7130-USIBWC-FalconPowerPlantCraneAssessment-5Dec2023.pdf

ENGINEERS AND CONSULTANTS

CORPORATION

GLOBEX

International Boundary and Water Commission United States and Mexico United States Section

FALCON POWER PLANT

75/20 Ton Bridge Crane Assessment

USIBWC Falcon Power Plant Cranes Starr, County Texas

Revision 0

USIBWC Contract No. : 191BWC23P0086 Globex Project No.: G-7130

DECEMBER 2023

Prepared By: Globex Corporation

Falcon Power Plant 75/20Ton Bridge Crane Assessment

Contents Introduction

Executive Summary

Recommendations

Appendix A: Condition Inspeciton Checklist Findings .................................................................................................. A-1

Appendix B: Crane Runway Survey Data ..............................................................................................................B-1

Introduction On November 07 and 08, 2023, Globex Corporation performed an assessment survey of the Bridge Crane located at the Falcon Power Plant in Falcon Heights, Texas. The Falcon Power Plant is a 3-unit hydroelectric power plant owned and operated by International Boundary Water Commission (USIBWC) located on Falcon Reservoir at the international border between the U.S. and Mexico. The subject crane is a double girder electric overhead traveling crane manufactured by Moffett Engineering Company Crane circa 1952. The crane has a 75 ton capacity main hoist and a 20 ton capacity auxiliary hoist both mounted on a single top running trolley. The bridge has a design span of 46’-10” and an A-2 drive arrangement. The trolley has a span of 11’-3” and a wheel base of 8’-0”. The crane is presently operable and primary use is for maintenance and servicing of the generator and turbine units inside the power plant.

For the assessment, a structural, mechanical, and electrical condition inspection was performed on the crane. In addition, no-load function testing of each crane motion was performed. A structural condition inspection and dimensional instrument survey were performed on the crane runway.

This report includes an executive summary and a recommendations section as well as several attachments in the appendix sections. The inspection report checklist with findings and the runway rail survey report are included in the appendixes.

Executive Summary As part of the assessment, Globex Corporation engineers performed a visual condition inspection of the crane’s structural, mechanical, and electrical systems and components. As part of the inspection, inspection covers and electrical enclosure cabinets were opened. The crane was accessed during the inspection with use of an electric articulating manlift and from the existing walkways, and platforms. The inspection findings along with photos of each deficiency are included in Appendix A.

The inspection included no-load function testing of the crane by operating it through all motions in each direction. Before any function testing was performed, impact damage was observed on the underside of the trolley, below the auxiliary hoist. During the no-load function test, the auxiliary hook block was slowly raised to test the function of the upper limit switch. During the testing, it was discovered that the auxiliary hoist upper limit switch was initially stuck and would have allowed the hook block to make contact with the underside of the trolley frame, if the hoisting was not manually stopped. During subsequent tests, the limit switch functioned properly. It was concluded that the limit switch was initially stuck likely from infrequent use. Also, when traveling North and South with the bridge at a slow rate of speed between units 3 and 4, the electrical power was interrupted causing the bridge travel to drop out and the bridge stop in place. The electrical power was de-energized and collector shoes manipulated.

The power restored and the bridge travel resumed. It was concluded that the electrical power often times drops out in this area due to intermittent contact between the collector shoes and conductor rails.

During the site visit, Globex engineers met with Falcon Power Plant personnel to request copies of the crane drawings and documentation that was available. No structural or mechanical layout/arrangement drawings were available, only some electrical diagrams and manuals.

The subject crane was recently painted and the paint coating remains intact. However, at the time of the painting, the motor, brake, etc. nameplates were painted over. Then, the paint was scraped off in an attempt to make the nameplate legible again. Many of the nameplate are not legible as a result.

The crane has been in service since around 1952 with nearly all original components still in use today.

Due to the age of the crane, many of the crane components are antiquated and replacement parts are not readily available. This situation will affect crane reliability and downtime associated with sourcing and installing replacement parts. Further, due to the age of the crane there are safety standards which do not comply with present day safety standards and are grandfathered in. For example, ASME B30.2 section 2-1.7.1(c) “Service platforms shall have a clear passageway at least 18 in. wide except at bridge drive mechanism where not less than 15 in. of clear passageway shall be allowed.” If the crane is modified or repaired, it is the owner’s responsibility to upgrade the crane to the current standards.

Based on the age of the crane, present condition of the crane and the critical maintenance duties performed with this crane, Globex recommends that the crane’s existing control system be upgraded with new variable frequency drives (VFDs) and a new radio control system installed.

Although the crane is 70 years old, no structural issues were observed except for the underside of the trolley. On the underside of the trolley frame, the trolley girt below the auxiliary hoist has impact damage and cracked welds (See Appendix A Finding No. 41). This was caused by a prior two-block event which occurred when the auxiliary hoist upper limit switch failed to stop the auxiliary hoist hook block and allowed it to contact the underside of the trolley frame. For this reason, we recommend an option to repair the trolley frame damage or replace the trolley frame as part of a complete trolley package.

