Attachment 2 NAVFAC Specification N6247020R1004.pdf

NAVFAC N62470-20-R-1004 Page 1 of 76

MODERNIZATION OF CRAFT PORTAL CRANES

SERVICE LIFE EXTENSION PROGRAM (SLEP) II

FOR

NORFOLK NAVAL SHIPYARD (NNSY)

PUGET SOUND NAVAL SHIPYARD & IMF (PSNSY)

PREPARED BY:

Navy Crane Center

Bldg. 491, Norfolk Naval Shipyard

Portsmouth Virginia 23709-5000

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TABLE OF CONTENTS

PART 1 GENERAL 4

1.1 REFERENCES 4

1.2 UNIT PRICES 8

1.3 SYSTEM DESCRIPTION 8

1.4 SUBMITTALS 9

1.5 QUALITY ASSURANCE 29

1.6 DELIVERY, STORAGE AND HANDLING 30

1.7 PROJECT/SITE CONDITIONS 31

1.8 SEQUENCING AND SCHEDULING 31

1.9 CONTRACTOR REQUESTED ENGINEERING CHANGES 31

1.10 WARRANTY 32

1.11 MAINTENANCE 32

PART 2 PRODUCTS 32

2.1 MATERIALS 32

2.2 MANUFACTURED UNITS 32

2.3 EQUIPMENT 32

2.4 COMPONENTS 68

2.5 ACCESSORIES 69

2.6 MIXES 69

2.7 FABRICATION 69

2.8 TESTS, INSPECTIONS, AND VERIFICATIONS 71

PART 3 EXECUTION 72

3.1 EXAMINATION 72

3.2 PREPARATION 72

3.3 ERECTION 73

3.4 REMOVAL AND INSTALLATION 73

3.5 APPLICATION 73

3.6 FIELD QUALITY CONTROL 73

3.7 ADJUSTING AND CLEANING 75

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3.8 TRAINING 75

3.9 PROTECTION 76

3.10 SCHEDULES 76

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PART 1 GENERAL

1.1 REFERENCES

The following documents, of the issue in effect on date of request for proposal, form a part of this specification to the extent specified herein. In case of difference between the following documents and this specification, this specification shall govern to the extent of such difference.

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

NEMA, OSHA, ASME, AWS, AISC, and NFPA rules shall govern.

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

360 - Specification for Structural Steel Buildings

AMERICAN NATIONAL STANDARD INSTITUTE (ANSI)

ANSI/IEC 60529 - Degrees of Protection Provided by Enclosures

AMERICAN SOCIETY OF MECHANICAL ENGINEERS INTERNATIONAL (ASME)

B1.1 - Unified Inch Screw Thread

B30.4 - Portal, Tower, and Pedestal Cranes

B30.10 - Hooks Safety Standard for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings

B30.30 - Ropes

AMERICAN SOCIETY OF NON-DESTRUCTIVE TESTING (ASNT)

Recommended Practice No. SNT-TC-1A Topical Outlines for Qualification of NDT Personnel

AMERICAN SOCIETY FOR QUALITY (ASQ)

9001 - Quality Management Systems – Requirements

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

A275 - Magnetic Particle Exam of Steel Forgings

A521 - Standard Specification for Steel, Closed Impression Die Forgings for General Industrial Use

A536 - Standard Specification for Ductile Iron Castings

A668 - Steel Forgings, Carbon and Alloy, General Industrial Use

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A1023/A - Standard Specification for Stranded Carbon Steel Wire Ropes for General Purposes

E543 - Standard Specification for agencies performing Nondestructive Testing

E1444 - Standard Practice for Magnetic Particle Testing

AMERICAN WELDING SOCIETY (AWS)

D1.1 - Structural Welding Code Steel

FEDERAL SPECIFICATION

RR-C-271 - Chains and Attachments, Carbon and Alloy Steel

RR-W-410 - Wire Rope and Strand

ENVIRONMENTAL PROTECTION AGENCY (EPA)

40 CFR Part 89 - Control of Emissions from New and In-use Nonroad Compression- Ignition Engines

40 CFR Part 1039 - Control of Emissions from New and In-use Nonroad Compression- Ignition Engines

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS, INC. (IEEE)

IEEE 519 - Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 60529 - Degrees of Protection Provided by Enclosures

INTERNATIONAL STANDARDS ORGANIZATION (ISO)

ISO 2631-1 - Evaluation of Human Posture to Whole Body Vibration

ISO 4309 - Cranes — Wire ropes — Care and Maintenance, Inspection and Discard

ISO 9001 - Quality Management Systems – Requirements

ISO 10012-1 - Quality Assurance Requirements for Measuring Equipment

ISO 11226 - Ergonomics, Evaluation of Static Working Postures

ISO 15408 - Common Criteria for Information Technology Security Evaluation

ISO 22241-1 - Diesel engines – NOx reduction agent AUS 3232 – Part 1: Quality requirements

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ISO 22241-3 - Diesel engines – Nox reduction agent AUS 32 – Part 3: Handling, transportation, and storage

MILITARY STANDARD (MIL-STD)

2035A - Nondestructive Testing Acceptance Criteria

NATIONAL ELECTRICAL CONTRACTORS ASSOCIATION (NECA)

NECA 1-2015 - Standard for Good Workmanship in Electrical Construction

NECA 130-2016 - Standard for Installing and Maintaining Wiring Devices

NECA 230-2016 - Standard for Selecting, Installing, and Maintaining of Electric Motors and Motor Controllers

