satisfactory compliance with the specification requirements contained in Section C of this Contract.

The following five levels of inspection and testing shall be performed for this contract:

LEVEL 1 PRE-TRIAL TESTS

LEVEL 2 PRELIMINARY DOCK TRIALS

LEVEL 3 DOCK TRIALS & CRANE TESTS

LEVEL 4 OPEN WATER TRIALS

LEVEL 5 FINAL ACCEPTANCE DEMONSTRATIONS

All demonstrations, tests, and trials shall be performed as specified herein and in Section C of this contract. The Contractor shall furnish all labor, materials, tools, and test equipment as necessary and perform the testing, trials, and demonstrations specified.

2. CONSUMABLES AND OPERATING FLUIDS

The Contractor shall furnish all fuel oil, lubricating oil, hydraulic oil, engine coolant, refrigerant, glycol/water mixture, treatment chemicals, degreasing agents, gases, potable water, and any other consumables required to perform the tests and demonstrations, and as required in Contract Section C.

3. GFE TESTING AND COMMISSIONING

The Government will provide the services of the GFE manufacturer for testing and commissioning of all GFE. These services will extend through all levels of testing. The GFE manufacturer will operate the GFE during the individual testing of the GFE systems as well as during the shipyards performance of the vessel testing.

The Contractor shall support GFE testing and commissioning. It is the responsibility of the Contractor to coordinate with the Government to develop a test agenda and test memoranda for these tests, record all applicable data, and provide materials and labor in accordance with these specifications in order to document performance of each system.

B. TEST AGENDA AND TEST MEMORANDA

The Contractor shall prepare an Agenda and Test Memoranda of the required tests and trials for the vessel in accordance with the requirements set forth herein. Two copies of the Agenda and Test Memoranda shall be submitted to the COR for review and approval. These documents shall be submitted sixty (60) days prior to testing.

1. TEST AGENDA

For the vessel, the Contractor shall prepare a Test Agenda for LEVEL 3 DOCK TRIALS & CRANE TESTS and the LEVEL 4 OPEN WATER TRIALS. The Test Agenda shall be a complete, detailed schedule of all tests, trials and demonstrations specified in this clause. The Test Agenda shall be arranged by day, not date, and shall list the specific tests, trials, and demonstrations, and the sequence in which these will be performed.

The Test Agenda shall specifically identify all tests which require GFE manufacturer support. The Government will provide GFE manufacturer’s representatives for these tests.

2. TEST MEMORANDA

For the vessel, the Contractor shall prepare Test Memoranda for all systems and equipment tested under the LEVELS 1, 2, 3, 4, and 5 test and trial requirements of this clause.

The test memoranda shall describe the actual test procedures and data to be taken. The procedures shall be in accordance with the “start-up” procedures for the equipment, as delineated in the operating manuals furnished for the equipment by the manufacturer. The Contractor shall incorporate demonstrations of all applicable controls, instruments, and alarms into each system’s PRELIMINARY DOCK TRIALS, DOCK TRIALS & CRANE TESTS, OPEN WATER TRIALS, and FINAL ACCEPTANCE DEMONSTRATIONS sections of the Test Memoranda. Data recorded in time intervals shall be tabular so that data trends can be easily recognized.

Each test memorandum shall:

List the major equipment Include a space for nameplate data, make, model and serial number of equipment, etc.

List the characteristics of equipment (i.e. impeller size, motor horsepower, flow capacity, cfm, etc.)

Reference the manufacturer’s manual(s) used to format the test procedure Describe instrumentation for each test Describe the test procedure List the Pass/Fail limits List the expected results Include a space for the actual results Include a space for the ambient conditions Include signature blocks for Contractor Representative, Government Representative, and GFE Manufacturer

Representative (where appropriate) witness signatures, times, and dates Include a space for writing comments

The Test Memoranda shall be typed on 8-1/2 inch by 11-inch sheets of paper, single side, in three-ring notebook, with dividers for each section. Each page shall include the contract number at the top, along with the Marine Design Center project number (#3451) and hull number (#574).

The memoranda shall be arranged by system and equipment, with each level of testing for a specific system or piece of equipment recorded under the respective heading.

The Test Memoranda shall be arranged by system and level of testing similar to the following outline:

X. System (or equipment)

a. PRE-TRIAL TEST

b. PRELIMINARY DOCK TRIALS

c. DOCK TRIALS & CRANE TESTS

d. OPEN WATER TRIALS (IF APPLICABLE)

e. FINAL ACCEPTANCE DEMONSTRATIONS

3. TEST REPORTS

Completion of system or vessel testing shall be reported to the COR in the following manner:

Within two (2) days of the completion of any tests, a copy of the memorandum for that specific test shall be available for review at the request of the COR.

Upon completion of any level of testing, the COR shall be notified that the specific level of testing has been completed. At their discretion, the COR may request to review the test memoranda for that level of testing.

