Attachment (d) - Specification.pdf

NAVFAC WO 1666674 Page 1 of 33

ONE BARGE MOUNTED BOOM CRANE

FOR

NAVAL SURFACE WARFARE CENTER

CARDEROCK DIVISION

ACOUSTICS RESEARCH DETACHMENT

BAYVIEW, IDAHO

PREPARED BY:

Navy Crane Center (NAVCRANECEN) Bldg. 491, Norfolk Naval Shipyard Portsmouth, Virginia 23709-1044

Lead Design Engineer: Christopher Burgess

Project Manager: David Strautmann Contract Specialist: Hattie Brown

NAVFAC WO 1666674 Page 2 of 33

PART 1 GENERAL 4

1.1 REFERENCES 4

1.2 UNIT PRICES 7

1.3 SYSTEM DESCRIPTION 7

1.3.1 DESIGN REQUIREMENTS 7

1.3.2 PERFORMANCE REQUIREMENTS 8

1.3.3 CAPACITY PLATE 8

1.3.4 UNIQUE IDENTIFIER TAG 9

1.4 SUBMITTALS 9

SD-01 PRECONSTRUCTION SUBMITTALS 9

SD-02 DRAWINGS 10

SD-03 PRODUCT DATA 11

SD-04 SAMPLES 12

SD-05 DESIGN DATA 12

SD-06 TEST REPORTS 13

SD-07 CERTIFICATES 14

SD-08 MANUFACTURER’S INSTRUCTIONS 15

SD-09 MANUFACTURER’S FIELD REPORTS 16

SD-10 OPERATION AND MAINTENANCE DATA 16

SD-11 CLOSEOUT SUBMITTALS 17

1.5 QUALITY ASSURANCE 18

1.5.1 QUALIFICATIONS 18

1.5.2 REGULATORY REQUIREMENTS 18

1.5.3 POST-AWARD CONFERENCE 18

1.5.4 PRE-INSTALLATION CONFERENCE 18

1.6 DELIVERY, STORAGE, AND HANDLING 19

1.7 PROJECT/SITE CONDITIONS 19

1.7.1 ENVIRONMENTAL REQUIREMENTS 19

1.7.2 EXISTING CONDITIONS 19

1.7.3 FURNISHED EQUIPMENT 19

1.8 SEQUENCING AND SCHEDULING 19

1.9 CONTRACTOR REQUESTED ENGINEERING CHANGES 19

1.10 WARRANTY 19

1.11 MAINTENANCE 19

PART 2 PRODUCTS 20

2.1 MATERIALS 20

2.1.1 DUCTILE MATERIAL 20

2.1.2 STRUCTURAL STEEL 20

2.1.3 CAST STEEL 20

2.1.4 DUCTILE CAST IRON 20

2.1.5 FORGED STEEL 20

2.1.6 STEEL SHAFTS 20

2.1.7 ALUMINUM CASTINGS 20

2.1.8 WELDING MATERIALS 20

NAVFAC WO 1666674 Page 3 of 33

2.2 MANUFACTURED UNITS 20

2.3 EQUIPMENT 20

2.3.1 STRUCTURAL DESIGN 20

2.3.2 MECHANICAL DESIGN 21

2.3.3 ELECTRICAL DESIGN 24

2.4 COMPONENTS 28

2.5 ACCESSORIES 29

2.6 MIXES 29

2.7 FABRICATION 29

2.7.1 SHOP ASSEMBLY 29

2.7.2 SHOP AND FACTORY FINISHING 30

2.7.3 TOLERANCES 31

2.8 TESTS, INSPECTIONS, AND VERIFICATIONS 31

2.8.1 CONTRACTOR’S SELF-TEST 31

2.8.2 GOVERNMENT WITNESSED SHOP TEST AND INSPECTION 31

PART 3 EXECUTION 32

3.1 EXAMINATION 32

3.2 PREPARATION 32

3.3 ERECTION 32

3.4 INSTALLATION 32

3.5 APPLICATION 32

3.6 QUALITY CONTROL 32

3.6.1 ACCEPTANCE 32

3.7 ADJUSTING AND CLEANING 32

3.8 DEMONSTRATION 32

3.9 PROTECTION 33

3.10 SCHEDULES 33

NAVFAC WO 1666674 Page 4 of 33

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, API, and NFPA rules shall govern.

FEDERAL SPECIFICATION

RR-C-271 -Chains and Attachments, Welded and Weldless

AMERICAN BUREAU OF SHIPPING

ABS Rules for Building and Classing Steel Barges ABS Rules for Building and Classing Naval Vessels

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

A14.3 - Fixed Ladders – Safety Requirements

AMERICAN GEAR MANUFACTURERS' ASSOCIATION (AGMA)

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

2015 - Accuracy Classification System 6013 - Standard for Industrial Enclosed Gear Drives 6034 - Practice for Enclosed Cylindrical Wormgear Speed Reducers and

Gearmotors 6035 - Design, Rating and Application of Industrial Globoidal Wormgearing

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

360 - Specification for Structural Steel Buildings

AMERICAN PETROLEUM INSTITUTE (API)

2C Specification for Offshore Pedestal-Mounted Cranes

AMERICAN SOCIETY OF NON-DESTRUCTIVE TESTING (ASNT)

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

AMERICAN SOCIETY OF MECHANICAL ENGINEERS INTERNATIONAL (ASME)

