A.07.24_Amendment_0001_16-R-0031.pdf

W68SBV60567218

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

STANDARD FORM 30 (Rev. 10-83) Prescribed by GSA

FAR (48 CFR) 53.243

The purpose of this amendment is to incorporate the changes to the solicitation as outlined in the sumamry of changes.

The propsal submission date remains unchanged.

1. CONTRACT ID CODE PAGE OF PAGES

J 1 2

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16C. DATE SIGNED

BY 12-Apr-2016

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street, County, State and Zip Code) X W912EF-16-R-0031

X 9B. DATED (SEE ITEM 11)

06-Apr-2016

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offer is extended, X is not extended.

Offer must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing Items 8 and 15, and returning 1 copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE

CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(B).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

10A. MOD. OF CONTRACT/ORDER NO.

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

12-Apr-2016

CODE

USAED, WALLA WALLA - CONTRACTING DIV.

HILLARY A. MORGAN

201 N. THIRD AVENUE

WALLA WALLA WA 99362

W912EF 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

W912EF-16-R-0031

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

Little Goose Bridge Crane Main Hoist Rehabilitation

Summary of Changes – Amendment 0001

W912EF-16-R-0031

Specifications:

41 01 20.71 26 BRIDGE CRANE DATA, TESTING AND TRAINING

• 1.3: Removed SD-07 submittal “VFD Configuration Technician” and added submittal “PLC Programmer”

• 3.8.2: Replaced the entirety of subpart 3.8.2 VFD Configuration Technician with new subpart 3.8.2 PLC Programmer

Other:

The submittal register has been updated to reflect the changes made in Section 41 01 20.71 26.

Drawings:

No changes

(End of Summary of Changes)

Little Goose Bridge Crane Main Hoist Rehab W912EF-16-R-0031 amendment 0001

PROJECT TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

01 00 00.00 28 GENERAL REQUIREMENTS

01 11 01.00 28 SUPPLEMENTARY REQUIREMENTS

01 14 00.10 28 PROJECT SITE RESTRICTIONS

01 14 00.90 28 INTEGRATING ANTITERRORISM (AT) AND OPERATIONS SECURITY

(OPSEC)

01 22 00.00 28 MEASUREMENT AND PAYMENT

01 32 01.00 28 PROJECT SCHEDULE

01 33 00 SUBMITTAL PROCEDURES

01 35 29.10 28 GOVERNMENTAL SAFETY REQUIREMENTS

01 42 00 SOURCES FOR REFERENCE PUBLICATIONS

01 45 02.00 28 QUALITY CONTROL SYSTEM (QCS)

01 45 04.00 28 CONTRACTOR QUALITY CONTROL

01 51 00.00 28 TEMPORARY UTILITIES

01 55 10.00 28 CONTRACTOR WORK, ACCESS AND STORAGE AREAS

01 57 20.00 28 ENVIRONMENTAL PROTECTION

01 78 00.00 28 CLOSEOUT SUBMITTALS

01 78 23.00 28 OPERATION AND MAINTENANCE DATA

DIVISION 02 - EXISTING CONDITIONS

02 83 33.13 28 LEAD BASED PAINT (LBP) REMOVAL AND DISPOSAL

DIVISION 05 - METALS

05 50 03.00 26 METALWORK FABRICATION, MACHINE WORK, AND MISCELLANEOUS

PROVISIONS

05 50 04.00 26 METALS: MISCELLANEOUS, STANDARD ARTICLES, SHOP FABRICATED

ITEMS

DIVISION 09 - FINISHES

09 90 00.01 26 PAINTS AND COATINGS

DIVISION 26 - ELECTRICAL

26 00 00.00 26 BASIC ELECTRICAL MATERIALS AND METHODS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