With completion of subsequent levels of testing, all test memoranda shall be filled-in, and placed in the Test Report. Results of all vendors’ tests shall be filled with the applicable test section. The Test Report, with all prior test results, must be current at all times, and shall be available for review at the request of the COR at any time.

The Test Report shall be reviewed and approved by both the Contractor and the COR at the conclusion of each level of testing. Review and approval of the Test Report by the Contractor and the COR is a precondition of moving to the next level of testing.

Within ten (10) calendar days following the successful completion of Final Acceptance Demonstrations (Level 5), the Contractor shall submit the Final Acceptance Demonstrations report to the COR for review.

The final version of the Test Report, including results of the previous four levels of the tests and trials, shall be bound in three ring binders. Two (2) copies shall be submitted within thirty (30) calendar days following successful completion of the Level 5 demonstrations prior to Final Payment. A scanned version of the final Test Report shall be provided to the Government. The electronic version of the Test Report shall be in .pdf file format.

4. DEFICIENCIES

The COR will compile a list of deficiencies which will be given to the Contractor. All deficiencies shall be corrected by the Contractor. Final Acceptance of the vessel will be made following remedy of all deficiencies.

The successful completion of all tests, trials, demonstrations, and remedied deficiencies shall be determined by the

COR.

C. PRE-TRIAL TESTING (LEVEL 1)

1. CRANE

The Contractor shall perform the following pre-operational tests for the crane with technical support and guidance provided by the manufacturer:

a. Pedestal Verification

After installation of the pedestal adapter and pedestal, Techcrane will provide technical support and guidance to the Contractor to ensure that the installation and assembly of the pedestal adapter and pedestal has been executed properly and according to Techcrane’s approved procedures and practices.

The installation dimensions shall be verified and recorded. The Contractor shall coordinate a sign off by the crane manufacturer and the Government to validate that the pedestal adapter and pedestal installation is acceptable and ready for the installation of the crane.

b. Principal Dimensions

After installation and assembly of the crane on the HAYWARD, Techcrane will provide technical support and guidance to the Contractor to verify that the installed crane complies with the following principal characteristics:

CRANE HEIGHT The height of the highest part of the crane in the stowed configuration measured above the main deck level.

CRANE TAIL SWING The tail swing of the crane measured from the center of rotation of the crane.

RETRACTED BOOM LENGTH From the heel pins to the center of the main hoist sheaves, the length shall be 35 feet.

EXTENDED BOOM LENGTH From the heel pins to the center of the main hoist sheaves, the length shall be 85 feet.

BOOM ALIGNMENT Verify that the boom is in alignment with itself and the rest of the crane.

RADIUS REACH Calibration of the radius reach indicator and measurement of the minimum radius reach for the main hoist.

DECK CLEARANCE HEIGHT Measure the height between the main deck and the lowest rotating part of the crane.

The above characteristics shall be verified and recorded, and the Contractor shall coordinate a sign off by the crane manufacturer and the COR.

c. Hydraulic Oil System

Air test the clean hydraulic piping at 1-1/2 times the system design pressure for a duration of no less than 10 minutes per test. Spray liquid dish detergent water solution on all system welds and joint connections and check for leaks.

Flush the system with hydraulic oil for a period of 30 minutes, at a flow rate which will provide a Reynolds number of at least 4000 (turbulent flow) in the circuit being flushed. Bypass all equipment furnished by the crane manufacturer with a jumper line.

d. Electrical Cabling

The cabling shall be tested, taking insulation resistance readings of all installed power and lighting cable, using a 500 volt resistance meter, (in accordance with IEEE Standard 45, Section 46). The measured cable insulation resistance must meet or exceed the minimum values outlined in the referenced IEEE publication.

e. Proof Load Criteria, Test Weight, and Rigging

In order to proof load the crane and demonstrate adequate crane performance, the Contractor shall provide at their own expense the following certified test weights:

40,000 lbs. – main hoist maximum capacity test load 6,000 lbs. – auxiliary hoist maximum capacity test load

Note: The weights listed above represent the total weight to be used during the testing, including the blocks, rigging and test weight. The weights of all blocks, rigging and test weight shall be certified to the satisfaction of the COR, the crane manufacturer, and ABS prior to performing the required test maneuvers. Test Weights must have been certified within 6 months for metal test weights and within 2 weeks for concrete test weights. If water bags are used, the flow meter shall be certified within 6 months.

The rigging for the test weights shall be provided by the Contractor, and shall be acceptable to the crane manufacturer and to the COR. The rigging shall be designed by the Contractor and submitted to the Marine Design Center for review and approval at least 30 days prior to the start of testing.

The Contractor shall develop a plan for load test rigging and weights, including details of the type and dimensions of rigging and weights. The riggings and weights shall be adequate to perform all the required crane test procedures.