B1.1 - Unified Inch Screw Threads B4.1 - Preferred Limits and Fits for Cylindrical Parts B17.1 - Keys and Keyseats B18.8.2 - Taper Pins, Dowel Pins, Straight Pins, Grooved Pins, and Spring Pins (Inch

Series) B30.8 - Floating Cranes and Floating Derricks B30.10 - Hooks

NAVFAC WO 1666674 Page 5 of 33

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE/SEI)

7 - Minimum Design Loads for Buildings and Other Structures

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

A27 - Standard Specification for Steel Castings, Carbon, for General Application A36 - Standard Specification for Carbon Structural Steel A148 - Standard Specification for Steel Castings, High Strength, for Structural

Purposes A194 - Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High

Pressure or High Temperature Service, or Both A275 - Standard Practice for Magnetic Particle Examination of Steel Forgings A434 - Standard Specification for Steel Bars, Alloy, Hot-Wrought or Cold-Finished, Quenched and Tempered A521 - Standard Specification for Steel, Closed-Impression Die Forgings for

General Industrial Use A536 - Standard Specification for Ductile Iron Castings A563 - Standard Specification for Carbon and Alloy Steel Nuts A572 - Standard Specification for High-Strength Low-Alloy Columbium-Vanadium

Structural Steel A588 - Standard Specification for High-Strength Low-Alloy Structural Steel, up to

50 ksi A668 - Standard Specification for Steel Forgings, Carbon and Alloy, General

Industrial Use A992 - Standard Specification for Structural A1023/A1023M - Standard Specification for Stranded Carbon Steel Wire Ropes for

General Purposes B26 - Standard Specification for Aluminum Alloy Sand Castings B108 - Standard Specification for Aluminum-Alloy Permanent Mold Castings E543 - Standard Specification for Agencies Performing Nondestructive Testing F436 - Standard Specification for Hardened Steel Washers F593 - Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs F594 - Standard Specification for Stainless Steel Nuts F3125 - Standard Specification for High Strength Structural Bolts and Assemblies, Steel and Alloy Steel, Heat Treated, Inch Dimensions 120 ksi and 150 ksi Minimum Tensile Strength and Metric Dimensions 830 MPa and 1040 MPa Minimum Tensile Strength

AMERICAN WELDING SOCIETY (AWS)

D1.1 - Structural Welding Code - Steel

DEFENSE FEDERAL ACQUISITION REGULATIONS (DFAR)

DFARS 252.211-7003 Item Unique Identification and Valuation

Electrification and Controls Manufacturers Association ECMA 15 – Specifications for Cableless Controls for Electric Overhead Traveling

Cranes

NAVFAC WO 1666674 Page 6 of 33

FEDERAL ACQUISTION REGULATIONS (FAR)

FAR Part 2 Definition of Words and Terms

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 45 - Recommended Practice for Electrical Installation on Shipboard

INTERNATIONAL STANDARDS ORGANIZATION (ISO)

4309 - Cranes, Wire Ropes, Care and Maintenance Inspection and Discard

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 8 - Industrial Control and Systems Crane and Hoist Controllers NEMA MG 1 - Motors and Generators NEMA 250 - Enclosures for Electrical Equipment (1000 Volts Maximum)

NATIONAL FIRE PROTECTION ASSOCIATION

NFPA 70 - National Electric Code NFPA 70E - Standard for Electrical Safety in the Workplace

NAVAL FACILITIES ENGINEERING COMMAND

NAVFAC P-307 Management of Weight Handling Equipment

NAVSEA TECHNICAL PUBLICATION

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

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

29 CFR, Part 1910.306 - Specific Purpose Equipment and Installations 29 CFR, Part 1910.23 - Ladders 29 CFR, Part 1910 Subpart D - Walking-Working Surfaces

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

WIRE ROPE TECHNICAL BOARD

Wire Rope Users Manual

NAVFAC WO 1666674 Page 7 of 33

1.2 UNIT PRICES

Not applicable to this specification.

1.3 SYSTEM DESCRIPTION

The intent of this specification is to procure a new electro-hydraulic, telescoping pedestal mounted crane suitable for use on a barge. Installation of the new crane and removal of the existing crane shall be accomplished as part of this specification. The new crane shall be installed on a steel research barge for the Naval Surface Warfare Center, Carderock Division (NSWCCD), Acoustic Research Detachment (ARD) in Bayview, Idaho.

The barge currently has a pedestal crane mounted to a steel pedestal. The intent is to utilize the lower portion of the existing pedestal to support the new crane. This specification also includes a requirement for the crane to withstand ancillary loads at points on the crane required for operations.

These loads will be applied only while the crane hook is unloaded. These loads will be applied as shown on appendix A.

The new crane system shall bear an API 2C Monogram.

The crane shall be designed, fabricated, assembled, shop tested, delivered, installed, and field tested accordance with this specification. The crane shall be built to the design drawings of a licensed Professional Engineer (PE).

Rotate platform(s) and ladder(s) will be removed and replaced in kind by the crane contractor.

