CLNC 41 22 13.15 BRIDGE CRANE OVERHEAD ELEC UNDER RUNNING TROLLEY.pdf

SECTION 41 22 13.15 Page 1

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 22 13.15

BRIDGE CRANES, OVERHEAD ELECTRIC, UNDER RUNNING TROLLEY

02/23

PART 1 GENERAL

1.1 REFERENCES

1.2 DEFINITIONS

1.3 SYSTEM DESCRIPTION

1.3.1 Crane Design Criteria

1.3.1.1 General

1.3.1.2 Classification

1.3.1.3 Rated Speeds

1.4 VERIFICATION OF DIMENSIONS

1.5 SUBMITTALS

1.6 QUALITY ASSURANCE

1.6.1 Manufacturer Qualification

1.6.2 Pre-Delivery Inspections

1.6.2.1 Inspection of Hook Assembly

1.6.2.1.1 Hook Non-Destructive Test (NDT)

1.6.3 Drawings: Overhead Electric Crane System

1.6.4 Design Data: Load and Sizing Calculations

1.6.5 Certificates

1.6.6 Welding Qualifications and Procedure

1.7 CRANE SAFETY

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 General

2.1.2 Nameplates

2.1.3 Capacity Marking

2.1.4 Safety Warnings

2.2 STRUCTURAL REQUIREMENTS

2.2.1 Structural Connections

2.2.2 Crane Bridge Girder

2.2.3 Bridge End Trucks

2.2.4 End Stops

2.2.5 Bumpers

2.2.6 Crane Runway System

2.3 MECHANICAL REQUIREMENTS

2.3.1 Threaded Fasteners

2.3.2 Hoist

2.3.2.1 Hoist Brakes

2.3.2.2 Load Block and Hook

2.3.3 Travel Drives

2.3.3.1 Trolley Drives

2.3.3.2 Bridge Drives

2.3.3.2.1 Bridge Travel Gearing

2.3.3.2.1.1 Bridge Travel Reducer

2.3.3.2.1.2 Bridge Open Gearing

2.3.4 Travel Brakes

2.3.4.1 Trolley Brake

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2.3.4.2 Bridge Brake

2.3.5 Wheels

2.3.6 Drip Pans

2.4 ELECTRICAL REQUIREMENTS

2.4.1 Motors

2.4.2 Controls

2.4.3 Protection

2.4.3.1 Conductors

2.4.4 Resistors

2.4.5 Transients and Harmonics Protection

2.4.6 Limit Switches

2.4.7 Operator Controls

2.4.7.1 Pendant Pushbutton Station

2.4.7.1.1 Pendant Conductor System

2.4.8 Electrification Systems

2.4.8.1 Runway Conductor System

2.4.8.2 Bridge Conductor System

2.4.9 Overload Protection

2.4.10 Enclosures

2.4.11 Warning Devices

2.4.12 Pilot Devices

2.4.13 Cyber Security of Control Systems

2.4.13.1 Control System and Network

2.4.13.2 Software and Services

2.4.13.3 Access Control

2.4.13.4 Control System Account Management

2.4.13.5 Session Management

2.4.13.6 Authentication/Password Policy and Management

2.4.13.7 Logging and Auditing

2.4.13.8 Heartbeat Signals

2.4.13.9 Patch Management and Updates

2.4.13.10 Malware Detection and Protection

2.4.13.11 Physical Security

2.4.13.12 Wireless Technology

2.4.13.13 Control System Inventory

2.5 PAINTING SYSTEM

2.6 IDENTIFICATION PLATES

2.6.1 Markings on Crane, Trolley, and Hook

2.7 ELECTRICAL ASSEMBLY

PART 3 EXECUTION

3.1 EXAMINATION

3.2 SHOP ASSEMBLY AND TESTS

3.3 ERECTION AND INSTALLATION

3.3.1 Mechanical Alignment

3.3.2 Electrical Adjustments

3.3.3 Field Welding

3.3.4 Field Painting

3.4 FIELD QUALITY CONTROL

3.4.1 Post-Erection Inspection

3.4.2 Operational Tests

3.4.2.1 No-Load Test

3.4.3 Test Data

3.4.4 Hook Tram Measurement

3.4.5 Load Tests

3.4.5.1 Rated Load Test

3.4.5.1.1 Hoist

3.4.5.1.2 Trolley

3.4.5.1.3 Bridge

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3.4.5.1.4 Trolley Loss of Power Test

3.4.5.1.5 Bridge Loss of Power Test

3.4.5.2 Overload Test

3.4.5.2.1 Hoist

3.4.5.2.2 Trolley

3.4.5.2.3 Bridge

3.5 MANUFACTURER'S FIELD SERVICE REPRESENTATIVE

3.6 OPERATION AND MAINTENANCE MANUALS

3.7 FIELD TRAINING

3.8 FINAL ACCEPTANCE

-- End of Section Table of Contents --

SECTION 41 22 13.15 Page 4

SECTION 41 22 13.15

BRIDGE CRANES, OVERHEAD ELECTRIC, UNDER RUNNING TROLLEY

02/23

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

AGMA 908 (1989B; R 1999) Information Sheet:

Geometry Factors for Determining the Pitting Resistance and Bending Strength of Spur, Helical and Herringbone Gear Teeth

ANSI/AGMA 2001 (2004D; R 2010) Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth

ANSI/AGMA 2015-1 (2001A; R 2014) Accuracy Classification System - Tangential Measurements for Cylindrical Gears

ANSI/AGMA 6013 (2006A; R 2016) Standard for Industrial Enclosed Gear Drives

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 360 (2016) Specification for Structural Steel Buildings

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B1.1 (2003; R 2018) Unified Inch Screw Threads (UN and UNR Thread Form)