41 01 20.71 26 BRIDGE CRANE DATA, TESTING AND TRAINING

41 01 20.72 26 BRIDGE CRANE MECHANICAL AND STRUCTURAL REHABILITATION

-- End of Project Table of Contents --

PROJECT TABLE OF CONTENTS Page 1

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 01 20.71 26

BRIDGE CRANE DATA, TESTING AND TRAINING

PART 1 GENERAL

1.1 GENERAL INFORMATION

1.2 REFERENCES

1.3 SUBMITTALS

1.4 DATA, CAPACITIES, SPEEDS AND TRAVEL

1.4.1 Definitions

1.4.2 Data, Capacities, Speeds, and Travel

1.4.2.1 Little Goose Powerhouse Bridge Crane

1.4.2.2 Main Hoists, one (1) per trolley

1.4.2.3 Auxiliary Hoists, one (1) per trolley

1.5 QUALIFICATIONS

1.5.1 General

1.5.2 Qualified Crane Inspectors

1.5.3 Qualified Craftsmen

1.5.4 Professional Surveyor

1.5.5 Qualified Crane Electricians

1.6 OPERATING MANUAL

PART 2 PRODUCTS

PART 3 EXECUTION

3.1 INSPECTION AND TESTING GENERAL

3.1.1 Inspection and Testing Phases

3.1.2 Equipment Monitoring During Inspections and Testing

3.2 INSPECTION AND TESTING TIMELINE

3.2.1 Timeline, General

3.2.2 Pre-Initial Phase

3.2.3 Initial Phase

3.2.4 Between Initial and Final Phases

3.2.5 Final Phase Activities

3.3 TEST WEIGHT

3.3.1 Test Weight Requirements

3.3.2 Water Bag Requirements

3.3.3 Test Weight Plan

3.4 INITIAL POST-REHABILITATION INSPECTION

3.4.1 General

3.4.2 Initial Post-Rehabilitation Inspection Report

3.5 INITIAL NO-LOAD PERFORMANCE TEST

3.5.1 General

3.5.2 Initial No-Load Performance Test Report

3.6 FINAL INSPECTION

3.6.1 General

3.6.2 Inspections to be Performed

3.6.3 Post-Rehabilitation Inspection Procedure

3.6.4 Final Inspection Report

3.7 ACCEPTANCE TESTING

3.7.1 General

SECTION 41 01 20.71 26 Page 1

3.7.2 Performance Requirements

3.7.2.1 Speed Control Point Definition

3.7.2.2 Speed Range

3.7.2.3 Tandem Main Hoisting and Lowering Performances

3.7.2.4 Tandem Travel Performance

3.7.2.5 Positioning Accuracy

3.7.3 Test Sequence

3.7.4 Acceptance Test Procedure

3.7.5 Data Measurement and Recording

3.7.6 No-Load Performance Test

3.7.7 100 Percent Rated Load Performance Test

3.7.8 125 Percent Rated Load Performance Test

3.7.9 Acceptance Test Report

3.8 MANUFACTURER'S SERVICES

3.8.1 General

3.8.2 PLC Programmer

3.9 SPEED REDUCER OIL TESTING

3.10 AS-COMMISSIONED VFD PARAMETERS

3.11 FIELD TRAINING

3.12 OPERATION AND MAINTENANCE DATA

-- End of Section Table of Contents --

SECTION 41 01 20.71 26 Page 2

SECTION 41 01 20.71 26

BRIDGE CRANE DATA, TESTING AND TRAINING

PART 1 GENERAL

1.1 GENERAL INFORMATION

This section covers definitions, capacities, inspections, testing, and personnel training for the Little Goose (abbreviated LGA) powerhouse bridge crane. The powerhouse contains one (1) bridge crane currently with a rated capacity of 600 tons.

1.2 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASME INTERNATIONAL (ASME)

ASME B30.2

(2011) Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Post-Rehabilitation Inspection Procedure; G HDC

Acceptance Test Procedure; G HDC

Test Weight Plan; G HDC

SD-06 Test Reports

Initial Post-Rehabilitation Inspection Report; G HDC

Initial No-Load Performance Test Report; G HDC

Final Inspection Report; G HDC

Acceptance Test Report; G HDC

Post-Load Testing Oil Test Results; G HDC

SD-07 Certificates

Crane Inspectors; G C

SECTION 41 01 20.71 26 Page 3

Qualified Craftsmen; G C

Professional Surveyor; I HDC

PLC Programmer; G HDC

Water Bag Cleanliness Certification; G HDC

SD-10 Operation and Maintenance Data

Operating Manual; G C

SD-11 Closeout Submittals

As-Commissioned VFD Parameters; G HDC

1.4 DATA, CAPACITIES, SPEEDS AND TRAVEL

1.4.1 Definitions

Main Hoist Rated Capacity - The maximum load that can be applied to the hooks of each main hoist.

Auxiliary Hoist Rated Capacity - The maximum load that can be applied to the hook of each auxiliary hoist.

Rated Hoisting Speed - The linear velocity of the load when lifting the rated capacity.

Bridge Rated Travel Speed - The linear velocity of the bridge when carrying a load equal to the rated capacity of both main hoists combined.

Trolley Rated Travel Speed - The linear velocity of the trolley when carrying a load equal to the rated capacity of the two main hoists combined.

1.4.2 Data, Capacities, Speeds, and Travel

Data, capacities, travel distances, and rated speeds of the rehabilitated crane are as follows:

1.4.2.1 Little Goose Powerhouse Bridge Crane

a. Rated Capacity, Tons (2,000 pounds)

b. Rated Capacity per trolley, Tons

c. Total Bridge Travel, Feet, approx

d. Total Trolley Travel, Feet, approx....................... 34.5

e. Rated Bridge Travel Speed, Feet Per Minute

f. Rated Trolley Travel Speed, Feet Per Minute

g. Bridge Span, Feet.................................. 74 feet-0 inches

1.4.2.2 Main Hoists, one (1) per trolley

a. Rated Capacity, Tons

b. Rated Hoisting Speed (Rated Load), Feet Per Minute....... 3.0

c. Hook Travel:

Upper limit of travel not lower than Elevation........ 599.0

SECTION 41 01 20.71 26 Page 4

G4EDDMTJ

Line

Lower limit of travel not higher than Elevation....... 504.0

1.4.2.3 Auxiliary Hoists, one (1) per trolley

a. Rated Capacity, Tons

b. Rated Hoisting Speed (Rated Load), Feet Per Minute

c. Hook Travel:

Upper limit of travel not lower than Elevation........ 596.5 Lower limit of travel not higher than Elevation....... 481.5

1.5 QUALIFICATIONS

1.5.1 General

Submit qualifications showing that crane inspectors and craftsmen meet the following qualifications:

1.5.2 Qualified Crane Inspectors

Crane inspectors must meet the following requirements:

a. Have experience and knowledge in performing inspection on bridge cranes of similar size and capacity.

b. Certifications showing they have attended crane inspection training seminars provided by established training institutions, such as Morris Material Institute (866-821-4006) or CraneTech (800-290-0007). Certifications issued by the Contractor do not meet this requirement.

c. Have been employed full time as crane inspectors for at least the last two (2) years by a firm specializing in crane inspection work.