NATIONAL ELECTRICAL MANUFACTURERS' ASSOCIATION (NEMA)

NEMA ICS 1.1 - Safety Guidelines for the Application, Installation, and Maintenance of Solid State Control

NEMA ICS 7 - Industrial Control and Systems Adjustable Speed Drives

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

NEMA ICS 9 - Industrial Control and Systems Power Circuit Accessories

NEMA MG 1 - Motors and Generators

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

NATIONAL FIRE PROTECTION ASSOCIATION

NFPA 12 - Standard on Carbon Dioxide Extinguishing Systems

NFPA 70 - National Electric Code

NFPA 70E - Standard for Electrical Safety in the Workplace

NFPA 72 - National Fire Alarm and Signaling Code

NFPA 79 - Electrical Standard for Industrial Machinery

NFPA 2001 - Standard on Clean Agent Fire Extinguishing Systems

NAVAL FACILITIES ENGINEERING COMMAND

NAVFAC P-307 - Management of Weight Handling Equipment

NAVAL SHIPS TECHNICAL COMMAND (NSTM)

Chapter 613 -Wire and Fiber Rope and Rigging

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NAVSEA TECHNICAL PUBLICATION

T9074-AS-GIB-010/271 Requirements for Nondestructive Testing Methods

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

Title 29 CFR, Part 1910.27, Fixed Ladders

Title 29 CFR, Part 1910.66, Appendix C, Personal Fall Arrest System

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, Occupational Exposure to Lead for Construction

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

Specification for Structural Joints Using High-Strength Bolts

SOCIETY OF AUTOMOTIVE ENGINEERS

SAE J159 - Rated Capacity System

SAE J429 - Mechanical and Material Requirements for Externally Threaded Fasteners

SAE J516 - Hydraulic Hose Fittings

SAE J517 - Hydraulic Hose

SAE J995 - Mechanical and Material Requirements for Steel Nuts

SAE J1065 - Nominal Reference Working Pressures for Steel Hydraulic Tubing

SAE J1273 - Recommended Practices for Hydraulic Hose Assemblies

SAE J1453-1 - Specification for O-ring Face Seal Connectors: Part 1 – Tube Connection Details and Common Requirements for Performance and Tests

SPANISH ASSOCIATION FOR STANDARDIZATION AND CERTIFICATION (AENOR)

EN13411 Part 8 - Terminations for steel wire ropes - Safety - Swage Terminals and Swaging

UNDERWRITERS LABORATORY

UL 60947-4 - Low-Voltage Switchgear and Controlgear

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1.2 UNIT PRICES

See Section B and Section J, Attachment - Exhibit Line Items Pricing Schedule, Exhibits, A, B, C, D and E.

1.3 SYSTEM DESCRIPTION

The intent of this specification is to modernize seven 60/15 ton portal cranes at Norfolk Naval Shipyard (NNSY) and Puget Sound Naval Shipyard & IMF (PSNSY). The cranes to be modernized are as follows: six cranes at NNSY (DC 38, DC 39, DC 42, DC 32, DC 33 and DC

34) and one crane at PSNSY (81). The modernization for all cranes will include replacing the existing DC drives, modifying the operator’s controls, replacing/modifying the electric control system, replacing the crane’s diesel engine generator set, adding a rail lubrication system (NNSY cranes only), adding new limit switches, replacing of whip hoist wire rope and replacing outdoor conduit. Additionally, the addition of a caliper disc brake mounted on the drum and associated caliper disc brake control system will be required on the whip hoist on one of the seven cranes. The modernization shall be performed in accordance with the design drawings of a registered professional engineer. All cranes shall be shop tested, modified, inspected, field tested, and made ready for use in accordance with this specification. The cranes’ capacity, hook radii, hook travel, and hook speed are listed below.

Note: ‘Long boom’ indicates cranes that have a boom length 40’ longer than the ‘short boom’ cranes. DC 38, DC 39 and DC 42 are the ‘long boom’ cranes and DC 32, DC 33, DC 34 and 81 are the ‘short boom’ cranes.

Hoist Capacity (tons) Hook Radius (ft-in) Hook Travel (ft-in) Hook Speed (ft/min)

Main 60 NNSY: 90–0 (max) 48-0 (min)

PSNS: 80-0 (max) 48-0 (min)

172-0 (long boom)

157-0 (short boom)

Whip 15

Long Boom:

160-0 (max) 65-0 (min)

Short Boom:

126-0 (max) 52-0 (min)

230-6 (long boom)

170-0 (short boom)

The existing portal cranes were designed by Amclyde and constructed by Craft. The cranes are controlled by five independent Rockwell Automation DC drive systems; three hoist drives (main hoist, whip hoist, luff hoist), a rotate drive, and a travel drive. These drives are controlled by five master switches located in the operator’s cab. As part of the hoisting system, there are primary and secondary electric brakes for all three hoist functions. One of the cranes (81) includes a hydraulic caliper disc brake installed on the main hoist, which remains open at all times during crane operations unless a broken shaft is detected. The cranes are powered by an

NAVFAC N62470-20-R-1004 Page 9 of 76 onboard diesel engine generator set which provides 480 VAC to the five DC drives. The Contractor shall remove all existing components that are not being reused.

Electrical schematics of the existing cranes have been provided in Appendix A. These drawings cannot be confirmed for accuracy or completeness and are for information only. Any information contained in the drawings must be confirmed by the Contractor.

