SAFETY--Testing of Cableways In Reply Refer To: May 26, 1989 WGS-Mail Stop 405 BRANCH OF OPERATIONS TECHNICAL MEMORANDUM 89.04 To: Regional Hydrologists and District Chiefs From: Chief, Branch of Operational Support Subject: SAFETY--Testing of Cableways In our memorandum titled "SAFETY--Nondestructive Testing of Cableways," dated January 6, 1989, we explained that we were continuing with the existing procurement mechanism for nondestructive testing and inspection of our cableways. In reviewing the present testing method, we have decided to add a load test to the inspection which will check the strength of the entire cableway system, especially the anchors, saddles, turnbuckles, and other periopheral cableway supporting equipment. We are purchasing a special trailer with equipment to conduct this load test from Halkin Services, Inc., and when the trailer is completed, Halkin will begin the load test. However, at this time we are only purchasing one trailer (including equipment), and Halkin will only be able to do the test at limited locations. If the test is successful, we will probably purchase more trailers with equipment. Attached are a Schedule of Articles (SOA) and a Justification for Other than Full and Open Competition (JOFOC) that incorporate the load test. When contacting Halkin Services to do nondestructive testing in your District, be sure to ask about the load test to see if it will be available to you. This test should only add about 1 hour to the already existing inspection. If the load test is available, be sure to use the updated SOA and JOFOC; otherwide, use the former one originally sent with our memorandum of September 29, 1986, and again with our January 6, 1989 memorandum. If you have any questions concerning this matter, you may contact Judy Claussen (703/648-5264) or Jim Heisel (703/648-5263) for assistance. Alberto Condes Attachments Key Words: Cableways, Nondestructive Testing, Safety, Procurement of Cableway Testing, Load Testing, Halkin Services SCHEDULE OF ARTICLES Article I. BACKGROUND The U.S. Geological Survey (USGS), Water Resources Division (WRD), has an immediate need to conduct testing of our cableway systems (excluding cable cars) in place at WRD cableway measuring locations. This testing consists of nondestructive testing of wire ropes and load testing of the entire system, particularly anchors. The USGS must take steps to insure that our cableways are as safe as possible, especially since fieldmen use the cableways during all seasons, sometimes over raging waters, and many in isolated locations. Although we have been addressing the need of the nondestructive testing of wire ropes in recent years, the load testing of the anchors and remaining system is a newly defined critical need. Article II. SCOPE OF WORK A. The work to be done consists of furnishing all labor, materials, and equipment in performing all work in strict compliance with these specifi- cations to provide nondestructive testing of wire ropes and load testing of the entire system, particularly the anchors, at USGS cableways located across rivers and streams. B. Location -- The locations of the cableways to be tested are as listed in Attachment A of this specificaiton. Article III. DESCRIPTION OF WORK A. Nondestructive Testing of Wire Rope The Contractor shall test the wire rope from anchor to anchor, testing the section between the anchor and the A-frame, if an A-frame is in place, and between A-frames with the nondestructive tester. The wire ropes vary in diameter from 3/4-inch to 1-1/4 inches. The wire rope shall be tested using a nondestructive wire rope tester which simultaneously measures metallic area loss caused by corrosion and wear and localized faults caused by broken wires, corrosion pits, and wire notching. Measurements shall be made with magnetic sensors which are not sensitive to rope speed. B. Load Testing of Anchors and Remaining Cableway System (excluding cable car) The Contractor shall conduct a load test of approximately 2,000 pounds on the entire cableway system, particularly the anchors. This test will consist of sliding four 55-gallon drums filled with water down the wire rope to the midpoint of the cableway. At that point the water would be dumped from the drums and returned to the starting point. 2 C. Visual Inspection The Contractor shall carefully make a visual inspection of the A-frames, back line guy wires, anchors, saddles, turnbuckles, and other peripheral cableway supporting equipment on both banks for corrosion and any other degradation or damage. The Contractor shall also inspect cable clips to insure that there are the proper number of clips, that they are the proper size, and that they are spaced correctly. D. The Report The Contractor shall provide a report on the nondestructive test and the load test to the Contracting Officer's Representative within 30 days of completion of the testing. The report shall include strip charts showing an inch-by-inch analysis of the inspection of the wire rope and a written report describing the findings and evaluation of the nondestructive wire rope test and the load test. The report shall interpret the loss of metallic area and point out localized