See the Recommendations section for details and option to replace the trolley frame.

A structural condition inspection was performed on the crane runway concrete support structure, runway rails and runway rail hardware, and runway end stops. In addition, a dimensional instrument survey was performed on the accessible portion of the runway rails along each column row. See Appendix B for survey results. The measured runway rail span exceeded the CMAA Allowable tolerance at two (2) locations. Due to the magnitude of the out of tolerance span conditions, Globex does not recommend any corrective action at this time. Each side of the runway was accessed along each column row at the rail elevation utilizing the existing horizontal lifeline fall protection systems and 100% tie-off. The crane was parked at the boarding platform, at the North end of the runway at the time of the survey.

Recommendations

Based on the age of the crane, present condition of the crane and the critical maintenance duties performed with this crane, Globex recommends that the crane’s existing control system be upgraded with new variable frequency drives (VFDs) and a new radio control system. Listed below are the recommended items and tasks to be included in the upgrade and modernize project for the subject crane.

1. Replace the existing control system with a new VFD control system that controls the X, Y, and Z movement of the bridge, hoists, and trolley. Replacement shall include:

a. New VFD Drives shall be Magnetek Impulse G+/VG+ Series 4 drives, or approved equal.

b. New inverter duty NEMA bridge motor, trolley motor main hoist motor and auxiliary hoist motor with space heaters for condensation control as described below:

i. MH Motor: 30 HP, 900 RPM, 460 Volt AC, 3 Phase

ii. AH Motor: 40 HP, 900 RPM, 460 Volt AC, 3 Phase

iii. Bridge Motor: 15 HP, 900 RPM, 460 Volt AC, 3 Phase

iv. Trolley Motor: 5 HP, 900 RPM, 460 Volt AC, 3 Phase

c. New hoist controls shall be variable frequency AC with closed-loop flux vector with feedback from motor shaft encoder.

d. New bridge and trolley controls shall be variable frequency AC with open loop vector control.

e. New shoe or disk type bridge brake, trolley brake, main hoist brake and auxiliary hoist brake.

f. Control Features shall include:

i. Micro speed

ii. Infinitely variable control

iii. New maximum hoist, trolley and bridge speeds shall match the existing speeds.

Contractor required to verify all maximum speeds.

g. All electrical enclosures as described below:

i. NEMA Type 12

ii. Access door with steel hinge and lockable handle

iii. Nameplate

iv. Space heaters for condensation control as required

v. Must provide minimum clear passageway as per ASME B30.2 section 2-1.7.1(c) “Service platforms shall have a clear passageway at 18 in. wide except at bridge drive mechanism where not less than 15 in. clear passageway shall be allowed.

Bridge footwalk modifications may be required to provide a minimum of 15”

h. Replace all electrical components and wiring on the crane. Many existing wires have asbestos insulation. All low voltage control wires shall be shielded with the following minimum sizes:

i. 12 AWG min. size for power wiring

ii. 14 AWG min. size for control wiring

iii. 16 AWG min. size for signal wiring

2. Install new Radio Frequency Controls as described follows:

a. The Radio Frequency controls shall be able to operate 4 motions (bridge motion, trolley motion, main hoist motion and auxiliary hoist motion).

b. Provide two (2) wireless controllers with 4 motions plus A/B selector main hoist/auxiliary hoist. Features shall include:

c. Momentary pushbutton contacts.

d. ON/OFF pushbutton.

e. Emergency stop pushbutton.

f. Horn/warning pushbutton.

g. Lever or joystick controls designed with spring return to neutral when the operator’s hand is removed.

3. Remove the existing master control switches in the cab and adapt the existing cab to accommodate the use of new wireless controls.

a. Provide a mounting apparatus to secure the radio control box to cab structure, located similarly to existing cab controls.

b. Provide AC power connection in cab to allow use of radio control box without batteries.

4. Replace the mainline disconnect switch with a new lockable disconnect switch.

5. Replace the 75 ton main hoist and 20 ton auxiliary hoist wire ropes in kind with new wire rope suited for the application and submit wire rope certifications.

6. Replace the bridge to runway electrification system with insulated 4 conductor bar system with all associated brackets and hangers, designed to operate on 480 Volt, 115 amp, 3-phase, 60- Hertz power in an indoor environment. Replace existing collector shoes with double shoe collectors.

7. Replace the bridge to trolley electrification system with a new cable festoon system for cross-bridge trolley including cables and wiring to make the electrical connections between VFDs, control system, and motors. Festoon shall include:

a. A flexible-looped Cable, multiple-conductor, stranded copper, extra-flexible, weather and sunlight resistant.

b. Cable Trolleys and Hardware shall be heavy-duty, corrosion-resistant steel components with bumpers provided.

c. Design and install a maintenance platform under stowed festoon.