ASME B30.10 (2019) Hooks

ASME B30.16 (2022) Overhead Underhung and Stationary Hoists

ASME B30.17 (2020) Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung Hoists)

ASME B30.30 (2019) Ropes

ASME HST-1 (2017) Performance Standard for Electric Chain Hoists

ASME HST-4 (2021) Performance Standard for Overhead Electric Wire Rope Hoists

SECTION 41 22 13.15 Page 5

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2020; Errata 1 2021) Structural Welding Code - Steel

AWS D14.1/D14.1M (2019) Specification for Welding of Industrial and Mill Cranes and Other Material Handling Equipment

ASTM INTERNATIONAL (ASTM)

ASTM A275/A275M (2018; R 2023) Standard Practice for Magnetic Particle Examination of Steel Forgings

ASTM A1023/A1023M (2021) Standard Specification for Stranded Carbon Steel Wire Ropes for General Purposes

ASTM E543 (2021) Standard Specification for Agencies Performing Non-Destructive Testing

ASTM E1417/E1417M (2016) Standard Practice for Liquid Penetrant Testing

ASTM F436/F436M (2019) Standard Specification for Hardened Steel Washers Inch and Metric Dimensions

ASTM F3125/F3125M (2019) 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

CRANE MANUFACTURERS ASSOCIATION OF AMERICA (CMAA)

CMAA 70 (2020) Specification for Top Running Bridge and Gantry Type Multiple Girder Electric Overhead Traveling Cranes

CMAA 74 (2020) Specifications for Single Girder Cranes

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC ISO 15408 (2022) Information Technology-Security Techniques-Evaluation Criteria for IT Security

MATERIAL HANDLING INDUSTRY OF AMERICA (MHI)

MHI MH27.1 (2016) Specifications for Underhung Cranes and Monorail Systems

NATIONAL ELECTRICAL CONTRACTORS ASSOCIATION (NECA)

NECA NEIS 1 (2015) Standard for Good Workmanship in Electrical Construction

SECTION 41 22 13.15 Page 6

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2020) Enclosures for Electrical Equipment (1000 Volts Maximum)

NEMA ICS 3 (2005; R 2010) Medium-Voltage Controllers Rated 2001 to 7200 V AC

NEMA ICS 5 (2017) Industrial Control and Systems:

Control Circuit and Pilot Devices

NEMA ICS 6 (1993; R 2016) Industrial Control and Systems: Enclosures

NEMA ICS 8 (2011) Crane and Hoist Controllers

NEMA MG 1 (2021) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2023; ERTA 4 2023) National Electrical Code

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

RCSC A348 (2020) RCSC Specification for Structural Joints Using High-strength Bolts

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC SP 6/NACE No.3 (2007) Commercial Blast Cleaning

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE J429 (2014) Mechanical and Material Requirements for Externally Threaded Fasteners

SAE J995 (2017) Mechanical and Material Requirements for Steel Nuts

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS RR-W-410 (2022; Rev J) Wire Rope and Strand

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910 Occupational Safety and Health Standards

29 CFR 1910.147 The Control of Hazardous Energy (Lock Out/Tag Out)

29 CFR 1910.179 Overhead and Gantry Cranes

29 CFR 1910.306 Specific Purpose Equipment and Installations

U.S. NAVAL SEA SYSTEMS COMMAND (NAVSEA)

NAVSEA T9074-AS-GIB-010/271 (2014; Revision 1) Requirements for Nondestructive Testing Methods

SECTION 41 22 13.15 Page 7

UNDERWRITERS LABORATORIES (UL)

UL 943 (2016; Reprint Sep 2023) UL Standard for Safety Ground-Fault Circuit-Interrupters

UL 1004-1 (2012; Reprint Nov 2020) UL Standard for Safety Rotating Electrical Machines - General Requirements

1.2 DEFINITIONS

a. Crane Bridge: That part of an overhead crane system consisting of a girder, end trucks, walkway, and drive mechanism which carries the trolley(s) and travels along the runway rails parallel to the runway.

b. Crane Runway: The track system along which the crane operates horizontally, including track hangar rods, track connection devices, and runway structural supports.

c. Dead Loads: The weight of all effective parts of the bridge structure, the machinery parts, and the fixed equipment supported by the structure.

d. Crane Bridge Girder: The principal horizontal beam of the crane bridge structure. It is supported by the crane end trucks. Typically for single girder cranes the trolley mounted hoist is suspended from the girder below the crane. For double girder cranes, the trolley is typically run on top of the bridge girder and the hoist is mounted on top of the trolley.

e. Insulated Link: A component normally installed between the hook and the lifting wire rope or lower load block, or below the hook to prevent the flow of electrical energy. Insulated links are primarily used when there is the possibility radio frequency energy collecting on the weight handling equipment structure. Insulated links are used extensively in the handling of ordnance.

f. Lifted Load: The load consisting of the rated load and the weight of lifting devices attached to the crane such as the load block, bucket, or other supplemental devices.

g. Original Equipment Manufacturer (OEM): the Company that produced the part or original equipment.

h. Packaged Hoist: A commercially designed and mass produced hoist characterized by the motor, gearing, brake(s), and drum contained in a single package often connected by the use of c, d, or p-face flanges.

i. Patented Track: A generic term referring to track built in accordance with MHI MH27.1 utilizing a composite track section incorporating a proprietary bottom flange shape. For this crane system, it is provided for the crane bridge girder and also the crane runway track, if under running.

j. Pendant: A control for a hoist and a crane. The pendant hangs from the hoist or the crane by a cable at a height that is easy for the operator to reach.

k. Rated Load: The maximum working load suspended under the load hook.