This plan shall be submitted to the COR for review and approval.

2. RESCUE BOAT DAVIT CRANE

The Contractor shall perform the following pre-operational tests for the rescue boat davit crane with technical support and guidance provided by the manufacturer.

a. Hydraulic Oil System

Air test the clean hydraulic piping at 1-1/2 times the system design pressure for a duration of no less than 10 minutes per test. Spray liquid dish detergent water solution on all system welds and joint connections and check for leaks.

Flush the system with hydraulic oil for a period of 30 minutes, at a flow rate which will provide a Reynolds number of at least 4000 (turbulent flow) in the circuit being flushed. Bypass all equipment with a jumper line furnished by the crane contractor.

b. Electrical Cabling

The cabling shall be tested, taking insulation resistance readings of all installed power and lighting cable, using a 500 volt resistance meter, (in accordance with IEEE Standard 45, Section 46). The measured cable insulation resistance must meet or exceed the minimum values outlined in the referenced IEEE publication.

c. Proof Load Criteria, Test Weight, and Rigging

In order to proof load the crane and demonstrate adequate crane performance, the Contractor shall provide at their own expense the following certified test weights:

2,200 lbs. – hoist maximum capacity test load

Note: The weights listed above represent the total weight to be used during the testing, including the blocks, rigging and test weight. The weights of all blocks, rigging and test weight shall be certified to the satisfaction of the COR, the crane manufacturer, and ABS prior to performing the required test maneuvers. Test Weights must have been certified within 6 months for metal test weights and within 2 weeks for concrete test weights. If water bags are used, the flow meter shall be certified within 6 months.

The rigging for the test weights shall be provided by the Contractor, and shall be acceptable to the crane manufacturer and to the COR. The rigging shall be designed by the Contractor and submitted to the Marine Design Center for review and approval at least 30 days prior to the start of testing.

The Contractor shall develop a plan for load test rigging and weights, including details of the type and dimensions of rigging and weights. The riggings and weights shall be adequate to perform all the required crane test procedures.

This plan shall be submitted to the COR for review and approval.

D. PRELIMINARY DOCK TRIALS (LEVEL 2)

PRELIMINARY DOCK TRIALS are a preliminary “run-through” of all required DOCK TRIALS & CRANE TESTS (LEVEL 3) by the Contractor. The intent of this testing is to provide both the Contractor and the COR reasonable assurance that all equipment and systems have been thoroughly prepared and are ready for formal testing and that the Contractor has made adequate provisions for DOCK TRIALS & CRANE TESTS (LEVEL 3).

PRELIMINARY DOCK TRIALS shall be conducted at the Contractor’s facility listed in Section B of the contract.

The COR shall be notified, in writing, at least five (5) working days prior to the scheduled commencement date of Preliminary Trials. The Test Report must be current prior to commencing PRELIMINARY DOCK TRIALS.

The LEVEL 2 tests on the vessel shall be of sufficient scope and duration to assure that all newly installed and modified machinery and equipment is properly installed, and all systems are complete. The intent of this testing is to provide the Contractor, the GFE Manufacturers, and the COR reasonable assurance that installation of equipment and assembly of systems have been executed satisfactorily and that the vessel is ready for formal DOCK TRIALS & CRANE TESTS

(LEVEL 3).

The Contractor shall identify all tests that require the assistance of the GFE manufacturer during development of the Test Agenda. The Contractor shall notify the COR of any testing that requires the assistance of a GFE manufacturer ten (10) business days in advance of the testing.

E. DOCK TRIALS AND CRANE TESTS (LEVEL 3)

1. GENERAL

DOCK TRIALS AND CRANE TESTS are the operability tests the Contractor must perform in the presence of the COR to demonstrate the proper installation, operation, control, and performance of all equipment, machinery, and systems as part of this Contract. Specific dock trials and demonstrations are defined in paragraph E05.F “SPECIFIC DOCK TRIALS”. Crane tests and demonstrations are defined in paragraph E05.G “CRANE TESTS”.

Each test or demonstration shall include control, instrumentation, and alarm operation as applicable. DOCK TRIALS AND CRANE TESTS shall be conducted at the Contractor’s facility and shall be of sufficient scope and duration for the intended objective.

Prior to the start of DOCK TRIALS AND CRANE TESTS, all installations must be complete, except for cleaning and touchup painting, and all LEVEL 1 and LEVEL 2 testing must be successfully completed and documented. The COR shall be notified immediately of any condition which would delay the start of DOCK TRIALS AND CRANE TESTS.

The COR shall be notified in writing ten (10) working days in advance of the date set for testing.

All testing and trials shall be conducted in the presence of a Government representative and manufacturer representatives for the following equipment:

Crane Crane HPU Rescue Boat Davit Crane

The success of all tests and the existence of any deficiencies shall be determined by the COR. Deficiencies shall be remedied prior to the start of FINAL ACCEPTANCE DEMONSTRATIONS (LEVEL 5).

