Bureau of Reclamation, Snake River Area Office, 214 Broadway Avenue, Boise, ID 83702

36 -- CRANE CONTROL REPLACEMENT EQUIPMENT SOL 00SQ110007 DUE 062300 POC Bruce Mccarthy, 208-365-2600 Ex.15, Marie Day, Purchasing Agent 208-334-1744 E-MAIL: MDAY@PN.USBR.GOV, MDAY@PN.USBR.GOV. This is a combined synopsis/solicitation for a commercial item requirement in accordance with the format FAR Subpart12.6 as supplemented with additional information included in this notice. This announcement constitutes Solicitation 00SQ110007 issued as an RFQ and incorporates provisions and clauses in effect through FAC 97-16. NAICS code is 335314, and the size standard is 750 employees. Anderson Ranch Powerplant Bridge Crane Control Upgrade a. General -- The contractor shall supply all equipment necessary to upgrade the control equipment for the existing 60 ton overhead bridge crane at the Anderson Ranch Powerplant. Cable between cabinets will be supplied by the government, except where specified below. The contractor is responsible for providing all other electrical equipment necessary to make the crane operational. If the contractor supplied equipment requires additional components from what is described in these specifications, the contractor shall provide them as part of the bid price for the contract. (1) Reclamation will have the existing wound rotor motors converted to squirrel cage type motors. Any special requirements needed to make the motors compatible with the contractor provided equipment shall be submitted within one week after notice to proceed. The contractor is not responsible for any modifications to the motors. (2) Reclamation personnel will install the equipment provided using detailed instructions supplied by the contractor. These instructions shall include a written description and appropriate electrical and mechanical drawings of the installation procedure, including all common problems with an installation of this type. (3) Upon completion of the installation Reclamation will contact the Contractor to schedule a contractor supplied onsite technician who specializes in all types of equipment being supplied. This technician will train government personnel in maintenance and configuration of the systems provided and assist in a final configuration and testing of the equipment. It is expected that the technician will be required onsite for five eight-hour days. If the contractor expects this work to take more time than the forty hours indicated, he will submit a schedule of activities with time required to complete each activity. If additional time is required to complete these activities the cost will be included in the bid for the project at a daily rate as specified in the bid schedule. b. Submittals. -- Unless otherwise specified, the Contractor shall submit the following drawings and data complete in accordance with these specifications within 30 days after notice to proceed. The government shall approve or disapprove the submittals within 30 calendar days. Submittals that are not approved or that require changes or revisions shall be revised and resubmitted for approval, and shall show changes and revisions with revision date. All requirements specified for the initial submittal shall apply to any resubmittals required. Unless otherwise specified, all submittals which are to be resubmitted shall be resubmitted by the Contractor within 30 calendar days after the Contractor has received the Government's comments. (1) Approval drawings and data (a) Commercial products data. (b) Electrical control schematic and operation description. (c) Installation instructions as specified in paragraph a(1). (d) Special motor modification instructions as specified in paragraph a(1) if required. (e) Estimated time required and schedule of activities for onsite technician if time is other that specified in paragraph a(3). (g) Complete data including manufacturer, type, size, and rating for the following: (aa) Adjustable frequency crane controls.(bb) Disconnecting device. (cc) Festooned conductors and support equipment. (dd) Radio control equipment (2) Final data. -- (a) Service manuals for commercial products. Data not applicable to equipment furnished shall be marked out. Service manuals shall also contain: (aa) General arrangement drawings including all drawings, electrical control schematics and wiring diagrams updated for the as-installed condition. (bb) operation instructions, maintenance requirements and intervals, and a list of spare parts. c. Existing Crane Specifications. All existing equipment is supplied power from a 100 amp breaker off the 480 VAC station service system. Crane lighting is supplied from this source through a 2 KVA 480 to 120 lighting transformer. (1) Main Hoist -- The main hoist has a travel of 35 ft and operates at speeds of up to 5 ft per minute. This 60-ton rated hoist is equipped with an electrical brake system utilizing 480v power and is driven by a 25-hp motor with a nameplate as follows. Westinghouse Type -- CI Sleeve Bearing Motor, Frame #405, 