1.3.1 Design Requirements

The crane shall be designed and fabricated in accordance with this specification, API 2C, ASME B30.8, and other requirements specified herein. The procurement of the pedestal-mounted crane is intended to consist of a commercially available product to be used in an outdoor marine environment that meets the requirements of this design specification. Capacities are illustrated in Appendix A. At a minimum, the crane shall be capable of lifting 30,000 pounds at 10 feet radius and 65 feet above the deck; 10,000 pounds at 25’ radius; 4,300 pounds at 55 feet radius and 12 feet. The capacity of 4,300 pounds at 55 feet may be limited to stable platform operations (1 degree list/trim, and 2 foot waves), provided the crane has a 3,000 pound capacity at 55 feet and 12 feet above the deck at Sea State 3. The minimum radius shall not be more than 10 feet. The hook shall be able to be lowered to the nominal waterline of the barge (3. 5’ below main deck) at all radii. The working radii shall be taken from the center of the pedestal to the centerline of the hook. The crane shall be able to slew 360 degrees continuously. The boom shall extend to a minimum of 55 feet with a maximum retracted length of 30 feet. The cranes shall be capable of periodic load testing up to 125% of rated capacity with no detrimental effect.

In addition to the main hoist requirements above, the telescopic boom shall have a fast line auxiliary hoist (auxiliary hoist may either one part or two) with a minimum capacity of 3 tons through all operating radii.

The barge has the following approximate characteristics: length = 80 feet, beam = 48 feet, and depth = 7 feet. The crane will be used primarily for maintenance of equipment. Crane operations will be conducted in sea state of 5 or less. The vertical boom tip velocity (Vc) and supply vessel velocity (Vd) shall be taken as 0. The horizontal crane acceleration (Av) for this vessel shall be taken as 0.0 g’s.

NAVFAC WO 1666674 Page 8 of 33

The Contractor shall provide all materials to be used in the installation. The crane shall be able to rotate, hoist, and luff simultaneously throughout the operating ranges and speeds. The crane shall be controlled in an operator’s cab above the rotate bearing. The operators cab shall be on the left side of the boom (as seen from the operators seat). The crane shall be able to operate with a barge maximum 2 degree roll and 2 degree pitch. The crane shall be designed for harbor operation at sea state 3. The crane pedestal base (at approximately 36” above the barge main deck) will normally be about 7 feet above the mean waterline of the barge. The crane shall be designed using the vessel specific method and for construction duty as defined in API Specification 2C. Crane contractor shall perform a site visit to verify all initial conditions prior to designing the crane.

1.3.2 Performance Requirements

The rated speeds, in feet per minute, for the crane shall be as follows:

Minimum Hoisting Speed with Rated Load 30 fpm

Minimum Luffing Speed with Rated Load* max to min ≤ 5 minutes

Maximum Slewing Time at Rated Load 0.5 rev per min

Maximum Operating Wind Speed 30 knots

Minimum Extended Boom Length 55 feet

Maximum Retracted Boom Length 30 feet

Minimum AUX Hoisting Speed with Rated Load See Note 1 Below

Note 1: AUX Hoisting Speed shall be determined by the commercial product the crane manufacture can provide.

1.3.3 Capacity Plate

Provide three capacity plates with permanent lettering. The capacity plate shall be marked with the maximum static crane capacity in pounds. One capacity plate shall be located inside the operator’s cab, such that it is visible to the operator when operating the crane and two capacity plates shall be securely mounted to the outside of the pedestal, such that it can be read easily from the deck. Beneath the rated capacity the following information shall be included:

Naval Facilities Engineering Command Contract Number XX Manufacturer’s Name, Address, and Crane Serial Number Voltage of AC power supply and phase and frequency of AC power supply

1.3.3.1 Load Charts

In addition to the capacity plates, Contractor shall provide one engraved permanent placard load chart for the whip hoist and the main hoist (as normally reeved), mounted on the crane pedestal, NAVFAC WO 1666674 Page 9 of 33 and shall be easily read from the barge deck. One engraved permanent placard load chart for the whip hoist and the main hoist (as normally reeved) shall also be provided in the operator’s cab.

1.3.4 Unique Identifier Tag

The Contractor shall assign a unique identifier to the crane in accordance with DFARS 252.211- 7003. The Unique Identification Tag shall be attached to the outside of the pedestal.

1.3.5 Ancillary Design Requirements

The ancillary rigging includes the following:

a. Padeyes located as shown on Appendix A.

b. Padeyes, padeye connection and padeye supporting structure designed for a line pull of

4300 pounds.

c. This load will only be applied while there is no load on the hook.

d. Each padeye shall be visually inspected before and after a 200% - 205% load test of its

WLL, held for at least two (2) minutes. Acceptance criteria shall be: no bending, cracking, or permanent deformation of the lifting attachments or associated structure.

e. Permanently label each lifting attachment point with its WLL and test date.

f. All design calculations are required to be submitted for review.

g. Existing shackles and snatch blocks will be attaching to these padeyes. Ensure the dimensions of the padeyes allow for proper attachment if rigging gear.

1.3.6 API Monogram

The crane shall receive the API monogram in accordance with API 2C Section 13 and API 2C Appendix C.

1.4 SUBMITTALS

The Contractor shall submit to the Contracting Officer all items of technical documentation listed hereinafter. 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.

For submittals that reference a NAVCRANECEN form, all forms can be found at http://navfac.navy.mil/navfac_worldwide/specialty_centers/ncc/about_us/resources/downloads.ht ml under the “Downloads” page.