2. SAFETY REQUIREMENTS

During DOCK TRIALS & CRANE TESTS and thereafter, the atmosphere in spaces being prepared for, and preserved by, paints and tank coatings dissolved in highly volatile, toxic, and flammable solvents (29 CFR 1915.35(b)), shall be tested frequently and shall be in accordance with the U.S. Occupational Safety and Health Agency standards regulations stated in CFR 1915.31-36.

Withing 24-hours of final inspection, and before any representative of the U.S. Government boards the vessel for such duties, each compartment or space to be inspected shall be certified “SAFE FOR WORKERS” by a National Fire Protection Association (NFPA) competent person. This means that in the compartment or space so designated:

The oxygen content in the atmosphere is at the least 19.5 percent by volume;

Toxic materials in the atmosphere are within permissible concentrations;

The residues are not capable of producing toxic materials under existing atmospheric conditions while maintained as directed on the Marine Chemist’s certificate.

The Contractor shall notify the Government when this certificate has been issued. The vessel will not be inspected and accepted by the Government without NFPA Marine Chemist certificate for each hull compartment designated

“SAFE FOR WORKERS”.

F. SPECIFIC DOCK TRIALS AND DEMONSTRATIONS (LEVEL 3)

The following paragraphs describe the minimum DOCK TRIAL and DEMONSTRATIONS required.

1. INCLINING TEST

Upon completion of all work and after the crane has been installed, the Contractor shall assist Technologies Associates Inc. (TAI) in performing an inclining test and deadweight survey.

TAI will be responsible for developing the inclining test procedure/plan, personnel, directing the experiment, recording all data, and completing the test report. The Contractor shall be responsible for supplying all test weights, pendulums, and any other support equipment required for the inclining test. The Contractor shall coordinate with TAI to schedule an ABS Inspector to witness the inclining test. The costs associated with ABS witnessing the inclining test shall be the responsibility of the Contractor. The Government will participate in the incline experiment as a witness.

After the inclining test, several no-load crane movements shall be performed. The crane shall be operated by the crane manufacturer.

With no load on the hook, the crane shall swing to 90 degrees starboard side and next to 90 degrees port side.

The crane radius shall not change. Pendulum readings shall be taken after each movement, as well as the vessel draft readings. This will be used to assess the heeling moment due to the crane’s own weight and CG.

The change in LCG shall be ignored during the experiment.

With the crane at 90 degrees over the starboard side, the crane boom angle shall be changed to cause the boom point to move transversely a known distance. Pendulum and draft readings shall be taken at each position. The initial and final boom angle shall be recorded. The change in the rigging radius shall be calculated. The heeling moment divided by the change in the rigging radius shall equal the boom point dead load by experiment. The change in VCG shall be ignored during the experiment.

With the crane at 90 degrees over the port side, and the rescue boat davit deployed simulating launching the rescue boat, the crane boom angle shall be changed to cause the boom point to move transversely a known distance. Pendulum and draft readings shall be taken at each position. The initial and final boom angle shall be recorded. The change in the rigging radius shall be calculated. The heeling moment divided by the change in the rigging radius shall equal the boom point dead load by experiment. The change in VCG shall be ignored during the experiment.

2. MAINTENANCE AND REPAIR ASSOCIATED TESTS

The following tasks in Contract Section C900 “Repairs” detail various testing requirements:

C917 “TANK TESTING”

C918 “REPLACEMENT OF DOCKING PLUGS”

C922 “PROPELLERS AND PROPELLER SHAFTS”

C923 “SEA VALVES”

C925 “KEEL COOLER MAINTENANCE”

The tests associated with these tasks shall be included in the Test Agenda and Test Memoranda.

3. CRANE HPU ENGINE

a. Cooling System

The Contractor shall:

Demonstrate proper cooling of the crane HPU engine.

Inspect the system for leaks.

Check expansion tank levels.

Check the inlet and outlet temperatures.

Demonstrate expansion tank level alarms.

b. Exhaust System

Demonstrate operation of exhaust system.

Verify that the back-pressure on the system is within the manufacturer’s requirements.

c. Fuel Oil System

Ensure proper fuel oil flow to the HPU engine.

Demonstrate the ability of the engine to take suction from the fuel oil day tank.

d. Engine Alarms and Monitoring

The Contractor shall demonstrate the ability/operation of all alarms and monitoring of the HPU engine.

G. MAIN CRANE TESTS (LEVEL 3)

1. General

The DOCK TRIALS shall culminate in a MAIN CRANE TEST which shall be performed only after successful completion of all components and system testing. The MAIN CRANE TESTS shall demonstrate proper installation, operation, control, and performance of the vessel as an integrated whole. All MAIN CRANE TESTS shall be performed in the presence of an authorized representative of the crane manufacturer. Only a certified operator designated by the crane manufacturer may operate the crane.