1.3.1 Design and Performance Requirements

The design of the modernized cranes shall conform to NFPA 70, ASME B30.4, and other requirements specified herein. The crane shall comply with all applicable requirements (“shall” statements) and recommendations (“should” statements). After contract award, the Contractor shall perform an initial site visit to NNSY and PSNSY to observe the current operation of the portal cranes. The Government will operate each crane prior to initiating work, to demonstrate to the Contractor the electrical and operational characteristics (including function speeds and ramp up/down rates) of the existing crane components, which will be used for comparison of the new components to be installed on the crane. All new components installed (i.e. drives, caliper disc brake control, diesel generator, etc.) shall duplicate the functionality of the existing crane except where otherwise specified herein. All electrical field work (i.e. work performed in the field, as differentiated from panel building at some OEM plant) shall be accomplished in accordance with NECA (National Electrical Contractors Association).

1.3.2 Capacity and Identification Markings

Provide capacity plate with permanent lettering and secure the plate to one of the gantry sides.

Each plate shall indicate the rated hoisting capacity of each hook in pound units. Beneath the rated capacity the following information shall be included:

Naval Facilities Engineering Command

Contract and Task Order Number (provided after contract award)

Date contract was awarded

Contractor’s Name, Address, and Crane Serial Number

Voltage, Phase and Frequency of AC power supply

1.4 SUBMITTALS

The Contractor shall submit to the Contracting Officer all items of technical documentation listed hereinafter. Large electronic files (maximum size of 8 GB) shall be submitted via DoD SAFE File Transfer (https://safe.apps.mil/). The Contractor shall ensure that all submittals are entirely legible and suitable for reproduction. The content, number of copies, time of submission, and distribution shall be in accordance with Exhibit A of this specification and as specified below. Compliance with the requirements of this specification will be determined by a review of the design and construction submittals by the Contracting Officer and by field inspection. Review of crane design packages and installation plans will be tracked through

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ProjNet (https://www.projnet.org/). Submittals are listed as general items. Some items may not be applicable based on specific crane design.

For submittals that reference a NAVCRANECEN form, all forms can be found at https://www.navfac.navy.mil/navfac_worldwide/specialty_centers/ncc.html under the “Downloads” page.

SD-01 Preconstruction Submittals The Contractor shall submit monthly status reports. The first page of the report shall contain the following identifying information: Title/Project Description, Reporting Period, Contract Number, Name and Title of Report Preparer, Security Classification (when required), and a Distribution Statement. The content of the report shall address the overall project status and the status of each milestone/task for each crane, for designs in process – indicate the percent complete and estimated submission dates, and for designs under review - indicate the level of Government review and projected approval dates. It shall also list and describe current Contractor Change Request Forms (CCRFs), describe outstanding problems and proposed resolutions indicating who has the next action, describe significant results from conferences and trips, list directives given from the Contracting Officer's representatives, list all contract modifications issued, provide a summary of work planned in the next month, and provide any necessary supporting documentation as an attached appendix. An updated milestone schedule shall be provided with every monthly status report. The Contractor shall submit a schedule which identifies key milestone events in the design, fabrication, and installation of each crane.

At a minimum, the schedule shall include the following:

a. Post Award Conference

b. Design Submittals (100% & Final)

c. Government Review (100% & Final)

d. Pre-Installation Conference

e. Shop Test

f. Receive materials required for upgrade

g. Removals and installation of components required for upgrade

h. Field Inspection & Acceptance Test

i. Crane Acceptance

j. Contract Completion Date

k. Receipt of Final Operation and Maintenance Manuals

l. Completion of Warranty

SD-02 Drawings The Contractor shall submit for approval the drawings and catalog cuts listed below via ProjNet (www.projnet.org). Drawings provided shall be of the complete electrical control system and all other parts of the crane that are modified by this contract. Initial drawing submittals shall bear a

NAVFAC N62470-20-R-1004 Page 11 of 76 complete title block with a permanent drawing number and a registered professional engineer’s original seal with a dated signature. Any subsequent drawing submittals satisfying a design review comment or Contractor initiated changes shall bear a new revision number and engineer’s seal with a dated signature for each sheet that has been modified. All revisions to the drawings shall show/track and indicate the changes made to the previous version of the drawings. Each resubmittal of the drawings shall include a list of affected drawings. Final and “As-built” drawings shall bear a complete title block with a permanent drawing number, a registered professional engineer’s original seal and dated signature. Each assembly and subassembly drawing shall include an integral Bill of Materials or shall be followed by a consecutively numbered drawing with the applicable Bill of Materials. There shall be no proprietary notes on any drawing. The Government shall have full rights to use, reproduce, “build-from”, modify, copy, and release all submitted information. All drawings shall be created for viewing in AutoCAD 2010 with a drawing file format of .dwg or .dxf, and a separate copy viewable in Adobe Acrobat as a bookmarked portable document file (.pdf). An index for all drawings, including applicable revisions, shall be included. Drawings within each category (such as structural, mechanical, etc.) shall be numbered consecutively. Discipline-specific submittals are identified by the letters "G" for general arrangement, "S" for structural, "M" for mechanical, "E" for electrical, and “C” for control system and network. Additionally, for all items installed (electrical and mechanical) that have an adjustable range, the drawings shall indicate the set-point and setting tolerances, this includes timer relays, proximity switches, surge protection devices, power supplies, heater BTU output (if adjustable), thermostats, power/voltage/current monitoring relays, transducers, signal conditioners, resistors, and any other devices that employ user adjustable settings. After Navy Crane Center design approval and prior to shop inspection, the contractor shall submit a complete set of Final design drawings. After the contractor’s self test and prior to the government inspection in the field, the Contracting officer shall be provided with a digital copy of the contractor’s “red line” drawings that outline any changes made during installation and final settings of adjustable components.