1.5.3 Qualified Craftsmen

Craftsmen must meet the following requirements:

a. Have experience and knowledge in performing work on hoist machinery of similar size and capacity.

b. Have continuously performed work on cranes of similar size and capacity for at least three (3) years.

c. Have been employed for at least the last two (2) years by a firm specializing in crane repair and rehabilitation work.

1.5.4 Professional Surveyor

Submit the credentials of the professional surveyor who will be performing the laser survey.

1.5.5 Qualified Crane Electricians

A minimum of one licensed electrician must be onsite during field wiring and critical aspects of the crane field work.

1.6 OPERATING MANUAL

Prepare and submit the Operating Manual a minimum of 45 calendar days

SECTION 41 01 20.71 26 Page 5 prior to the final inspection and load testing. The Operating manual is a separate manual from the Operations And Maintenance Manual specified in SECTION 01 78 23.00 25 OPERATION AND MAINTENANCE DATA. Include the following information in the Operating Manual:

a. Load ratings of crane;

b. Crane make, model, serial number, year of manufacture, year of rehabilitation, manufacturer's name and rehabilitation's name;

c. Operating instructions;

d. Warnings.

Provide a hard copy of the manual to be placed in the operator cab as well as an electronic copy.

PART 2 PRODUCTS

NOT USED

PART 3 EXECUTION

3.1 INSPECTION AND TESTING GENERAL

3.1.1 Inspection and Testing Phases

Perform inspection and testing in two (2) phases: Initial and Final. The purpose of the initial phase is to have a trial run and to ensure all deficiencies are discovered and corrected before the final phase. It is not required that the Government witness the activities performed during the initial phase.

The Government will witness all final phase activities. No Final phase activities shall occur without the presence of the designated Government witness, unless previously waived in writing.

Initial phase activities shall consist of the following:

(1) Initial Post-Rehabilitation Inspection

(2) Initial No-Load Performance Testing

Final phase activities shall consist of the following:

(1) Final Inspection

(2) Acceptance Testing

3.1.2 Equipment Monitoring During Inspections and Testing

During all inspections and testing, monitor for improper operation or poor condition of safety devices, electrical components, mechanical equipment, and structural assemblies. Immediately report to the Contracting Officer any observed defects critical continued inspection or testing. Suspend inspection and testing activities until the deficiency has been corrected. Resume inspection and testing activities after the corrective action has been verified by the Government. Perform the following at each activity of inspection and testing:

SECTION 41 01 20.71 26 Page 6

a. Inspect for evidence of bending, warping, permanent deformation, cracking or malfunction of structural components.

b. Visually examine the motors, brakes, gearing, and other mechanical or electrical equipment to ensure no damage has occurred.

c. Inspect for evidence of slippage in wire rope sockets and fittings.

d. Check for overheating in brake operation; check for proper stopping. Inspect and test all safety devices, including emergency stop switches and power off pushbuttons, separately, to verify proper operation of the brakes.

e. Check for abnormal noise or vibration and overheating in machinery drive components.

f. Check wire rope sheaves and drum spooling for proper operation, freedom of movement, abnormal noise or vibration.

h. Inspect external gears for abnormal wear patterns, damage or inadequate lubrication.

h. Check electrical drive components for proper operation, freedom from chatter, noise, or overheating.

i. Remove inspection covers from gear reducers for inspection of gearing after all testing.

3.2 INSPECTION AND TESTING TIMELINE

3.2.1 Timeline, General

Perform inspection and testing after all rehabilitation work is completed and the crane has been completely reassembled, adjusted, lubricated, and otherwise made ready for operation. The following sub-paragraphs list the required notification windows, submittal windows, and other time sensitive actions during the inspection and testing period.

3.2.2 Pre-Initial Phase

a. Submit all inspection and testing procedures a minimum of 45 days prior to the planned start of initial phase activities. The procedures that need to be submitted are:

(1) Post-Rehabilitation Inspection Procedure

(2) Acceptance Test Procedure

(3) Test Weight Plan

b. Do not begin inspection and testing activities until the following has occurred:

(1) The Post-Rehabilitation Inspection Plan has been approved by the Government.

(2) Shaft Alignment, per SECTION 41 01 20.72 26 BRIDGE CRANE MECHANICAL AND STRUCTURAL REHABILITATION, Paragraph SHAFT ALIGNMENT is

SECTION 41 01 20.71 26 Page 7 complete and the alignment report has been approved by the Government.

(3) Dynamic Balancing of Machinery, per SECTION 41 01 20.72 26 BRIDGE CRANE MECHANICAL AND STRUCTURAL REHABILITATION, Paragraph DYNAMIC BALANCING OF MACHINERY is complete and the Dynamic Balancing Report has been approved by the Government.

(4) Wire Rope Magnetic Flux Leakage Test, per SECTION 41 01 20.72 26 BRIDGE CRANE MECHANICAL AND STRUCTURAL REHABILITATION, Paragraph: Wire Rope Flux Leakage Testing.

(5) Alignment of the main hoist gears, at light load, per SECTION

41 01 20.72 26 BRIDGE CRANE MECHANICAL AND STRUCTURAL REHABILITATION,

Paragraph: Open Gear Alignment.