The inclining test experiment (see Contract Section E05.E.1) shall be completed at least fourteen (14) days prior to the testing of the crane. The Contractor shall coordinate with TAI regarding the duration of the ABS stability review following the inclining experiment and the submission of the updated as-built stability documents.

MAIN CRANE TESTS shall be performed with the crane operated by a certified Techcrane crane operator/technical representative at the Contractor’s facility, with the vessel in the water. The Contractor shall furnish all labor, materials, fuel, test media, oils, tools, test equipment, rigging, and test weights required for testing the crane.

The Contractor shall engage the services of ABS to inspect and witness the MAIN CRANE TESTS (LEVEL 3). The Contractor shall be responsible for all ABS costs during this phase.

Prior to the start of MAIN CRANE TESTS, all installations and maintenance work on the vessel must be complete (except for final cleaning and touch-up painting), and all LEVEL 1 and LEVEL 2 testing must be successfully completed and documented by the Contractor.

The Contractor shall provide two independent digital inclinometers for use during the crane tests to gather data and confirm the expected vessel reactions during the load and lift tests. In addition, Contractor personnel and equipment shall be made available to take draft and freeboard readings during the crane load and lift tests.

The system is designed for a maximum inclination of 5 degrees crane list and 5 degrees crane trim.

2. Proof Load Criteria, Test Weight, and Rigging

In order to proof load the crane and demonstrate adequate crane performance and vessel stability, the Contractor shall provide at their own expense the following certified test weights:

40,000 lbs. – main hoist maximum capacity test load 6,000 lbs. – auxiliary hoist maximum capacity test load

Note: The weights listed above represent the total weight to be used during the testing, including the blocks, rigging, and test weight. The weights of all blocks, rigging, and test weight shall be certified to the satisfaction of the COR, the crane manufacturer, and ABS prior to performing the required test maneuvers. Test weights must have been certified within six (6) months for metal test weights and within two (2) months for concrete test weights. If water bags are used, the flow meter shall be certified within six (6) months.

The rigging for the test weights shall be provided by the Contractor and shall be acceptable to the crane manufacturer and to the COR. The rigging shall be designed by the Contractor and submitted to the Marine Design Center for review and approval at least thirty (30) days prior to the start of testing.

The Contractor shall develop a plan for load test rigging and weights, including details of the type and dimensions of rigging and weights. The rigging and weights shall be adequate to perform all the required crane test procedures. The plan shall be submitted to the COR for review and approval at least 30 days prior to the start of testing.

3. Mooring

The Contractor shall tie the vessel in a quiet and sheltered area. The arrangement of the mooring lines and the depth of the water under the hull shall not restrain flotation during load handling testing. The location and arrangement shall be acceptable to the COR, ABS, and the crane manufacturer.

4. Ready Condition

The Contractor shall provide the vessel in ready condition for the CRANE TESTS.

All installations shall be complete prior to testing.

The boom shall be in stowed position, and the rigging and test weights shall be ready. No deck loads shall be aboard the vessel.

5. Survey

The vessel condition shall be surveyed and documented at the start and completion of the testing. All tank levels and void conditions shall be noted. Minimal personnel shall be allowed on board the vessel during the CRANE TESTS.

The Contractor and a government representative shall conduct a weight survey and sound all tanks. The Contractor shall read and record draft and freeboard readings at the “four corners” of the vessel for each the ready condition and the pause after each CRANE TEST maneuver required in the testing sequence.

6. Load Moment Indicator (LMI) and Data Logger Function

The Load Moment Indicator (LMI) and the Data Logger shall be fully operational and in use during all load handling tests.

7. Unloaded Operation

The unloaded operations tests shall consist of the following:

Demonstrate the operation of the crane raising the boom to its maximum position and lowering to its lowest position, once while fully retracted, once while partially extended, and once while fully extended.

Rotate the crane to its maximum degree both port and starboard.

Raise and lower the load blocks.

Verify the operation of the crane HPU and each winch.

Verify that the crane is capable of slewing, booming, and hoisting simultaneously.

Verify the unloaded main fall hook speed of 25 feet per minute with the six-part block.

Verify the unloaded auxiliary fall hook speed of 150 feet per minute.

Demonstrate the ability of the crane to lift and lower all of the hooks through the full hook range. This shall be achieved by powering the hooks up and down and then overhauling the hooks.

Demonstrate all safety devices (i.e., anti two-block) Verify sufficient hoist spooling to reach 20 feet below the water’s surface with he boom at its highest elevation for both the main hoist and auxiliary hoist. At least five (5) wraps of the wire rope shall remain on the drums.

Demonstrate the operation of all brakes and fail-safe devices under simulated loss of power conditions.