SD-01 Preconstruction Submittals The Contractor shall submit monthly status reports that include an up to date project schedule.

The schedule shall identify key milestone events in the design, fabrication, and installation of the crane acquisition. At a minimum, the schedule shall include the following:

a. Post Award Conference

b. Initial General Arrangement and Design Submittals

c. Government Review of First Design

d. Second General Arrangement and Design Submittals http://navfac.navy.mil/navfac_worldwide/specialty_centers/ncc/about_us/resources/downloads.html http://navfac.navy.mil/navfac_worldwide/specialty_centers/ncc/about_us/resources/downloads.html

NAVFAC WO 1666674 Page 10 of 33

e. Government Review of Second Design

f. Third General Arrangement and Design Submittals

g. Government Review of Third Design

h. Fabrication Initiation

i. Fabrication Completion

j. Government Witnessed Shop and Load Test

k. New Crane System Installation Instructions

l. Crane Acceptance

m. Contract Completion Date

n. Receipt of Final O&M Manuals

o. Completion of Warranty

SD-02 Drawings The Contractor shall submit for approval the drawings and catalog cuts listed below. After NAVCRANECEN design approval and prior to shop test, the Contractor shall submit a complete set of final design drawings. All drawings shall bear a complete title block with a permanent drawing number and a licensed PE’s original seal and dated signature. Drawings within each category (general, structural, mechanical, electrical) shall be numbered consecutively. 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. All drawings shall be created for viewing in AutoCAD 2020 with a drawing file format of .dwg or .dxf, and a separate copy viewable in Adobe Acrobat as a bookmarked portable document format (.pdf). An index for all drawings shall be included.

The following drawings shall be included:

SD-02.G General Drawings

a. Load and information charts in accordance with API 2C Section 8.2.

b. Plan and elevation views of the crane.

c. Major dimensions.

d. Clearances.

e. Lift heights.

f. Hoist, boom, and slewing speeds.

g. Weight and centroids of all major crane components, as well as assembled weight.

h. Maximum pedestal load and moment under rated load.

i. Maximum upper wind limit and maximum allowable list and trim for operations.

j. Information for crane foundation support structure design including:

1. Maximum overturning moment with corresponding axial and radial load, and torque and side movements at the crane and supporting structure interface in accordance with API 2C Section 6.2.

2. Maximum axial load with corresponding overturning moment and radial load, and torque and side moments at the crane and supporting structure interface in accordance with API 2C Section 6.2.

3. Fatigue design moment and corresponding other loads to be used to design supporting for 1,000,000 cycles in accordance with API 2C Section 6.4.

NAVFAC WO 1666674 Page 11 of 33

k. Reeving Diagram(s)

l. Details of connection to existing pedestal

m. Stowage configuration and requirements

n. Hydraulic schematic diagrams and Bill of Materials required for connecting HPU. HPU shall be integral to the crane’s pedestal.

o. Ancillary rigging padeyes (fabrication details, connection details, and dimensioned locations)

p. New platform(s) and ladder(s)

SD-02.E Electrical Drawings These drawings shall show the layout of electrical equipment on the crane, including control panel enclosures, motors, brakes, limit switches, conduits, disconnects, and conductor systems. These drawings shall at a minimum include:

a. Complete schematic diagram with narrative of any special description of operation. All components shown on schematics shall have labels that correspond to the nameplates that will be on the crane. Wiring type, size, and temperature ratings shall be included on schematic diagrams. All optional equipment not installed on the crane shall be removed from the schematic diagrams. 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 and types of over-current protective devices

d. A comprehensive component material list showing all electrical components used on the crane

e. Layout diagrams showing component placement in control panel enclosures

f. Complete assembly (wiring) diagrams showing all conductor routings and terminations.

SD-02.CSI Crane System Interface Drawings These drawings shall depict the intended interface details with the research barge. At a minimum, these drawings shall include:

a. Detailed List of Materials to be procured by the Contractor for interface purposes.

b. Actual weights and centroids for all major crane system components (e.g., lower pedestal/foundation, upper pedestal, turret, winch, luffing cylinder(s), boom assembly (retracted and extended), wire rope, and hook).

c. Typical installation details for:

i. deck watertight stuffing tubes to be used with deck cabling

ii. ancillary padeye use and limitations.

SD-03 Product Data Original manufacturers' catalog data (catalog cuts) shall be provided, listing the original part numbers. 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

NAVFAC WO 1666674 Page 12 of 33 compliance with specification requirements. Catalog cuts that show any 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 drive or system to which it applies. All catalog cuts shall be submitted in one file viewable in Adobe Acrobat and bookmarked as to the location of each catalog cut. The Contractor shall submit for approval the catalog cuts listed below in accordance with Exhibit A.

SD-03.G General Product Data

a. Crane

b. Painting System

c. Brakes (including electrical information)

d. Hooks and Load Block

e. Load Indication System

f. Operator’s Cab

g. Wire Rope and End Connections

h. Hydraulic Power Unit

i. Swing gates

SD-03.E Electrical Product Data

a. Power Supply System, if provided

b. Variable Frequency Drives (including Dynamic Braking Resistor and Reactor selection, if applicable)

c. Motors and Encoders (if applicable)

d. Electrical Enclosures

e. Limit Switches

f. Warning and Pilot Devices

g. Disconnect Switches

h. Contactors and Relays

i. Operator Controls, including Radio Control System if provided

j. Lighting/Heating/Air Conditioning

k. Anemometer

l. Slack line indicator

SD-04 Samples

SD-05 Design Data These calculations shall demonstrate compliance with all design requirements. Design data will not be approved if their evaluation/review is dependent on data or information not previously approved. All variables shall be listed and defined at the beginning of each calculation section;

variables shall be in accordance with required references.