3.2.3 Initial Phase

a. Notify the Government, a minimum of 7 calendar days in advance, the planned start of any inspection or test.

b. Submit the Initial Post-Rehabilitation Inspection Report within 1 business day of completing the inspections.

c. Submit the Initial No-Load Performance Test Report within 1 business day of completing the testing.

3.2.4 Between Initial and Final Phases

Allow the Government a minimum of two (2) full business days to review the Initial No-Load Performance Test Report prior to start of final phase activities. "Two (2) full business days" constitutes the Government receiving the reports electronically, not later than 0800 hours of the first date of review, to allow all Government reviewers adequate time to review the reports.

3.2.5 Final Phase Activities

a. Notify the Contracting Officer, a minimum of 7 calendar days in advance, the planned start of any inspection or test.

b. Notify the Contracting Officer, a minimum of five (5) business days in advance, any revisions to the dates of the final inspections and acceptance tests.

c. The designated Government witness and HDC representatives will be on site for the final inspection and acceptance tests no earlier than one (1) business day after approval of the Initial Post-Rehabilitation Inspection Report and Initial No-Load Performance Test Report.

d. Final inspection and acceptance testing must be conducted within the following hour and day restrictions. Written permission from the Contracting Officer is required to deviate from the following:

(1) The final inspection and acceptance testing must occur on separate days.

(2) The final inspection and acceptance testing must not occur during the week of a Federal Holiday.

SECTION 41 01 20.71 26 Page 8

(3) Accomplish final inspection activities on a Tuesday through Thursday schedule.

(4) The 100 and 125 percent Rated Load Performance Tests must be completed on a Thursday through Sunday schedule only; with testing activities starting no later than 0800 on Thursday.

(4) Government personnel will be available for the final inspection and acceptance testing for a maximum of 12 continuous hours in a 24 hour time period.

e. Government witness representatives will not arrive onsite until all test materials and Contractor personnel are on-site and ready for testing.

f. Provide the Final Inspection Report to the Contracting Officer and HDC representatives on-site for approval before starting the acceptance tests.

3.3 TEST WEIGHT

3.3.1 Test Weight Requirements

Test loads must weigh within plus 5 percent, minus 0 percent, of the nominal load. The load limit on the powerhouse floor is 1,000 lbf per square foot

3.3.2 Water Bag Requirements

If water bags are used, maintain adequate clearance from electrical equipment and provide method of containment below the testing area to contain any water leakage. Seal all hatches to prevent water leakage to lower levels (include in the test weight plan, the materials planned for use to seal hatches).

Provide means of pumping water into the water bags from the tailrace and after testing, a means of draining the bags into the tailrace. Do not drain water bags into the powerhouse drainage system. Size pumps, piping/headers and valves such that the total time to fill the main hoist water bags from 0-100% is no longer than four (4) hours. Use basket strainers that are approved by the pump manufacturer on the pump suction.

Provide water bags that are non-contaminated so that the water can be discharged back into the river. Submit water bag cleanliness certification 10 days prior to the start of testing. Include the following information in the certification:

a. Storage locations and all locations that the bags have been used since the last certification.

b. Invasive species removal verification.

c. Description of the techniques and process used to clean the bags after each usage.

If the bags are used at a different location between the time that the cleanliness certification is submitted to the Government, submit an updated cleanliness certificate. Do not use the bags on-site until an updated certificate has been approved by the Government.

If a bag cleanliness certification is not provided, or there is evidence

SECTION 41 01 20.71 26 Page 9 that the bags do not meet the required cleanliness requirements, provide complete containment, clean-up, and disposal of all water used during the load testing procedure, including any spilled water.

Check water bags, hoses, valves, and other associated equipment for leaks prior to using them on-site. Replace leaking equipment so that the volume of spilled water is minimized

3.3.3 Test Weight Plan

Prepare and submit a Test Weight Plan that contains the following:

a. Type of test weight.

b. Test weight handling and setup procedure.

c. Detailed drawings showing test weight configuration (to scale) with the crane, powerhouse, generator, and other features shown on the drawings. Show details of lifting beams, shackles, slings, and related equipment. If water weights are used, show the configuration of the fill and drain system.

d. Copies of up-to-date calibration certificates for any instrumentation that is going to be used.

3.4 INITIAL POST-REHABILITATION INSPECTION

3.4.1 General

The initial post-rehabilitation inspection is the same inspection as the final inspection. Perform the initial post-rehabilitation inspection in accordance with the approved Post-Rehabilitation Inspection Procedure.

Only approved, qualified crane inspectors will be allowed to perform post-rehabilitation crane inspections.

Correct any deficiencies or anomalies prior to preparing and submitting the inspection report.

3.4.2 Initial Post-Rehabilitation Inspection Report

Prepare and submit a Initial Post-Rehabilitation Inspection Report after all initial phase inspections are complete. The report shall include the following elements, at a minimum:

a. Completed inspection checklist.

b. Discussion of any deficiencies that were discovered during the inspections. If no deficiencies were found, state it in the report.

c. If deficiencies were found, include a description of the means and measures taken to correct the deficiency as well as verification that the deficiency has been corrected and re-inspected.

3.5 INITIAL NO-LOAD PERFORMANCE TEST

3.5.1 General

The Initial No-Load Performance Test requirements and procedure are

SECTION 41 01 20.71 26 Page 10 identical to the No-Load Performance Test that is performed during acceptance testing. Perform the Initial No-Load Performance test in accordance with the procedures of the approved Acceptance Test Procedure.