SD-02.S Structural Drawings Structural drawings shall be provided for any modification to, addition to, or removal from the existing structure. Structural drawings shall be provided for the following as a minimum:

a. Engine Room Layout

b. Machinery House Layout

c. Modification Details

SD-02.E Electrical Drawings Schematics shall specifically detail all circuitry used by the crane and shall not show ‘typical’ or ‘representative’ circuit representation that may or may not have been followed/used. Schematics shall also document how the new systems interface with existing legacy systems that were not replaced. The drawings shall at a minimum include:

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a. Contractor shall provide comprehensive schematics of all replaced electrical systems.

The schematic diagrams shall include narratives for any special descriptions of operation. All components shown on schematics shall have labels that correspond to the nameplates that will be on the crane. Wiring nominal voltage, type, size, and temperature ratings shall be included on schematic diagrams and material list(s). All optional equipment not installed on the crane shall not appear on the schematic diagrams unless specifically intended to be pre-built spare components which shall be declared as “SPARE”. Locations of contacts and coils shall be cross-referenced to each other within the schematic diagrams. For components with adjustable settings, final settings shall be shown on the schematics.

b. Motor nameplate data (including all information called for in NFPA 70, Section 430.7

(A) items 1 through 7).

c. Rating, types, and allowable settings of over-current protective devices.

d. Schematics of all electrical systems shall be provided.

e. The machinery house layout drawings shall include locations for all electrical equipment on the crane, including control panel enclosures, motors, brakes, limit switches, conduits, and conductor systems.

f. Layout diagrams showing component placement in control panel enclosures. These drawings shall include a comprehensive bill of materials listing showing all electrical components used on the crane.

g. Operator’s console arrangement

h. Schematic showing crane rail lubrication system (if required)

i. Load Moment Indicator (LMI) system

j. System Flow Diagram for each function and overall system interactions.

k. Diesel Generator Electrical Schematic that correlates to the control system schematic, main/shore power distribution system, auxiliary/hotel power distribution system (including lighting system). The drawings shall include but is not limited to engine control interfaces, voltage regulator, control panel, load bank, diesel generator grounding schematic, and how the generator interfaces with the crane’s power distribution system.

l. At a minimum provide theory of operation for the following components: whip hoist BSDS, hydraulic power unit, load bank/regen systems, load moment indicator, rotate spud lock, luff drum pawl.

SD-02.M Mechanical Drawings The drawings shall at a minimum include:

a. Hoist Caliper Disc Brake Installation Drawings including hydraulic schematics

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b. Rail Lubricator Installation Drawings (if required)

c. Whip Hoist Headache Ball Drawing

d. Diesel Engine Installation Drawing (skid)

e. Diesel Exhaust Fluid (DEF) Piping System Drawing

SD-02.C Control System and Network Drawings The drawings shall at a minimum include:

a. Network diagram must show interconnection cabling, equipment locations, names, models, and IP addresses on network communications schematic for all PLC, RTU, Supervisory Controller, and Other Network-Capable Devices

b. Software block, flow, and ladder diagrams

SD-03 Product Data (Required only for new equipment/components) Manufacturer’s catalog data shall be provided for all major components of the crane. The catalog cuts shall be marked-up or supplemented with additional sheets to clearly identify the model or size, selected options, features, and/or modifications to demonstrate compliance with specification requirements. Catalog cuts which show modifications beyond the standard options and all supplemental pages, shall bear original signatures and dates of the equipment manufacturer’s authorized representative. Each catalog cut and each supplemental sheet shall clearly identify the item to which it applies by using the schematic designator name and/or by part noun name used in the general arrangement drawings. All catalog cuts shall be submitted in one file viewable in Adobe Acrobat and bookmarked as to the location of each catalog cut.

Discipline-specific submittals are identified by the letters "S" for structural, "M" for mechanical, "E" for electrical, and “C for control system and network. In accordance with Exhibit A, the Contractor shall submit, for approval, the catalog cuts listed below:

SD-03.M Mechanical Product Data SD-03.M1 Caliper Disc Brakes (including electrical and hydraulic information)

SD-03.M2 Brake Lining

SD-03.M3 Diesel Engine and Generator (including fuel consumption data, approved lubricants, service intervals, and overhaul intervals)

SD-03.M4 Rail Lubrication System (if required)

SD-03.M5 Whip Hoist Headache Ball

SD-03.M6 Wire Rope and End Fittings

SD-03.M7 Diesel Engine Control System (including starter system and voltage regulator)

SD-03.M8 Load Indicating Device (LID)

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SD-03.E Electrical Product Data SD-03.E1 Electronic DC Drive (including silicon-controlled rectifier (SCR) information and drive diagnostic display)

SD-03.E2 Electrical Enclosures

SD-03.E3 Encoders

SD-03.E4 Limit Switches

SD-03.E5 Operator Controls

SD-03.E6 Warning and Pilot Devices

SD-03.E7 Disconnect/Transfer Switches

SD-03.E8 Electric Spudlock

SD-03.E9 Load Moment Indicator System

SD-03.E10 Caliper Disc Brake Control System

SD-03.E11 Resistors

SD-03.E12 Rail Lubrication System (if required)

SD-03.E13 Sound Powered Phone

SD-03.E14 Operator’s Chair

SD-03.E15 Contactors and Relays

SD-03.E16 Human Machine Interfaces (HMI)

SD-03.E17 PLC Modules

SD-03.E18 HVAC Components (including panel heating and/or cooling)

SD-03.E19 Luff Drum Pawl Actuator

SD-03.E20 Transformers

SD-03.E21 Programming Ports

SD-03.E22 Wiring Devices/Components

SD-03.E23 Audible Tone Modules

SD-03.E24 Alarms/Sirens

SD-03.E25 Crane Regeneration System Components

SD-03.E26 Diesel Engine Load Bank System Components

SD-03.E27 Laptop. To include a list of all provided accessories (interface cables, loaded operating system, loaded software, etc.)