NAVFAC WO 1666674 Page 13 of 33

SD-05.S Structural Calculations Provide calculations verifying the pedestal and supporting structure adequacy in accordance with section 2.3.1 of this specification

SD-05.M Mechanical Calculations

a. Wire Rope Line Pull

b. Brake sizing (including hoisting torque)

SD-05.E Electrical Calculations

a. Overcurrent Protection

b. Conduit Fill

c. Lighting

SD-05.F Failure Mode Calculations The Contractor shall perform failure-mode calculations of the principle load-carrying components of the crane (i.e. boom, load-lines, load block, boom-lines, pendants, boom-lifting cylinder, gantry, kingpost and pedestal, swing-bearing assembly, and all critical fasteners) in accordance with the API 2C. The Contractor shall verify that in the event of an unbounded gross overload applied to the load block by a moving load (e.g. load entanglement), the applicable components supporting the crane operator’s control station shall not be the point of failure. The following shall also apply:

a. These calculations shall assume that wire rope is not paid out from the hoist drum(s)

b. The sequence of failure shall be such that the first component to fail shall cause the crane to enter a less critical situation with respect to the safety of the crane operator

c. If the operator’s station is supported by the crane, the ratio between the calculated failure load of any component supporting the crane operator’s control station and the first component to fail shall not be less than 1.3 for any radius

d. The load conditions used for the calculations (i.e. wind, offlead, sidelead, crane base inclinations and accelerations) shall be the same as those used to calculate the offboard load rating chart(s)

Actual lift conditions and equipment condition can differ substantially from the ideal theoretical conditions assumed in failure-mode calculations. Under no circumstances should the calculated failure loads be used to justify operating the crane outside of the normal rated load chart limits.

SD-06 Test Reports The following reports, outlines, and plans shall be submitted in accordance with Exhibit A.

SD-06.1 Hook Non-Destructive Test (NDT) Report SD-06.1.1 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-06.1.2 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

NAVFAC WO 1666674 Page 14 of 33 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 approval signature of a SNT-TC-1A qualified Level III examiner stating they are independent of the vendor.

SD-06.1.3 Prior to performing any operational testing of the crane, the hook and eye pin or swivel eye bar (as applicable) 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 accuracy of ± 5% 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 criteria 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 and eye pin or swivel eye bar (as applicable).

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 equipment being certified. Each certification shall clearly identify the hoist, drive, component, 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 rope meets the published breaking strength, or the actual breaking strength of a sample taken from reel and tested. Certification shall be traceable to the hoist, crane and reel.

SD-07.2 Periodic Overload Testing The Contractor shall certify the crane and support systems are capable of being load tested semi-annually up to and not exceeding 125% (-5%/+0%) of the rated capacity without any detrimental effects.

SD-07.3 Crane Runway Rail Not applicable to this specification.

SD-07.4 Hazardous Material The Contractor shall certify that the crane contains no asbestos, lead paint, Polychlorinated Biphenyls (PCBs), or elemental mercury, and that chromates have been avoided where feasible.

NAVFAC WO 1666674 Page 15 of 33

SD-07.5 Loss of Power Test The Contractor shall certify that the loss of power tests can be performed without any detrimental effects to the crane (including hydraulic pressure).

SD-07.6 Coupling Alignments, if applicable The Contractor shall submit coupling alignment data records with certification that the alignment of all shafting connected by means of flexible couplings are within the manufacturer's installation tolerances. The shaft alignments shall be made using laser alignment equipment.

Barrel couplings may be aligned using lasers or the OEM recommended method. 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 installation. Barrel coupling alignment data record(s) shall be submitted on the official NAVCRANECEN form titled “Drum Barrel Alignment Data Sheet” located on the NAVCRANECEN website. All other coupling alignment data record(s) shall be submitted on the official NAVCRANECEN form titled “Shaft/Coupling Alignment Record Form” located on the NAVCRANECEN website.

SD-07.7 Hook Proof Test The Contractor shall submit certification that the hook and hook nut has been proof tested based on the rated capacity of the hook and satisfies the acceptance criteria of ASME B30.10. Proof test shall be performed prior to the hook non-destructive testing.

SD-07.8 Welding Certifications The Contractor shall provide a certificate stating that all welders, welding operators, weld inspectors and welding procedures (qualification) meet the requirements of AWS D 1.1 and ABS as applicable for all work performed in manufacturing this crane and installing parts supporting the crane at/to barge interfaces.

SD-08 Manufacturer’s Instructions

SD-08.1 Shop Test Procedure The Contractor shall develop and submit a shop test procedure that will demonstrate operation, performance, and safety of the crane. The test procedures shall be submitted and approved prior to conducting the shop test. As a minimum, the test procedures shall conform to those requirements outlined in section 3.6.1 which are capable of being tested prior to shipment.