Correct any deficiencies or anomalies prior to preparing and submitting the test report.

3.5.2 Initial No-Load Performance Test Report

Prepare and submit a Initial No-Load Performance Test Report, after all Initial Phase No-Load Performance tests are complete. Include the following elements in the report, at a minimum:

a. A narrative summary that describes the testing that took place.

Include notation that all planned tests were completed with successful outcomes;

b. Completed inspection checklist and verification each required inspection was successfully completed.

c. Descriptions of any deficiencies that were discovered during the testing. If no deficiencies were found, state it in the report;

d. If deficiencies were found, include a description of the means and measures taken to correct the deficiency, as well as verification that the deficiency has been corrected and tests were re-run.

3.6 FINAL INSPECTION

3.6.1 General

Perform a Final Inspection. Perform inspections in accordance with ASME B30.2 , Periodic Inspection. Correct any deficiencies that are discovered during inspections, and repeat portions of inspections to verify corrections prior to preparing and submitting the inspection report.

Only approved, qualified crane inspectors will be allowed to perform post-rehabilitation crane inspections.

The Final Inspection is the post-rehabilitation inspection that is witnessed by the Government. Do not perform the Final Inspection until the following has occurred:

a. The Initial Post-Rehabilitation Inspection Report has been submitted and approved by the Government.

b. The Initial No-Load Performance Test Report has been submitted and approved by the Government.

3.6.2 Inspections to be Performed

Perform all inspections as required by ASME B30.2 , Periodic Inspection.

Perform the following additional inspections:

(1) Verify that the work to be performed under this contract was completed, including all cleaning activities.

(2) Test all auxiliary equipment for proper operation and calibration, including, but not limited to - load cells, cable

SECTION 41 01 20.71 26 Page 11 carriers or festoons, locking and indicating devices, and lights.

(3) Brakes - For each brake, verify the following:

a. Brake Wheels - Verify that brake wheels have been burnished in accordance with the manufacturer's instructions.

b. Pad Clearance - Verify that brake pad clearance is correctly adjusted to be within the manufacturer's recommended range.

c. Torque Settings - Psychically verify and test that brake torque settings are correct.

d. Emergency Stop - For each hoist, trolley and bridge, while slowly operating at normal speed or micro speed, disconnect the main power source by pressing one of the emergency stop push buttons. Verify the brake closes and that there are no more than four (4) brake wheel revolutions after the brake sets.

(4) Hoist Travel - Verify each hoist operates correctly at all five

(5) drive speed control points, in each direction, at normal speed, micro speed and ultra-lift speed. Verify correct brake operation.

(5) Hoist Limits - Verify the operation of all upper and lower limit switches on each hoist.

(1) Upper Limit Switches - Stop the load block below the upper limit switch. Raise the load block at the first speed control point in normal speed mode. Verify activation of the upper limit switch and that the load blocks stop at the correct elevation.

(2) Lower Limit Switches - Manually activate the lower limit switch, as the blocks cannot be lowered to the lowest elevation.

(6) Trolley Travel - Verify each trolley operates correctly at all five (5) drive speed control points, in each direction, at normal speed and micro speed. Verify correct brake operation. Verify all travel limits activate correctly and are adjusted to stop the trolleys correctly. When activated, the trolley speed is limited to 10% rated speed. If the trolley is traveling faster than 10% rated speed when the limit switch is tripped, the trolley must slow to 10% rated speed.

(7) Bridge Travel - Verify the bridge operates correctly at all five

(5) drive speed control points, in each direction, at normal speed and micro speed. Verify correct brake operation. Verify all travel limits activate correctly and are adjusted to stop the bridges correctly. When activated, the bridge speed is limited to 10% of rated speed. If the bridge is traveling faster than 10% rated speed when the limit switch is tripped, the bridge must slow to 10% rated speed.

(8) Emergency Stop Pushbuttons - Verify correct operation of every emergency stop pushbutton (operator chair, remote control, powerhouse, Variable Frequency Drive (VFD) console). To verify correct operation, activate each pushbutton and verify that all power is removed from the bridge crane.

(9) Remote Control - Verify all functions of the remote control operation. Demonstrate the "fail-safe" design of the remote (radio)

SECTION 41 01 20.71 26 Page 12 control system, including loss of signal. Verify remote control operation with each remote controller that the project has.

(10) Tandem Operation - Verify that the main hoist and trolley drive tandem operation works correctly.

3.6.3 Post-Rehabilitation Inspection Procedure

Prepare and submit a Post-Rehabilitation Inspection Procedure. Include the following elements in the procedure, at a minimum:

a. A list of names and contact information for key Contractor personnel who will be involved with the inspections; including the qualified crane inspectors.

b. A checklist of all inspections to be performed.

c. A step-by-step, repeatable procedure for each inspection to be performed.

d. A list of equipment that will be used during the inspections.

e. Sample data sheet(s) or form(s) that inspection data will be recorded on.

3.6.4 Final Inspection Report

Prepare and submit a Final Inspection Report immediately after all final inspections are complete. Include the following elements in the report, at a minimum:

a. A brief narrative summary that describes the inspections that took place.

b. Completed inspection checklist and verification each required inspection was successfully completed.

c. Descriptions of any deficiencies that were discovered during the inspections. If no deficiencies were found, state it in the report.

d. If deficiencies were found, include a description of the means and measures taken to correct the deficiency as well as verification that the deficiency has been corrected and re-inspected.