8. Rigging Radius Maneuver

The rigging radius maneuver shall consist of the following:

This is the verification of proper calibration of the radius measurement function of the LMI, which will be conducted with the boom on the centerline forward, and the vessel on an even keel (no trim, no list)

The crane operator shall boom out or in, until the radius indicator in the pilothouse reads the correct radius marked on deck (main load block freely suspended near the deck).

The radius indicator shall be adjusted to the mark on the deck if required.

This test shall be performed three (3) times: once with boom fully retracted, once with boom partially extended, and once with boom fully extended.

9. Main Hoist Proof Load Test

The main hoist proof load test shall consist of the following:

Verify that the main hoist has a swiveling type hook equipped with a safety latch provided by the crane

Verify that the main hoist has a six (6) part load block rated for 25 tons provided by the crane manufacturer.

The main hoist proof load test shall be a fair weather demonstration of adequate crane strength.

Test the crane main hoist proof load of 40,000 lbs. at 15 ft radius reach.

Verify the minimum main hoist speed with the load suspended is 13.25 feet per minute.

Raise and lower the test load and smoothly stop and start hoist movement at least two times to demonstrate satisfactory operation of the hoisting system. Hold the load in one location for a minimum of 5 minutes.

Verify that the LMI is properly installed, calibrated, programmed, and functioning correctly.

10. Luffing Maneuver

With the 6,000 lbs. proof load on centerline over the bow at the maximum safe working load of 80 feet, the operator will boom up from zero degrees boom angle to the maximum permissible boom angle to demonstrate a full travel time of one minute.

During this maneuver, the operator will smoothly stop and hold at least two (2) times.

11. Boom Extension and Retraction Maneuver

With the 6,000 lbs. proof load on centerline over the bow, the operator will extend the boom to its maximum (80 feet) to demonstrate a full travel time of 130 seconds.

The operator will then retract the boom to its minimum (35 feet) to demonstrate a full travel time of 130 seconds.

12. Swing Maneuver

Demonstrate the ability of the swing drive to work against maximum crane list at the required slewing speed of 1 RPM, uphill and downhill.

The maneuver will be accomplished by swinging the 40,000 lbs. proof load from centerline over the crane end towards either side until causing vessel heel and a maximum list of 5 degrees on the crane. Approaching the maximum list position, the crane shall be capable to slow down and stop, hold the position, and return to centerline rotating uphill. Repeat the test to the other side. The Government will provide a maximum off center crane azimuth prior to the test. The load shall not be swung further from the centerline than this azimuth.

13. Crane List Strength Maneuver

Demonstrate the capability of the boom to endure side loading at maximum crane list. This maneuver may be combined with the Swing Maneuver to create the maximum list on the crane.

14. Auxiliary Hoist Proof Load Test:

Verify that the auxiliary hoist has a headache ball and swivel hook rated for its maximum lift capacity of 6,000 lbs.

Test the crane auxiliary hoist to a proof load equivalent to the maximum SWL of 6,000 lbs at all radiuses.

Demonstrate power down capability.

Raise and lower the test load and smoothly stop and start hoist movement at least two times to demonstrate satisfactory operation of the hoisting system.

15. Clamshell Operation Testing

Verify that the main hoist can deploy the 5/8 yard clamshell provided by the crane manufacturer.

Demonstrate the ability of the clamshell to be opened and closed via the auxiliary winch.

H. RESCUE BOAT DAVIT CRANE TESTS (LEVEL 3)

The DOCK TRIALS shall culminate in a RESCUE BOAT DAVIT CRANE TEST which shall be performed only after successful completion of all components and system testing. The RESCUE BOAT DAVIT CRANE TESTS shall demonstrate proper installation, operation, control, and performance of the vessel as an integrated whole. All RESCUE BOAT DAVIT CRANE TESTS shall be performed in the presence of an authorized representative of the crane manufacturer. Only a certified operator designated by the crane manufacturer may operate the crane.

The inclining test experiment (see Contract Section E05.E.1) shall be completed at least fourteen (14) days prior to the testing of the crane. The Contractor shall coordinate with TAI regarding the duration of the ABS stability review following the inclining experiment and the submission of the updated as-built stability documents.

RESCUE BOAT DAVIT CRANE TEST shall be performed with the crane operated by a certified Techcrane crane operator/technical representative at the Contractor’s facility, with the vessel in the water. The Contractor shall furnish all labor, materials, fuel, test media, oils, tools, test equipment, rigging, and test weights required for testing the crane.

The Contractor shall engage the services of ABS to inspect and witness the CRANE TESTS (LEVEL 3). The Contractor shall be responsible for all ABS costs during this phase.

Prior to the start of RESCUE BOAT DAVIT CRANE TESTS, all installations and maintenance work on the vessel must be complete (except for final cleaning and touch-up painting), and all LEVEL 1 and LEVEL 2 testing must be successfully completed and documented by the Contractor.