SD-08.2 Crane Installation/ Removal Plan The contractor shall submit a plan detailing the logistics involved in crane mobilization to the site and installation of the new crane and removal of the existing crane. The plan shall include, as a minimum, lifting configurations, lay-down areas, installation, and transport through the activity. A detailed lifting and handling plan meeting the minimum requirements shown in Appendix D and NAVFAC P-307 Section 11.1 shall be submitted by the contractor, for review and acceptance by the Government. The construction crane and rigging gear shall comply with OSHA requirements and any local requirements. Lifts of all major components for crane removal and installation are considered to be critical lifts and include any lifts performed by equipment

NAVFAC WO 1666674 Page 16 of 33 such as forklifts and jacks. Actual locations of center of gravity and location of lifting points for completely assembled crane and for each major component shall be provided with the crane installation and removal plans.

NOTE: On site changes of the plan are not allowed without Government approval.

SD-08.3 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 cranes cannot proceed prior to the review and acceptance of the APP by the Contracting Officer..

SD-08.4 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-09 Manufacturer’s Field Reports

SD-09.1 Brake Adjustment Records The Contractor shall provide a brake adjustment record and installation/maintenance manuals for each brake on the crane. The brake adjustment record shall be submitted on the official NAVCRANECEN form titled “Brake Adjustment Record Form” located on the NAVCRANECEN 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 the record.

SD-09.2 Shop Test Deficient Items List Upon completion of the Government witnessed shop test and inspection of the crane, a list of deficient items will be compiled and attached to the “Navy Crane Center Post Shop Test Sign Off Sheet,” and signed by the Contractor, NAVCRANECEN representative, and activity representative (if applicable) and forwarded to the Contracting Officer.

SD-09.3 Shop Test Record Upon successful completion of the shop test for the crane, the Contractor shall submit records of all test data.

SD-09.4 Field Test Record The Contractor shall develop and submit a field test procedure that will demonstrate operation, performance, and safety of the crane. The test procedures shall be submitted with design submission and shall be approved by the Government.

SD-10 Operation and Maintenance Data The Contractor shall submit the crane’s operation and maintenance manual to the Government for review. The operation and maintenance manuals shall include a table of contents, operation

NAVFAC WO 1666674 Page 17 of 33 instructions, maintenance information, parts information, drawing list, all drawings, catalog cuts, and calculations.

Operation instructions shall include Contractor’s detailed written procedures as well as crane operating and safety instructions including special precautions for starting/stopping.

Maintenance information shall include recommended maintenance procedures, preventative maintenance, any purchased component manufacturer’s installation and maintenance manuals, lubrication instructions, and maintenance and programming instructions for any supplied drives.

Lubrication instructions shall include the location of lubrication points, type of lubricant to be used, and the frequency of lubrication, which shall agree with the lubrication drawing provided.

Maintenance instructions shall include alignment, adjustment, and calibration instructions for commercial components and parts lists. Programming instructions shall include a complete listing of all control system parameters with an explanation of their functions.

Parts information shall include a recommended spare parts list, information on all Contractor-designed parts, and all purchased sub-assemblies and components including the manufacturer’s part number. The information shall be broken-out to the smallest replacement part.

SD-11 Closeout Submittals

SD-11.1 Drawings The Contractor shall provide the crane’s as-built drawings on CDs and three (3) hard copies following final Government acceptance of the as-built drawings. Drawings on CD shall be viewable in AutoCAD 2020. The file shall be in .dwg or .dxf format and a separate copy in a bookmarked .pdf. The as-built drawings shall be submitted to the Government following final Government acceptance of the crane. The CDs shall include an index of the drawings.

SD-11.2 Operation and Maintenance Manuals The Contactor shall provide the operation and maintenance manuals on CDs and three (3) hard copies following final Government acceptance of the manuals. The manuals shall be a bookmarked and indexed .pdf document.

SD-11.3 Control System Parameter Record (as applicable) After the crane has passed the final field test, the Contractor shall complete a control system parameter record for the crane and provide the crane parameter file downloaded from the crane at time of acceptance, if applicable. The record shall include the contract number, Contractor’s name, address, date, all control system parameters, and their final settings. Each control system parameter shall be designated as either used or unused.

SD-11.4 Product Data Catalog cuts shall be submitted electronically, in .pdf format, as one unit with a cover sheet containing a title block and an index sheet identifying each catalog cut. Ensure each page is numbered and identified to allow proper filing if separated. Linked bookmarking is acceptable vice page numbering for the .pdf file. The minimum sections for indexing shall be the sections noted in paragraph SD-03.

NAVFAC WO 1666674 Page 18 of 33

SD-11.5 Frequency Allocation Application as applicable

Not applicable

SD-11.6 Property Transfer Verification After the crane has passed the final field tests, the Contractor shall transfer possession of all small items associated with the operation and maintenance of the cranes, including but not limited to keys, software, computer cabling, remote controls, etc. The property shall be given to the point of contact at the supported command. The Contractor shall prepare and submit an itemized dated invoice showing the quantity and description of items transferred with a signature and date from the recipient. The Property Transfer form will be provided by the Government.

1.5 QUALITY ASSURANCE

1.5.1 Qualifications

Crane design shall be accomplished by, or directly supervised by, a licensed PE. PE licensing shall be by a board or agency authorized to license and register PEs in the U.S. or Canada. The PE may be the Contractor's regular employee or a consultant. The PE's review and attestation of specification compliance and professional responsibility shall be signified by his or her PE original seal and dated signature on the final drawing and design calculations.