SECTION 41 22 13.15 Page 8

l. Standard Commercial Cataloged Product: A product which is currently being sold, or previously has been sold, in substantial quantities to the general public, industry or Government in the course of normal business operations. Models, samples, prototypes or experimental units do not meet this definition. The term "cataloged" as specified in this section is defined as "appearing on the manufacturer's published product data sheets. These data sheets must have been published or copyrighted prior to the issue date of this solicitation and have a document identification number or bulletin number.

m. Top Running Crane: An overhead electric traveling crane that is supported by end trucks which run on top of supporting rails.

n. Trolley Load: The weight of the trolley and its associated equipment carried by the trolley wheels.

o. Under running (Underhung) Crane: An electric overhead traveling crane that is supported by crane end trucks suspended below the crane runway. The load is supported by hanging from the lower flange of a beam or patented track.

1.3 SYSTEM DESCRIPTION

1.3.1 Crane Design Criteria

Cranes will operate in the given spaces and match the runway dimensions and rails indicated. Hook coverage, hook lift, clearances, lifting capacity, and load test weight must not be less than that indicated.

Provide loaded hook coverage to the maximum extent possible.

1.3.1.1 General

Include the following: Number of cranes [one (1)], located in building identified as [1047], with the capacity expressed in [two (2)] tons. Also clearly locate and identify each hoist and system components.

1.3.1.2 Classification

Provide [under running] single girder electric bridge crane, with under running trolley mounted hoist, conforming to MHI MH27.1, CMAA 70, and CMAA 74 service class [C], as applicable. The crane must be designed for operation in an [indoor] environment, [general purpose] service, meeting the requirements of ASME B30.16 and ASME B30.17, with an ambient temperature range of [40] to [100] degrees Fahrenheit. The total crane span must be [23] feet with a minimum vertical hook lift of [18] feet and as specified herein. Provide runways for multiple span cranes equally spaced apart.

The crane must be [pendant controlled] and operate in the spaces and within the loading conditions indicated. Provide a crane, including hooks and hoisting rope or load chain, that is able to clear permanent obstructions in all operating configurations. [The pendant controller must be mounted on a separate festooned cable system from the trolley power supply.] The crane must operate on [260/480]-volts AC, [60 Hz], [three] phase power source. Maximum loading on the facility (without impact) due to dead loads, trolley loads, and lifted loads, with the trolley in any position, must not exceed the allowable wheel loading and wheel spacing of the facility.

SECTION 41 22 13.15 Page 9

1.3.1.3 Rated Speeds

Provide the crane with rated (maximum) speeds within plus or minus 10 percent (in feet/min) for the main hoist, bridge, and trolley at the rated load as specified in the table below. The minimum speed must not exceed the values listed.

Rated Speeds meters/second feet/min

Description Minimum Maximum

Main Hoist [ ] [8 ]

Trolley [ ] [30 ]

Bridge [ ] [50 ]

The hook lift capacity and speed must be the manufacturer's standard within the limits specified.

1.4 VERIFICATION OF DIMENSIONS

The Contractor is responsible for the coordination and proper relation of their work to the building structure and to the work of all trades.

Coordinate with the crane support structure design, where applicable, to provide the desired crane operating envelope (i.e., hook envelope and hook height). Verify all dimensions of the building that relate to fabrication of the crane and notify the Contracting Officer of any discrepancy before finalizing the crane order.

1.5 SUBMITTALS

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are for information only. Submit the following in accordance with Section 01

33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Overhead Electric Crane System; G

Complete Schematic Wiring Diagram; G

Control System and Network Drawings; G

SD-03 Product Data

Hoist Brakes; G

Travel Brakes; G

Load Block and Hook; G

Hoist and Trolley Units; G

Hoisting Rope; G

Travel Reducer; G

SECTION 41 22 13.15 Page 10

Wheels; G

Bridge End Trucks; G

Crane Bridge Girder; G[, [ ]]

End Stops; G[, [ ]]

Bumpers; G[, [ ]]

Crane Runway System; G[, [ ]]

Motors; G[, [ ]]

Contactors and Relays; G[, [ ]]

Variable Frequency Drives; G[, [ ]]

Pendant Push-Button Station; G[, [ ]]

Pendant Conductor System; G[, [ ]]

Crane Controllers; G[, [ ]]

Control Parameter Settings; G[, [ ]]

Pilot Devices; G[, [ ]]

Warning Devices; G[, [ ]]

Runway Conductor System; G[, [ ]]

Bridge Conductor System; G[, [ ]]

Overload Protection; G[, [ ]]

Painting System; G[, [ ]]

Control System and Network; G[, [ ]]

SD-05 Design Data

Load and Sizing Calculations; G[, [ ]]

SD-06 Test Reports

Hook Proof Test; G[, [ ]]

Hook Non-Destructive Test (NDT); G[, [ ]]

Post-Erection Inspection; G[, [ ]]

Operational Tests; G[, [ ]]

Hook Tram Measurement; G[, [ ]]

Load Tests; G[, [ ]]

SD-07 Certificates

SECTION 41 22 13.15 Page 11

Wire Rope; G[, [ ]]

Drawn Galvanized Wire Rope End User Notification; G[, [ ]]

Crane Runway; G[, [ ]]

Hazardous Material; G[, [ ]]

Loss of Power Test; G[, [ ]]

Overload Test; G[, [ ]]

Brake Adjustment Record; G[, [ ]]

Contractor Hazardous Environment; G[, [ ]]

Public Domain Software; G[, [ ]]

Software and Services; G[, [ ]]

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals, Data Package 3; G[, [ ]]

SD-11 Closeout Submittals

Network-Capable Control Devices; G[, [ ]]

Disabled Ports, Connectors, and Interfaces; G[, [ ]]

Evaluation Status of Hardware and Software; G[, [ ]]

Control System Access Control; G[, [ ]]

Control System Account Management; G[, [ ]]

Patch Management and Updates; G[, [ ]]

Malware Detection and Protection; G[, [ ]]

Wireless Technology Provisions; G[, [ ]]

Control System Inventory; G[, [ ]]

1.6 QUALITY ASSURANCE

1.6.1 Manufacturer Qualification

Overhead Electric Crane System, including sub-system components manufactured by vendors, must be designed by, or directly supervised by, a registered professional engineer (PE). PE licensing must be by a board or agency authorized to license and register professional engineers. The PE may be a Contractor's regular employee or a consultant. The PE's review and attestation of specification compliance and professional responsibility must be signified by their PE original seal and dated signature on the final drawings. The professional engineers must only undertake and perform work under this contract in the branch(s) of engineering in which they are licensed.

