Weight Handling Equipment Inspection

SCOPE OF SERVICES PART-1 GENERAL 1.1 APPLICABLE REFERENCES 1.1.1. The Contractor is responsible to perform all services in accordance with current standards and contents of the references listed in this specification. 1.1.2. Occupational Safety and Health Administration (OSHA) Code of Federal Regulations (29 CFR 1910, 1917 SubPart C & 1919). 1.1.3. American National Standards Institute (ANSI) series B-30. 1.1.4. Crane Manufacturers Association of America Specifications #70 and #74 1.1.5. National Electrical Code Article 610 - Cranes and Hoists 1.1.6. Wire Rope Technical Boards Wire Rope User's Manual 1.1.7. Power Crane Shovel Association Standards #4 and #5 1.1.8. CEU Cleveland General Unit Location Map. 1.2. WORK INCLUDED: 1.2.1. The Contractor shall provide an inspector accredited by the United States Department of Labor to inspect, test, and report the condition of weight handling equipment at Training Center Cape May, NJ in accordance with 29 CFR 1919. Actual equipment types and locations are shown in Enclosure (1). The Contractor shall provide all necessary transportation, labor, equipment, materials, weights, measures, testing materials, and perform all operations to inspect, test and reporting the condition of the weight handling equipment. 1.2.2. The Contractor shall certify that each piece of equipment has been tested and inspected in accordance with (IAW) 29 CFR 1919 and meets the requirements set forth in the current applicable regulations/standards governing that piece/type of equipment. 1.2.3. The Contractor shall submit reports IAW 29 CFR 1910 & 1919 to the Contracting Officers Point of Contact (POC) for each piece of equipment tested and inspected. 1.3. QUALIFICATION OF CONTRACTOR EMPLOYEES: 1.3.1. The Contractor shall employ competent and qualified technicians and engineers to perform the required work of this contract. All personnel performing inspections and tests shall be certified as required by the applicable reference/standard by the United States Department of Labor as authorized to inspect, test and issue documents and/or papers of certification on cranes, hoists, forklifts, chain falls and other weight handling and material handling equipment. Each inspector shall be qualified academically and operationally in the practical application of the equipment listed in Enclosure (1). All personnel assigned by the Contractor to perform work under this contract shall be physically able to perform assigned work. 1.3.2. The Contractor (inspector) shall be responsible for setting-up and performing all operational tests and rated load tests as described in this specification. The Contractor (inspector) shall attach and inspect all rigging in accordance with the manufacturers written requirements for the rated load test and be responsible for determining the setup of the specific piece of equipment; i.e. boom angle, radius and all other operational factors including the calculation of appropriate weights to be imposed on equipment. PART-2 PRODUCTS 2.1 GENERAL 2.1.1. The Contractor will furnish all equipment, instruments, tools, safety lines and harnesses, and other items necessary for accomplishment of these services. PART-3 EXECUTION 3.1. INSPECTIONS, TESTS, REPAIRS AND CERTIFICATIONS - GENERAL REQUIREMENTS: 3.1.1 The Contractor shall inspect, test, certify and provide separate quotation for repair of any weight handling equipment not meeting required operational specifications at each unit that is listed in Enclosure (1). The inspection shall include all accessories generic to the piece of equipment. Equipment identified as requiring a rated load or unit proof test shall also have the tests performed in accordance with the applicable sections of the reference section of this specification. Testing shall be conducted in accordance with the manufactures written instructions. In the absence of the manufactures instructions, prudent industry practices shall be followed in order to comply with the applicable ANSI/ASME standard for each piece of equipment. In no case shall repairs be made prior to receiving specific authorization from the Contracting Officer. 3.2. TESTS AND INSPECTIONS: When applicable to the individual piece of equipment, an inspection shall include, but is not limited to, the following items: 3.2.1. All safety devices for malfunction and compliance with applicable 29 CFR 1900 series regulations. 3.2.2. All control mechanisms for adjustment, wear, and lubrication. 3.2.3. Gasoline, diesel, electric, or other power plants for improper performance or noncompliance with safety requirements. 3.2.4. Electrical apparatus for malfunctioning, signs of excessive deterioration, dirt or moisture accumulation. 3.2.5. All limit switches or limiting devices without a load on the hoist. 3.2.6. Loose bolts or rivets. 3.2.7. Foundation supports for continued ability to sustain imposed loads. 