A04.01 Statment of Work BRIDGE CRANES SPECIFICATION DRAFT.pdf

OVERHEAD ELECTRIC TRAVELING BRIDGE

CRANES FOR

PUGET SOUND NAVAL SHIPYARD (PSNS)

PREPARED BY:

Code 713

Bldg. 978, PSNS

Bremerton Washington 98314

SPECIFICATION PREPARED BY:

Project Engineer: Luke Berry

Branch Head Supervisor: Bryan Lemos-Goncalves

Contract Representative: Rickie Edmonds

DRAFT

Contract Number 2

TABLE OF CONTENTS

1 GENERAL

STANDARDS

DEFINITIONS

CONTRACTOR COMPLIANCE

SUBMITTALS

DRAWINGS

QUALITY ASSURANCE

2 PRODUCTS

SYSTEM DESCRIPTION

CRANE REQUIREMENTS

PAINTING

LETTERING, MARKINGS, AND LABEL PLATES

UNIQUE IDENTIFIER TAG

3 EXECUTION

SITE SPECIFIC REQUIREMENTS

CONSTRUCTION PREPARATION

CRANE REMOVAL/INSTALLATION

TRAINING

4 APPENDIX (A) CRANE ENVELOPE DRAWING

5 APPENDIX (B) SHOP TEST PROCEDURE

GENERAL INSTRUCTIONS

SHOP TEST PROCEDURE

HOUR READINGS

RUNWAY CONDUCTOR ENERGIZED (SIMULATION)

MAIN LINE CONTACTOR ENERGIZED

DE-ENERGIZE USING E-STOP

MASTER SWITCH FUNCTIONALITY

TROLLEY BUMPER ALIGNMENT

MOTOR CONTROLS

UPPER LIMIT SWITCHES

LOWER LIMIT SWITCHES .................................................................................. Error! Bookmark not defined.

CRANE FAULT SIMULATION

DRIVE CONTROLLER FAULT SIMULATION

BRAKES

Contract Number 3

6 APPENDIX (C) ACCEPTANCE TEST PROCEDURE

GENERAL INSTRUCTIONS

ACCEPTANCE TEST PROCEDURE

NO LOAD OPERATIONS

LOADED OPERATIONS (100% +/-5% LOAD)

TEST LOAD OPERATIONS (125% LOAD)

FINAL VERIFICATION

7 APPENDIX (D) BRAKE DATA SHEET

8 APPENDIX (E) SITE SPECIFIC REQUIREMENTS FOR PUGET SOUND NAVAL SHIPYARD & INTERMEDIATE

MAINTENANCE FACILITY BREMERTON NAVAL COMPLEX, WASHINGTON

SCOPE

APPLICABLE DOCUMENTS

GENERAL REQUIREMENTS

ENVIRONMENTAL AND SAFETY COMPLIANCE, GENERAL AWARENESS TRAINING, AND REGULATORY

INTERFACE

DEFINITIONS

MANAGEMENT OF HAZARDOUS MATERIALS

CONTRACTOR PLAN

HANDLING AND DISPOSAL OF WASTE

SPILLS

WATER POLLUTION AND BEST MANGEMENT PRACTICES (BMPs)

AIR POLLUTION CONTROL AND REPORTING

HEALTH AND SAFETY

SECURITY REQUIREMENTS

SECURITY CAUTIONS

CONTRACTOR CRANES

9 APPENDIX (F) CONTROL SYSTEM INVENTORY

10 APPENDIX (G) SHAFT ALIGNMENT RECORD

Contract Number 4

1 GENERAL

STANDARDS

If standards other than those listed below are used, proof of equivalence shall be provided.

The most recent revision on the day the contract is awarded shall be used for all standards listed in this specification.

AMERICAN GEAR MANUFACTURERS’ ASSOCIATION (AGMA)

2001-D04 – Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear

Teeth

2015-2-B15 – Gear Tooth Flank Tolerance Classification System, American Gear Manufacturers

Association

6013-B16– Standard for Industrial Enclosed Gear Drives

6034-C21 – Practice for Enclosed Cylindrical Wormgear Speed Reducers and Gearmotors

6035-A02 – Design, Rating and Application of Industrial Globoidal Wormgearing

6123-C16 – Enclosed Epicylic Gear Drives

ASSOCIATION FOR IRON & STEEL TECHNOLOGY (AIST)

TR-06 - Specification for Electric Overhead Traveling Cranes for Steel Mill Service

TR-11 – Brake Standards for Mill Motors

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

A14.3 – Fixed Ladders

B4.1 – Preferred Limits and Fits for Cylindrical Parts

B17.1 – Keys and Keyseats

Z359 – Fall Protection and Fall Restraint

60529 – Degrees of Protection Provided by Enclosures

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE)

7-22 – Minimum Design Loads and Associated Criteria for Buildings and Other Structures

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

B30.2 – Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running

Trolley Hoist)

Contract Number 5

B30.10 – Hooks

B30.20 – Below the Hook Lifting Devices

B30.30 – Ropes

BTH-1 – Design of Below-the-Hook Lifting Devices

AMERICAN SOCIETY OF NONDESTRUCTIVE TESTING (ASNT)

SNT-TC-1A – Personnel Qualification and Certification in Nondestructive Testing

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

A668 – Standard Specification for Steel Forgings, Carbon and Alloy, for General Industry Use

A1023 – Standard Specification for Stranded Carbon Steel Wire Ropes for General Purposes

E94 – Standard Guide for Radiographic Examination

E164 – Standard Practice for Contact Ultrasonic Testing of Weldments

E543 – Standard Specification for Agencies Performing Nondestructive Testing

E709 – Standard Guide for Magnetic Particle Testing

F3125 – Standard Specification for High Strength Structural Bolts and Assemblies

F436 – Standard Specification for Hardened Steel Washers

AMERICAN WELDING SOCIETY (AWS)

A2.4 – Standard Symbols for Welding, Brazing, and Nondestructive Examination

D14.1 – Welding of Industrial and Mill Cranes and Other Material Handling Equipment

CRANE MANUFACTURERS' ASSOCIATION OF AMERICA, INC (CMAA)