25HP 878 RPM, 220/440 volt 55 amps -- Measured maximum no-load current 3 phase 60 HZ Style No. 1-N-5242 (2) Auxiliary Hoist -- The auxiliary hoist has a travel of 44 ft and operates at speeds of up to 31.5 ft per minute. This 10-ton hoist is equipped with an electrical brake system utilizing 480v power and is driven by a motor with the same nameplate as the Main Hoist. (3) Crane Trolley -- The trolley can travel at speeds of up to 29.2 ft per minute and is driven by a 5-hp motor with a nameplate as follows. The crane trolley has an electrical brake system utilizing 480v power. Westinghouse Type -- CI Ball Bearing Motor Frame #324 5HP 850 RPM, 220/440 volt, 9 amps -- Measured maximum no-load current, 3 phase 60 HZ, The Span of the Bridge is 50'-0 (4) Crane Bridge -- The bridge can travel at speeds of up to 70.5 ft per minute and is driven by a 25-hp motor with a nameplate as follows. Westinghouse Type -- CI Sleeve Bearing Motor, Frame #405, 25HP, 860 RPM, 220/440 volt, 47 amps -- Measured maximum no-load current, 3 phase, 60 HZ, Style No. 1082 735. The existing bridge brake is hydraulic and is operated by a pedal in the cab. A new electrical brake shall be provided to replace the old system. The dimensions of the Bridge Brake Assembly are shown on Drawing 1. (5) Cab controls -- The existing cab controls are Westinghouse AC powered Type A Drum Controllers. d. Minimum Equipment Supplied (1) Panel or panels with all motor control brake control and adjustable frequency drive controllers to be mounted in the crane cab shall be provided. These panels should include all components necessary to drive the existing motors including resistors and other power filtering equipment. Cab dimensions are provided in Drawing 2. Wireways can be utilized, as long as the access opening area and an operating area are maintained. (2) A control box or boxes to replace cab drum controllers shall be provided. Controls shall be as specified in paragraph e(1). Cab dimensions are provided in Drawing 2. Wireways can be utilized, as long as the access opening area and an operating area are maintained. (3) Electric brake assembly to replace hydraulic bridge brakes shall be provided. See Drawing 1 for dimensions of the existing brake drum and mounting area. (4) Radio control, shoulder hung, operating console with all equipment required to operate the crane. This shall include any peripheral equipment such as battery chargers and wall hangers. Radio controls shall be as specified in subparagraph e(1)(d). (5) Equipment required to upgrade the existing mainline runway collector assembly shall be provided as required. Equipment provided shall be compatible with the existing collector rails. For details on the existing equipment see Drawing 1. Mainline runway collector assembly shall be as specified in subparagraph e.(2). (6) Festooned conductors with supports for suppling power and controlling motors and brakes on the moving trolley shall be provided. This conductor must have sufficient length to cover full travel of the trolley. A termination box with terminal blocks shall be provided for each end of the Festooned conductors. Loops in the cable shall not hang down more than 1.5 feet from support cable. (7) Six full sets of maintenance and operations manuals including written description and appropriate electrical and mechanical drawings shall be provided. Written installation procedure, including all common problems with an installation of this type shall also be provided. e. Electrical equipment. -- All electrical equipment shall be designed for operation within its rated temperature limits in an ambient temperature of 40 C. (1) Controls (a) General. -- Controls for the crane motions shall be an adjustable frequency speed control for a squirrel cage motor with speed control ranges as indicated in subparagraph c. Existing Crane Specifications. Simultaneous operation of the main hoist, trolley, and bridge drives is required. The controls for the crane shall have overload protection for each motor and undervoltage protection for motors over 20 horsepower. Control circuit voltage shall be 120 volts. The loss of control voltage shall cause the brakes to set. Master control equipment, whereby the operator may control the functions of the crane, located in the operator's cab shall be arranged to give the operator maximum convenience and view. The master controllers shall have ball and rod handles mounted on vertical radial arms and shall return to neutral if not held. Detents or other means shall be provided to indicate each speed step. An individual controller shall be furnished for each motion of the crane. The handle of the hoist controller shall pull back to hoist. The travel controllers, located in the cab, shall be arranged so the handle moves in the direction of travel. Preliminary operation of controller to set up control circuits prior to initiating motion will not be permitted. The operator shall be able to stop the motors, without time delay, from any position of the master controllers. The