3.2.8. Structural members for deformation, cracks and corrosion. 3.2.9. Load carrying ropes or hoist rope for excessive stretch, wear, broken wires and dis'tor'tion. 3.2.10. Rope reeving for noncompliance with manufacturer's recommendations. 3.2.11. Dye check hooks for deformations or cracks, wear, severs, nicks or gouges, latch enlargement and damaged or malfunctioning latch (if provided). 3.2.12. Check hooks for enlarged throat opening, excessive hook point twist and excessive surface wear. 3.2.13. Cracked or worn sheaves and drums. 3.2.14. Worn, cracked or distorted parts such as pins, bearings, shafts, gears, rollers and locking devices. 3.2.15. Excessive wear of chain drive sprockets and excessive chain stretch. 3.2.16. Hoist brakes, clutches and operating levers for proper functioning before beginning any operational tests. 3.2.17. Travel steering, braking and locking devices for malfunction. 3.2.18. Excessive wear on brake and clutch system parts, linings, pawls and ratchets. 3.2.19. Load, boom angle, and other indicators over their full range, for any significant inaccuracies. 3.2.20. Radiators and oil coolers, for leakage, improper performance, or blockage of air passages. 3.2.21. Deterioration or leakage in air or hydraulic systems. 3.2.22. Cleanliness of oil filters and strainers. 3.2.23. Excessively worn tires. 3.2.24. Plumb of mast, chords, lacing, and tension in guys. 3.2.25. Rust on piston rods and control valves when a crane has been idle for a period of time. 3.2.26. Check Runways and Rails for plumb columns, well-seated columns, sagging girders, level rails, and strait rails. 3.2.27. Check Tracks and Track Wheels for cracks, wear, distortion, alignment etc. 3.3. OPERATIONAL TEST: 3.3.1. The Contractor shall perform an operational test on each piece of equipment. Operational tests shall include the operation of all operating and control mechanisms. Tests shall note improper function, maladjustment, and excessive component wear. The operational test shall include operation of all components with partial load, in which all functions and movements including rotations (where applicable) are performed. 3.4. RATED LOAD TEST. 3.4.1. All equipment within shall be rate or unit proof tested every other year. All required tests shall be carried out in accordance with the manufacturers written instructions. In the absence of manufacturers' instructions, all tests shall be done by the use of weights as a dead load, limited to the percentage identified in the applicable reference/standard governing the testing of that piece of equipment. Typically, this is 110% or 125% of the manufacturers rated load for the applicable piece of equipment. Only where the equipment being tested is located in such a manner as to damage other equipment if load failure occurs during testing, may dynamometers or other recording test equipment be used rather than dead load testing. The Contractor shall ensure that accuracy is maintained and proof loads adjusted accordingly. Dynamometers may however, be utilized on fixed stationary equipment that has no range of movement outside the vertical plane. 3.4.2. Any dynamometers or recording test equipment, owned by an accredited person meeting the requirement of 29 CFR 1919, shall have been tested for accuracy within one (1) year of the start of this contract. Such test shall be performed with calibrating equipment which has been checked in turn, so that indications are traceable to the National Bureau of Standards. 3.4.3. Where the test equipment is not the property of the accredited person meeting the requirements of 29 CFR 1919, that person shall not issue any certificate based upon the use of such equipment, unless the owner of said equipment has made available a certificate of accuracy based on the requirements of this specification obtained within one (1) year prior to the start of this contract, and stating the errors of the equipment. 3.8. CERTIFICATION LABEL. 3.8.1. This label shall be impervious to weather and shall not interfere with the operation of the equipment. The label shall contain the following information: Initial Inspection Date Load Test Date Make Model Serial Number Capacity Inspector's name and certification number. 3.9. INSPECTION SCHEDULING. 3.9.1. The schedule for work will be at the Contractors discretion provided inspections and testing are accomplished within thirty (30) calendar days after receipt of the written Notice to Proceed, provide the Contracting Officer a schedule of inspections and the date that the equipment will be inspected. 3.9.2 The Contractor shall schedule tests and inspections at the Coast Guard units where the subject equipment resides with the Commanding Officer/Officer in Charge (CO/OIC) of the unit. Tests and inspections shall be scheduled so as to minimize interference with normal Coast Guard activity. Inspections shall be performed Monday through Friday (except Federal Holidays) between 8:00 AM and 4:30 PM. 3.9.4. The Contractor shall notify each Coast Guard unit by telephone not less than two (2) working days prior to arrival for inspections. 