faults in the wire rope. The Contractor shall make a recommendation in the report as to the condition of the wire rope and his estimate of the remaining strength in the wire rope tested within 45 days. The report shall include findings from the magnetic sensor test, the load test, and from the visual examination made of the cableway and of the anchors and A-frames. Article IV. CONTRACTOR EXPERIENCE The Contractor must have at least 4 years experience actually performing nondestructive testing of wire ropes as his primary duty (at least 80 percent of his daily function). The USGS has determined this is necessary because of the safety factor involved. The Contractor shall also have experience in preparing reports as described in Article III.D. Article V. CONTRACTOR EQUIPMENT A. The wire rope testing unit must be compact enough to be placed in the cable car and moved across cableways which may, in some instances, exceed 1,000 feet. The power unit for the wire rope tester must also be compact enough to be placed in the cable car. At most sites, AC power will not be available. This wire rope tester shall be able to test wire ropes varying in diameter from 3/4-inch to 1-1/4 inch. B. It is the Contractor's responsibility to insure that the wire rope tester is operating properly when brought to the cableway site. No payment will be made to the Contractor if the wire rope is not tested. C. It is the Contractor's responsibility to transport the testing equipment to the cableway site. In some instances, access may be made only on foot. 3 Article VI. CONTRACTING OFFICER'S REPRESENTATIVE A. The performance required herein shall be subject to the technical direction of the Contracting Officer's Representatiave (COR). As used herein, "Technical Direction" is direction to the Contractor which fills in details, suggests possible line of inquiry, or otherwise supplements the scope of work set forth herein and shall not constitute a new assignment, nor supersede, nor modify any article or clause of this contract. B. Upon contract award, the COR assigned cognizance shall be: ____________________________________________ ____________________________________________ ____________________________________________ Article VII. GOVERNMENT FURNISHED PROPERTY At each cableway, the Government will have in place a cable car which can be used for the testing of the wire ropes. The USGS will furnish a specialized trailer, including a generator, a water pump, and a hoisting apparatus, for the Contractor's use in conducting the load test. THis trailer and equipment is valued at about $5,000 and will be licensed by the USGS. The Contractor shall maintain the trailer and equipment in good, safe working condition while in his possession. Article VIII. ASSISTANCE FROM GOVERNMENT PERSONNEL A Government employee will accompany the Contractor's personnel to each cable- way location for assisting in operation of the cable car during the testing. Article IX. INCLEMENT WEATHER If inclement weather occurs to the extent that the Contractor may not complete the inspection, the testing will be rescheduled with the Contracting Officer's Representative. No payment will be made for work scheduled but not completed because of inclement weather. Article X. CONTRACTOR LIABILITY The Contractor shall assume all liability for any injury to Contractor person- nel while working in cable cars, on A-frames, and around the cableway in general. The Contractor shall also assume all liability in relation to the trailer and equipment while in his possession. 4 Article XI. SCHEDULING THE WORK On receipt of the authorization to proceed with the cableway testing, the Contractor shall contact the Contracting Officer's Representative within 10 days to establish a schedule for testing the cableway. The Contractor shall complete the work as scheduled unless changes to the schedule are approved by the COR. Article XII. DELIVERABLES The Contractor shall deliver the report described in Article III.D to the COR within 30 days of completion of the cableway testing. Article XIII. PERIOD OF PERFORMANCE The period of performance is from date of award through ____________________. JUSTIFICATION FOR OTHER THAN FULL AND OPEN COMPETITION INTRODUCTION The U.S. Geological Survey (USGS), Water Resources Division (WRD), requests a noncompetitive award to Halkin Services, Inc., Commerce City, Colorado. IDENTIFICATION OF NEED The USGS, WRD, has an immediate need to conduct testing of our cableway sys- tems (excluding cable cars) in place at WRD cableway measuring locations. This testing consists of nondestructive testing of wire ropes and load testing of the entire system, particularly anchors. The USGS must take steps to insure that our cableways are as safe as possible, especially since fieldmen use the cableways during all seasons, sometimes over raging waters, and many in iso- lated locations. Although we have been addressing the need of the nondestruc- tive testing of wire ropes in recent years, the load testing of the anchors and remaining system is a newly defined critical need. CIRCUMSTANCES PERMITTING NONCOMPETITIVE PROCUREMENT Cableways are being used throughout the country for streamflow