motor controllers shall have definite speed control points in each direction of operation. Instantaneous forward and reverse jog buttons shall be provided for the trolley controllers. The drift point of the trolley is bypassed on jog. Each of the speed points shall be capable of 60 minute continuous operation without overheating or overloading any part of the crane system. The starters for the motors shall be the full voltage, magnetic type. The overload protection shall be provided in each phase of all the motors and shall be automatic resetting. The overload device shall provide sufficient time delay to permit the motor to draw starting current during a normal starting period with rated or lesser loads applied to the hoist without causing the relays to trip. Operation of an overload device shall deenergize the motor. The control circuit shall be such that the controls must be released before the motor can be restarted. (b) Disconnecting device. -- A disconnecting device with overcurrent protection shall be provided between the runway collectors and the electrical equipment on the crane and shall be electrically operable (open and close) from the remote radio control pushbutton station or the operator's cab. The device shall provide means for being locked in the open position and shall be rated to interrupt a minimum fault current of 10,000 amps, symmetrical at rated voltage. (c) Adjustable frequency control. -- The adjustable frequency controls shall be microprocessor-based. Software must include inverter plug reverse operation, load check function for hoist applications, and automatic data write-protection. Inverters shall have stepless/infinitely variable control. The method shall provide for any speed between a programmed minimum and maximum speed by using detent points for each direction of motion. as follows: 1st Detent: Motor soft starts (ramps up) to a field programmable minimum speed. Direction shall be selected by lst detent. To 2nd Detent: Motor speed holds To 3rd Detent: Motor speed increases over a field programmable time ramp until desired speed is attained (Note: Maintaining the 3rd detent position -- maximum speed will ultimately result.) Back to 2nd: Motor speed holds Detent Back to lst Motor speed decreases down a field programmable Detent: time ramp until desired speed is attained. (Note: Maintaining the lst detent position—minimum speed will ultimately result.) Release to An electrically released, spring-set motor Off Position: holding brake shall be released by means of an electromechanical contactor that supplies full voltage to the brake coil. The adjustable frequency speed control shall equal "IMPULSE G+, with Open Loop Vector Mode" as manufactured by Electromotive Systems, Inc, PO Box 13616, Milwaukee "Smartorque," as manufactured by Harnischfeger, P.O. Box M-2015, Milwaukee, WI 53201; or Toshiba Tosvert-130G2, as manufactured by Toshiba International Corporation, 13131 West Little York Road, Houston, TX 77041. (d) Radio control. -- Radio control shall operate through the static controllers provided for cab control; however, simultaneous control from both cab and remote radio shall not be possible. Radio control shall be provided for all crane motions with complete range of speed control and remote control of the crane disconnect means. Specific requirements for the radio control are as follows: (aa) Controlled rangeon all functions with a maximum of 200 feet adjustable down to 50 feet. (bb) Solid-state, fail-safe electronic control circuits on all remote control devices and receiver equipment. (cc) The crane disconnect device shall be operable from the radio transmitter via electrical means. (dd) The radio controlled crane shall be under the full control of the operator on the floor at all times. A special additional safety channel shall be built into the transmitter. The absence of a signal on this channel shall cause all crane motion to stop. The failure of an electronic part shall not result in runaway of a crane motion. All circuits up to the output relays shall be designed so that the failure of an electronic component will result in the immediate stopping of the crane or the involved motion. All crane motions shall stop automatically when the receiver is out of range of the control transmitter. The station shall be capable of controlling the main or auxiliary hoists, trolley and bridge in the same manor as the equipment in the cab. Markings on the station shall clearly identify the load will travel when a function is activated. The controls for the hoist shall be marked "UP" and "DOWN"; for the bridge, "FORWARD" and "REVERSE"; for the trolley, "UP STREAM and "DOWN STREAM"; and for the disconnect device, "START and "STOP". (ee) No electrical interference or extraneous signal from within or without the plant shall result in unsafe operation of the system. Also, the radio system shall not generate any signal which will interfere with the powerplant control, excitation, protection, or communication systems. The radio system shall