The Contractor shall provide two independent digital inclinometers for use during the crane tests to gather data and confirm the expected vessel reactions during the load and lift tests. In addition, Contractor personnel and equipment shall be made available to take draft and freeboard readings during the crane load and lift tests.

The system is designed for a maximum inclination of 5 degrees crane list and 5 degrees crane trim.

2. Proof Load Criteria, Test Weight, and Rigging

In order to proof load the crane and demonstrate adequate crane performance and vessel stability, the Contractor shall provide at their own expense the following certified test weights:

2000 lbs. – main hoist maximum capacity test load

Note: The weights listed above represent the total weight to be used during the testing, including the blocks, rigging, and test weight. The weights of all blocks, rigging, and test weight shall be certified to the satisfaction of the COR, the crane manufacturer, and ABS prior to performing the required test maneuvers. Test weights must have been certified within six (6) months for metal test weights and within two (2) months for concrete test weights. If water bags are used, the flow meter shall be certified within six (6) months.

The rigging for the test weights shall be provided by the Contractor and shall be acceptable to the crane manufacturer and to the COR. The rigging shall be designed by the Contractor and submitted to the Marine Design Center for review and approval at least thirty (30) days prior to the start of testing.

The Contractor shall develop a plan for load test rigging and weights, including details of the type and dimensions of rigging and weights. The rigging and weights shall be adequate to perform all the required crane test procedures. The plan shall be submitted to the COR for review and approval at least 30 days prior to the start of testing.

3. Mooring

The Contractor shall tie the vessel in a quiet and sheltered area. The arrangement of the mooring lines and the depth of the water under the hull shall not restrain flotation during load handling testing. The location and arrangement shall be acceptable to the COR, ABS, and the crane manufacturer.

4. Ready Condition

The Contractor shall provide the vessel in ready condition for the RESCUE BOAT DAVIT CRANE TESTS.

All installations shall be complete prior to testing.

The boom shall be in stowed position, and the rigging and test weights shall be ready. No deck loads shall be aboard the vessel.

5. Survey

The vessel condition shall be surveyed and documented at the start and completion of the testing. All tank levels and void conditions shall be noted. Minimal personnel shall be allowed on board the vessel during the RESCUE BOAT

DAVIT CRANE TESTS.

The Contractor and a government representative shall conduct a weight survey and sound all tanks. The Contractor shall read and record draft and freeboard readings at the “four corners” of the vessel for each the ready condition and the pause after each RESCUE BOAT DAVIT CRANE TEST maneuver required in the testing sequence.

6. Unloaded Operation

The unloaded operations tests shall consist of the following:

Demonstrate the operation of the crane raising the boom to its maximum position and lowering to its lowest position, once while fully retracted, once while partially extended, and once while fully extended.

Rotate the crane to its maximum degree both port and starboard.

Raise and lower the load block.

Verify the operation of the crane HPU and winch.

Verify that the crane is capable of slewing, booming, and hoisting simultaneously.

Verify the unloaded hook speed of 50 feet per minute with the single part block.

Demonstrate the ability of the crane to lift and lower the hook through the full hook range. This shall be achieved by powering the hooks up and down and then overhauling the hooks.

Demonstrate all safety devices (i.e., anti two-block) Verify sufficient hoist spooling to reach 35 feet below the the rotating works with the boom at a 5-ft radius.

At least three (3) wraps of the wire rope shall remain on the drums.

Demonstrate the operation of all brakes and fail-safe devices under simulated loss of power conditions.

7. Main Hoist Proof Load Test

The main hoist proof load test shall consist of the following:

Verify that the main hoist has a swiveling type hook equipped with a safety latch provided by the crane

Verify that the main hoist has a single part load block rated for 2000 lbs provided by the crane manufacturer.

The main hoist proof load test shall be a fair weather demonstration of adequate crane strength.

Test the crane main hoist proof load of 2000 lbs. at 16 ft radius reach.

Verify the minimum main hoist speed with the load suspended is 50 feet per minute.

Raise and lower the test load and smoothly stop and start hoist movement at least two times to demonstrate satisfactory operation of the hoisting system. Hold the load in one location for a minimum of 5 minutes.

8. Luffing Maneuver

With the 2,000 lbs. proof load athwartship at the maximum safe working load of 12 feet, the operator will boom up from zero degrees boom angle to the maximum permissible boom angle to demonstrate a full travel time of one minute.

9. Boom Extension and Retraction Maneuver

With the 2,000 lbs. proof load athwartship, the operator will extend the boom to its maximum (16 feet) and document the full travel time.

The operator will then retract the boom to its minimum (12 feet) to document the full travel time.

10. Swing Maneuver

Demonstrate the ability of the swing drive to work against maximum crane list at the required slewing speed of 1.5 RPM, uphill and downhill.