70 – Specification for Top Running & Gantry Type Multiple Girder Electric Overhead Traveling

Cranes

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

15408 – Common Criteria for Information Technology Security Evaluation

NATIONAL ELECTRIC CONTRACTORS ASSOCIATION (NECA)

NECA 1 – Good Workmanship in Electrical Construction

NECA 130 – Installing and Maintaining Wiring Devices

NECA 230 – Electric Motors and Motor Controllers (1000 Volts and Less)

NATIONAL ELECTRICAL MANUFACTURERS' ASSOCIATION (NEMA)

NEMA ICS 8 – Industrial Control and Systems Crane and Hoist Controllers

Contract Number 6

NEMA MG 1 – Motors and Generators

NEMA 250 – Enclosures for Electrical Equipment (1000 Volts Maximum)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 – National Electric Code

NFPA 70E – Standard for Electrical Safety in the Workplace

NFPA 79 – Electrical Standard for Industrial Machinery

NAVAL SHIPS TECHNICAL MANUAL (NSTM)

NSTM - Chp 613, Wire and Fiber Rope and Rigging

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

Title 29 CFR, Part 1910 Subpart D, Walking-Working Surfaces

Title 29 CFR, Part 1910.140, Personal Fall Protection Systems

Title 29 CFR, Part 1910.147, The Control of Hazardous Energy (lockout/tagout)

Title 29 CFR, Part 1910.179, Overhead and Gantry Cranes

Title 29 CFR, Part 1910.306, Specific Purpose Equipment and Installations

Title 29 CFR Part 1926.62, Safety and Health Regulations for Construction (Lead)

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

Specification for Structural Joints Using High-Strength Bolts

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE J429 – Mechanical and Material Requirements for Externally Threaded Fasteners

SAE J995 – Mechanical and Material Requirements for Steel Nuts

SOCIETY OF PROTECTIVE COATINGS (SSPC)

SSPC – SP 10, Near-White Metal Blast Cleaning

UNDERWRITERS LABORATORIES

UL 60947-4 – Low Voltage Switchgear and Controlgear

WIRE ROPE TECHNICAL BOARD

Wire Rope Users Manual

Contract Number 7

DEFINITIONS

Words that are italicized throughout this specification are defined below:

Angularity: Angle of shaft centerline measured from other shaft centerline.

Collision forces (CF): Defined per CMAA No. 70.

Control Circuit Type (Limit Switch): When activated this type of limit switch restricts the control operations of the crane.

End gap: Distance between the ends of two shafts after a coupling is installed.

Flex-Rigid Coupling: A coupling that allows for angularity but does not allow for offset.

Holding Brake: A brake that does not set on a moving shaft during normal operations, not including testing operations.

Joint Class I: Defined per section 6.9.1 of AWS D14.1.

Joint Class II: Defined per section 6.9.2 of AWS D14.1.

Load Bearing: Components are considered load bearing if they contribute to holding up a portion or all of the lifted load or dead weight of the crane.

Loss of Power Test: A test where the crane is lifting 125% load, and the power is removed from the hoist, bridge, or trolley when in operation, simulating a loss of power.

Offset: Vertical and horizontal distance between the center line of two shafts

Primary Hoist Brake: Hoist brake closest to hoist motor that is located on high speed shaft.

Primary Welds: Defined per section 3 of AWS D14.1.

Rigid-rigid Coupling: A coupling that does not allow for any angularity or offset misalignment.

Flange-to-flange shaft connections are examples of rigid-rigid couplings.

Secondary Hoist Brake: Hoist brake that is furthest from motor located on the high speed shaft.

Secondary Welds: Defined per section 3 of AWS D14.1.

Spliced Connection: Is a connection of two structural members where the two members are treated as one continuous member.

CONTRACTOR COMPLIANCE

The Contractor is required to read, understand, and comply with this entire specification.

The Government will determine compliance with the requirements of this specification by reviewing and accepting the submittals shown in section 1.4.3, attending an on-site shop test

(Appendix B), performing crane inspections, and witnessing the Contractor complete the Acceptance

Test (Appendix C).

Contract Number 8

SUBMITTALS

The Contractor is required, per this specification, to provide a submittal to the Government anytime there is a SUBMITTAL REQUIRED designation after a sentence. The Government will review each submittal within the time period stated in the Submittal Summary Table (section 1.4.3), and either provide comments or accept the submittal. For convenience each occurrence is listed in the

Submittal Summary Table (section 1.4.3) along with the file format, location, due dates, and number of copies. The Contractor shall ensure that all submittals are entirely legible and suitable for reproduction.

A complete design submittal (e.g. Catalog cuts, calculations, drawings/schematics) must be submitted before the Government will begin its review. The Government reserves the right to require changes to submittals, which may change the design, if the requirements of this specification are not met. Any fabrication work performed prior to obtaining design approval is at the Contractor’s risk.

Design approval from the Government will be given upon a satisfactory completion of the Final

Design Submittal. DRAFT

Contract Number 9

SUBMITTAL SUMMARY TABLE:

SUBMITTAL

FILE

FORMAT

SPECIFICATION

SECTION

CONTRACTOR DUE

DATE

GOVERNMENT

DUE DATE

COPIES

TECHNICAL FORMS

Preliminarily Catalog Cuts

(Structural, Mechanical, Electrical and Control

System/Networking)

.pdf 1.4.4.2 Prior to manufacturing of crane

Review, comment, and submit within fifteen (15) business days after date received

Final Catalog Cuts

(Structural, Mechanical, Electrical and Control

System/Networking)

.pdf 1.4.4.2 Prior to manufacturing of crane

Review, comment, and submit within fifteen (15) business days after date received

Preliminary Drawings

(Structural, Mechanical, Electrical, General

Arrangement and Control

System/Network)

.pdf 1.5.1.1 Prior to manufacturing of crane

Review, comment, and submit within fifteen (15) business days after date received

Final Drawings (Structural, Mechanical, Electrical, General Arrangement and

Control System/Network)

.pdf 1.5.1.1 Prior to manufacturing of crane

Review, comment, and submit within fifteen (15) business days after date received