provide safe, reliable, fail-safe operation under all conditions including substantial momentary voltage drops on the system supplying crane power. (ff) System shall give positive operation under all conditions of temperature, humidity, and vibration encountered in the plant. This system shall be designed to have an extremely long service life, commensurate with the service life of the crane. (gg) Response to the operator's signals of the complete radio control system shall be virtually instantaneous. No noticeable lag shall be encountered. (hh) Components of the system shall withstand normal handling by lay users. Mechanical design shall be conservative. Rugged, industrial type parts and construction shall be used throughout. Operator shall require no special training or electronic knowledge. (ii) All electronic circuits and mechanical work shall be designed at the outset to be troubleproof. No vacuum tubes shall be used. Long-lived semiconductor active elements shall be used throughout the system. Other long-lived electronic components shall be used to complement the long service life of the semiconductor elements. As far as is practical, electronic circuits shall be fabricated in module form and be readily replaced should they ever require service. No in-plant maintenance beyond the occasional replacement of plug-in relays or plug-in circuit module shall be required. Transmitter shall be completely self-contained with battery low voltage light or gauge. No wires or external antennas shall be attached to the transmitter. Control shall be entirely by means of radio signals. Battery pack shall be self-contained. (jj) The batteries for the remote transmitter shall be rechargeable batteries designed to provide a minimum of 8 hours of continuous operation before recharging. Each remote transmitter shall have spare rechargeable batteries, and a charger capable of charging all batteries at one time. This battery system shall be capable of continuous operation of the radio system for an indefinite period of time. Low voltage of these batteries shall not cause misoperation of the crane. (kk) Motion switches shall be especially designed with spring return to neutral when the operator's hand is removed for full "deadman" operation. Spring restoring force shall be light to minimize fatigue. Operator shall be able to readily control crane without looking at switch positions so that his full attention may be given to the crane and its load. (ll) An additional safety channel shall be built into the control box. It shall automatically come on when the operator throws the master-on toggle switch. In addition to any motion command, this safety channel shall be on for the crane to move in any direction. A crane light shall also be tied to this control safety channel in the receiver. The operator then knows he has full control of the crane when the crane light is on. (mm) A pushbutton switch shall be provided to sound a crane warning gong, or horn. (nn) Preferably, an FCC license shall not be required. Contractor shall certify in writing to the owner that transmitter fulfills all pertinent FCC regulations in effect at the time of delivery. There shall be no wait for the assignment of special frequencies by FCC. (oo) The control switches shall give directional commands and control all speeds in each direction. The crane control must respond to the radio commands properly, regardless of how rapidly the transmitter levers are manipulated including plugging operation. The transmitter shall be capable of transmitting the master command, all motion commands, and all auxiliary function commands simultaneously. The receiver shall be equally capable of simultaneous control. (pp) The enclosure which houses the receiver shall be a NEMA type 12 box providing protection against dust, moisture, etc. The enclosure door shall be neoprene gasketed. The door shall have a special key to prevent access by unauthorized personnel. (qq) A lockable selector switch shall be provided in the cab for transmitting (transforming) the control from radio to cab backup station. (rr) System design shall provide for rapid identification of faults to the module involved by operating or electrical maintenance personnel. Test lights shall be provided on all decoding/relay-driving modules to indicate whether or not those modules are functioning properly. A simple portable test device, the use of which shall require no interpretive readings, shall be provided with thesystem to test the transmitter. (ss) The radio system shall operate through, yet be separable from, the regular control system. Radio control system malfunction or failure shall not prevent normal cab control operation. The radio control system shall equal Series 9000 by Telemotive, as manufactured by Maxtec International Corp., 6470 W. Cortland Street, Chicago IL 60635. (2) Collectors. -- The collectors shall be of the double-shoe pantograph type (parallel hinged Posted 05/19/00 (W-SN456907). (0140)

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