SD-03.C Control System and Network Product Data Ensure the following is provided in the product data for PLC, RTU, Supervisory Controller, or other network-capable (whether networked or not upon delivery) control devices as applicable:

(a) Hardware list (Hardware list must include the following for each device):

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i. Manufacturer,

ii. Model,

iii. Location,

iv. Key technical ratings (e.g. memory),

v. Serial number,

vi. MAC addresses,

vii. IP addresses.

(b) Software List (Software list must include the following for each device):

i. Manufacturer,

ii. Version/subversion,

iii. Location/device,

iv. Used network ports/protocols/services.

(c) List and discussion of all security features of Vendor hardware and software.

SD-04 Samples Not applicable to this specification.

SD-05 Design Data The Contractor at a minimum shall electronically submit the calculations listed below for approval. The initial submittal shall bear a descriptive title and the date. Subsequent submittals shall bear a new revision number and date. All calculations shall have a registered professional engineer’s original seal with dated signature. These calculations shall demonstrate compliance with the design requirements of this specification. Design data and calculations will not be approved if their evaluation/review is dependent on data or information not previously approved. All references and assumptions used in the calculations shall be clearly stated within the calculation submittals.

SD-05.E Electrical Calculations SD-05.E1 Overcurrent protection

SD-05.E2 Wire sizing for connections to the new drives

SD-05.E3 Conduit fill calculations for new conduit or for conduit where conductors are being added or repurposed (using tables from NFPA 70, Chapter 9, or manufacturer’s data sheets). Grounding conductors shall be included in the calculations

SD-05.E4 Protective device coordination study showing proper coordination for any overcurrent devices.

SD-05.E5 Arc flash energy calculations for each electrical control panel showing proper data necessary for appropriate arc flash labels per NFPA 70E.

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SD-05.E6 Calculation showing if loadbank resistors for the diesel engine are required.

SD-05.E7 Diesel engine-generator sizing calculations

SD-05.E8 Temperature Rise Calculations for Enclosures

SD-05.M Mechanical Calculations SD-05.M1 Calculations verifying caliper disc brake selection and compatibility with existing components

SD-05.M2 Calculations verifying coupling selections (if applicable)

SD-05.M3 Calculations verifying whip hoist headache ball downhaul weight/rope tautness

SD-05.M4 Calculations verifying whip hoist wire rope line pull (including safety factor)

SD-05.M5 Calculation showing that the diesel exhaust fluid (DEF) tank is suitably sized to ensure the entire capacity of the diesel fuel tank will empty before the DEF tank at the worst case DEF consumption rate relative to diesel consumption

SD-05.S Structural Calculations SD-05.S1 Calculations verifying compliance with the original design criteria for any structural components that are modified, added to, or removed from the existing structure. Calculations verifying the existing structure can support all new components.

SD-05.S2 Calculations verifying that the crane center of the gravity has not exceeded the requirements identified in section 2.3.1.2 due to the change in crane components.

SD-05.DB Whip Hoist Wire Rope Drum Caliper Disc Brake Calculations

SD-05.DB.1 Caliper Disc Brake Setting on Intact Drive Train

The Contractor shall perform analysis, or provide technical documentation from component OEM’s, to demonstrate adequacy of mechanical and structural components in the event of emergency drum brake setting on an intact hoist drive train. This load condition is considered an extraordinary, infrequent load condition.

Calculations shall verify the whip hoist drive brake application process avoids causing an impact greater that that used in the design load cases for the whip hoist drive and adjacent mechanical and structural components (see paragraph 2.3.7.4). The energy which would have to be absorbed, with no contribution from the other brake(s) in the drive train, and dissipated during an emergency stop shall be taken into consideration. The calculations and technical documentation shall demonstrate acceptability of each component. The analysis shall consider

NAVFAC N62470-20-R-1004 Page 17 of 76 the caliper disc brake conditions that produce the maximum torque, including: air gap, friction coefficient, drive/PLC response times, and setting reaction time. The analysis shall account for impacts in the drive train caused by the load path reversal when the drum brake sets in the lowering direction.

As a minimum, the following hoist drive train mechanical and structural components shall be evaluated (as applicable): gearbox, external pinion gear, drum mounted bull gear, drum stub shafts, shaft to shaft couplings, all shaft key/keyseat connections, wire rope drum, drum bearings, pinion stand bearings, reducer bearings, drum bearing foundations, pinion stand foundation, gearbox foundation, and new brake foundation(s). As a minimum, the following load cases shall be considered with the load and radius that produces the maximum drum line pull for each hoist:

a. Test load, full speed raising

b. Test load, full speed lowering

c. No load, full speed raising

d. No load, full speed lowering

For each load case above, consider:

a. Emergency drum brake sets only, with applicable dynamic braking

b. All brakes set simultaneously (emergency drum brake, primary brake, secondary brake, and applicable dynamic braking)

c. Location of line pull on drum

SD-05.DB.2 Caliper Disc Brake Setting on Broken Drive Train

The Contractor shall perform analysis to demonstrate the hoist caliper disc brake will safely stop and hold a rated capacity load considering a drive train failure, which separates the primary and secondary brakes from the load. This load condition is considered an extraordinary, infrequent load condition.