1.6.2 Pre-Delivery Inspections

SECTION 41 22 13.15 Page 12

Contractor is responsible for performance of quality control inspections, testing, and documentation.

1.6.2.1 Inspection of Hook Assembly

Inspect hook [by a magnetic particle type inspection] [by liquid penetrant type inspection] [and X-rayed] [and tested ultrasonically] prior to delivery. Furnish documentation of hook inspection to Contracting Officer prior to field operational testing.

Acceptance standard is no defects. A defect is defined as a linear indication for which the largest dimension is greater than [1/16 inch] long. Welding repairs of hooks are not permitted. A hook showing linear indications, damage, or deformation is not acceptable.

1.6.2.1.1 Hook Non-Destructive Test (NDT)

For hooks of ferromagnetic materials, magnetic-particle inspect the hook over the entire area in accordance with NAVSEA T9074-AS-GIB-010/271 or ASTM A275/A275M. For hooks of non-magnetic material, NDT must be liquid penetrant (PT) method in accordance with ASTM E1417/E1417M or NAVSEA T9074-AS-GIB-010/271. For PT testing of hooks containing stainless steels, titanium, or nickel based alloys, total halogens and Sulphur used in the NDT process must be controlled as specified in

NAVSEA T9074-AS-GIB-010/271.

Inspect each hook and shank over the entire surface area. If NDT cannot be performed on surfaces inside small holes (e.g., hook/nut captivation roll pin holes), visually inspect those surfaces to the maximum extent practical.

a. Procedure for magnetic particle inspection: Conduct magnetic particle inspection in accordance with NAVSEA T9074-AS-GIB-010/271.

ASTM A275/A275M may be used with the following restrictions: Do not use DC yokes (including switchable AC/DC yokes used in the DC mode) or permanent magnet yokes. Do not use automatic powder blowers or any other form of forced air other than from a hand-held bulb for the application or removal of dry magnetic particles. Remove arc strikes. Equipment ammeters must have an accuracy of plus or minus 5 percent of full scale (equipment ammeter accuracy other than that stated is acceptable provided the MT procedure states that a magnetic field indicator is used to establish and verify adequate field strength for all aspects of the inspection.)

b. Acceptance Criteria: Defects found on the hook will result in rejection of defective items for use on furnished hoist.

c. Test Report: Submit a test report of the inspection of each hook to the Contracting Officer for approval prior to final acceptance of hoist installation. Certify test reports by the testing organization. The performing organization must provide a written statement of certification to ASTM E543, current within one year of the date the NDT was performed. The NDT procedures including technique sheets specific to the types, shapes, and size of the parts being examined must adequately describe the orientation of the hooks within the magnetizing equipment, as applicable. The performing organization must have the NDT procedures and its technique sheet used for testing of the hook reviewed and approved by an independent Level III examiner. Submit the (Level III examiner) approved procedures, technique sheets, and certification to the Contracting Officer with the test report.

SECTION 41 22 13.15 Page 13

1.6.3 Drawings: Overhead Electric Crane System

a. Submit drawings showing the general arrangement of all components in plan, elevation, and end views to demonstrate proper interface with the facility and relation to other cranes on the same rail system, if applicable. Show all major features of the crane including: hook approaches on all four sides, clearances and principal dimensions, hoist, trolley and bridge drives, motor nameplate data, overcurrent protective device ratings, and electrical schematic drawings. Include weights and centers of gravity of major components (e.g., bridge girder(s), trolley/hoist).

b. Submit shop drawings of all fabricated components. Shop drawing quality must be equivalent to the contract drawings accompanying this solicitation. Drawings must be reviewed, signed and sealed by a licensed professional engineer.

c. Provide Bill of Materials for crane components on each drawing. The schedule must provide a cross reference between manufacturer data and shop drawings. Components listed on the schedule of crane components must include total quantity, description, original manufacturer, and part number. Distributing agents will not be acceptable in lieu of the original manufacturer.

d. Provide control system and network drawings. Network diagram must show equipment locations, names, models, and IP addresses on network communications schematic for all Programmable Logic Controllers (PLCs), Remote Terminal Unit (RTU), Supervisory Controller, and Other Network-Capable Devices. In addition, the drawings must consist of all software block, flow, and ladder diagrams.

1.6.4 Design Data: Load and Sizing Calculations

Submit complete list of equipment and materials, including manufacturer's descriptive data, technical literature, and performance charts and curves. Submit calculations reviewed, signed, and sealed by a registered professional engineer verifying the load cases, sizing of the bridge girder(s), end trucks, travel drives, motors, overcurrent protection, and conduit. Provide a list of all codes and standards, design assumptions, equations, specified efficiencies, limits, factors of safety, component ratings, and sources of values used. Include free body diagrams or sketches of each load case.

