SpecificationRev1.doc

USCG-ELC

MARINE CRANE AND HYDRAULIC SYSTEM PURCHASE SPECIFICATION FOR 400’ WAGB POLAR ICEBREAKERS

ELC-025-P-573-0518

REVISION No. 1 . CHANGE NO. .

MARINE CRANE AND HYDRAULIC SYSTEM PURCHASE SPECIFICATION FOR 400’ WAGB POLAR ICEBREAKERS P-573-0518 ORGINATED BY: ELC – 025, John Palmer

DATE (06/23/08).

Engineering Logistics Center, Equipment Management Division INTERNAL REVIEWERS: ELC – 025, Mark Tilyou

DATE

SOWRB APPROVAL . DATE .

TABLE OF CONTENTS

1MARINE CRANE AND HYDRAULIC SYSTEM PURCHASE SPECIFICATION FOR 400’ WAGB POLAR ICEBREAKERS

31.0

SCOPE

31.1

GENERAL

41.2

INITIAL INSTALLATION

42.0

APPLICABLE DOCUMENTS

42.1

ORDER OF PRECEDENCE

42.2

DOCUMENT AVAILABILITY

42.3

GOVERNMENT DOCUMENTS

72.4

COMMERCIAL DOCUMENTS

93.0

GENERAL MINIMUM REQUIREMENTS FOR MARINE CRANES

93.1

103.2

ENVIRONMENTAL CONDITIONS

123.3

FORWARD MARINE CRANE REQUIREMENTS

233.4

AFT MARINE CRANES REQUIREMENTS

333.5

HYDRAULIC SYSTEM REQUIREMENTS

533.6

INTEGRATED LOGISTICS SUPPORT (ILS)

583.7

TECHNICAL SUPPORT

634.0

QUALITY ASSURANCE AND WARRANTY

634.1

634.2

RECORDS/REPORTS

644.3

CALIBRATION SYSTEM

644.4

RESPONSIBILITY FOR INSPECTION

644.5

RESPONSIBILITY FOR COMPLIANCE

644.6

QUALITY ASSURANCE PLAN

645.0

PRESERVATION, MARKING AND PACKING

656.0

NOTES:

656.1

GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

1.0 SCOPE

1.1 GENERAL

This specification sets forth the minimum requirements for purchase of Marine Crane equipment for the US Coast Guard to install on the 400’ Polar Icebreaker (WAGB) class. The Coast Guard will be replacing the three existing Marine Cranes on each of these icebreakers with new cranes, consisting of one forward and two on the aft of the vessel.

The forward crane shall be capable of: (a) transferring 6,000 pounds (lbs.) of cargo from ship to shore at a reach of 60 feet, and (b) servicing a cargo hatch at a radius of 18 feet. The crane shall have a telescopic, extending, or knuckle boom configuration.

The aft cranes shall be capable of: (a) transferring 30,000 lbs. of cargo from ship to shore at a maximum reach of 70 feet; (b) launching and retrieving from the water a Landing Craft Vehicle Personnel (LCVP) that is 36 foot in length, 11 foot beam, and weighs 26,000 lbs. fully loaded from a radius of 25 feet; (c) launching and retrieving from the water an Arctic Survey Boat (ASB) that is 39 foot in length, 12 foot beam, and weighs 25,000 lbs. fully loaded from a radius of 27 feet; (d) servicing a flight deck hatch at a radius of 45 feet; and (e) servicing a storage container that is located on the starboard side of the vessel at a radius of 64 feet. The crane shall have a knuckle boom configuration which limits load pendulation by keeping the boom tip as close as possible to the load during lifting and slewing operations (level luffing).

All cranes shall be located in the same position as the current cranes. The cranes’ performance parameters shall be based upon operating within the constraints of these locations. It is highly recommended that the contractor perform a shipcheck of USCGC POLAR SEA (WAGB 11), prior to submission of bid.

In general the contractor shall be responsible for supplying:

· all related hardware and machinery up to the point that the supplied equipment are welded/bolted to the ships structure. This includes the control station pedestal, electric control panel, and hydraulic pump units.

· design drawings, information, and interface requirements for installation of the cranes, and identification of any currently installed equipment needed to be moved for the installation,

· logistics information and materials, and

· warranty, technical and training services.

The Contractor will not be responsible for the installation of the equipment. The installation contractor will provide connecting piping and hydraulic reservoirs.