Final As-Built Drawings

(Structural, Mechanical, Electrical, General

Arrangement and Control

System/Network)

.pdf and .dxf or .dwg & CD 1.5.1.1

Ten (10) business days after crane acceptance

Review, comment, and submit within twenty (20) business days after date received

Preliminary Maintenance, Technical, and Operations

Manual

.pdf 1.5.6.1

Twenty (20) business days prior to crane delivery

Review, comment, and submit within fifteen (15) business days after date received

Final Maintenance, Technical, and Operations

Manuals

Hard copy and .pdf 1.5.6.1

Ten (10) business days after crane acceptance

Review, comment, and submit within twenty (20) business days after date received

2 Hard

Copies, 1 pdf

Contractor Schedule .pdf 1.6.1.1

First submittal prior to post-award meeting

(after first submission an updated schedule shall be submitted monthly at a minimum)

Continual Feedback and Communication

Regarding Schedule

Crane Envelope Drawing .pdf, .dxf or

.dwg Error! Reference source not found.

Prior to manufacturing of crane

Review, comment, and submit within five (5) business days after date received

Appendix (B) Shop Test .pdf 1.6.5.2 Ten (10) days after completion of shop test

Review, comment, and submit within ten (10) business days after date received

Contract Number 10

SUBMITTAL

FILE

FORMAT

SPECIFICATION

SECTION

CONTRACTOR DUE

DATE

GOVERNMENT

DUE DATE

COPIES

Request to Ship .pdf 1.6.5.2 Fifteen (15) days prior to intended shipping date

Review, comment, and submit within five (5) business days after date received

Appendix (C) Field

Acceptance Test .pdf 1.6.8.1

Ten (10) days after completion of field acceptance test

Review, comment, and submit within ten (10) business days after date received

Final Parameter Record .pdf &

CD/DVD

1.6.8.3 After field acceptance test

Review, comment, and submit within three (3) business days after date received

1 pdf &

1 CD/

DVD

Preliminary Calculations

(Structural, Mechanical, and

Electrical)

.pdf 1.6.13.1 Prior to manufacturing of crane

Review, comment, and submit within fifteen (15) business days after date received

Final Calculations

(Structural, Mechanical, and

Electrical)

.pdf 1.6.13.1 Prior to manufacturing of crane

Review, comment, and submit within fifteen (15) business days after date received

Welder Certifications .pdf 1.6.14.1 Prior to performing welding

Review, comment and submit within five (5) business days after date received

NDT Qualification Report .pdf 1.6.15.1 Prior to performing any

NDT

Review, comment, and submit within five (5) business days after date received

Weld NDT Reports .pdf 1.6.15.2 Prior to shop test meeting

Review, comment, and submit within five (5) business days after date received

Cybersecurity Certificate –

Public Domain Software .pdf 1.6.16.1

Prior to manufacturing of crane

Review, comment, and submit within ten (10) business days after date received

Cybersecurity Certificate –

Software and Services .pdf 1.6.16.2

Prior to manufacturing of crane

Review, comment, and submit within ten (10) business days after date received

Cybersecurity Closeout

Submittals

.pdf and

CD/DVD

1.16.7

Forty (40) business days prior to crane delivery

Review, comment, and submit within twenty (20) business days after date received

1 pdf &

1CD/

DVD

Overload Test Certificate .pdf 2.2.1 Prior to crane delivery

Review, comment, and submit within two (2) business

Contract Number 11

FILE

FORMAT

SPECIFICATION

SECTION

CONTRACTOR DUE

DATE

GOVERNMENT

DUE DATE

COPIES

days after date received

Loss of Power Test Certificate .pdf 2.2.4 Prior to crane delivery

Review, comment, and submit within two (2) business days after date received

Hazardous Material

Certificate .pdf 2.2.6.4.1 Prior to shop test meeting

Review, comment, and submit within one (1) business days after date received

Coupling Alignment

Certificate .pdf 2.2.9.3.4

Prior to acceptance of crane

Review, comment, and submit within five (5) business days after date received

Barrel Coupling Alignment

Certificate .pdf 2.2.9.4.10

Prior to acceptance of crane

Review, comment, and submit within five (5) business days after date received

Trolley and Bridge Wheel

Specification Sheet .pdf 2.2.9.5.3

Provide report after completion of wheel sample

Review, comment, and submit within five (5) business days after date received

Vendor ASTM E543

Certification Letter .pdf 2.2.9.9.4.1 Prior to hook NDT

Review, comment, and submit within five (5) business days after date received

Hook NDT Procedure .pdf 2.2.9.9.4.2 Prior to hook NDT

Review, comment, and submit within five (5) business days after date received

Hook NDT Report .pdf 2.2.9.9.4.2 Fifteen (15) business days prior to shop test

Review, comment, and submit within five (5) business days after date received

Wire Rope Braking Strength and Specification Certificate .pdf 2.2.9.10.3 Prior to crane delivery

Review, comment, and submit within two (2) business days after date received

Wire Rope End Connection

Proof Test Certificate .pdf 2.2.9.10.5 Prior to crane delivery

Review, comment, and submit within two (2) business days after date received

Brake Setting Certificate .pdf 2.2.9.19.5 Prior to shop test

Review, comment, and submit within two (2) business days after date received

Contract Number 12

FILE

FORMAT

SPECIFICATION

SECTION

CONTRACTOR DUE

DATE

GOVERNMENT

DUE DATE

COPIES

Lubrication SDS .pdf 2.2.9.22.1

Prior to applying lubrication or filling gearbox

Review, comment, and submit within five (5) business days after date received

Contractor Hazardous

Material Inventory (CHMI)

(Attachment 1)

Hard Copy or .pdf 3.1.2.1

Ten (10) business days prior to crane delivery

NA TBD

Solid Waste Tracking Sheet

(SWTS) (Attachment 3) Hard Copy or .pdf 3.1.2.2

Filled out when disposing of waste at Contractor determined disposal facility

NA TBD

Contractor’s Monthly

Project Waste Summary

Report (CMPWSR)

(Attachment 4)