8. Repair reported deficiencies on the bridge, operators cab and boarding platform as noted in the inspection report (See Appendix A).

9. Replace the main and auxiliary lower hook blocks in kind with new hook blocks.

10. Remove and properly dispose components that will be replaced from the existing crane. This includes removal and disposal of hazardous materials (i.e. asbestos, gear oil, hydraulic fluid, etc.).

11. Load test and certify crane to industry codes and standards.

12. Trolley Replacement Option: Replace the existing trolley and all components with a new complete trolley package that includes new VFD control systems as described below. This option will allow for the hoist and trolley controls and machinery to be shop-assembled and tested before being delivered to the field. However, there is limited headroom clearance between the trolley and power plant building structure above which may present challenges for removal of existing and installation of new trolley.

a. Contractor shall provide all materials, equipment and labor necessary to replace the existing trolley with a new top running trolley that sits on the double girder bridge, can traverse the full length of the bridge girders, and has both a 75 ton main hoist and a 20 ton auxiliary hoist.

b. The general design manufacturer, performance and operation of the trolley shall conform to OSHA 29 CFR 1910.179, ASME B30.2-latest edition, and CMAA No. 70 Specification Class C for Top Running Bridge and Gantry Type Multiple Girder Electric Overhead Traveling Cranes.

c. The trolley and hoist components shall be designed to operate in an indoor environment and match the existing equipment dimensions.

d. The crane’s maximum wheel loads due to dead load and rated capacity live loads with the trolley in any position , shall not be increased by any new component.

e. The trolley wheel span was field measured to be approximately 11’-3”. No reference drawings exist showing this dimension. Verification is required.

f. The trolley wheelbase was field measured to be approximately 8’-0”. No reference drawings exist showing this dimension. Verification is required.

g. New main and auxiliary hook lifts shall match existing.

h. New main and auxiliary hook spacing and approaches shall match existing.

i. Contractor shall verify:

i. Main Hoist Hook lift

ii. Auxiliary Hoist Hook lift

iii. Hook Spacing and Approaches

iv. Trolley dimensions

v. All clearance dimensions.

13. Trolley Repair Option: Upgrade the existing trolley and hoist drives and repair the structural damage to the existing trolley frame. This option will require field assembly and testing of the hoist and trolley drive controls and machinery. Further, due to the limited headroom clearances between the trolley and power plant building structure above, removal and replacement of hoist and trolley components may present challenges.

In preparation for the crane modernization tasks listed above, Globex recommends the following:

1. A thorough review of the drawing archives to locate structural and mechanical drawings for the crane.

2. Perform a final review on all available technical information and prepare a performance work statement and bid specification updated with any additional information that is located and in accordance with USIBWC requirements.

A-1

Appendix A

Condition Inspection Checklist and Findings

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Crane Condition Inspection Checklist Multiple Girder Electric Traveling Overhead Crane

USIBWC-Falcon Power Plant Contract No. 191BWC23P0086

Crane Identification:

Falcon Power Plant Crane

Location:

Falcon Dam

Manufacture/Capacity:

Moffett Engineering Company

Globex Project No.:

G-7130

Crane Serial No.:

N/A

75/20 Ton

Type of Inspection:

Mechanical/Electrical/ Structural

Legend: S = Satisfactory U = Unsatisfactory NA = Not Applicable

Date Started:

11-07-2023

Date Completed:

11-08-2023

Item No. Item Description

S U NA

(Refer To The Last Page For An Explanation of An Unsatisfactory Condition)

G-1 GIRDER SOUTH

1 Bridge Motor: (a) Mounting bolts, (b) Bearings, (c) Inspection Cover, (d) Brushes(e) Communicator, (f) Brush Holders, (g) Others

2 Bridge Brake: (a) Alignment, (b) Mounting bolts, (c) Shoe Linings, (d) Pins & Keepers, (e) Electric, (f) Brake Wheel, (g) Brake Wheel Keeper, (h) Others

3 Bridge Motor Coupling: (a) Alignment, (b) Bolts, (c) Lubrication, (d) Guard,

(e) Guard Mounting Bolts, (f) Others

Bridge Center Reduction: (a) Input Coupling, (b) Coupling Bolts, (c) Coupling Guard,

(d) Reduction Mounting, (e) Split Line Bolts, (f) Bearing Glands, (g) Bearing Retainers, (h) Inspection Cover, (k) Gearing, (l) Bearings, (n) Lubrication, (p) Others

5 Line Shaft(s): (a) Gearbox Coupling, (b) Axle Coupling, (c) Coupling Bolts, (d) Coupling Guards (e) Bearings (f) Bearing Bolts (g) Bearing Pedestals, (h) Others d