1.2 INITIAL INSTALLATION

The Coast Guard intends to install one of the aft cranes first for evaluation prior to placing any optional orders. The contractor will not be responsible for installing the equipment but shall be responsible for commissioning, training, and technical assistance as detailed later herein.

The Coast Guard intends to replace the central hydraulic system on each vessel with new hydraulic power units (HPUs) and a central control panel, concurrent to or prior to replacement of the first crane on that vessel.

2.0 APPLICABLE DOCUMENTS

2.1 ORDER OF PRECEDENCE

The design and manufacture of the marine crane shall comply with all the government requirements in section 2.3 and shall comply with the requirements of the documents in section 2.4 where called out in the specification. In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence. The Contractor is required to notify the Contracting Officer in writing for a resolution of any ambiguity or conflict found in these specifications.

2.2 DOCUMENT AVAILABILITY

To obtain the referenced documents, see section 6.1. Unless otherwise indicated, copies of Department of Defense documents are available as stated in the solicitation/contract clauses stating availability of specifications and standards listed in the GSA Index of Federal Specifications, Standards and Commercial Item Descriptions and the DOD Index of Specifications and Standards (DODISS).

2.3 GOVERNMENT DOCUMENTS

The following documents form a part of this specification to the extent specified herein.

2.3.1 Coast Guard Documents

COMDINST M9085.1B, Naval Engineering Computer Aided Design Standards, 10/18/04.

COMDTINST M10360.3C, Coatings and Color Manual, 2005.

ELC-D-000-0100 G, Bar Coding for USCG ELC Material, 2/06.

ELC-D-083-0351, Data for Provisioning, 1/00.

ELC D-084-0481, Equipment Unit Preservation, Packaging and Marking Standard Requirements for USCG ELC Auxiliary Machinery Branch, 3/06

ELC D-085-0482, Drawings for USCG ELC Auxiliary Machinery Branch, 3/06

ELC D-086-0483, Technical Publications for USCG ELC Auxiliary Machinery Branch, 3/06

ELC D-086-0484, Preparation of Maintenance Procedure Cards for USCG ELC Auxiliary Machinery Branch, 3/06

FED-STD-595B Colors Used In Government Procurement, 1/94 MLCPAC S9PC0-AD-SIB-010-/PC-4, Section 507, Machinery and Piping Designation Marking USCG Drawing 400-WAGB-0103-3, Rev. N, Booklet of General Plans 1/8 Scale (POLAR STAR), 8/99 USCG Drawing 400-WAGB-0103-14, Rev. Q, Booklet of General Plans (POLAR SEA), 8/99

USCG Drawing 400-WAGB-0103-18, Rev. -, Science Facilities Booklet, 7/94

USCG Drawing 400-WAGB-1112-10, Rev. E, FDNS for DK Cranes, 10/75 USCG Drawing 400-WAGB-1112-28, Rev. T, Foundations Hyd Sys Pwr Room 1 & 2 & Sewage Treatment USCG Drawing 400-WAGB-2002-1, Rev. B, DK Cranes Arrg and Stowage Dets, 7/75 USCG Drawing 400-WAGB-2100-10, Rev. B, Central Hydraulic Piping Modification Arrangement and Det, 11/03

USCG Drawing 400-WAGB-2100-11, Rev. B, Central Hydraulic System Piping Modification Diagram, 11/03

USCG Drawing 400-WAGB-4800-5, Rev. AG, Arrgt of Hydraulic Piping in Power Rms, 3/03

USCG Drawing 400-WAGB-4800-10, Rev. U, Arr Hyd Interconnecting Piping FWD Fr 150, 4/76

USCG Drawing 400-WAGB-4800-16, Rev. V, Arr Hyd Interconnecting Piping Aft Fr 150, 2/78

USCG Drawing 400-WAGB-4800-18, Rev. E, Diagram Hydraulic Power System, 3/03 USCG ELC Maintenance Procedure Card (MPC) Word form “MPC Form.doc”.

USCG Technical Publication 4409 – Central Hydraulic System (being removed).

USCG Technical Publication 4414 – 15 Ton and 3 Ton Cranes (being removed).

USCG Technical Publication 4415 – Anchor Windlass System.

2.3.2 Military Specifications

MIL-STD-167-1, Mechanical Vibrations of Shipboard Equipment (Type I – Environmental and Type II – Internally Excited) MIL-STD-419D – Cleaning and Protecting Piping, Tubing, and Fittings for Hydraulic Power Transmission Equipment, 7/13/87.