Hard Copy or .pdf 3.1.2.3

Monthly during on-site work

NA TBD

Personal Information for

Visitor Request (Attachment 6) Hard Copy or .pdf

3.1.2.4 Ten (10) business days

prior to coming to PSNS

NA TBD

AIS Survey (Attachment 7) Hard Copy or .pdf 3.1.2.5

Twenty (20) business days prior to bringing a laptop into the CIA

NA TBD

Radio Operations Request

(Attachment 8) Hard Copy or .pdf 3.1.2.6

Ten (10) business days prior to coming to PSNS with a radio

NA TBD

Vehicle Pass Request for

Access to the Controlled

Industrial Area (CIA)

(Attachment 12)

Hard Copy or .pdf 3.1.2.7

Twenty (20) business days prior to bringing a vehicle into the CIA at

PSNS

NA TBD

Foreign Interest

Determination (Attachment 13) Hard Copy or .pdf 3.1.2.8

Twenty (20) business days prior to coming to

PSNS

NA TBD

Certificate of Compliance

Form (Attachment 16) Hard Copy or .pdf 3.1.2.9

Prior to use of crane/lifting and handling equipment at

PSNS

Government will fill out form on-site with

Contractor

TBD

Waste Information Sheet (WIS) Hard Copy or.pdf 3.1.2.10

Ongoing as waste is generated

NA TBD

Lifting & Handling Certificate of Compliance (NAVFAC P-

307, P1 form)

.pdf 3.2.2

Prior to use of crane/lifting and handling equipment at

PSNS

Reviewed on site during equipment inspection (prior to PSNS entry)

Removal and Installation

Lifting Plans .pdf 3.2.4.1

Forty (40) business days prior to crane delivery

Review, comment, and submit within twenty (20) business days after date received

Lead Work Plan .pdf 3.3.4

Thirty (30) business days prior to crane delivery (if applicable)

Review, comment, and submit within two (2) business days after date received

Electrical Safety plan Hard Copy or .pdf 3.3.8.3

Twenty (20) business days prior to crane delivery

Review, comment, and submit within ten (10) business days after date received

Contract Number 13

FILE

FORMAT

SPECIFICATION

SECTION

CONTRACTOR DUE

DATE

GOVERNMENT

DUE DATE

COPIES

Fall Protection Plan Hard Copy or.pdf 3.3.8.4

Twenty (20) business days prior to crane delivery

Review, comment, and submit within ten (10) business days after date received

Training Syllabus .pdf 3.4.4 Prior to crane delivery

Review, comment, and submit within ten

(10) business days after date received

Contractor Operator License Hard Copy or .pdf 8.12.7

Submit License(s) prior to operating equipment such as fork lift, aerial work platform, crane, and other types of equipment

NA TBD

CATALOG CUTS:

Catalog cuts for all commercially available components shall be provided as a submittal to the

Government. The catalog cuts shall be marked to clearly display what component and component options are used on the crane, e.g., part number, model, and load rating.

The Contractor shall submit for approval all applicable component catalog cuts listed below and any other commercially available components not listed. If components below are fabricated by the Contractor then design drawings will need to be submitted in place of catalog cuts.

(SUBMITTALS REQUIRED)

STRUCTURAL CATALOG CUTS

1.4.4.3.1 End trucks (including drive units)

1.4.4.3.2 Product information for all paint used on the crane

1.4.4.3.3 Trolley end stops

1.4.4.3.4 Bridge rails and associated hardware (e.g. clips, splice bars)

1.4.4.3.5 Commercial lifting attachment points, fall protection anchorage(s) and ADD anchor points.

1.4.4.3.6 Swing gates, including manufacturer’s installation instructions.

MECHANICAL CATALOG CUTS

1.4.4.4.1 Speed reducers (including gear ratio, HP rating, speed ratings, service factors)

1.4.4.4.2 Brakes (including electrical information, installation, servicing and adjusting)

1.4.4.4.3 Bearings and housings (including lubrication instructions, load ratings)

1.4.4.4.4 Couplings (including acceptable offset, angularity, and end gap values as applicable)

1.4.4.4.5 Load blocks and hooks

Contract Number 14

1.4.4.4.6 Wheels

1.4.4.4.7 Sheaves

1.4.4.4.8 Bumpers (including bumper compression and the resulting force based on the total kinetic energy absorbed)

1.4.4.4.9 Wire rope and end fittings

ELECTRICAL CATALOG CUTS

1.4.4.5.1 Variable Frequency Drive Controllers (including dynamic braking resistors and line reactor selection/isolation transformers)

1.4.4.5.2 Motors

1.4.4.5.3 Encoders

1.4.4.5.4 Electrical Enclosures

1.4.4.5.5 Collector Shoes and Assembly

1.4.4.5.6 Limit Switches

1.4.4.5.7 Bridge-to-Trolley Electrification

1.4.4.5.8 Warning Devices

1.4.4.5.9 Disconnect Switches

1.4.4.5.10 Contactors and Relays

1.4.4.5.11 Pendant Controls

1.4.4.5.12 Auxiliary Devices (Floodlight, Horn, etc.)

1.4.4.5.13 Circuit Breakers

1.4.4.5.14 Fuses

NETWORKED CONTROL SYSTEM AND NETWORK PRODUCT DATA

1.4.4.6.1 To include, but not limited to the following devices: Crane Supervisory Controller, Programmable Logic Controller/Relay (PLC/PLR), Remote Terminal Unit (RTU), Human

Machine Interface (HMI), Motor Drive Interface Terminal, Network Communication

Module, Network Router, Network Switch/Hub, or other network-capable (whether networked or not upon delivery) device as applicable.