1.6.5 Certificates

All certifications must be dated and bear the original signature (above the printed name) of the authorized representative of the Contractor or the manufacturer of the items or equipment being certified. Submit certifications that clearly identify the crane, the drives, components, and location (as applicable) to which it applies:

a. Wire Rope Certification with either the wire rope manufacturer's certification that the rope meets the published breaking force, or certification of the actual breaking force of a sample taken from the reel and tested. Show the published breaking force on the wire rope certificate; the actual wire rope breaking force must meet or exceed the published value. Certification must be traceable to the hoist, crane, and reel.

b. Crane Runway Certificate stating that the new crane will operate properly on the runway. For runways provided by Contractor, include

SECTION 41 22 13.15 Page 14 statement certifying runway has been aligned in accordance with CMAA 74 or MHI MH27.1, as applicable.

c. Hazardous Material Certificate that the crane does not contain hazardous material including asbestos, lead, cadmium, chromium, PCBs, or elemental mercury. Products required for the designing and manufacturing of cranes must not contain the prohibited materials.

d. Loss of Power Test Certificate stating that a test may be performed in which power is removed during operation without any detrimental effects to the crane.

e. Overload Test Certificate stating that the crane can be periodically load tested to 125 percent (plus 0 minus 5 percent) of rated load.

f. Certificate of the Brake Adjustment Record. Provide a brake adjustment record and installation/maintenance manuals for each brake on the crane. Each brake measurement must 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.

g. Contractor Hazardous Environment Certificate stating that the new crane and all associated components including the hoist are designed for operation in the hazardous environment specified in the paragraph

CLASSIFICATION.

h. Public Domain Software Certificate declaring that public domain software (e.g., freeware, shareware) is not used in the system.

i. Certificate stating that all Software and Services that are not required for operation and/or maintenance of the product have been removed. The software/services to be removed are identified in paragraph SOFTWARE AND SERVICES.

1.6.6 Welding Qualifications and Procedure

Welding must be in accordance with qualified procedures using AWS D14.1/D14.1M as modified. Written welding procedures must specify the Contractor's standard dimensional tolerances for deviation from camber and sweep and not exceed those specified in AWS D14.1/D14.1M, MHI MH27.1 and CMAA 74. Welders and welding operators must be qualified in accordance with AWS D1.1/D1.1M or AWS D14.1/D14.1M.

1.7 CRANE SAFETY

Comply with the mandatory and advisory safety requirements of ASME B30.10, ASME B30.16, ASME B30.17, ASME HST-4 or ASME HST-1, 29 CFR 1910.147, 29 CFR 1910.179, 29 CFR 1910.306, and all applicable provisions of 29 CFR 1910 and NFPA 70.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 General

Provide materials and equipment which are standard products of manufacturers regularly engaged in the fabrication of complete and totally functional cranes including necessary ancillary equipment. Material will

SECTION 41 22 13.15 Page 15 be free from defects and imperfections that might affect the serviceability and appearance of the finished product. All material must be new and unused.

2.1.2 Nameplates

Secure nameplates to each major component of equipment with the manufacturer's name, address, type or style, model or catalog number, and serial number. Provide two bridge identification plates, one for each side of the bridge. Provide noncorrosive metal identification plates with letters which are easily read from the floor, showing a separate number such as BC-1, BC-2, for each bridge crane.

2.1.3 Capacity Marking

Mark the rated capacity in pound units on each side of the crane on the bridge girder. Capacity marks must be large enough to be clearly visible from the floor. Individual hoist units must have their rated capacity clearly marked on their lower block, and additionally labeled on the hoist body.

2.1.4 Safety Warnings

Affix labels in a readable position to each lift block or control station in accordance with ASME B30.16 and ASME B30.17. Submit safety warnings, diagrams and other instructions suitably framed and protected for display as indicated by the Contracting Officer as follows:

Design and locate the word "WARNING" or other legend to bring the label to the attention of the operator. Provide durable type warning labels and display the following information concerning safe-operating procedures:

Cautionary language against lifting more than the rated load; operating the hoist when the hook is not centered under the hoist; operating hoist with twisted, kinked or damaged rope; operating damaged or malfunctioning hoist; operating a rope hoist with a rope that is not properly seated in its hoist drum groove; lifting people; lifting loads over people; and removing or obscuring the warning label.

2.2 STRUCTURAL REQUIREMENTS

Structural requirements must be in accordance with CMAA 74 and MHI MH27.1, as applicable. Structural steel materials must conform to the standards permitted in CMAA 74, MHI MH27.1, and AISC 360. Skewing and other applicable lateral loads must be considered in the design.

2.2.1 Structural Connections

High-strength bolted structural connections must be designed and installed in accordance with RCSC A348. Bolts must be of ASTM F3125/F3125M Grade A325/A325M or Grade A490/A490M material. Galvanized bolts are not acceptable.

Welded connections for the crane must be performed in accordance with AWS D14.1/D14.1M. Welded connections to the building must be performed in accordance with AWS D1.1/D1.1M. Allowable stress values must comply with CMAA 74 or MHI MH27.1, as applicable.

2.2.2 Crane Bridge Girder

a. Provide crane bridge girder(s) of [rolled steel shape conforming to

SECTION 41 22 13.15 Page 16

CMAA 74]. Intermittent ("skip") welds on bridge girder elements (e.g., web and flange interfaces) are prohibited. If the girder is notched to fit over the end trucks, reinforce the girder ends with vertical and horizontal stiffeners. Splices in the unsupported length of the girder are prohibited.

b. Keep splices in the bridge girder(s) to a minimum and splices in high stress locations must be avoided. Make splices with complete joint penetration welds. Field (on-site) welded splices are prohibited.

2.2.3 Bridge End Trucks

Provide bridge end trucks conforming to ASME B30.17 and CMAA 74 or MHI MH27.1, as applicable. Configure end trucks with a feature that limits end truck movement to one inch in the event of wheel or shaft failure.

2.2.4 End Stops

Fit the crane bridge girder(s) with structural steel end stops. Locate stops to permit maximum trolley travel. Design end stops in accordance with MHI MH27.1 and ASME B30.17. Provide a system in which the travel wheels do not contact the end stops. End stops must be designed to absorb the maximum kinetic energy and impact force developed by the bumper contact. Provide end stops compatible with trolley bumpers and designed to bolt to the crane bridge girder.