measurement and sampling. These cableways vary in length from less than 100 feet to over 1,000 feet and can be over 50 feet above the streambed. The wire ropes vary in diameter from 3/4-inch to 1 1/4-inch. Some cableways have been in place and exposed to the elements for over 70 years, and a large number for over 50 years. We have an urgent need to perform nondestructive testing of the wire ropes and load tsting of the entire system (excluding cable cars), particularly anchors. Because of the critical nature of the assessment--the life or health of hydrog- raphers could be affected--the test must be performed by a reliable firm which is experienced in testing cableways and in preparing reports on their con- ditions. For safety purposes--because of the remote locations and the danger involved--we require the Contracator to have at least 4 years experience testing wire ropes regularly as their primary duty. The Halkin Services, Inc., provides nondestructive testing of wire rope for mines and ski lifts. Halkins uses a MAGNOGRAPH which measures loss of metallic area and local faults in the wire rope. The MAGNOGRAPH rides on the cableway and is operated by a battery-powered unit which can be placed in the cable car. This allows it to access the entire length of wire rope including the link to the far bank which sometimes is not easily accessible by vehicle or on foot. There is no electrical power (AC) available at most cableway sites, so a battery-powered testing unit is essential. The MAGNOGRAPH provides a graphical chart which shows the loss of metallic area and the local faults in the wire rope for each foot of the wire rope traversed. 2 Halkins has also developed a load test which would work for the entire system and particularly the anchors. This test consists of sliding four 55-gallon drums filled with water down the wire rope to the midpoint of the cableway. At that point the water would be dumped from the drums and returned to the starting point. Halkin Services, Inc., has been providing nondestructive testing of wire ropes for more than 7 years, and it constitutes about 90 percent of their total workload. OTHER SOURCES CONSIDERED A market search was conducted by the Branch of Operational Support, WRD, Reston, Virginia, by checking with the Information Handling Services and the "Capital Cities Regional Industrial Purchasing Guide," calling manufacturers of wire ropes, calling manufacturers of wire rope testers, and following up on any leads these contacts provided. Details are as follows: A. The Information Handling Services found no companies that did nondestruc- tive testing of wire ropes. They only had a name of a company in Canada that manufactured a wire rope tester. The company turned out to be the same company where Halkins had purchased their equipment. B. After looking in the "Capital Cities Regional Industrial Purchasing Guide," the only leads we came up with were manufacturers/distributors of wire ropes. We called several companies but only came up with one lead, Pittsburgh Testing Laboratories, that did nondestructive testing. They test by x-rays using radioactive isotopes and could only tell if wires were broken; they could not determine loss of metallic area or local faults. It would also be extremely more expensive and time consuming to x-ray every foot of cableway which is one of our requirements. There is also a safety factor involved with using x-rays to that extreme. C. We called the manufacturer of the wire rope testers that Halkins uses (Heath and Sherwood) to see if they sold any testers to other firms that perform services. They knew of none besides Halkins that performed services for others. D. We found a wire rope tester on the NIIS Federal Supply Schedule (non- mandatory) that only tested wire ropes much smaller than our requirement, but we called the company (NDT Technologies, Inc.) to see if they knew of any companies that performed the services using their tester. They would not give us any names but said they could probably do our work. We asked for some more information on this. They only do this service as a side- line, if asked, and don't look for this type of work. Therefore, they perform this service on a very irregular basis and don't have employees with the experience in this service which we consider essential for this requirement. The USGS really believes that it is imperative that the Contractor be very experienced in this service and that it is their main duty performed on a daily basis. Therefore, we do not consider NDT qualified to do this service. 3 After conducting this market search and not finding a qualified Contractor except Halkins Services, Inc., and taking into consideration the urgency of this requirement, the Water Resources Division, USGS, recommends a noncompeti- tive procurement be awarded to Halkins Services, Inc. This recommendation is made in recognition of the fact that competition must be obtained to the maximum extent possible. /S/ 5/22/89 _______________________________________ _______________________ Alberto Condes, Chief Date Branch of Operational Support, WRD Approved:______________________________ _______________________ Contracting Officer Date