1.4.4.6.2 Provide the each of the following pieces of data for each applicable device:

1.4.4.6.2.1 Device Manufacturer

1.4.4.6.2.2 Device Model

1.4.4.6.2.3 Device (relative) Location

Contract Number 15

1.4.4.6.2.4 Key Technical Ratings (e.g. memory, capacity, format, compatibility, etc.)

1.4.4.6.2.5 Serial Number

1.4.4.6.2.6 Unique Network Identifier/Address

1.4.4.6.3 Provide each of the following pieces of data for software:

1.4.4.6.3.1 Manufacturer

1.4.4.6.3.2 Version/Sub-Version

1.4.4.6.3.3 Associated device (relative) location

1.4.4.6.3.4 Used network ports/protocols/services

1.4.4.6.4 Descriptions of all security features associated to vendor hardware and software.

DRAWINGS

All drawings

Provide a preliminary drawing package to the Government for review (SUBMITTAL

REQUIRED). Provide a final design drawing package that complies with all requirements listed in section 1.5 (SUBMITTAL REQUIRED). The preliminary and final design drawing packages shall include all general arrangement drawings, structural/mechanical drawings, and electrical drawings.

Drawings that use foreign language and nomenclature shall include corresponding English equivalents. Metric units may be used for drawings, but they shall include conversions to English units on the drawings.

All drawings shall have a complete title block that includes the crane number, and the signature and seal of a registered Professional Engineer that directly oversees the work. There shall be no proprietary notes on any of the drawings.

All drawings shall have a comprehensive and complete bill of materials for the given drawing.

Each revision shall be tracked and marked on the drawing. An index of drawings shall be included that tracks current revisions of drawings.

All drawings must be provided in PDF format during the design review phase and in PDF and

DWG or DXF for final as built drawings. These files shall be compatible with AutoCAD 2021.

GENERAL ARRANGEMENT DRAWINGS

Provide general arrangement drawings that show all assemblies in plan, elevation, and side views. These drawings shall show all mechanical components and assemblies, e.g., hoist assemblies, trolley and bridge drivetrains, building clearances, and principal dimensions that include tolerances.

Contract Number 16

Provide general arrangement drawings that show major components in plan, elevation, and end views. All major features of the crane shall be shown including: clearances, lifts, spans, wheel spacing, rated speeds, trolley gage, hook approaches on all sides, maximum wheel loads, electrical power supply, and general locations of components, e.g., brakes, motors, speed reducers, electrical enclosures (including size).

Include weights of all components and maximum bridge wheel loads (without impact), wheel spacing, and show the location of the center of gravity of the trolley and bridge assemblies.

STRUCTURAL/MECHANICAL DRAWINGS

Provide a complete drawing package clearly detailing all fabricated components and structural assemblies/weldments, include tolerances, size and location (dimensions), camber requirements, weld call outs per AWS A2.4, material type and the standard associated with the material type, e.g., ASTM A36. For structural fasteners, include size and type of fastener, associated hardware and joint type for RCSC Specification for Structural Joints Using High-Strength Bolts.

Wheels and shafts (excluding motor and gearbox) machining detail including material type, hardness and ultimate and yield strength. Gearbox assembly/setup drawings including any backlash limits, bearing size and type, shim stacks or preload requirements.

Reeving diagram including wire rope specification to include diameter, construction, material, length and terminations. Sheave assemblies including machining details, dimensions, material type and hardness.

Component bolt torque values shall be provided for installed fasteners with consideration for any lubrication and washers type. A general table may be used however, any special torques shall be called out on the applicable drawing.

Coupling & brake installation drawings including: locations, applicable shaft engagement, allowable misalignment, and bore and key details.

Wire rope drum assembly drawing with bearing size and type, alignment criteria and material type.

Hook block assembly drawing with bearing size, load ratings, part numbers and material type.

Lubrication drawing detailing the location of lubrication points, type of lubricant used, quantity and frequency of lubrication.

Joining/assembly details (including girder to endtruck, cab, etc.).

Dimensioned locations of lift points, estimated weight and approximate locations of center of gravity for each major component.

Dimensioned locations of fall protection anchorages (if applicable).

Dimensioned location of ADD anchor point.

Contract Number 17

ELECTRICAL DRAWINGS

Provide electrical schematics, layout drawings, and wiring diagrams for all electrical components and drives. The schematics shall show; all electrical components and wired connections including rating and type of protective devices and grounding. All devices with adjustable set points shall have the range and desired set point shown. All electrical components shall list power requirements except control circuits. The wiring diagram shall show all electrical component device placement, wiring size, wiring type, wiring color. Wiring diagram shall include a bill of materials listing all electrical components with OEM name and part number.

Provide crane electrification detail drawings that include the runway conductor installation including method of attachment to building and spacing, the electrical supply circuit (conduit) routing path between existing circuit breaker and the connection point to the overhead runway conductor system and conductor size and approximate length of supply feeder conductors.

Provide motor nameplate data and overcurrent device ratings including all information called for in NFPA 70 Section 430.7.

Provide a comprehensive and complete drive parameter listing and all custom programming associated with the crane.

CONTROL SYSTEM AND NETWORK DRAWINGS

Network diagram must show interconnecting cabling, equipment locations, names, models, and unique network identification on network communications schematic for all network-capable devices.

Software logic graphical diagram (e.g. flow or block diagram, ladder-logic diagram, etc.)

1.5.5.2.1 Ladder logic and/or software flow/block diagrams shall include comments explaining the function of each unique software task or operation.

Network variable cross-reference list (or table) for all variables spanning multiple network protocols shall be provided in a drawing format. This list or table shall provide variable names and register addresses used in each communication protocol and each variable shall be correlated to the hardware/device served.

OPERATIONS AND MAINTENANCE/TECHNICAL DATA

The Contractor shall submit a preliminary copy of the crane’s operations and maintenance/technical manuals to the Government for review. (SUBMITTAL REQUIRED)

The Contractor shall submit final copies of the operations and maintenance/technical manuals once all Government comments have been addressed. (SUBMITTAL REQUIRED)

The operations and maintenance/technical manual may be combined into one manual or may be separated out into multiple manuals. A detailed table of contents is required and all pages shall be individually numbered in a manner that corresponds to the table of contents.

The operation and maintenance manuals shall be tailored to the crane and include a coversheet indicating the revision number, table of contents, operation instructions, maintenance information, parts information, drawing list, all drawings, product data, and calculations.

OPERATIONS MANUAL:

Contract Number 18

1.5.6.4.1 The body of the operations manual shall include detailed crane operating and safety instructions including specific starting/stopping instructions.