6 East Bridge Reduction: (a) Bearings (b) Pinion, (c) Pinion Shaft, (e) Mounting Bolts, (f) Others

7 West Bridge Reduction: (a) Bearings (b) Pinion, (c) Pinion Shaft, (e) Mounting Bolts (f) Others

8 Girder and Footwalk: (a) Structure, (b) Connections, (c) Rail, (d) Trolley Stops (e) Footwalk Supports (f) Footwalk Grating (g) Others

G, E

G-2 GIRDER NORTH

9 Girder and Footwalk: (a) Structure, (b) Connections, (c) Rail, (d) Trolley Stops, (e) Footwalk Supports, (f) Footwalk Grating, (g) Others

10 Festoon: (a) Support, (b) festoon track, (c) track connections, (d) festoon Cable, (e) Junction Boxes

EAST END CARRIAGE

11 Drive Wheel(s): (a) Drive Wheel, (b)Wheel and Gear Bearing/Bushing, (c) Wheel Strap, (d) Wheel Strap Bolts, (e) Drive Gear/Pinion, (f) Gear Guard (g) Other

12 Idler Wheels: (a) Drive Wheel, (b)Wheel and Gear Bearing/Bushing, (c) Wheel Strap, (d)

13 East End Carriage: (a) Structure, (b) Connections, (c) Axle Keeper, (d) Keeper Bolts, (e) Drive Gear, (g) Gear Guard (g) Rail Sweep

14 Bridge Bumpers: (a) Mounting, (b) Plungers, (c) Safety Cables c 15 Rail Sweeps: (a) Structure, (b) Connections, (c) Safety Cables a, c

7130-FalconPPCranelnspChecklist-1Dec2023 Page 2

S U NA

(Refer To the Last Page for An Explanation of An Unsatisfactory Condition)

WEST END CARRIAGE

16 Drive Wheel(s): (a) Drive Wheel, (b)Wheel and Gear Bearing/Bushing, (c) Wheel Strap, (d)

17 Idler Wheels: (a) Drive Wheel, (b)Wheel and Gear Bearing/Bushing, (c) Wheel Strap, (d)

18 East End Carriage: (a) Structure, (b) Connections, (c) Axle Keeper, (d) Keeper Bolts, (e) Drive Gear, (g) Gear Guard (g) Rail Sweep

19 Bridge Bumpers: (a) Mounting, (b) Plungers, (c) Safety Cables c 20 Rail Sweeps: (a) Structure, (b) Connections, (c) Safety Cables c

MAIN HOIST ASSEMBLY

21 Main Hoist Motor: (a) Mounting bolts, (b) Bearings, (c) Inspection Cover, (d) Brushes (e) Communicator, (f) Brush Holders, (g) Others

Main Hoist Brake: (a) Alignment, (b) Mounting bolts, (c) Shoe Linings, (d) Pins & Keepers,

(e) Electric, (f) Brake Wheel, (g) Brake Wheel Keeper, (h) Others

23 Main Hoist Motor Coupling: (a) Alignment, (b) Bolts, (c) Lubrication, (d) Guard,

(e) Guard Mounting Bolts, (f) Others d

Main Hoist Gearbox with Load Brake: (a) Mounting Bolts, (b) Split Line Bolts, (c) Inspection Cover, (d) First Reduction Pinion, (e) Bearing Retainer Bolts, (f) Bearings, (g) Second Reduction Pinion, (h) Motor Gear Load Brake, (j) Bearing Retainer Bolts, (k) Second Reduction Gear, 25 Main Hoist Open Gearing: (a) Drum Pinion, (b) Drum Gear, (c) Outboard Bearing Pillow Block, (d) Gear Guard (e) Inspection Cover

26 Main Hoist Drum: (a) Drum Shaft, (b) Shaft Bearing Gearbox Side, (c) Bearing Mounting Bolts, (d) Tail Shaft Bearing, (f) Bearing Mounting Bolts, (h) Others

27 Main Hoist Equalizer Sheaves: (a) Sheave Bearings, (b) Sheave Wear, (c) Sheave Pin,

(d) Sheave Pin Keepers, (e) Keeper Bolts, (f) Hanger (g) Hanger Bearings (h)Bearing Bolts

28 Main Hoist Limit Switch: (a) Mounting, (b) Counterweight, (c) Cable Connection

29 Main Hoist Hook Block: (a) L.S. Trip, (b) Sheaves, (c) Sheave Pin, (d) Sheave Pin Keeper, (e) Keeper Bolts, (f) Other f

30 Main Hoist Wire Rope: (a) End Terminations, (b) Wires/Strands, (c) Lubrication, (d) Reeving, (e) Other c

AUXILIARY HOIST ASSEMBLY

31 Auxiliary Hoist Motor: (a) Mounting bolts, (b) Bearings, (c) Inspection Cover, (d) Brushes (e) Communicator, (f) Brush Holders, (g) Others

Auxiliary Hoist Brake: (a) Alignment, (b) Mounting bolts, (c) Shoe Linings, (d) Pins & Keepers,