MIL-STD-740-1 (SH), Airborne Sound Measurements and Acceptance Criteria of Shipboard Equipment MIL-STD-1310G, Shipboard bonding, grounding and Other Techniques for Electromagnetic Compatibility and Safety, 6/28/96.

MIL-STD-1399C Section 300A, Interface Standard for Shipboard Systems, Electric Power, Alternating Current, 02/02/88.

MIL-STD-1399C Section 301A, Interface Standard For Shipboard Systems Ship Motion And Attitude, 07/21/86

MIL-PRF-17672D, Specification for Hydraulic Fluid, Petroleum, inhibited, Amend. 3, 5/31/95.

MIL-PRF-18458C – Grease, Wire Rope, Type II, 5/30/07.

MIL-DTL-24643B – Cables and Cords, Electric, Low Smoke, for Shipboard Use, General Specification for, 8/22/02.

MIL-G-18997E(2), Gauge, Pressure, Dial Indicating, 3/14/06.

MIL-V-24695 - Valve, Hose Assembly and Adapter, Vent and Test, Hydraulic Service, General Specification for, 12/23/91.

MIL-V-81940/1B, Valve, Sampling And Bleed, Hydraulic, Type II Systems In/Lb

2.3.3 Other Government Documents

Code of Federal Regulations (CFR 46), U.S. Coast Guard, Subchapters F and J NAVSEA S9086-CM-STM-000, Naval Ships Technical Manual (NSTM), Chapter 078.

2.4 COMMERCIAL DOCUMENTS

2.4.1 American Gear Manufacturing Association (AGMA)

AGMA 6001-D97 (1997) - Design and Selection of Components for Enclosed Gear Drives.

AGMA 6010-F97 (2003) – Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives

AGMA 6023-A88 (2000), Design Manual for Enclosed Epicyclic Gear Drives

AGMA 9005-E02 (2002), Industrial Gear Lubrication

2.4.2 American Society for Quality (ASQ)

ANSI/ISO/ASQC Q9001- Quality Management Systems: Requirements, 2000.

ANSI/ISO/ASQC Q9002- Quality Systems – Model for Quality Assurance in Production, Installation, and Servicing, 1994.

ANSI/ISO/ASQC Q9003- Quality Systems – Model for Quality Assurance in Final Inspection and Test, 1994.

2.4.3 American Society for Testing and Materials (ASTM)

ASTM F 1166, Standard Practice for Human Engineering Design for Marine Systems, Equipment and Facilities, 2007.

ASTM F 1836M, Standard Specification for Stuffing Tubes, Nylon, and Packing Assemblies.

ASTM F 1837M, Standard Specification for Heat-Shrink Cable Entry Seals.

ASTM D-3951 – Standard for Commercial Packaging, 2004.

2.4.4 American Petroleum Institute (API)

API-2C Specification for Offshore Pedestal Mounted Cranes, 6th Ed., 2004

API-9A Specification for Wire Rope, 1995

2.4.5 American Welding Society (AWS)

AWS D1.1, Structural Welding Code, Steel, 2004.

AWS D1.2, Structural Welding Code, Aluminum, 2003.

AWS D1.6, Structural Welding Code, Stainless Steel, 2007.

2.4.6 Institute of Electrical and Electronic Engineers (IEEE)

IEEE Standard 45, Recommended Practice and Electrical Installation on Shipboard, 2002.

2.4.7 International Maritime Organization (IMO)

IMO International Life Saving Appliance (LSA) Code (2003).

2.4.8 International Standards Organization (ISO)

ISO 4406, Hydraulic Fluid Power-Fluids-Method for Coding the Level of Contamination by Solid Particles, 1999

ISO 7241 / 1 Series B, Quick Disconnect Couplings, 2001

2.4.9 National Electrical Manufacturers Association (NEMA)

NEMA MG1, Motors and Generators, 2007.

NEMA Standard 250– Enclosures for Electrical Equipment, 2003 NEMA Standard ICS-1– Industrial Control and Systems (series), 2005

2.4.10 National Conference of Standards Laboratories (NCSL)

NCSL Z540-1, Calibration Laboratories and Measuring and Test Equipment – General Requirements, 2004.

2.4.11 National Fluid Power Association (NFPA)

NFPA B93.92M / ISO 7181 Hydraulic Fluid Power, Cylinders, 160 bar, 1987 NFPA B93.106M / ISO 8136 Hydraulic Fluid Power - Single Rod Cylinders, 160 Bar, 1994

NFPA B93.107M / ISO 8137 – Hydraulic Fluid Power, Cylinders, 250 bar, 1994 NFPA T2.6.1 R2, Fluid power components – Method for verifying the fatigue and establishing the burst pressure ratings of the pressure containing envelope of a metal fluid power component, 2001.