1.5.6.4.2 The operation manual shall be specific to the crane and include Contractor’s detailed written procedures as well as crane operating and safety instructions including special precautions for starting/stopping.

MAINTENANCE / TECHNICAL MANUAL:

1.5.6.5.1 The maintenance/technical manual shall include detailed written procedures necessary to maintain the crane, all catalog cuts, a recommended spare parts list, and the final as-built crane drawing package.

1.5.6.5.2 The maintenance/technical manual shall include detailed maintenance procedures, and manufacturer’s installation and maintenance manuals for commercial components. If applicable, the manuals shall include alignment, adjustment, and calibration instructions.

1.5.6.5.3 Provide preventative maintenance instructions including location of lubrication points, type of lubricant used, and the frequency of lubrication.

1.5.6.5.4 Provide part numbers and all available information for all Contractor-designed parts, purchased sub-assemblies and components. The information shall be broken down to the smallest replacement part.

1.5.6.5.5 The maintenance/technical manual shall include all of the crane’s final as-built programming, i.e., ladder logic diagrams, software flow diagrams, parameter listings, or any other type of machine controlling software code that is used in the Contractor’s design.

Ladder logic and software flow diagrams shall include comments explaining the function of each unique software task/operation. The maintenance/technical manual shall include the

Contractor’s recommended methods for tuning the motion controlling electronics to achieve various levels of performance, while staying within crane design allowances and/or limitations; and include a functional description of each subsystem and how each subsystem interfaces to the rest of the crane.

QUALITY ASSURANCE

CONTRACTOR SCHEDULE

The Contractor shall submit a preliminary schedule that details key events in the design, fabrication, and installation of the crane. The schedule shall be updated and submitted, at a minimum, monthly throughout the duration of the contract (SUBMITTAL REQUIRED). At a minimum the schedule shall include the information below (the order of events shown below is not fixed):

1.6.1.1.1 Post-Award Meeting

1.6.1.1.2 Crane Envelope and Dimension Verification

1.6.1.1.3 Preliminary Drawings and Calculation Submittals

1.6.1.1.4 Government Review of Initial Design

1.6.1.1.5 Final Drawings and Calculation Submittals

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1.6.1.1.6 Government Review of Final Design

1.6.1.1.7 Start of Fabrication

1.6.1.1.8 Shop Test Meeting

1.6.1.1.9 Completion of Fabrication

1.6.1.1.10 Pre-Installation Meeting

1.6.1.1.11 Crane Delivery

1.6.1.1.12 Existing Crane Removal

1.6.1.1.13 New Crane Installation

1.6.1.1.14 Post Installation Government Inspection

1.6.1.1.15 Acceptance Test

1.6.1.1.16 Crane Acceptance

1.6.1.1.17 Completion of Warranty

CONTRACTOR VERIFICATION AND POST-AWARD MEETING (CONTRACTOR AT PSNS

OR VIRTUAL)

The Contractor shall meet with the Government at PSNS after the contract has been awarded.

This meeting will be used to discuss the contract and any other questions that arise.

The Contractor shall be responsible to ensure, by verification of existing or replacement as necessary all electrification information necessary to install new runway conductors/grounding, conduit, and wiring from the crane to the building control panel (see section 2.2.10 for requirements).

CRANE ENVELOPE SURVEY

The Contractor shall verify all crane envelope clearances, hook approaches, hook heights, spans, access to other crane and other building/runway features, bumpers on the alternate crane on the rail and existing rail end stops, prior to designing the crane and shall submit a crane envelope drawing similar to the one shown in Appendix (A). The location and dimensions of the boarding platform shall also be included in this survey, see section 2.2.6. The purpose of

Appendix (A) is to provide an example crane envelope and should not be used to design the crane. (SUBMITTAL REQUIRED). The Contractor shall verify existing rail end stops as well as the bumpers on the alternate crane on the rail.

CONTRACTOR TESTING

Contract Number 20

Prior to the Shop Test and Inspection (see section 1.6.5), the Contractor shall test the operations of the crane under a no load condition. The Contractor shall perform a detailed inspection of the crane and its components and test all possible functions of the assembled crane.

The crane is to be fully assembled during the test and inspection, unless otherwise approved by the Government. The crane shall not be reeved. Once the Contractor successfully tests and inspects the crane, the Contractor shall provide a copy of the completed self-test, recorded on the shop test procedure verifying the Contractor’s self-test has been completed (SUBMITTAL

REQUIRED). The Contractor shall then work with the Government to schedule the Shop Test and Inspection.

SHOP TEST AND INSPECTION (GOVERNMENT AT CONTRACTOR’S FACILITY)

The Contractor shall allow the Government to come to the Contractor’s facility and participate in a crane inspection and Shop Test. This meeting will cover the submittals that the Contractor is responsible for providing to the Government, shop testing, shipping, site mobilization, erection dates, crane installation plan, roles and responsibilities of the entities involved, and the overall schedule. The shop test shall occur after the Government approves the final design submittal of the crane. Sufficient time shall be provided to allow the Government to thoroughly inspect the crane prior to the start of the shop test. The Contractor shall establish the specific energy control requirements and lockout/tagout (LO/TO) procedures in accordance with 29 CFR Part 1910.147 to ensure all hazardous energy will be secured prior to the start of the inspection. The Contractor shall advise the Government of the anticipated shop test two weeks prior to the beginning of the

Government witnessed shop test.

The Contractor shall be available to operate the crane, perform the shop test, complete the shop test shown in Appendix (B) (SUBMITTAL REQUIRED), and answer any questions that arise. All contract violations found during the shop test and inspection will be recorded by the

Government on a punch list. The Government will conduct an out-brief with the Contractor and will go over every punch list item with the Contractor before leaving the Contractor’s facility. All punch list items shall be resolved by the Contractor prior to shipping the crane to PSNS. The crane shall not be shipped to PSNS until the Government accepts the Contractor’s request to ship

(SUBMITTAL REQUIRED). The request to ship shall include details of how the crane will be shipped to the site, along with all submittals required in Appendix E.