2.2.5 Bumpers

Fit bridge end trucks and trolley frames with shock-absorbing bumpers capable of decelerating and stopping the bridge and trolley within the limits stated by ASME B30.17. Ensure bumpers conform to ASME B30.17.

Bumpers must fully engage end stops. Mount bumpers so that there is no direct shear on mounting bolts (if any) upon impact. Bumpers must provide adequate clearance between the crane and surrounding structure when compressed to preclude damaging equipment (clearance requirements are defined in MHI MH27.1 or CMAA 74, as applicable, and ASME B30.17). When more than one crane is located and operated on the same runway, bumpers must be provided on their adjacent ends or on one end of one crane. Fit the other end of the end-truck with a structural steel stop to engage the bumpers of the adjacent crane. Ensure bridge bumpers are properly aligned with runway end stops.

2.2.6 Crane Runway System

a. Provide the complete runway track suspension system that is required to hang the crane runway track at its indicated location from the structural supports indicated on the drawings. Provide runway and support structure for under running crane of rolled steel shapes conforming to CMAA 74 or patented track girders conforming to

MHI MH27.1.

b. For rolled steel shapes, locate splices under structural support members.

c. For patented track girders, perform splices as necessary in accordance with the manufacturer's recommendations and requirements. Align ends of lower T-section to minimize the horizontal gap on the running surface to not greater than 1/16 inch and not greater than a vertical difference of 1/32 inch for the wheel running surface alignment for a

SECTION 41 22 13.15 Page 17 smooth crossing by the wheels. Splice assemblies must be from the same manufacturer as the patented track and located under structural support members. When runways are suspended, bracing preventing damaging lateral or longitudinal movement is required. Loads transmitted to the building through the suspension must have the review and approval of the building engineer of record (EOR) prior to installation. Submit manufacturer's standard published tables that verify the crane runway track is sized in compliance with all specification requirements. When standard published tables are not available, provide calculations for the strength design and deflection of the beams.

d. Runway support structure must be designed, fabricated, and installed such that runway rails meet the alignment tolerances of CMAA 74 or MHI MH27.1, as applicable. Provide means to allow for vertical adjustment of the runway track both before and after the system has been put in operation so that track can be erected and maintained level. Brace runway to restrain the track against damaging lateral and longitudinal movements. Where the runway track is suspended from hanger rods, provide means preventing the hanger rod nuts from backing off the rods. Allowable stress in hanger rods is 20 percent of the minimum specified ultimate strength of the material used.

e. For under running crane runways, design, fabricate, and install new runway end stops in accordance with ASME B30.17 and CMAA 74 or MHI MH27.1, as applicable. End stops must be designed to absorb the maximum kinetic energy and impact force developed by the bumper contact. Provide end stops compatible with end truck bumpers, designed to bolt to the runway support girders, and maximize bridge travel.

2.3 MECHANICAL REQUIREMENTS

a. Provide steel shafts, gears, and keys, with the exception of worm gears which may be bronze. No three or more bearing shaft configurations are allowed.

b. Cast iron and aluminum used to support components of the hoist power transmission train must be ductile. For the purposes of this specification, "ductile" is defined as having a minimum elongation of 5 percent in 2.00 inches. Gray cast iron load bearing parts are prohibited. Provide hoist speed reducer housings that are steel or ductile/malleable cast iron and hoist electric motor housings that are steel or ductile/malleable cast iron or cast aluminum.

c. Provide steel or ductile/malleable cast iron brake housings of motor mounted disc brakes, brake lining backing plates, shoes and shoe holders. Provide spring-set brake shoe or pad linings of a non-asbestos material.

d. All mechanical components must be accurately aligned and positively secured to maintain the alignment. Parts must not be forced into position to obtain apparent alignment.

e. Provide minimum bearing life in accordance with ASME hoist performance standards and MHI MH27.1 or CMAA 74, as applicable.

f. All "should" statements in CMAA 74, MHI MH27.1, and ASME B30 are considered to be "shall" statements.

2.3.1 Threaded Fasteners

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Fasten mechanical connections that are not part of a commercial packaged assembly with SAE J429 Grade 5 fasteners, ASTM F436/F436M washers, and SAE J995 Grade 5 nuts. Lubricate all mechanical fasteners unless otherwise specified by the original component manufacturer.

2.3.2 Hoist

Provide hoist conforming to ASME B30.16, except as modified and supplemented in this section. Packaged hoist and trolley units (packaged hoists) must be [electric chain hoist conforming to ASME HST-1] Duty Class [H3] or better and be rated for the operating environment.

Configure trolley such that the trolley frame contacts the trolley stops and prevents the trolley from dropping more than one inch in the event of an axle or wheel failure. Provide drop (safety) stops with contact surfaces of non-sparking materials. Metal to metal contact at the bumper to end stop connection is not permitted.

2.3.2.1 Hoist Brakes

a. Equip the hoist with two holding brakes, each with a minimum torque rating of 125 percent of the rated load hoisting torque. Provide a brake configuration with one electro-mechanical spring set brake and one mechanical load brake, or self-locking worm gear, that stops and holds 125 percent of the hoist's rated load and does not require the load to be raised before being lowered.

b. Electro-mechanical brakes must have an externally accessible means of manual release. Provide manual-adjusting brakes designed to permit inspection and adjustment without disassembly of the brake. The brakes must be equipped with a manual self-return to ON brake release;

maintained brake releases must reset when power is applied. Double face-mounted brakes are not permitted.

2.3.2.2 Load Block and Hook

a. Provide a load block constructed of steel. The load block must be designed to prevent metal-to-metal contact of moving parts. The design must preclude the load chain from being cut, pinched, crushed, or chafed in case of two-blocking. Standard commercial blocks may be used at their published ratings when their published design factors are 5.0 or greater.

b. Provide an unpainted and unplated forged carbon steel single barbed hook with a minimum material longitudinal elongation of 16 percent in 2 inches. Hooks must conform to the requirements of ASME B30.10.