NFPA T3.9.2 R3, Hydraulic fluid power – Positive displacement pumps and motors – Dimensions and identification code for mounting flanges and shaft ends, 1998.

NFPA T3.9.22 R2 – Fluid Power, Pressure Ratings for Pumps and Motors, 2005.

NFPA) T3.9.17 R2, Hydraulic fluid power – Positive displacement pumps, motors and integral transmissions – Method of testing and presenting basic performance data, 2004.

NFPA T-3.10.8.8 R1 / ISO 16889 – Fluid Power, Filter, Multi-pass Method for Evaluation, 1994

2.4.12 Society of Automotive Engineers (SAE) International, SAE J514, Hydraulic Tube Fittings, 2004.

SAE J518, Hydraulic Flanged Tube, Pipe, and Hose Connections, Four-Bolt Split Flange Type, 1993.

SAE J1273, Recommended Practices for Hydraulic Hose Assemblies, 2004.

SAE J1475, Hydraulic Hose Fittings for Marine Applications, 2004.

SAE H1086, Metals and Alloys in the Unified Numbering System, 2004

SAE-J1780, Hydraulic System Diagrams and Associated Tables for Marine Vehicles, 1991

SAE-J1782, Noise Control in Fluid Power System of Marine Vehicles, 2006 SAE-J1942, Hose and Hose Assemblies for Marine Applications, 2007 SAE-J1942-1, Qualified Hoses for Marine Applications, 2005.

SAE J2321, Ship Systems and Equipment – General Specification for Filter Elements – Hydraulic and Lube Oil Service, 2002

SAE J2333, Ship Systems and Equipment – Filter Selection Parameters, 2004 SAE - AMS 7259, Rings, Sealing, Fluorocarbon (FKM) Rubber, High-Temperature-Fluid Resistant, Low Compression, Set 85-90, 2001.

SAE - AMS 7276, Rings, Sealing, Fluorocarbon (FKM) Rubber, High-Temperature-Fluid Resistant, Low Compression, Set 70-80, 2001.

3.0 GENERAL MINIMUM REQUIREMENTS FOR MARINE CRANES

3.1 GENERAL

3.1.1 Equipment Procurement

The contractor shall provide all labor and material to provide Marine Crane equipment for the US Coast Guard to install on the 400’ Polar Icebreaker (WAGB) class. Any materials and components sub-contracted for shall be the responsibility of the contractor. The marine crane systems shall be provided as factory assembled and tested systems. The government will install this crane under a separate contract.

The following drawings provide guidance into the available location for each crane, the installation location and the existing system as guidance:

USCG Drawing 400-WAGB-0103-3, Rev. N, Booklet of General Plans 1/8 Scale (POLAR STAR)

USCG Drawing 400-WAGB-0103-14, Rev. Q, Booklet of General Plans (POLAR SEA)

USCG Drawing 400-WAGB-0103-18, Rev. -, Science Facilities Booklet

3.2 ENVIRONMENTAL CONDITIONS

3.2.1 Ship Motions

3.2.1.1. Forward Crane

The forward crane shall be designed to withstand the following survival accelerations interface data per MilStd 1399 301A while in the stowed position on a 400 ft WAGB icebreaker in marine Sea State 8 environmental conditions:

Acceleration Factor Magnitude Direction

Ax

1.362g

Parallel to centerplane

Ay

1.888g

Perpendicular to centerplane

Az

3.407g

Perpendicular to baseplane

The contractor shall be responsible to provide with the system any stowage brackets needed for support of the crane in order to meet the above requirements and to include the necessary bracket placement in their recommended installation sketch. The above values are based upon the crane in the stowed position with its center of gravity assumed to be at:

Longitudinal = Fr 28

Transverse =

0 ft

Vertical =

69 ft

The crane shall be designed to transfer cargo in marine Sea State 3 environmental conditions. The following operational interface acceleration data has been calculated for the extended crane head on a 400 ft WAGB icebreaker and shall be considered in the design of the crane. Boom tip is kept near the minimum height.