PRE-INSTALLATION MEETING (TELECONFERENCE OR CONTRACTOR AT PSNS)

The Contractor shall attend a Government conducted pre-installation conference that will either be a teleconference or will be held at the installation site. This conference will provide the

Contractor/Sub-Contractors, and the Government the ability to review all aspects of the crane installation to ensure accuracy and safety.

GOVERNMENT INSPECTION

Once the Contractor has installed, tuned, and tested the crane to verify it is ready for acceptance testing, the Contractor shall allow the Government to conduct a 5 day inspection prior to field acceptance testing. The Contractor shall be available to operate the crane at the request of the inspectors during this 3-5 day period. The Government shall be given a 2 day notice that the crane is ready for inspection before the 3-5 day period begins. All references to “days” in this section are considered working days (M-F) excluding federal holidays.

Contract Number 21

All items that are found during the Government inspection that do not meet the requirements of this contract shall be written on the punch list and corrected by the Contractor prior to acceptance testing. After the corrections have been made, the Government has one day (per crane) to re-inspect the crane to ensure all the corrections have been made.

FIELD ACCEPTANCE TEST

The Acceptance Test, shown in Appendix (C) (SUBMITTAL REQUIRED), shall be satisfactorily completed after each crane is installed inside building 978 at PSNS by the

Contractor. The Government will provide all test weights and rigging gear. If the crane fails to complete an item listed in Appendix (C) the test shall be repeated after repairs/adjustments have been made until the test is passed. Any repairs that would affect an already tested component will require retesting of the previously tested component. The Government may, if necessary, request additional tests to determine that the crane meets the requirements of this specification.

The Government shall have one regular work day to conduct a final inspection after the Field

Acceptance Testing is completed.

After the crane has passed the field acceptance test, the contractor shall complete a control system parameter record, including authorized parameter range tolerances, for the crane and provide the crane parameter file downloaded from the crane at a time of acceptance, if applicable.

The record shall include the contract number, contractor's name and address, date, all control system parameters and their final settings. Each control system parameter shall be designated as either used or unused. A copy of the parameter file records shall be provided to the Government on CD. (SUBMITTAL REQUIRED)

ACCEPTANCE

Final Government acceptance of the cranes shall take place only after the following conditions are met:

1.6.9.1.1 Contractor receives Government approval for all tests, inspections, and verification that all submittals have been received and acceptable.

1.6.9.1.2 The cranes meet all contract requirements.

1.6.9.1.3 The cranes pass a final inspection by the Government.

1.6.9.1.4 All punch list items have been corrected or a method of resolution has been determined.

Outstanding punch list items not corrected prior to the Government's acceptance shall be carried as warranty items, which shall be corrected by the Contractor.

CONFERENCE CALLS

The Contractor shall support 30 minute weekly teleconferences at the Government’s request including the Contractor project manager and lead engineer.

GOVERNMENT INSPECTIONS

The Government may perform scheduled inspections of material, workmanship, and documentation throughout the life of the contract. If the Government determines there is a problem with quality, then they will submit a written notification to the Contractor and they shall respond to each identified problem within ten day(s) of receiving the notification.

Contract Number 22

MANUFACTURER QUALIFICATIONS

The overhead electric crane system, including sub-system components manufactured by vendors, shall be designed and manufactured by a company with experience in designing this type of crane or system and can meet the requirements of this specification.

CALCULATIONS

The Contractor shall provide preliminary (SUBMITTAL REQUIRED) and final

(SUBMITTAL REQUIRED) structural, mechanical, electrical, and rail analysis (of the supporting structure) calculations to the Government that validate that the design complies with the requirements in section 1.6.13, CMAA No. 70, and all other applicable requirements in this specification. Design calculations shall be provided for custom items, and sizing calculations shall be provided for commercial items. Calculations shall be stamped and signed by a PE. The stamp and signature shall be original, or otherwise comply with the applicable rules or regulations pertaining to their reproduction.

Design calculations that use foreign language and nomenclature shall include English equivalent nomenclature. Metric units may be used for calculations, but they shall include conversions to English units. In the case of calculations, only the initial inputs and final results need to be converted.

All calculation submittals shall be labeled with the crane number.

Any Finite Element Analysis (FEA) that is provided as a submittal shall come with hand calculations that verify the FEA model and a write-up that details the designer’s assumptions and explains the thought process behind the model.

STRUCTURAL CALCULATIONS

1.6.13.5.1 Operating Wind loads and Stored Wind Loads (WLO and WLS) shall be neglected since the crane will be indoors. Collision forces (CF) due to the crane impacting the bridge and trolley end stops shall be accounted for. The cranes shall also be designed to withstand collisions with an identical second crane on the same rail at the maximum rated bridge speed.

The crane shall be designed for all other applicable CMAA No. 70 load cases as required by section 2.2.8.1.2. Building drawings will be provided by the Government. Calculations are required for verifying the design and sizing of the girders, end trucks, welds and bolt sizes.

1.6.13.5.2 Calculations verifying the design of trolley frame shall be provided in accordance with

CMAA No. 70 for any non-commercial items.

1.6.13.5.3 Calculations verifying the design of structural connections in accordance with this specification.

1.6.13.5.4 Calculations shall be provided that verify all lifting attachment points for the trolley and the bridge. Custom designed attachments shall be designed to Category B, Service Class

0 criteria of ASME BTH-1. All lifting attachment points shall meet ASME B30.20 provisions that apply to the marking, construction, installation, inspection, and testing. If requested by the government, load testing per ASME B30.20 of the lifting attachments shall be performed and witness by the government.

1.6.13.5.5 Perform a seismic analysis per the requirements of section 2.2.8.7.

Contract Number 23

1.6.13.5.6 Calculations shall be provided to verify the sizing of new runway end stops.

MECHANICAL CALCULATIONS

1.6.13.6.1 Calculations are required for sizing of couplings, brakes, sheaves, wheels, end stops, bumpers, gear reducers, drum, wire rope and bearing life.

1.6.13.6.2 Fatigue calculations shall be provided for any custom design shafts. The calculations shall address the stresses and fatigue induced by the OEM allowed misalignment of couplings in addition to other applied forces.