Calculations shall include load drop distances for the brake setting on a broken drivetrain. The load drop distance for all broken drive train load cases shall not exceed 100 inches.

Mechanical and structural components shall be analyzed to demonstrate adequacy when the emergency brake applies due to a broken drive train.

As a minimum, the following load cases shall be considered with the load and radius that produces the maximum drum line pull for each hoist:

a. 100% load, full speed raising

b. 100% load, full speed lowering

For each load case above, consider:

a. Drive train failure at gearbox input shaft locations (motor to gearbox coupling, input shaft pinion)

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b. Drive train failure at output shaft location (separating gearbox from external pinion gear)

c. Location of line pull on the drum

SD-06 Test Reports

SD-06.1 Pre-Work Inspection Report For each crane, the Contractor shall submit a report documenting the speeds, performance, and any other applicable information recorded during witnessing of the government post-award crane demonstration (para. 1.5.5.1) or the pre-work crane demonstration (para. 1.5.5.2).

Additionally, for each crane, the Contractor shall document all electrical deficiencies and mechanical/structural deficiencies that are uncovered at the post-award crane inspection (para.

1.5.5.1) or the pre-work crane inspection (para. 1.5.5.2) that are outside the scope of the maintenance and repairs required by this contract. Reports of these deficiencies shall contain a detailed cost estimate, with labor and material costs, to repair deficiencies. Deficiency, as defined here, is any defect or problem that can or will prevent safe operation of the crane or a violation of NFPA 70, ASME B30.4, or OSHA requirements.

SD-06.2 Post-Work Inspection Report For each crane, the Contractor shall document in a single report all electrical deficiencies and mechanical/structural deficiencies related to electrical components that are uncovered during the course of the modernization that are outside the scope of this contract. The report shall contain a detailed cost estimate, with labor and material costs, to repair the deficiencies. Deficiency, as defined here, is any defect or problem that can or will prevent safe operation of the crane or a violation of NFPA 70, ASME B30.4, or OSHA requirements.

SD-06.3 Whip Hoist Hook Eye Pin Non-Destructive Test (NDT) Report SD-06.3.1 The contractor shall provide a certification that the NDT vendor meets the requirements of ASTM E543. The certification shall be current, within one year of the date the NDT was performed.

SD-06.3.2 The contractor shall submit for review the NDT vendor’s procedures, including technique sheets specific to the types, shapes, and size of the parts being examined (e.g., shank hook, eye hook, duplex hook, eye pin, swivel eye bar). For the magnetic particle method, the procedures shall adequately describe the orientation of the hooks, swivel eye bar, or eye pins with the magnetizing equipment. Procedures must be reviewed and bear the signature of an SNT-TC-1A qualified Level III examiner stating they are independent of the vendor.

SD-06.3.3 Prior to performing any operational testing of the crane, the hook eye pin shall be inspected by the magnetic particle method over their entire surface area in accordance with NAVSEA Technical Publication T9074- AS-GIB-010/271. ASTM A275 may be used with the following restrictions: DC yokes (including switchable AC/DC yokes used in the DC mode) and permanent magnet yokes shall not be used; automatic powder blowers or any other form of forced air other than from a handheld bulb shall not be used for the application or removal of dry magnetic particles; arc strikes shall be removed; and equipment ammeters shall have an

NAVFAC N62470-20-R-1004 Page 19 of 76 accuracy of ± 5 percent of full scale (equipment ammeter accuracy other than that stated is acceptable provided the magnetic particle method procedure states that a magnetic field indicator is used to establish and verify adequate field strength for all aspects of the inspection).

If NDT cannot be performed on surfaces inside holes, those surfaces shall be visually inspected to the maximum extent practical. Acceptance criterion shall be no linear indications greater than 1/16 inch. The NDT report shall be provided to the Government and shall be traceable to the unique ID number of the hook eye pin.

SD-06.4 Weld Non-Destructive Test (NDT) Report As a minimum, the Contractor shall perform the following NDT for welds to structural components performed for this contract. A test record shall be provided for each weld NDT, including visual inspections. The test records shall contain, as a minimum, the test/inspection procedure used, the acceptance criteria, identification of the welds tested, the test results, and signature of the qualified person performing the test. The Government will perform random review of weld NDT records. The Government will report all deficiencies found to the Contractor for resolution.

a. For all welds, perform visual inspection per the requirements and acceptance criteria specified in AWS D1.1.

b. For all welds to components considered to support the loads from the application of caliper disc brake and any modification to the hoist frame, perform magnetic particle inspection on the full length of each weld, per the requirements and acceptance criteria specified in AWS D1.1.

c. For all full penetration welds to components considered to support the loads from the application of the caliper disc brake and any modification to the hoist frame, perform ultrasonic inspection on the full length of each weld, per the requirements and acceptance criteria specified in AWS D1.1.