3.7 ACCEPTANCE TESTING

3.7.1 General

Perform acceptance testing. Acceptance testing consists of three parts:

No-Load, 100% rated load, and 125% rated load. Do not perform acceptance testing until the following are complete:

a. The final inspection is complete and the Government has provided on-site approval of the Final Inspection Report.

b. The Test Weight Plan has been submitted and approved by the Government

Provide all personnel and equipment necessary to conduct the tests

SECTION 41 01 20.71 26 Page 13 including, but not limited to, crane operators, riggers, data recorders (personnel), rigging gear, test weights, and measuring instruments.

Performance requirements for testing are defined below. During the process of attaching the test loads to the hoists, verify the brakes are holding the load correctly at 50 percent load before proceeding to 100 percent.

3.7.2 Performance Requirements

3.7.2.1 Speed Control Point Definition

The speed control points on the hoists, bridge and trolley travel are defined as the following

a. Speed Point One - Twenty percent (20%) of the maximum speed in the active speed range.

b. Speed Point Two - Forty percent (40%) of the maximum speed in the active speed range.

c. Speed Point Three - Sixty percent (60%) of the maximum speed in the active speed range.

d. Speed Point Four - Eighty percent (80%) of the maximum speed in the active speed range.

e. Speed Point Five - One hundred percent (100%) of the maximum speed in the active speed range.

3.7.2.2 Speed Range

The speed ranges are defined as follows. For all speed ranges, the minimum speed is 0% rated speed:

(1) Normal Speed: Maximum speed is equal to 100% of rated speed.

(2) Micro Speed: The maximum speed is programmable between 10% and 30% rated speed. It is initially set at 10%

(3) Ultra-Lift: The maximum speed is adjustable up to 250% of rated speed. It is initially set to 200%.

3.7.2.3 Tandem Main Hoisting and Lowering Performances

The maximum allowable difference in elevation of hoist hooks operating in tandem is 1/4 inch per 20 feet of motion.

3.7.2.4 Tandem Travel Performance

The maximum allowable difference in one direction, between trolleys operating in tandem is 1/4 inch per 20 feet of motion.

3.7.2.5 Positioning Accuracy

The minimum unit of motion for any hoist or travel motion, when operating in microspeed is 0.0625 inches, or less.

SECTION 41 01 20.71 26 Page 14

3.7.3 Test Sequence

Perform the following tests in the order that is listed. The specifics for each test are specified below:

(1) No-Load Performance Test

(2) 100 Percent Rated Load Performance Test

(3) 125 Percent Rated Load Performance Test.

During acceptance testing, all collected data will be reviewed after each test has been completed, and prior to starting the next test. If there are unexpected results or inconsistencies in the data, rerun that portion of the test to verify the data. If repairs or adjustments are needed, take the corrective action and re-run the appropriate portions of the test.

3.7.4 Acceptance Test Procedure

Prepare and submit an Acceptance Test Procedure. Include the following elements in the procedure, at a minimum:

a. A list of names and contact information for key Contractor personnel who will be involved with the test, including the qualified laser survey technician.

b. A step-by-step procedure of each test to be performed. For each test to be performed, include the criteria that must be met for the test to be considered successful. For the position accuracy verification test procedure, include sketches for positioning laser equipment and procedures for measuring and documenting hoists, trolley and bridge position relative to a reference point.

c. A list of equipment that will be used during the testing. Include up-to-date calibration certificates for each measurement instrument, including the laser survey equipment, that will be used.

d. Sample copies of the data recording sheets that will be used.

3.7.5 Data Measurement and Recording

For each test, record a full set of calculated and measured readings.

Take measurements at each speed point and load float. At each speed point, compute the output speed, based on output frequency.

Take calculated readings from the digital display unit of the associated VFD. Record values for output voltage, output current and output frequency.

Take measured readings from the output terminals of the associated VFD.

Record values for true root mean square (rms) voltage, rms current, and frequency.

Monitor and verify all hoist position information via the HMI.

3.7.6 No-Load Performance Test

Perform the following performance tests with no-load attached to the hoist:

SECTION 41 01 20.71 26 Page 15

(1) Main Hoist No-Load Performance - Raise and lower the load block, Exercise all five (5) speed control points at normal speed, microspeed, and ultra-lift speed, in each direction (raising only in ultra-lift).

(2) Trolley Travel No-Load Performance - Operate the trolley in both directions. Exercise all five (5) speed control points in normal speed and microspeed, in each direction.

(3) Bridge Travel No-Load Performance - Operate the bridge in both directions. Exercise all five (5) speed control points in normal speed and microspeed, in each direction. Take a full set of readings from each motor to ensure that they are operating properly (synchronized).

(4) Main Hoist Tandem No-Load Performance - Operate the main hoists in tandem operation. Exercise all five (5) speed control points at normal speed and microspeed, in each direction.

(5) Trolley Tandem No-Load Performance - Operate the trolleys in tandem operation. Exercise all five (5) speed control points, in each direction at normal speed and microspeed, while the trolleys are mechanically unlocked. Exercise the fifth speed control point at normal speed in each direction, with the trolleys mechanically locked together.

(6) Positioning Accuracy Verification - Verify the positioning accuracy for the main hoists, both trolleys, and the bridge. Use laser survey equipment to perform the position accuracy verification.