(e) Electric, (f) Brake Wheel, (g) Brake Wheel Keeper, (h) Others

33 Auxiliary Hoist Motor Coupling: (a) Alignment, (b) Bolts, (c) Lubrication, (d) Guard,

(e) Guard Mounting Bolts, (f) Others d

Auxiliary Hoist Gearbox with Load Brake: (a) Mounting Bolts, (b) Split Line Bolts, (c) Inspection Cover, (d) First Reduction Pinion, (e) Bearing Retainer Bolts, (f) Bearings,

(g) Second Reduction Pinion, (h) Motor Gear Load Brake, (j) Bearing Retainer Bolts, (k) Second Reduction Gear, 35 Auxiliary Hoist Open Gearing: (a) Drum Pinion, (b) Drum Gear, (c) Outboard Bearing Pillow Block, (d) Gear Guard (e) Inspection Cover

36 Auxiliary Hoist Drum: (a) Drum Shaft, (b) Shaft Bearing Gearbox Side, (c) Bearing Mounting Bolts, (d) Tail Shaft Bearing, (f) Bearing Mounting Bolts, (h) Others

Auxiliary Hoist Equalizer Sheaves: (a) Sheave Bearings, (b) Sheave Wear, (c) Sheave Pin, (d) Sheave Pin Keepers, (e) Keeper Bolts, (f) Hanger (g) Hanger Bearings (h)Bearing Bolts

7130-FalconPPCranelnspChecklist-1Dec2023 Page 3

S U Prior.

NA (Refer To The Last Page For An Explanation of An Unsatisfactory Condition)

AUXILIARY HOIST ASSEMBLY – (continued)

38 Auxiliary Hoist Limit Switch: (a) Mounting, (b) Counterweight, (c) Cable Connection

39 Auxiliary Hoist Hook Block: (a) L.S. Trip, (b) Sheaves, (c) Sheave Pin, (d) Sheave Pin Keeper, (e) Keeper Bolts, (f) Other a, f

40 Auxiliary Hoist Wire Rope: (a) End Terminations, (b) Wires/Strands, (c) Lubrication, (d) Reeving, (e) Other c

TROLLEY FRAME AND TRAVEL DRIVE ASSEMBLY

41 Trolley Frame: (a) Load Girts, (b) Bolted Connections, (c) Welds (d) Bumpers, (e) Others a, c

42 Trolley Travel Motor: (a) Mounting bolts, (b) Bearings, (c) Inspection Cover, (d) Brushes

(e) Communicator, (f) Brush Holders, (g) Others

43 Trolley Travel Brake: (a) Alignment, (b) Mounting bolts, (c) Shoe Linings, (d) Pins & Keepers, (e) Electric, (f) Brake Wheel, (g) Brake Wheel Keeper, (h) Others

44 Trolley Travel Coupling: (a) Alignment, (b) Bolts, (c) Lubrication, (d) Guard,

(e) Guard Mounting Bolts, (f) Others

45 Trolley Reduction: (a) Mounting Bolts, (b) Split Line Bolts, (c) Bearing Retainers, (e) Inspection Cover, (g) Gearing, (h) Bearings, (k) Lubrication, (l) Others

Reducer Output Shaft: (a) Drive Pinion (b) Pillow Block Bearing, (c)Mounting Bolts, (d) Gear Guard, (d) Guard Mounting Bolts, (e) Axle Coupling, (f) Coupling Bolts, (g) Coupling Guard, (h) shaft, (i) Others

47 Drive Wheels: (a) Drive Wheel, (b)Wheel and Gear Bushing, (c) Axle Keeper, (d) Keeper Bolts, ( e) Drive Gear, (g) Gear Guard (g) Rail Sweep

48 Idler Wheels: (a) Idler Wheel, (b) Axle Keeper (c) Keeper Bolts, (c) Wheel Bushing, (d), Rail Sweep

ELECTRICAL

49 Main Hoist: (a) Knife Switches, (b) Overloads, (c) Contactor, (d) Relays, (e) Panel Mounting, (f) Wiring, (g) Others (h) Arc Shield, 50 Auxiliary Hoist: (a) Knife Switches, (b) Overloads, (c) Contactor, (d) Relays, (e) Panel Mounting, (f) Wiring, (g) Others (h) Arc Shield, 51 Trolley: (a) Knife Switches, (b) Overloads, (c) Contactor, (d) Relays, (e) Panel Mounting, (f) Wiring, (g) Others (h) Arc Shield, 52 Bridge: (a) Knife Switches, (b) Overloads, (c) Contactor, (d) Relays, (e) Panel Mounting, (f) Wiring, (g) Others, (h) Arc Shield

53 Resistors: (a) Structure, (b) Mounting, (c) Top Cover, (d) Screen Front, (e) Screen, (f) Resistor Grids, (g) Insulator, (h) Wiring, (j) Terminals, (k) Others

54 Bridge to Trolley Conductor System: (a) Rails/Wires/Conductor Bars, (b) Splices (c) Mounting Brackets/Connections, (d) Insulation, (e)mast, (f) Shoes, (g) Other g

55 Runway to Bridge Conductor System: (a) Rails/Wires/Conductor Bars, (b) Splices (c) Mounting Brackets/Connections, (d) Insulation, (e) Shoes

56 General Wiring and Conduits: (a) Wire Insulation, (b) Mounting Brackets/Connections, (c) Splices (d) Covers (e) Others a, d

57 Lighting: (a) Fixture, (b) Guarding (c) Safety Chains (d) Others b

7130-FalconPPCranelnspChecklist-1Dec2023 Page 4

S U Prior.

