St_Stephen_Bridge_Crane_Rehab_-_Scope_of_Work_Final_V_1_(2).docx

REHABILITATION OF 135-TON BRIDGE

CRANE AT ST STEPHEN POWER HOUSE

ST STEPHEN SOUTH CAROLINA

Scope of Work Rehabilitation of 135-Ton Bridge Crane at St Stephen Power House

GENERAL

This section describes the requirements to rehabilitate the 135-Ton Bridge Crane located at St. Stephen Power Plant, St Stephen South Carolina.

The paragraph entitled “Basic Renovation” contains general project requirements. The paragraph entitled “Bid Options” describes additional aspects of work not covered in the “Basic Renovation” section. The paragraphs entitled “Products” of Section 41 01 20.73 26 Bridge Crane Electrical Rehabilitation, Section 41 01 20.71 26 Bridge Crane Data, Testing and Training, and Section 26 05 00.00 26 Basic Electrical Materials and Methods, contains additional detailed project requirements which applies to both the “Basic Renovation” and all other bid options. All aspects of design, construction, and testing shall be in accordance with the criteria listed in the paragraph entitled “References” and the requirements of the paragraph entitled “Execution” in Specification Section 41 01 20.73 26 Bridge Crane Electrical Rehabilitation, Section 41 01 20.71 26 Bridge Crane Data, Testing and Training, and Section 26 05 00.00 26 Basic Electrical Materials and Methods as included in this solicitation.

Scope The contractor shall furnish all labor, materials, equipment and other associated incidentals necessary to perform, in strict accordance with the requirements of this scope of work and Specifications 41 01 20.73 26 Bridge Crane Electrical Rehabilitation, 41 01 20.71 26 Bridge Crane Data, Testing and Training, and 26 05 00.00 26 Basic Electrical Materials and Methods, all the work necessary to rehabilitate the controls and motors of the 135-ton crane. All work shall comply with the latest edition of the USACE Safety and Health Requirements Manual, EM-385-1-1 CHANGE 6. All rehabilitation, testing, and design work shall be in accordance with the standards referenced in the specification paragraph entitled “References” of section 41 01 20.73 26 Bridge Crane Electrical Rehabilitation.

Shop Drawings Shop drawings have been included with this solicitation.

O&M Manual Operation and Maintenance (O&M) Manual information has been included in this solicitation. The 135-Ton Bridge Crane operation and maintenance (O&M) manual describes crane function and current maintenance procedures and materials.

Verification of Dimensions The Contractor shall verify all dimensions in the field and shall advise the Authorized Representative of the Contracting Officer of any discrepancy before performing any work.

Site Investigation The contractor shall verify the dimensional accuracies of the contract and shop drawings against the actual dimensions for all equipment replaced or repaired.

Submittals Provide submittals in accordance with the Specification Section 41 01 20.73 26 Bridge Crane Electrical Rehabilitation included with this solicitation.

Government Inspection The Government reserves the right to witness any contractor testing, repair, and inspection.

Delivery, Storage, and Handling Equipment delivered shall be placed in a storage area as directed by the Authorized Representative of the Contracting Officer, protected from the weather, humidity and temperature variations, dirt and dust, or other contaminants.

BASIC RENOVATION

Provide all labor and materials to perform all work required for a fully operational crane.

General The 135-Ton Bridge Crane is a single purpose item of equipment designed and arranged for handling the generator rotors, the turbine shaft, runner and inner head cover assembly, and numerous other equipment. The bridge has a span of 61-1/2 feet and is fed from a 480 volt, 3-phase feedrail running almost the length of the powerhouse. The operator’s cab is entered from a platform in the south corner of the powerhouse. The crane rails are at elevation 81.94. The main hoist unit has a lifting capacity of 148 tons (10% overload) and the auxiliary hoist unit has a lifting capacity of 20 tons. An operator’s cab is entered from a platform in the south corner of the powerhouse.

Crane Operating Requirements:

Main Hoist – constant speed 3.86 fpm Auxiliary Hoist – constant speed 20.26 fpm Trolley – constant speed 28.1 fpm Bridge – 67.7 fpm Crane Travel – 241’-2” Machinery Deck Clean the machinery deck where renovation work is required. Provide reconfiguration of motors, shafts, and machinery bases in order to support new and replacement equipment.