SD-06.5 Steel Castings Non-Destructive Test (NDT) Report All steel castings that are considered in the design calculations to support the hook loads shall be magnetic particle inspected in accordance with ASTM E1444. Acceptance criteria shall be in accordance with MIL-STD-2035A, Section 6.3, Class 2. A test record shall be provided for all steel casting NDTs. The test records shall contain, as a minimum, the test/inspection procedure used, the acceptance criteria, identification of casting tested, the test results, and signature of the qualified person performing the test. The Government will perform random review of casting NDT records. The Government will report all deficiencies found to the Contractor for resolution.

SD-07 Certificates All certifications shall be dated and shall bear the original signature (above the printed name) of the authorized representative of the Contractor or the manufacturer of the items or equipment

NAVFAC N62470-20-R-1004 Page 20 of 76 being certified. Each certification shall clearly identify the crane, drives, components, and location (as applicable) to which it applies.

SD-07.1 Wire Rope The Contractor shall provide the wire rope manufacturer’s certification that the new whip hoist wire rope meets the published breaking strength of samples taken from reels and tested.

Certification shall be traceable to the hoist, crane, and reel.

SD-07.2 Periodic Overload Testing The Contractor shall certify crane components purchased and/or modified by this contract are capable of being load tested semi-annually up to and not exceeding 131.25% of the rated capacity without any detrimental effects.

SD-07.3 Hazardous Material The Contractor shall certify that the crane components purchased and/or modified by this contract do not contain asbestos, lead paint, Polychlorinated Biphenyl’s (PCB’s), chromates, elemental mercury, or other toxic or noxious industrial materials. The Contractor shall submit a certification from the brake vendor(s) that all purchased brake linings do not contain asbestos.

SD-07.4 Loss of Power Test The Contractor shall certify that when hoisting a test load, a loss of power test, can be performed without any detrimental effects to the electronic control system.

SD-07.5 Welding Certifications Contractor shall provide the following welding certificates for all work performed in manufacturing the crane(s):

SD-07.5.1 Welders and Welding Operators

Before assigning any welder, welding operator, or tack welder to perform work covered by this specification, the Contractor shall submit certification for each welder to be employed in the work. The certification shall state the type of welding and positions for which the welder, welding operator, or tack welder is qualified, the code and procedure under which they are qualified, the qualification date, and the name of the firm and person certifying the qualification tests.

SD-07.5.2 Welding Procedure Qualification

Contractor shall qualify the welding procedure specification for any welding procedure used in the work covered by this specification except for procedures that are considered prequalified under the applicable welding code. Contractor shall submit for approval copies of the welding procedure specification and the procedure qualification records for each type of welding being performed.

SD-07.5.3 Non-Destructive Examination of Welds

NAVFAC N62470-20-R-1004 Page 21 of 76

Non-destructive examination (NDE) of welds shall be in accordance with AWS D1.1. All non-destructive examination performed, including visual inspection, shall be fully documented. The inspection documentation shall indicate the examiner’s name and employer, the examination method, the location and amount of weld examined, the acceptance/rejection criteria, and the results of the examination. Welds requiring ultrasonic or magnetic particle examination shall be clearly identified on the fabrication drawings.

All welds shall be visually examined over their entire lengths. Additional non-destructive examination methods shall be employed for welded structural connections as specified below.

Welds at the following joints shall be subjected to ultrasonic examination: butt joints with complete joint penetration (CJP) welds made with or without backing and loaded in tension transversely to the longitudinal axis. Full (100%) volumetric examination by ultrasonic testing is required for each weld.

Welds at the following joints shall be subjected to magnetic particle examination: components considered to support the loads from the application of caliper disc brake and any modification to the hoist frame.

Examination is required for 10 percent of all other welds. Percentages of welds specified for inspection are measured along each joint face.

SD-07.6 EPA Emission Certification The Contractor shall submit certification that the provided diesel engine meets the applicable EPA Tier Level requirements.

SD-07.7 Coupling Alignments (if applicable) Contractor shall submit coupling alignment data records with certification that the alignment of all shafting connected by means of flexible couplings are within manufacturer's installation tolerances. The coupling alignments shall be made using laser alignment equipment. The data records shall be taken after the coupling's final installation and after installation of shear bars or dowel pins in all base-mounted components. Coupling alignments shall be verified by the Contractor after crane component installation. The coupling alignment data record(s) shall be submitted on the official form titled, “Shaft/Coupling Alignment Record Form,” which can be found on the NCC website

SD-07.8 Contractor’s Self Test The Contractor shall provide a copy of the completed self-test, recorded on the contractor’s shop test document, verifying the Contractor’s self-test has been completed in accordance with section 2.8.1 of this specification.

SD-07.9 Quality Management System The Contractor or Subcontractor performing the work on the crane shall have a quality system in place certified to the requirements of ISO 9001. The quality system shall be certified by a third party registrar accredited by ISO. Certification to ASQ/ANSI/ISO 9001 is also acceptable.

NAVFAC N62470-20-R-1004 Page 22 of 76

The Contractor or Subcontractor working on the crane shall provide proof of certification to

ISO 9001.

SD-07.10 Public Domain Software The Contractor shall provide a declaration that public domain software (e.g., freeware, shareware) is not used in the system.

SD-07.11 Software and Services The Contractor shall provide a certificate stating that all software and services not required for operation and/or maintenance of the product has been removed. If removal is not technically feasible, then disable software not required for the operation and/or maintenance of the product.