The hook must be a standard commercial product with a published design factor of 5.0 or greater. Fit hook with a safety latch designed to preclude inadvertent displacement of slings from the hook saddle. The hook and hook nut must be removable without unreeving of the hoist. Provide hook nut secured to the hook with a commercial standard removable and reusable means. Do not weld hook nut. When provided, provide shank and nut threads with a Class 1 or 2 fit, per ASME B1.1. Uniquely mark the hook in a permanent fashion that is traceable to the NDT certification. The nut must be marked to match the hook. The hook nut must be of non-sparking materials. Hook must be free to rotate through 360 degrees when supporting the test load up to 125 percent of the rated capacity.

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2.3.3 Travel Drives

Provide under running travel assemblies with a minimum of one driven wheel on each side of the web and at least one quarter of all wheels driven.

The travel drive arrangement must consist of motor(s) driving through self-contained gear reduction units located at each driven wheel assembly. Gear reducers must be fully enclosed in an oil-tight housing and provided with a convenient means of lubricant level indication and draining. Open-type gearing is not acceptable, except for final drives.

2.3.3.1 Trolley Drives

Provide a motor-driven trolley arrangement. Acceleration and deceleration must meet the requirements specified in CMAA 70. Provide trolley travel limit switches.

2.3.3.2 Bridge Drives

Provide a motor-driven bridge arrangement. Acceleration and deceleration must meet the requirements specified in CMAA 74. Provide bridge travel limit switches.

2.3.3.2.1 Bridge Travel Gearing

Gearing must conform to ANSI/AGMA 2001 and AGMA 908, with internal and external gear dimensional tolerances conforming to the applicable AGMA standard for tooth geometry and tolerances.

2.3.3.2.1.1 Bridge Travel Reducer

Gear reducers must be standard commercial products designed, manufactured, and rated in accordance with ANSI/AGMA 6013. Provide cranes with a CMAA service class "C" or higher with the corresponding "Industrial Duty" service factors. The speed reducer input (high speed) gear set must use helical (including double helical and herringbone), spiral bevel, or worm gear tooth forms. Provide torque arms that are not of the threaded rod type. Operation must be smooth and quiet.

2.3.3.2.1.2 Bridge Open Gearing

Provide all gears and pinions with adequate strength and durability for the crane service class and manufactured to ANSI/AGMA 2015-1 Accuracy Grade A8 or better. Wherever feasible, open gears must be enclosed with safety guards provided with openings with covers for inspection and access for grease lubrication.

2.3.4 Travel Brakes

Provide travel drives with an end-mounted electro-mechanical spring set brake conforming to the requirements of CMAA 74 or non-freecoasting mechanical drive capable of stopping the motion of the travel function within a distance in feet equal to 10 percent of the full load speed in feet per minute when traveling at full speed with a full load.

Spring set brakes must be provided with an externally accessible means to manually release the brake. Provide manual-adjusting brakes designed to permit inspection and adjustment without disassembly of the brake. The brakes must be equipped with a manual self-return to ON brake release;

maintained brake releases must reset when power is applied. Double face-mounted brakes are not permitted.

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2.3.4.1 Trolley Brake

Provide brakes for underrunning trolleys/carriers sized in accordance with ASME B30.17, but not sized larger than 150 percent of the drive motor rated torque.

2.3.4.2 Bridge Brake

Provide brakes with a minimum torque rating per CMAA 74 according to the applicable environment, but not sized larger than 150 percent of the drive motor rated torque.

2.3.5 Wheels

a. Top running wheels are to be straight tread, double flanged, and sized in accordance with CMAA 74 recommendations for wheel sizing and flange to rail head clearances. Wheel material must be forged steel.

Provide wheels made from non-sparking material. Bronze wheels must have a minimum tread hardness of 225 BHN. Hollow stamped and gray cast iron wheels may not be used; the use of plate steel is prohibited. Provide steel wheels with a minimum tread hardness of 320

BHN.

b. Provide under running wheel sizing and flange-to-rail head clearances in accordance with MHI MH27.1 and CMAA 74 recommendations, as applicable. The wheels must be compatible with their respective runway profile. Wheel material is to be cast or forged steel, or ductile or malleable cast iron. Hollow stamped and gray cast iron wheels may not be used; the use of plate steel is prohibited. Minimum tread hardness for underhung wheels (non-bronze) that run on patented track is 375 BHN. Minimum tread hardness for wheels (non-bronze) running on structural shapes is 320 BHN.

2.3.6 Drip Pans

a. The crane must be designed to preclude leakage of lubricants onto the lifted loads or the floor. Equipment or components, which cannot be made leak-proof, must be fitted with unpainted corrosion resistant steel drip pans or must have the foundations seal welded to create a dam. Drip pans that utilize liquid sealant to prevent leakage of lubricants are not permitted.

b. The drip pans must be sized to hold the entire gear case fluid capacity, installed under all drive machinery, designed to permit easy removal of collected lubricant. A trolley floor designed to contain any lubricant drips may be used as fluid containment for any equipment that is mounted on it.

2.4 ELECTRICAL REQUIREMENTS

a. The design, selection, rating, and installation of the electrical portions of the crane and its accessories must conform to the requirements of NEMA ICS 3,NEMA ICS 8, the applicable ASME HST standard, and NFPA 70, and other requirements specified herein.

b. All electrical components must be industrial grade, commercially available and comply with established national or internationally recognized approving organizations such as Underwriters Laboratories (UL) and Canadian Standards Association (CSA).