NA (Refer To The Last Page For An Explanation of An Unsatisfactory Condition)

GENERAL

58 Crane Access: (a) Structures (b) Connections, (c) Fall Protection Devices, (d) Safety Gates

59 Pendant: (a) Enclosure/Buttons/Switches, (b) Support Connections, (c) Function Labels (e) Trolleys (f) Others

60 Operators Cab: (a) Hangers, (b) Cab Structure, (c) function labels, (d) fire extinguisher, (e) controls, (f) Other d, e

61 General Lubrication: (a) Evidence of Neglect (b) Leaks

62 Lockable Disconnect Switch: (a) Does Not Exist, (b) Not in View of Crane, (c) Not Labeled

63 Preoperational Checklist: (a) Missing or (b) Illegible Remarks:

5d) At the bridge line shaft, the bridge drive machinery has no coupling guards.

BG 4215

7130-FalconPPCranelnspChecklist-1Dec2023 Page 5

Remarks: - (Continued)

14c and 19c) On 4 of 4 of the bumper plungers on the crane, there are no safety cables.

ES 0295

15a) On the East end carriage, the South rail sweep is bent.

ES 0293

7130-FalconPPCranelnspChecklist-1Dec2023 Page 6

15c and 20c) On 4 of 4 rail sweeps, there are no safety cables.

ES 0289

7130-FalconPPCranelnspChecklist-1Dec2023 Page 7

23d and 33d) On the trolley, the main and auxiliary hoist machinery has no coupling guards.

ES 0309

29f and 39f) On the main hook and auxiliary hook, there are no safety latches.

ES 0260

7130-FalconPPCranelnspChecklist-1Dec2023 Page 8

30c and 40c) The main and auxiliary hoist wire ropes are dry and require proper penetrating lubrication.

ES 0266

30d) On the main hoist drum, on the East side in the retracted position, at the 6th wrap from the South, the wire rope is mis‐reeved with a loose wrap on the drum.

ES 0282 ES 0283

7130-FalconPPCranelnspChecklist-1Dec2023 Page 9

38c) On the auxiliary hoist, at the weighted upper limit switch, at the support cable end termination, there is excess tail. Also, during function testing, the upper limit switch was initially stuck and did not trip.

ES 0279

39a) On the auxiliary block, on the Southeast corner, the weighted limit switch contact plate is worn from the hoist wire rope rubbing.

ES 0263 ES 0264

7130-FalconPPCranelnspChecklist-1Dec2023 Page 10

41a) At the underside of the trolley frame, below the auxiliaruy hoist, the trolley girt channels are bent upward from a prior two‐block incident with the auxiliary hoist hook block.

BG4206

41c) At the underside of the trolley frame, below the auxilairy hoist, at the trolley girt channel to equalizer sheave support plate, the intermittant welds are cracked.

BG 4207

7130-FalconPPCranelnspChecklist-1Dec2023 Page 11

54) The bridge to trolley electrical conductor system is antiquated and consists of multiple exposed wires.

BG4209 BG4210

55) The runway to bridge electrical conductor system is antiquated and consists of exposed conductor angles and is missing a ground circuit. Also, during the function testing the power to the crane dropped out while bridging South.

BG4346

7130-FalconPPCranelnspChecklist-1Dec2023 Page 12

56a) The electrical power wires are insulated with suspected asbestos containing materials.

BG 4211

56d) On the underside of the bridge at the overhead light, the LB conduit fitting is missing a cover.

ES 0298

7130-FalconPPCranelnspChecklist-1Dec2023 Page 13

56d) At the operator’s cab, there are 3 LB conduit fittings with missing covers.

ES 0300 BG 4238

BG 4236

7130-FalconPPCranelnspChecklist-1Dec2023 Page 14

57b) At the operator’s cab, the overhead light is an incandescent bulb and the is unguarded.

BG 4213

58c) At the boarding ladder, the fall arrest SRL, is mounted on a ladder rung instead of an approved anchorage.

BG4216

7130-FalconPPCranelnspChecklist-1Dec2023 Page 15

60e) At the operator’s cab, the bridge, main hist and auxiliary hoist controls do not automatically return to the "off" position when released by the operator.

BG4231

60d) At the operator’s cab, the fire extinguisher is past due for inspection according to the tag.