The maneuver will be accomplished by swinging the 2,000 lbs. proof load from athwartship over the port side until causing vessel heel and a maximum list of 5 degrees on the crane. Approaching the maximum list position, the crane shall be capable to slow down and stop, hold the position, and return to centerline rotating uphill. Repeat the test to the other side. The Government will provide a maximum off center crane azimuth prior to the test. The load shall not be swung further from the centerline than this azimuth.

11. Crane List Strength Maneuver

Demonstrate the capability of the boom to endure side loading at maximum crane list. This maneuver may be combined with the Swing Maneuver to create the maximum list on the crane.

12. Emergency HPU Hand Pump Operation Test:

Demonstrate the operation of the Emergency HPU Hand Pump and it’s ability to luff, swing and deploy the proof load in a “dead ship” condition.

13. OPEN WATER TRIALS (LEVEL 4)

After all items on the schedule of Dock Tests (Level 3) have been satisfactorily completed and any deficiencies corrected to the satisfaction of the COR, the Contractor shall commence a program of Open Water Trials.

The Contractor’s personnel shall operate the vessel and shall make all observations and record all data. The Contractor shall provide appropriately licensed personnel as may be required by the USCG for conduct of trials. The Contractor shall coordinate with ABS to assure that all trials required to be witnessed for class are witnessed.

Commencement of Open Water Trials shall not be sooner than one full working day after completion of Dock Tests.

The COR shall be notified immediately of any condition which would delay the conduct of the Open Water Trials.

The COR shall be notified in writing ten (10) working days in advance of the date set for the trials.

All testing and trials shall be conducted in the presence of a Government representative and any vendor representatives required by the Contract.

2. Trial Location

The site of the trials shall be free from fog and traffic and shall allow for all maneuvers necessary to calibrate the Electronic Charting System..

3. Electronic Charting System

The Contractor shall hire technical representatives from the electronic charting system manufacturer to calibrate the system. The Contractor shall provide support to the technical representative to ensure that the system is properly calibrated. The system shall be tested in open waters to verify the calibration of the system.

14. FINAL ACCEPTANCE DEMONSTRATIONS (LEVEL 5)

Final acceptance demonstrations are operability tests the Contractor shall perform for the USACE operators. The intent of LEVEL 5 testing is to demonstrate the capabilities and features of the newly installed and modified equipment to the operators and to verify that the vessel is in peak operating condition.

The Contractor shall operate all newly installed and modified equipment and systems on the vessel to demonstrate features, characteristics, and capabilities. The duration and complexity of each procedure shall be sufficient to fully demonstrate the operating condition of the vessel and crane to the operators.

During this time, the crane manufacturer shall operate all equipment and systems on the crane to demonstrate their features, characteristics, and capabilities. The duration and complexity of each procedure shall be sufficient to fully demonstrate the operating condition of the crane to the operators. For bidding purposes, plan for these demonstrations to have a duration of two (2) days.

E06 INSPECTIONS

A. CRANE DELIVERY INSPECTION

At delivery of the crane and its components to the Contractor’s facility, both the Contractor and the crane manufacturer shall inspect the crane and its components for any visual damage. After satisfactory inspection by both the Contractor and crane manufacturer, the Contractor shall officially take possession of the crane.

B. FINAL INSPECTION

When all Level 2 and 3 testing has been satisfactorily completed, the Contractor, crane manufacturer, and the Government Representative(s) shall perform a complete physical inspection of the new and modified equipment and vessel structure against the contract requirements.

A punch list of any deficiencies shall be developed and presented to the Contractor for corrective action. The Contractor and the crane manufacturer shall take corrective action to address all items on their respective punch lists.

Upon correction and completion of the punch list items, a Government representative will reinspect the items to ensure that the items are complete and meet the terms of the contract. Both the crane manufacturer and the Contractor shall give the COR seven (7) business days notice prior to the date of re-inspection for clearing the punch list.

E07 FINAL ACCEPTANCE

Final Acceptance will be made after completion of Final Inspection, correction of all punch list deficiencies, and after the vessel is “Ready for Service”.

“Ready for Service” is defined as:

Clean inside and out.

All trash, dunnage, lashings, and delivery related material disposed of.

Loose items of outfit in place.

All newly installed and modified electrical and mechanical systems operational.

Equipment properly adjusted.

Instruments and electronics calibrated or aligned.

All waste fluid tanks empty (waste oil, sewage water).

Paint damaged touched up.

Completion of Final Acceptance Demonstrations (Level 4 Testing) Submission of all required contract deliverables to the Government

E08 COMMERCIAL WARRANTY OF SUPPLIES

The Contractor shall assign, in writing, all commercial warranties for equipment provided under this contract to the Government.

The effective date of all commercial warranties shall be the date of final acceptance.