Verify that the laser survey data matches the the data from the crane position feedback instrumentation.

(7) Special Ultra-Lift Test - Verify that each hoist will not enter ultra-lift speed when a load (equal to 5% or less than rated hook capacity) is attached to the hook.

3.7.7 100 Percent Rated Load Performance Test

After loading the main hoists to 100% rated load, but prior to performing performance testing, align the main hoist gears in accordance with SECTION

41 01 20.72 26 BRIDGE CRANE MECHANICAL AND STRUCTURAL REHABILITATION,

Paragraph: Open Gear Alignment. Do not proceed with the 100 Percent Rated Load Performance Test until the main hoist gears have been aligned and the Government has given onsite approval of the gear alignment report.

Perform the following 100 percent rated load performance tests:

(1) Hoist Loss of Power Performance Test - Perform the Hoist Loss of Power Performance Test for each main hoist. Perform each test with a test load equal to 100 percent of the rated load of the hoist that is being tested. Lower the load at the first speed control point in normal speed. While the test load is being lowered, press the "Emergency Stop" push button. Verify that the brakes set and there are no more than four (4) brake wheel revolutions before the load comes to a stop.

(2) Hoist Performance Test - Perform the Hoist Performance Test for each main hoist. Perform each test with a test load equal to 100 percent of the rated load of the hoist that is being tested. Raise

SECTION 41 01 20.71 26 Page 16 and lower the load block. Exercise all five (5) drive speed control points in each direction at normal speed and microspeed.

(3) Trolley Performance Test - Perform the Trolley Performance Test for each trolley. Perform the Trolley Performance Test with the main hoist loaded to 100 percent of rated load. Operate the trolley in both directions and travel the full span of the bridge. Exercise all five (5) drive speed control points in each direction at normal speed and microspeed.

(4) Bridge Performance Test - Perform the Bridge Performance Test with both main hoists loaded to 100 percent of rated load. Operate the bridge in both directions and travel. Exercise all five (5) drive speed control points in each direction at normal speed and microspeed.

(5) Main Hoist Tandem Performance Test - Perform the Main Hoist Tandem Performance Test both main hoists loaded to 100 percent of rated load. Operate the main hoists in tandem operation. Exercise all five (5) speed control points at normal speed and microspeed, in each direction. Verify positioning accuracy through the HMI

(6) Trolley Tandem Performance Test - Perform the Trolley Tandem Performance Test with both main hoists loaded to 100 percent of rated load. Operate the trolleys in tandem operation. Exercise all five

(5) speed control points, in each direction at normal speed and microspeed, while the trolleys are mechanically unlocked. Exercise the first speed control point at normal speed in each direction, with the trolleys mechanically locked together.

3.7.8 125 Percent Rated Load Performance Test

Perform the following 125 percent rated load performance tests. :

(1) Hoist Dynamic Load Test - Perform the Hoist Dynamic Load Test for each main hoist. Perform each test with a test load equal to 125 percent of the rated load of the hoist that is being tested. With the test load applied, operate the hoist at the first speed control point on normal speed. Raise and lower the load at least two (2) feet or one (1) complete revolution of the drum. Stop the machinery at least once in each hoisting direction to ensure proper brake operation.

(2) Trolley Dynamic Load Test - Perform the Trolley Dynamic Load Test for each trolley. Perform the Trolley Dynamic Load Test with the main hoist loaded to 125 percent of rated load. Operate the trolley at the first speed control point on normal speed. Travel the trolley at least five (5) feet in each direction.

(3) Bridge Dynamic Load Test - Perform the Bridge Dynamic Load Test with both main hoists loaded to 125 percent of rated load. Operate the bridge at the lowest speed control point on normal speed. Travel the bridge at least 20 feet in each direction. Stop the bridge at least once in each direction to ensure proper brake operation.

3.7.9 Acceptance Test Report

Prepare and submit an Acceptance Test Report after all acceptance testing is complete. Include the following in the report at a minimum:

a. A narrative summary that describes the testing that took place.

SECTION 41 01 20.71 26 Page 17

Include verification that all planned tests were completed with successful outcomes;

b. Completed data sheets;

c. Descriptions of any deficiencies that were discovered during the testing. If no deficiencies were found, state it in the report;

d. If deficiencies were found, include a description of the means and measures taken to correct the deficiency, as well as verification that the deficiency has been corrected and tests were re-run.

3.8 MANUFACTURER'S SERVICES

3.8.1 General

Provide the services of factory technicians during equipment installation, startup, and testing. The technicians must be an employee of the manufacturer of the equipment that is being installed, started up or tested. Technicians shall have the responsibility of checking the installation and making any field adjustments necessary to obtain a working system within the applicable requirements.

3.8.2 PLC Programmer

Provide programming services for the variable frequency drives, crane PLC, and load cells. The programmer must be on-site during the entire duration of the Government witnessed crane acceptance and load testing. The programmer must have a minimum of two (2) years experience in this type of equipment used in crane applications. Submit qualifications for the PLC Programmer who will be performing the on-site programming support.