1.5.2 Regulatory Requirements

All crane functions and components shall comply with all OSHA requirements and other listed references in this specification. Anchorages to which personnel fall arrest equipment is attached shall be capable of supporting at least 5,000 pounds per person attached, or it must be designed, installed, and used as part of a complete personal fall arrest system which maintains a design factor of at least 2.0 under the supervision of a qualified person as required by 29 CFR 1910.66.

All guards shall be removable type and allow for a visual inspection of the covered component when installed. The guards shall be securely fastened and shall be capable of supporting, without permanent deformation, the weight of a 200-pound person, unless the guard is located where it is impossible for a person to step on it. All open gearing shall be guarded.

1.5.3 Post-Award Conference

The Contractor shall attend a post-award conference that will typically be held at the fabrication site or via teleconference. This conference will cover contract requirements, including but not limited to design submissions, shop testing, shipping, site mobilization, erection dates, Exhibit A submissions, the APP and Crane Installation Plan, roles and responsibilities of the entities involved, and the overall schedule. Meeting minutes shall be prepared by the Contractor and reviewed by the Government.

1.5.4 Pre-Installation Conference

The Contractor shall attend a pre-installation conference that will be held at the installation site.

This conference will allow the Contractor and any sub-Contractors, the Navy Crane Center and the supported command the ability to review any necessary precautions to insure a safe and accurate installation. A draft of the Crane Installation Plan should be available at the pre-

NAVFAC WO 1666674 Page 19 of 33 installation conference. Meeting minutes will be prepared by the Contractor and submitted for review and approval by the Government in accordance with Exhibit A.

1.6 DELIVERY, STORAGE, AND HANDLING

In the event that the Government is unable to receive the crane from the contractor as scheduled by the contract, the Contracting Officer will notify the contractor.

1.7 PROJECT/SITE CONDITIONS

1.7.1 Environmental Requirements

The crane shall be designed to operate in an outdoor marine environment with an ambient temperature of 0º to 104º F. The crane will be exposed to the elements year round, including snow, dust, and rain. Wave action is up to 3 feet while operating. The crane will be exposed to Sea State 5 while out of service. The crane will not operate in hazardous areas.

1.7.2 Existing Conditions

Not applicable to this specification.

1.7.3 Furnished Equipment

The Contractor shall provide NIST certified test weights and any associated rigging necessary to test the crane at their shop.

1.8 SEQUENCING AND SCHEDULING

The Contractor shall be responsible for transporting the new crane to NSWCCD, Bayview, Idaho. The Contractor shall be responsible for removal and disposal of the existing crane. The Contractor shall provide shipping information and schedule.

1.8.1 Scheduling and Mobilization Requirements

The Contractor shall provide notice a minimum of thirty days prior to their desired mobilization date at NSWCCD, Bayview, Idaho. The Government will determine a final mobilization date.

1.9 CONTRACTOR REQUESTED ENGINEERING CHANGES

All contractor requested engineering changes must be submitted to the Navy Crane Center on the "Contractor Change Request Form" (NCC Form 07-001). The "Cost Worksheet" (NCC Form 07- 001A) shall be attached to any engineering changes when a price increase/decrease is proposed by the contractor. The worksheet shall compare the price of equipment as specified in the contract with the price of the proposed change. CCRFs shall be disapproved if submitted without Price Worksheet. The forms are available at http://navfac.navy.mil/navfac_worldwide/specialty_centers/ncc/about_us/resources/downloads.ht ml.

1.10 WARRANTY

See Section I of the contract for warranty information.

1.11 MAINTENANCE

NAVFAC WO 1666674 Page 20 of 33

PART 2 PRODUCTS

2.1 MATERIALS

Material shall be free from defects and imperfections that might affect the serviceability and appearance of the finished product. All material shall be new and unused.

2.1.1 Ductile Material

All components directly supporting the load shall be of ductile material. For the purposes of this specification, ductile is defined as having a minimum elongation of 5% in 2 inches.

2.1.2 Structural Steel

Structural steel material shall conform to the standards referenced in section 2.3.1.

2.1.3 Cast Steel

Cast steel shall conform to ASTM A27 or A148.

2.1.4 Ductile Cast Iron

Ductile cast iron shall conform to ASTM A536.

2.1.5 Forged Steel

Forged steel shall conform to ASTM A668 or A521, grade as applicable.

2.1.6 Steel Shafts

Steel shafts shall conform to ASTM A434.

2.1.7 Aluminum Castings

Aluminum castings shall conform to ASTM B26 or B108.

2.1.8 Welding Materials

Welding materials shall conform to AWS D1.1 and ABS as applicable.

2.2 MANUFACTURED UNITS

Not applicable to this specification.

2.3 EQUIPMENT

2.3.1 Structural Design

2.3.1.1 General Requirements.

The crane shall be a pedestal mounted crane. The crane’s pedestal and housing shall be fully welded structures, designed to withstand all operational stresses. The pedestal shall be sealed to preclude damage from the environment. Provisions shall be made to prevent wildlife habitation inside the structure. Structural design shall be in accordance with AISC Steel Construction Manual. Structural components shall be designed to operate in the environmental conditions noted in section 1.7.1. The minimum time between overhaul (TBO) for all structural components is 5 years, with an objective of 7 years, using the Construction Duty Cycle described in API 2C.