Main Hoist Unit Remove and replace main hoist motors on the hoist.

Auxiliary Hoist Units Remove and replace auxiliary hoist motors on both of the auxiliary hoists.

Trolley Drive Units Remove and replace trolley motors and brakes on both trolleys.

Bridge Drive Unit Remove and replace bridge drive motor and brake on the crane. The bridge drive shall be the A-1 arrangement.

Crane Controls Remove and replace existing crane controls. New crane controls systems shall be as specified in the Specification 41 01 20.73 26 Bridge Crane Electrical Rehabilitation included with the solicitation.

Power Panel Remove and replace existing 480V power distribution panel. The panel shall be as specified in the Specification 41 01 20.73 26 Bridge Crane Electrical Rehabilitation included with the solicitation.

Collector System Remove and replace existing collector shoes.

BID OPTIONS

Provide itemized costs for all labor and materials to perform all work for the following bid options.

Main-line Conductors Replace existing main-line conductors. The new main-line conductors shall be as specified in the Specification 41 01 20.73 26 Bridge Crane Electrical Rehabilitation included with the solicitation.

Main-line Disconnect and Contactor Replace main-line disconnect and contactor as specified in Specification 41 01 20.73 26 Bridge Crane Electrical Rehabilitation included with the solicitation.

Phase Monitor Replace existing phase monitor.

Surge Protection Provide surge protection for the crane.

Cable Carrier System Replace existing cable carrier system. The cable carrier system shall be as specified in the Specification 41 01 20.73 26 Bridge Crane Electrical Rehabilitation included with the solicitation.

Limit Switches Provide new limit switches on main hoist to limit hook travel. Limit switches shall operate at all hoist speeds.

Human Machine Interface (HMI) Provide HMI units for the crane. The HMI shall be as specified in the Specification 41 01 20.73 26 Bridge Crane Electrical Rehabilitation included with the solicitation.

PRODUCTS

Materials General Materials and equipment shall be standard products of manufacturers regularly engaged in the fabrication of complete and totally functional cranes including necessary ancillary equipment.

Use of Asbestos Products Materials and products required for designing and manufacturing cranes shall not contain asbestos.

EXECUTION

General Execution of work shall be performed as indicated in Part 3 of Specification Section 41 01 20.73 26 Bridge Crane Electrical Rehabilitation as included in this solicitation.

Load Test Hoist One hundred percent rated load test shall be tested for all hoist per ASME B30.2 2011 and the latest edition of the USACE Safety and Health Requirements Manual, EM-385-1-1 CHANGE 6.

a. Hoist Static Load Test: Holding brakes and hoisting components shall be tested by raising the test load approximately 1 foot and manually releasing one of the holding brakes. Load shall be held for 10 minutes. First holding brake shall be reapplied and second holding brake released. Load shall be held for 10 minutes. Any lowering that may occur indicates a malfunction of brakes or lowering components.

b. Dynamic Load Test: Test load shall be raised and lowered through the full range operating in each speed. Machinery shall be completely stopped at least once in each direction to ensure proper brake operation.

c. Hoist Load Brake: With test load raised approximately 5 feet and with the hoist controller in the neutral position, holding brake shall be released. Load brake shall be capable of holding the test load. With holding brake in released position, test load shall be lowered (first point) and the controller shall be returned to OFF position as the test load lowers. Load brake shall prevent the test load from accelerating.

d. Hoist Loss of Power Test: After raising test load to approximately 8 feet, slowly lowering the test load, the main power source and control pushbutton shall be released verifying that the test load will not lower and that both brakes will set.

e. Trolley Dynamic Load Test: While operating the trolley the full distance of bridge rails in each direction with test load on the hook(one cycle), proper functioning of all drive speed control points and proper brake action shall be tested.

f. Bridge Dynamic Load Test: With test load on hook, bridge shall be operated for the full length of the erection bay in both directions with trolley at each extreme end of bridge. Proper functioning of all drive and speed control points and brake action shall be verified. Binding of the bridge end trucks shall indicate malfunction.

END OF SECTION

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