The bridge crane uses the following equipment for the controls and drives:

PLC - Allen Bradley CompactLogix 5370 L3 Controller, catalog number

1769-L33ER

Main Hoist VFD - Allen Bradley, catalog number 20G1ND125AA

Aux Hoist VFD - Allen Bradley, catalog number 20G1ND125AA

Bridge Drive VFD - Allen Bradley, catalog number 20G1ND034AA

Trolley Drive VFD - Allen Bradley, catalog number 20G1ND022AA

Main Hoist Load Cells - Water Weights Series 1010

The programmer must perform the following:

1. Verify the firmware version on all VFD sets match (i.e. all main hoist VFDs have the same firmware, all aux hoist VFDs have the same firmware, etc) and that the firmware version is the most recent. If there is a difference in firmware version, or the firmware version is not the most recent, upgrade the VFD firmware.

2. Autotune both main hoist drives.

3. Verify the existing VFD parameters and program the main hoist VFDs as needed such that the main hoist performance complies with the

SECTION 41 01 20.71 26 Page 18

Contract Specifications.

4. Program and calibrate the main hoist load cells. Verify that all load cell displays(crane HMI, 1010 panel weighing instrument and all radio remote control) match.

3.9 SPEED REDUCER OIL TESTING

Collect oil samples from each new speed reducer after the completion of all load testing. Collect and prepare the samples in accordance with

SECTION 41 01 20.72 26 BRIDGE CRANE MECHANICAL AND STRUCTURAL

REHABILITATION, paragraph SPEED REDUCER OIL TESTING. Submit Post-Load Testing Oil Test Results. Submit test results no more than 15 days after samples are collected.

3.10 AS-COMMISSIONED VFD PARAMETERS

Submit the As-Commissioned VFD Parameters for all drives. The as-commissioned VFD parameters for each drive on the crane shall be provided in table format, including description of each parameter and engineering units.

3.11 FIELD TRAINING

Perform training in accordance with the requirements of SECTION:

01 11 01.00 28 SUPPLEMENTARY REQUIREMENTS.

3.12 OPERATION AND MAINTENANCE DATA

In addition to the requirements of SECTION 01 78 23.00 25 OPERATION AND MAINTENANCE DATA, include approved, final copies of the following in the operation and maintenance manual:

a. Dynamic Balancing Report

b. Shaft Alignment Report

c. Final Inspection Report

d. Acceptance Test Report

e. Post-Load Testing Oil Test Report

f. As-Commissioned VFD Parameters

-- End of Section --

SECTION 41 01 20.71 26 Page 19

SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 1 OF 8 PAGES

Little Goose Bridge Crane Main Hoist Rehab

01 11 01.00 28 SD-01 Preconstruction Submittals

1.6 I CProperty Management Plan

1.8 I CEquipment List

1.12 I CPre-Work Survey

1.16 I CAir Purity Control Program

1.20 I CProject Superintendent

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1.18 G CInstallation Supervisor

1.21 G CKey Personnel Substitution

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1.12 I CPost-Work Survey

1.7 G CGovernment Issued Items

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1.3 I SLEAnti Terrorism (AT) Level 1

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1.3 G CQualifications

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1.7 G CAccident Prevention Plan (APP)

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Little Goose Bridge Crane Main Hoist Rehab

01 35 29.10 28 1.9 G CSafe Clearance

1.9 G CAuthorized Individuals

1.7.2.1 G CStandard Lift Plan

1.7.2.2 G CCritical Lift Plan

1.7.2.6 G ECCLead Compliance Plan

1.6.1.5 G CCrane Wheel And Outrigger

Loading Diagram And Deck

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SD-06 Test Reports

1.4 I CMonthly Exposure Reports

1.13 I CNotifications and Reports

1.13.2 I CAccident Reports

1.13.3 I CLHE Inspection Reports

SD-07 Certificates

1.6.1.4 I CCrane Operators/Riggers

1.10.1 I CConfined Space Entry Permit

1.10.1 I CHot Work Permit

1.13.4 I CCertificate of Compliance

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3.2 G CContractor Quality Control (CQC)

Plan

01 55 10.00 28 SD-01 Preconstruction Submittals

1.7 G STTransport Loading Diagrams

1.8 I CDust Control Plan

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1.8 G ECCEnvironmental Protection Plan

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01 57 20.00 28 3.5.4 G ECCWaste Determination

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3.5.3 G ECCHazardous Waste Handling Plan

3.1 G ECCRCRA Metals Waste

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01 78 00.00 28 SD-03 Product Data

3.1.1 G CWarranty Management Plan

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3.5 G CGovernment Issued Items

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Data

1.2.2 G CDraft O&M Manuals and Parts

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1.4 G CO&M Database

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1.2.2 G CFinal Operation And Maintenance

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02 83 33.13 28 1.5 G SOQualified Personnel

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1.3.2 G SOTest Results

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1.3.2 G SOTesting Laboratory

1.6 G SOLead-Based Paint

Removal/Control Plan

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3.4 G ECCLBP Documentation Report

05 50 03.00 26 SD-01 Preconstruction Submittals

1.4.2.2 G CNDE Written Practice

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3.2.4.1 G CWelding Procedures

3.3.2.6 G CWelding Repair Plan

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3.3.2.4 G CWeld Inspection Reports

SD-07 Certificates

3.2.4.1 G CProcedure Qualification Records

(PQR)

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Welding Operators

3.3.2.1 G CCertified Weld Inspector's

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1.4 G CTest of Materials

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Little Goose Bridge Crane Main Hoist Rehab

05 50 04.00 26 2.1 G HDCMaterials

09 90 00.01 26 SD-01 Preconstruction Submittals

1.6 G CSafety and Health Provisions

1.7.2 G CWaste Classification, Handling, and…