3.9.5. All tests and inspections shall be observed by a Coast Guard representative. 3.9.6. The Contractor shall conduct a closing conference with the Coast Guard. The purpose of this conference is to inform Coast Guard personnel of the results of the tests and inspections, and to make recommendations relative to the correction of deficiencies, maintenance procedures, operations and any other considerations for continued safe operation of the equipment. The Contractor shall immediately notify the Coast Guard representative if a piece of equipment is discovered unsafe to operate, so that the equipment can be immediately removed from service. 3.10. INSPECTION REPORTS. 3.10.1. In accordance with 29CFR 1919, the Contractor shall provide written reports to the Coast Guard stating the results of all tests and inspections. The reports shall be of two types, Initial Reports and Final Reports. Each piece of equipment tested and inspected shall have a separate initial and final report completed for it. 3.10.2. Initial Report. Two (2) legible, hand written (one original and one scanned copy) copies of the Initial Inspection Report shall be submitted to the Coast Guard Representative for signature, upon completion of the inspection. The signature attests to the fact that tests and inspections were performed as required. The original report is to be delivered to the Coast Guard Unit for their equipment records. The Initial Report shall include but not be limited to : a. A title block containing the Contractors name and address; b. The equipment manufacturers name c. The equipment type d. The model number e. The serial number f. The capacity g. The Coast Guard Unit (location of the equipment) h. The date the equipment was tested i. The equipment serial number as listed in Section 04 or as corrected on the equipment verification form. j. The Signature of the certified inspector who performed the test and/or inspection attesting to the fact that the inspection/testing was completed k. The Coast Guard Representative signature attesting/acknowledging that the work was performed as required. 3.10.3. Final Report. A Final Report shall be submitted for each piece of equipment tested and inspected. Within thirty (30) calendar days after the test and inspection. The Contractor shall submit one original and one electronic copy of a typewritten report including the information provided on the initial report, to Civil Engineering Unit Cleveland. The Final Report shall include but not be limited to: a. A United States Department of Labor Certification Form. b. A title block containing the Contractors name and address; the equipment manufacturers name; equipment type, serial number, capacity; Coast Guard unit (location of the equipment); date equipment was tested; and the equipment serial number as listed in Section 04. c. A diagram/schematic containing a checklist for the specific piece of equipment that was tested and inspected. d. A columnar table to indicate the status of each inspection item so as to indicate whether the item inspected/tested was satisfactory or unsatisfactory and whether and unsatisfactory items were corrected or not. e. A Deficiency and Recommendation Report noting in detail any deficiencies and/or recommendations. f. Violations of 29 CFR 1900 series or ANSI/ASME B.30 series, shall be addressed in a separate paragraph of the report. g. The Signature of the certified inspector who performed the test and/or inspection attesting to the fact that the inspection/testing was completed 3.10.4. Recommendations - Provide recommendations in the initial or final report as appropriate for the following categories of work: a. Immediate repairs. b. Routine maintenance and repair. c. Modifications for OSHA compliance. 3.10.5. Discrepancies shall be cross-referenced to drawings, sketches and/or photographs and applicable ANSI/ASME B30/56 series standards and 29 CFR 1900 series regulations. Note any significant affects or consequences that could occur if the maintenance or repair work is not complete. 3.10.6. Authorized Repair and Maintenance Costs - Provide detailed cost figures for all repairs, repainting, modifications maintenance work conducted. Each element of work shall be a separate line item with details of labor, materials and equipment costs. The costs shall be complete in-place costs, and shall include overhead, profit, and applicable taxes. 3.12. TRAVEL AND LODGING. 3.11.1. Claims for travel or lodging except where otherwise noted herein will not be authorized or accepted. Unless otherwise noted, all travel and lodging associated with this contract is to be considered as part of the inspection, testing, and certification for all equipment inspected, and shall be included in the Contractor's bid or proposal. Enclosure (1) Weight Handling Equipment Locations