NAVFAC WO 1666674 Page 21 of 33

2.3.1.2 Barge Interface

The research barge has the following characteristics: length = 80 feet, beam = 48 feet, and depth = 7 feet. The Contractor shall be responsible for providing an engineered attachment of the crane to the barge via existing pedestal. The crane shall mate with the existing pedestal about three feet above the deck. The existing crane pedestal is a 10-foot-long, 41” diameter, ½” thick, rolled steel tube suitable for serving as a foundation for the new crane. The assumed attachment point is at the existing cranes welded attachment point at about 36” above the weather deck.

2.3.1.3 Crane Boom (Jib)

The boom shall be of the telescoping design and a completely closed type box section.

Telescoping and retraction will be done completely through hydraulics, without the use of a cable-crowd system.

2.3.1.4 Structural Connections

Structural connections shall be designed in accordance with AISC-360.

Welding procedures and qualifications shall be in accordance with the requirements of AWS D1.1 as required by SD-07.8.

Structural bolted connections shall be designed and installed in accordance with RCSC Specification for Structural Joints Using High-Strength Bolts.

2.3.1.5 Lift Points

Major components shall be designed with structural or mechanical attachment points (lifting lugs, swivel hoist rings, hoist rings or approved equivalent) when they are to be lifted or handled by suspended rigging.

2.3.1.6 Crane Pedestal

The crane’s pedestal and housing shall be fully welded structures, designed to withstand all operational stresses. The pedestal shall be equipped with a roller bearing that transfers the moment created by the load to the barge and allows the crane to rotate. The pedestal interior shall be accessible and provided with a watertight bolted access to preclude damage from the environment.

2.3.1.7 Access Structures

All access structures shall be in accordance with OSHA and ASME B30.8. The crane shall be equipped with the necessary stairways, walkways, platforms, and ladders to provide safe access to all areas necessary for crane operation, lubrication, adjustment, servicing, and inspection.

Crane contractor shall remove the existing platforms and ladders and replace them in kind (as shown in Appendix A).

2.3.2 Mechanical Design

Mechanical components shall be designed to operate in the environmental conditions noted in section 1.7.1.

2.3.2.1 Hydraulic Systems.

NAVFAC WO 1666674 Page 22 of 33

All hydraulic tubing shall be stainless steel. The hydraulic system of the crane shall utilize SAE 37 degree flared or O-ring face connections between tubing and fittings. Hydraulic tubing and fittings shall be coated for protection against weather. All hydraulic hoses shall be equipped with sleeves for UV protection and abrasion resistance. The hydraulic system shall have a reservoir that is not less than 3 times the charge pump capacity. The hydraulic system shall be supplied with Chevron Clarity ISO 46 lubricant. The HPU shall be integral with the pedestal or on the rotating platform. Unless the HPU tank is located within the confines of the pedestal, and protected by the pedestal, the HPU tank shall be double walled with interstitial leak indication.

The hydraulic system shall have filters with replaceable elements, sized to limit the pressure drop across a clean element to not more than 10 psi at the operating fluid temperature and viscosity and to provide at least six months of service life at the anticipated level of crane operation.

Filters shall limit the hydraulic system contamination to ISO range numbers of 18/17/14. Filter elements and housings shall have sufficient strength to prevent collapse or rupture under the most adverse operating conditions, and to withstand fatigue due to pressure or flow pulsations.

Test ports at common maintenance points and system control points are required elsewhere, and shall be made for easy attachment of portable measuring devices. Additional instrumentation shall include at minimum: hydraulic reservoir temperature, hydraulic oil level gauge and alarm.

With the exception of local instrumentation for pressure and flow, all additional instrumentation shall have redundant readouts at points of measurement and within operator’s cabin. Controls (E-stop) for HPU shutdown shall be available at the HPU, on the pedestal from the barge deck, and within the operator’s cabin.

2.3.2.2 Hoist

The hoist and luffing or telescoping winches, as applicable, shall be driven by high speed hydraulic motors through planetary gearboxes to provide precise handling capabilities. Each hoist shall be equipped with two independent braking means. The primary brake shall be a spring-applied, hydraulically released disc brake rated to independently stop and hold the test load. The additional hoist braking means shall be provided and may be either: an additional spring applied, hydraulically released brake or a hydraulic circuit designed to act as a controlled braking means. Hydraulic circuitry and valves shall be compatible with the winch. All brakes shall be automatically applied by the return springs if the system pressure fails. The wire rope drums shall be grooved. If the wire rope drum employs multiple layers of wire rope, it shall be of the LEBUS-groove design. The hoist drum shall be equipped with adjustable lower limit switches to maintain a minimum of two wraps of rope on the hoist drum when the hook is at its lowest position. A means of precluding damage from two-blocking at all points shall be provided.

2.3.2.3 Wire Rope.

Wire ropes shall have an independent wire rope core conforming to ASTM A1023/A1023M and be thoroughly lubricated. Wire ropes shall have no less than a 5.0 to 1 design factor based on the minimum breaking strength of the wire rope. The use of wedge sockets as wire rope end terminations are prohibited. The use of galvanized wire rope is prohibited. All end connections shall develop 100% of the wire rope manufactures published breaking strength. Any 34 or higher strand construction rotation resistant wire rope shall employ poured sockets.