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c. All electrical components must be located so they are easily accessible for inspection and maintenance without removing other parts, doors, or door center posts. Electrical equipment and panel wiring must be installed in a neat and workmanlike manner in accordance with Electrical Construction Standard NECA NEIS 1. Each motion of the crane must be provided with a separate control system or drive. The loss of any one function must not prevent the operation of other unaffected functions. Two independent relays, contactors, drive inputs, or other equivalent components/logic must be utilized for each function to provide directional control such that the failure of a single relay/contactor/component cannot result in motion in an unintended direction.

d. Disconnecting means for cranes must be in accordance with NFPA 70 Article 610.32. A permanent placard must be installed on the face of the main line disconnect that states "WARNING – THIS DOES NOT ISOLATE

POWER TO LIGHTING, RECEPTACLES, AND ANCILLARY EQUIPMENT".

Additionally, a lighting (ancillary equipment) disconnect must be provided, with lockout feature, as the isolation means for the lighting transformer and lighting circuit breaker panel, which must power the crane's ancillary equipment. It must feed [230/480] VAC to the primary side of the transformer directly from the runway conductors via tapping the line side of the main power disconnect.

Provide individual disconnects, with lockout feature, capable of being locked in the open position for bridge lights and receptacles.

e. Unless otherwise specified, interconnecting wiring must be of copper stranded construction complying with Table 310.104(A) of NFPA 70.

Interconnecting wiring containing asbestos in the insulation or outer covering are prohibited. Aluminum conductors must not be used.

Aluminum connectors are allowed if they are rated for use with copper conductors (marked "AL/CU"). All conductors connected to or routed above resistors must have insulation shown in NFPA 70 Table 610.14(a) for 125 degrees C 257 degrees F. For packaged hoists and hoist/trolleys, provide wiring sizes in accordance with NFPA 70 Table 610.14(a). Motor branch circuit conductors not part of a packaged hoist and hoist/trolley must be sized as to have an ampacity not less than 150 percent of the motor full load current rating and to be no smaller than 12 AWG. Conductors must be selected and de-rated based on maximum ambient temperature. Continuous loads such as utility, heating, lighting, and air conditioning must be multiplied by 2.25 to determine ampacity in order to permit application of NFPA 70 610.14

(A) for crane supply conductors. Wire-nuts are not permitted on splices. However, connections for lighting ballasts may be made using wire-nuts (if applicable).

f. Excluding conduit directly connected to dynamic breaking resistors, raceways must maintain a 12-inch clearance between the raceway and dynamic braking resistors. A separate grounding wire, sized in accordance with Section 250.122 of NFPA 70, must be routed with all ungrounded conductors. Only one equipment grounding conductor must be run in each conduit and be the largest size required for any circuit routed in that conduit. All wiring must be numbered or tagged at all connection points. Power conductors which are shielded such that their wire size cannot be easily determined must be labeled as to the conductor size. All unused conduit openings must be plugged.

g. When fiber optic cable is utilized, inspections and performance checks must be accomplished upon completion of on-site installation to ensure cable cleanliness and proper signal integrity. Testing and verification must be conducted by a knowledgeable fiber optics

SECTION 41 22 13.15 Page 22 technician using specialized, calibrated equipment. Cables must be tested for signal loss/attenuation. The fiber optic system must also be tested using an Optical Time Domain Reflectometer (OTDR). Final attenuation and OTDR readings from each fiber optic cable run, including spares, must be documented as a baseline for future reference. All spare fiber optic cables must have protective covers over their ends to maintain cleanliness while not in use. When fiber optic cable is utilized the drive OEM's recommendations for encoders and optical to digital converters must be followed. All system components utilized for this purpose must have known compatibility prior to integration.

h. Power cables and low voltage signal cables may not be mixed in the same conduit.

i. The crane manufacturer must furnish and install all electrical equipment on the crane conforming to NEMA ICS 6, including motors, conforming to NEMA MG 1, electrically released brakes, switches, crane controllers, panels, operating station, wiring system, cables, and crane electrification.

2.4.1 Motors

Motors must meet all applicable requirements of NEMA MG 1 and UL 1004-1.

CMAA 70 calculations for motor horsepower shall be used in selecting bridge, trolley, and hoist drive motors. All motors must have a minimum of a [60] minute duty rating and be Totally Enclosed Non Ventilated (TENV), Totally Enclosed Fan Cooled (TEFC), or Totally Enclosed Blower Cooled (TEBC). Provide inverter duty motors for Open Loop Variable Frequency Drives (VFD). Provide motors with a minimum of Class F insulation. Provide motor overload protection utilizing a thermal sensitive device embedded in its windings.

2.4.2 Controls

a. Provide static reversing, VFD, speed regulated, closed loop, flux vector electric controls for the bridge, trolley and hoist. For feedback, provide hoist motors with encoders. The hoist controller must enable the drive motor to develop full torque continuously at zero speed. The hoist secondary brake must be controlled separate from the primary and connected to different output (within the drive) from the primary brake. VFD controllers must meet NEMA ICS 8, Part 8 and at a minimum, provide under-voltage protection, electronic instantaneous over current protection, DC bus over voltage protection, and be able to withstand output line to line shorts without component failure. Select bridge and trolley drives such that the continuous rating of the controller is not less than the calculated motor full load current based on CMAA 70 paragraph

5.2.9.1.1.1 and NFPA 70 Table 430.250. Select hoist drives such that the continuous rating of the controller is not less than 125 percent of the calculated motor full load current based on CMAA 70 paragraph

5.2.9.1.1.1 and NFPA 70 Table 430.250. All hoist drives must have a motor over-torque limit to lock out the hoist and prevent gross overload of the associated hoist. Provide dynamic braking for each electric drive that is sized per VFD manufacturer's requirements.

Submit VFD Control Parameter Settings.

c. Provide speed control which is infinitely variable for each function, controlled via [pendant pushbutton…