1.6.13.6.3 The calculations shall address overstressing the drivetrain and reducers during a situation where both the primary and secondary brakes set at the same time without the drive controls stopping the test load. The calculations shall address the worst case scenarios regarding hoist up/down, no load/max load, and slow speed/rated speed. This load case is considered a momentary peak load. The stress due to this load case shall not exceed the component OEM’s peak load rating or for custom designed components, 75% of the yield strength of the material.

1.6.13.6.4 Any non-commercial mechanical components shall be analyzed to show compliance with CMAA No. 70.

ELECTRICAL CALCULATIONS

1.6.13.7.1 Provide conduit fill calculations (using tables from NFPA 70 or manufacturer’s data sheets). Grounding conductors shall be included in the calculations.

1.6.13.7.2 Protective device coordination study showing proper coordination for any overcurrent devices that have the same rating as another overcurrent device upstream. This study shall include all devices from the line side of the primary facility overcurrent device.

1.6.13.7.3 Provide arc flash energy calculations for each electrical enclosure showing proper data necessary for appropriate arc flash labels per NFPA 70E.

1.6.13.7.4 Provide wire sizing calculations for all power circuit conductors.

1.6.13.7.5 Provide component and device sizing calculations for transformers, reactors, resistors, electronic drives, and control panel environmental controls.

1.6.13.7.6 Provide an analysis of the temperature inside the electrical enclosures shall be conducted to ensure that the OEM recommended climate of the components inside is being maintained.

1.6.13.7.7 Provide motor sizing calculations per CMAA No. 70.

1.6.13.7.8 Provide lighting calculations to verify floodlights comply with section 2.2.13.7.1 of this specification.

Contract Number 24

WELDING

Welders shall be qualified per AWS D14.1 section 9. (SUBMITTAL REQUIRED)

Welded or fabricated items (not including commercially purchased components) shall be per

AWS D14.1.

Workmanship regarding welds shall be performed per Section 7 of AWS D14.1.

All weld repairs for primary and secondary welds shall be per section 12 of AWS D14.1.

NON-DESTRUCTIVE TESTING (NDT)

The Contractor shall provide a certificate with qualification data showing that the inspector performing NDT on the crane is qualified as a level 2 examiner per ASNT-SNT-TC-1A

(SUBMITTAL REQUIRED).

All NDT performed per the NDT Table section 1.6.15.3, including visual inspection, shall be fully documented, and submitted to the Government. (SUBMITTAL REQUIRED). At a minimum, the test document shall provide the acceptance criteria used, identification of the weld or component that was tested, test results, and the individual who performed the test/inspection.

NDT TABLE

DESCRIPTION EXAMINATION METHOD

*Primary Welds V, MT

*All Joint Class I and II welds that are considered Primary Welds (Section 10.8.1 of AWS D14.1)

V, MT, UT

All Lifting Attachment Welds V, MT

*All Secondary Welds V

Hook and Eye Pin or Swivel Eye Bar V, MT

*See section 0 for definitions regarding joint class, primary welds, and secondary welds

Radiographic examination can be used in place of ultrasonic examination.

VISUAL EXAMINATION (V):

1.6.15.5.1 All welds shall first undergo a visual examination. Acceptance criteria for a Visual

Examination shall be per section 7, 10.6, and 10.7 of AWS D14.1 and any other applicable standards included in these sections.

MAGNETIC PARTICLE TESTING (MT):

1.6.15.6.1 All magnetic particle testing shall be performed per ASTM E709.

Contract Number 25

1.6.15.6.2 Acceptance criteria shall be per section 10.16.4 of AWS D14.1. A minimum length of

20% of the primary welds shall be randomly selected for MT; if a sample shows defects, two adjacent locations shall be inspected. The entire length of weld is required to be inspected if either of the sample locations show defects.

1.6.15.6.3 The entire weld of a lift attachment point shall be magnetic particle tested.

RADIOGRAPHY EXAMINATIONS (R):

1.6.15.7.1 All radiography examinations shall be conducted per ASTM E94.

1.6.15.7.2 Acceptance criteria for Radiographed welds shall be per section 10.11 of AWS D14.1 and any applicable standards included in this section.

ULTRASONIC EXAMINATIONS (UT):

1.6.15.8.1 All ultrasonic examinations shall be conducted per section 10.13 and 10.14 of AWS

D14.1 and ASTM E164/E317.

1.6.15.8.2 Acceptance criteria for ultrasonic examinations shall be per section 10.15 of AWS

D14.1 and any applicable standards included in this section. A minimum length of 20% of joint class I and II primary welds shall be randomly selected for UT; if a spot shows defects, two adjacent locations shall be inspected. The entire length of weld is required to be inspected if either of the spot locations show defects.

CYBERSECURITY CERTIFICATES

The Contractor shall provide a declaration that public domain software (e.g., freeware, shareware) is not used in the system (SUBMITTAL REQUIRED).

The Contractor shall provide a certificate stating that all software and services that are not required for operation and/or maintenance of the product have been removed (SUBMITTAL

REQUIRED). If removal is not technically feasible, then the contractor shall take action to disable software not required for the operation and/or maintenance of the product, and shall note this on the submitted certificate. Configure the product to allow the ability to re-enable ports and/or services if they are disabled by software. The removal of software or services shall not impede the primary function of the product. If software that is not required cannot be removed or disabled, document a specific explanation and provide risk mitigating recommendations and/or specific technical justification. The software/service to be removed and/or disabled shall include, but not be limited to:

1.6.16.2.1 Cameras

1.6.16.2.2 Games

1.6.16.2.3 Device drives or product components not procured/delivered

1.6.16.2.4 Messaging services (e.g. Email, instant messenger, peer-to-peer file sharing, etc.)

1.6.16.2.5 Source code

1.6.16.2.6 Software compilers in workstations

1.6.16.2.7 Software compilers for programming languages that are not used in the control system

Contract Number 26

1.6.16.2.8 Unused networking and communications protocols

1.6.16.2.9 Unused administrative utilities, diagnostics, network management, and system management functions

1.6.16.2.10 Backups of files, databases, and programs used only during system development

1.6.16.2.11 All…