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:

a. Cameras

b. Games

c. Device drivers for product components not procured/delivered

d. Messaging services (e.g., email, instant messenger, peer-to-peer file sharing)

e. Source code

f. Software compilers in user workstations and servers

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

h. Unused networking and communications protocols

i. Unused administrative utilities, diagnostics, network management, and system management functions

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

k. All unused data and configuration files

l. Remove and/or disable, through software, physical disconnection, or engineered barriers, all services and/or ports in the procured product not required for normal operation, emergency operations, or troubleshooting. This shall include communication ports and physical input/output ports (e.g., USB docking ports, video ports, and serial ports).

SD-07.12 Fire Protection System The installing Contractor shall submit written certification stating that the system has been installed in accordance with approved plans and tested in accordance with the manufacturer’s published instructions and the appropriate NFPA requirements.

NAVFAC N62470-20-R-1004 Page 23 of 76

SD-07.13 LMI System Calibration The Contractor shall submit certification that the LMI system has been calibrated to meet the accuracy requirements of section 2.3.14.

SD-07.14 Wire Rope End Fitting The Contractor shall provide documentation that the wire rope end fitting meets the requirements in Paragraph 2.3.18, including the results of the Charpy testing, for the wire rope end fitting, as applicable.

SD-08 Manufacturer’s Instructions

SD-08.1 Shop Test Procedure Not applicable to this specification. A shop test procedure is not required to be submitted;

however, the Government will be given an opportunity to perform a shop inspection and witness the shop test of the equipment required for the crane modernizations at the Contractor’s facility in accordance with para. 2.8.2.

SD-08.2 Removal and Installation Plan The Contractor shall submit a plan detailing the logistics and procedures for installation and removal of the components on the existing crane. The plan and equipment shall meet the requirements of section 3.4, Appendix D, and Appendix E and include, as a minimum, lifting configurations, lifting equipment ground loading and support details, laydown and work areas, transportation through the activity (i.e. egress and ingress), and critical lift plans. The plan shall also include details on the removal and reinstallation of existing crane components (e.g. roof sections, hatches, and other accesses) that are required for accessing the equipment necessary for the crane modernization. There is not a roof access in the existing crane diesel engine room.

The entire roof may be removed for the diesel generator set replacement. The lifting and rigging gear shall comply with OSHA requirements and any local requirements.

The Contractor shall submit the plan for review and acceptance by the Government. On-site changes of the plan shall be prohibited without Government review and acceptance.

SD-08.3 Field Test Procedure The Contractor shall develop and submit a field test procedure that will demonstrate operation, performance, and safety of the modernized cranes. This test shall be based on the pre-work inspection report and shall prove the functionality of the crane matches the functionality of the crane prior to modernization. The test procedure shall be submitted and approved prior to conducting the field test. A sample can be found at Appendix C. This test shall, at minimum, include:

a. All demonstrations performed by the government at the post-award crane demonstration (para 1.5.5) including tests with no load, 50% load, 100% load, and 125% load.

b. A procedure to test the diesel engine safety system warnings, alarms, and shutdowns.

NAVFAC N62470-20-R-1004 Page 24 of 76

c. Inspections necessary to verify safety of the crane (including verification of whip hoist caliper disc brake settings) that must be performed prior to beginning of load testing.

d. A procedure to test the whip hoist caliper disc brake system (if applicable) to demonstrate that it will meet the capacity and operational characteristics specified. The drive trains need not be disconnected for these tests.

e. An Appendix with the generator set startup and shutdown procedure.

f. Diagnostic Fault Indication Test Plan: For each diagnostic fault that is not part of the standard drive platform (provided automatically to all drive purchasers) or that involves accessible code, the Contractor shall submit a test plan detailing its procedure for test/verification of functionality on the crane. Examples of hardware component inputs to be verified include those that are specific to this crane (i.e. not included in the normal OEM system package) and stop the drive or provide separate output or indication (i.e.

buzzer or light, etc), Additionally, the indicative fault messages associated with the diagnostic fault shall be documented. Diagnostic faults that are disabled are not required to be tested.

SD-08.4 Accident Prevention Plan (APP) The APP shall be prepared in accordance with Appendix E, Exhibit A, and Exhibit B and shall be submitted for review and comment by the Contracting Officer. Installation of the crane components cannot proceed prior to the review and acceptance of the APP by the Contracting Officer.

SD-08.5 Training Course Outline The Contractor shall prepare and submit to the Contracting Officer for approval, a training course outline. The outline shall contain enough detail for the Government to determine that all topics are adequately covered as prescribed in section 3.8 of this specification.

SD-08.6 Fire Protection System Test Procedure A manufacturer’s test procedure shall be provided for testing of the system. This procedure shall provide for the initial testing of the equipment as well as for periodic test inspection of the system.

SD-09 Contractor’s Field Reports

SD-09.1 Brake Adjustment Records The Contractor shall provide a brake adjustment record and installation/maintenance manual for the new caliper disc brake installed on the whip hoist. The brake adjustment report shall contain actual settings and the tolerance (minimum and maximum) for each setting, including;

torque setting (actual, minimum tolerance, maximum tolerance), air gap (actual, minimum tolerance, maximum tolerance), lining thickness (actual, minimum tolerance), and lining contact (actual, minimum tolerance). The brake adjustment record shall include any unique adjustment settings and tolerances for the specific brake design. The brake adjustment record shall be

NAVFAC N62470-20-R-1004 Page 25 of 76 submitted on the applicable brake record form located on the NCC website. Each brake measurement shall have a tolerance traceable to the associated brake manual or documentation provided by the brake manufacturer, location of measurements, and the actual brake setting.

Changes made to settings of the brake, at any time, will void this record.

SD-09.2 Shop Test Deficient Items List Upon completion of the government inspection of the…