BG 4234

7130-FalconPPCranelnspChecklist-1Dec2023 Page 16

60d) At the operator’s cab, the fire extinguisher is sitting loose on the cab floor and is not properly mounted.

BG 4235

B-1

Appendix B

Crane Runway Survey Data

TASK

No.

TASK DESCRIPTION

FINDING

No.

SUMMARY WITH RESPECT TO CMAA TOLERANCES

PAGE

No.

1.0 Rail Span 1.0 The rail span measurements exceed the CMAA runway rail span allowable tolerance of +/- 3/16 in. at column no. 2.5 and 3. The rail span rate of change measurements exceed the CMAA allowable rate of change between column no. 2.5 to column 14.

2.0 Rail Straightness 2.0 The rail straightness measurements are within the CMAA runway rail straightness allowable tolerance of +/- 3/8 in. at the locations measured.

The West rail straightness does not exceed the CMAA allowable tolerance for rate of change.

The East rail straightness does not exceed the CMAA allowable tolerance for rate of change.

3.0 Rail to Rail Elevation 3.0 At column row c (West) the rail elevation measurements are within CMAA runway rail elevation allowable tolerance of +/- 3/8 in. at the locations measured. At column row c (West), the rate of change is within the CMAA allowable rate of change.

At column row f (East), the rail elevation measurements are within CMAA runway rail elevation allowable tolerance of +/- 3/8 in. at the locations measured. At column row f (East), the rate of change is within the CMAA allowable rate of change.

The rail to rail elevations are within the CMAA allowable tolerance of +/- 3/16 in. at all locations measured.

4.0 Comments/Remarks 4.0 The rails and rail hardware (clips, splices, etc.) were inspected at the time of the survey and no deficiencies were found.

CRANE RUNWAY RAIL SURVEY

USIWBC POWER PLANT

& INSPECTION REPORT Crane Manufacturer:

Dates: 11/08/2023 Location: Falcon Power Plant

Summary 1 G7130-FalconPowerPlantRailSurveyRpt-Runway-08Nov2023

Location: Item Description:

1.0 Rail Span

Area Description: Temperature/Conditions:

90 Degrees

BETWEEN COLUMN ROWS: COLUMN SPACING: Varies (ft.)

CMAA ALLOWABLE SPAN TOLERANCE: 0.1875 (in.) DESIGN RAIL SPAN: 46.833 (ft.)

Remarks:

G-7130 Technician: Date:

BG

ES

4. The crane was parked at the North runway ends stops at the time of the survey.

no

561.8125 no no

561.8125 no no no no no

-0.1875

9 & 10 no

-0.125

4 & 5

Difference (In.)

562 0.0625

0.1875

562.3125

562.125

0.3125

0.3125

0.125

562.3125 yes

Rate Of Change Out of Tolerance

Span Out of

Tolerance yes no

Difference (In.)

Measured Span (in.)

Location (Col. No.)

Design Span (in.)

no no no

Rate Of Change Out of Tolerance c & f

Design Span (in.)

Span Out of

Tolerance no

2.5 no0 no no562.1875

-0.1875 no

562 561.875

562.0625

-0.187425561.812575

Falcon Power Plant

Power Plant Crane Runway

Measured Span (in.)

Location (Col. No.)

(Crane)

(Crane) no

1. The rail span was measured with a Leica Disto Meter starting at the East Crane and every 15' to the West Crane.

for L > 100' - tolerance = 3/8". Maximum rate of change = 1/4" in 20'-0".

2. CMAA Span Overall Tolerance for L ≤ 50'-tolerance = 3/16", for L > 50' ≤ 100' - tolerance = 1/4", 11/8/2023

3. The span values shown above are not to be used for making necessary rail adjustments. The rail span values are for the purpose of identifying out of tolerance conditions at the time of the survey. Any necessary rail adjustments shall be verified and confirmed by contractor's survey at the time of the adjustments.

1.0 Rail Span 2 G7130-FalconPowerPlantRailSurveyRpt-Runway-08Nov2023

2.0 Rail Straightness

Area Description: Temperature/Conditions:

90 Degrees

MEASUREMENT SPACING: Varies (ft.) DESIGN RAIL SPAN: 46.833 (ft.)

c (West) f (East)

Remarks:

1. North Column Row Crane Rail Horizontal Misalignment "Y" = (Baseline Rail End Value - "B" Measured Rail Offset)

2. South Column Row Crane Rail Horizontal Misalignment "Z" = (Baseline Rail End Value + Design Span - ("B" Measured Rail Offset + "A" Measured Rail Span)

3. CMAA RAIL STRAIGHTNESS = +/- 3/8". CMAA MAXIMUM RATE OF CHANGE = 1/4" in 20'-0"

5. Positive (+) Straightness Value Represents an outboard offset. Negative (-) Straightness Value Represents an inboard offset.

6. The crane was parked at the North runway end stops at the time of the survey. G-7130

Technician: Date:

BG 11/8/2023

ES

no no no no

561.8125

4 -0.125 no

4.125 no no no

561.875

4.1875 562

562.1875 no

COLUMN ROW:

562.125 no-0.1875

562.3125

Falcon Power Plant

Power Plant Crane Runway

Rate Of Change Out of Tolerance

Design Rail Span (in.)

"A" Measured Rail Span (in.)

(Crane)

"Y" Rail Straightness

(In.)

Rail Straightness Out of Tolerance

COLUMN ROW:

4 & 5

Location (Col. No.)

Baseline Side "B" Measured

Rail Offset (In.)

-0.125

Baseline End Value

Offset (in.)

Rate Of Change Out of Tolerance

"Z" Rail Straightness

(in.)

Rail Straightness Out of Tolerance

4. The straightness values shown above are not to be used for making necessary rail adjustments. The rail straightness values are for the purpose of identifying out of tolerance conditions at the time of the survey. Any necessary rail adjustments shall be verified and confirmed by contractor's survey at the time of the adjustments.

(Crane)

2.5 0

4 no

562.06257

9 & 10

4.125

4 4.1875

4.1875 no0.31250000 no no no0.3125 no no no no no0.0625

-0.125 no no

561.8125 no

561.8125

-0.1875 no

-0.1875

562.3125 no no no no no

0.0625

-0.1875

0.125

0.3125 no no

0.3125

0.25 no no no no no no

12 -0.254.25

-0.0625 no no

56214 4 no no

4.06254 no562

2.0 Rail Straightness 3 G7130-FalconPowerPlantRailSurveyRpt-Runway-08Nov2023

3.0 Rail to Rail Elevation

Area Description: Temperature/Conditions:

90 Degrees

MEASUREMENT SPACING: Varies (ft.) DATUM ROD READING (HIGH POINT) c Row: 19.75 (in.)

DATUM ROD READING (HIGH POINT) f Row: 19.9375 (in.)

DESIGN RAIL SPAN: 46.833 (ft.) CMAA RAIL to RAIL ELEVATION TOLERANCE: 0.25 (in.)

c (West) f (East)

Remarks:

5. The crane was parked at the North runway end stops at the time of the survey. G-7130 Technician: Date:

BG 11/8/2023

ES

no no no no no no no

19.875

19.875

19.75

-0.125

-0.125

-0.0625

-0.125

-0.125

-0.125

4. Relative Elevation Offset = (Datum Rod Reading) - Rod Reading

3 20.0625

4 & 5 20 no no

-0.375

-0.3125

20.125

4 & 5 no no

2.5

-0.25

-0.25 no

20.125 no 20.25

20.3125

20.1875 no

20.125 no19.9375 no

19.875

19.875

19.8125

19.875 no

0.1875 no-0.1875 no no

-0.0625

0.18759 & 10

-0.18757

-0.187520.125

7no no no no no no no no no

9 & 10 no no no no no no no no no no no no no no

0.1875 no no no

COLUMN ROW:

(Crane)

20.3125

Rate of Change Out of Tolerance

RAIL TO RAIL ELEVATION

Elevation Difference

(in.)

-0.3125

(Crane) no

-0.375

2.5

Relative Elevation

Offset (in.)

Relative Elevation

Offset (in.)

(Crane)

Column No. Rod Reading (in.)

Rate of Change Out of Tolerance

Relative Elevation Out of Tolerance

(Crane)

Falcon Power Plant

Power Plant Crane Runway

COLUMN ROW:

2.5

(Crane) --

Column No. Rod Reading (in.)

(Crane) --

11 11 no no

-0.1875 no

Elevation Out of Tolerance

0.25 no

0.25

0.25 no

0.25

Rate of Change Out of Tolerance

-0.125

-0.0625

0.25 no

Relative Elevation Out of Tolerance

Column No.

no no no

0.25

9 & 10

-0.375

4 & 5 no no 20 no0.125 no0.18750 no20.0625

3. The elevation values shown above are not to be used for making necessary rail adjustments. The rail elevation values are for the purpose of identify out of tolerance conditions at the time of the survey. Any necessary rail adjustments shall be verified and confirmed by contractor's survey at the time of adjustments.

2. CMAA rail elevation overall tolerance = ± 3/8". Maximum rate of change = 1/4" in 20'-0". CMAA rail to rail elevation overall tolerance for L ≤ 50' - tolerance = ± 3/16", for L > 50' ≤ 100' - tolerance = ± 1/4", for L > 100' - tolerance = ± 3/8". Maximum rate of change = 1/4" in 20'-0".

no

1. The rail elevations were measured with a laser level. The rail measurements were taken at the top of the rail head, every 15' between the Cranes. Cranes were parked at the extreme East and West ends of the runway at the time of survey.

no

14 19.9375

3.0 Rail to Rail Elevation 4 G7130-FalconPowerPlantRailSurveyRpt-Runway-08Nov2023