Acceleration Factor Magnitude Direction

Ax

0.152g

Parallel to centerplane Ay

0.263g

Perpendicular to centerplane Az

1.369g

The above values are based upon the crane at the cargo transfer position with the boom tip assumed to be at:

Fr 43

Transverse =

60 ft Port or Starboard

Vertical =

66.75 ft

3.2.1.2. Aft Cranes

The aft cranes shall be designed to withstand the following survival accelerations interface data per MilStd 1399 301A while in the stowed position on a 400 ft WAGB icebreaker in marine Sea State 8 environmental conditions:

Acceleration Factor Magnitude Direction

Ax

1.207g

Parallel to centerplane

Ay

1.756g

Perpendicular to centerplane

Az

3.116g

The contractor shall be responsible to provide with the system any stowage brackets needed for support of the crane in order to meet the above requirements and to include the necessary bracket placement in their recommended installation sketch. The above values are based upon the cranes in the stowed position with their centers of gravity assumed to be at:

Fr 202

29.5 ft Port and Starboard

64 ft

The crane shall be designed to transfer cargo and launch and retrieve the cutter boats in marine Sea State 3 environmental conditions. The following operational interface acceleration data has been calculated for the extended crane head on a 400 ft WAGB icebreaker and shall be considered in the design of the crane. Boom tip is kept near the minimum height.

Acceleration Factor Magnitude Direction

Ax

0.154g

Parallel to centerplane

Ay

0.236g

Perpendicular to centerplane

Az

1.314g

The above values are based upon the crane at the cargo transfer position with the boom tips assumed to be at:

Fr 194

70 ft Port and Starboard

67.75 ft

3.2.2 Temperature Limits.

The cranes shall withstand, in the stowed position, continuous exposure to weather, salt, spray, winds, and extreme icy conditions. The cranes shall be designed to operate at rated load and speed at a temperature of -20 degrees F and a concurrent sea state of 3 and wind velocity of 40 knots, and shall be operable at reduced ratings (not less than 2/3), at a temperature of -50 degrees and a wind velocity of 70 knots. The cranes’ control and drive systems shall be of a design with proven reliability for use in arctic or Antarctic marine operating environments. Systems shall operate in all conditions spanning relative humidity of 100 percent to icing on exposed surfaces. Surfaces subject to ultra violet ray (sunlight) degradation shall be UV protected.

For the aft cranes, the hydraulic power units and motor controllers shall be suitable for installation in the Hydraulic System Power Room No. 2 (3-143-5-Q). This compartment is naturally vented, heated, and currently contains electro-hydraulic equipment for the anchor windlasses and existing cranes. The compartment temperature reaches 135 degrees F with 100% humidity in the summer, and can reach 40 degrees F in the winter.

For the forward crane (and anchor windlasses), the hydraulic power units and motor controllers shall be suitable for installation in the Deck Gear Storeroom (2-E-0-A). This compartment is naturally vented and heated. The compartment temperature can reach 135 degrees F with 100% humidity in the summer, and can reach 40 degrees F in the winter.

3.2.3 List and Trim

The crane shall be designed to perform all functions at Safe Working Load (SWL) against a permanent list of 15 degrees and permanent trim of 10 degrees.

In a stowed condition, the cranes shall survive the cutter rolling 45 degrees – single amplitude and pitching 15 degrees single amplitude, which may occur simultaneously.

3.3 FORWARD MARINE CRANE REQUIREMENTS

3.3.1 Certification.

The crane shall be certified to API Specification 2C under the Minimum Purchaser-Defined Requirements sheet, Attachment 4, and as further detailed herein (Should the contractor consider there is any disagreement between that document and this specification they should contact the Contracting Officer for clarification, it is intended to be a restatement of these specifications). It shall have a Safe Working Load (SWL) of 6,000 lbs. in all positions. There are several lifting cases which shall be met, each of which could be a limiting factor in the design of the crane.

Lifting cases which must be met are:

· The longest reach with cargo (6,000 lbs) suspended is 60 feet, perpendicular to the centerline of the cutter.

· The minimum lift radius of the crane shall be at most 18 feet to the pick point of the cargo hatch located on deck.

The marine crane system shall not be rated for handling of personnel within the context of API-2C.

The Contractor shall prepare calculations to document compliance with API-2C and other equipment performance requirements herein and include same in the Design and Interface Report required by 3.6.1. In the calculation of structural and mechanical loads and stresses, see 3.2.1 Ship Motions.

3.3.2 Crane System Layout and Design

The crane shall be a knuckle, telescopic or extending boom style configuration. The location of the crane machinery shall be in the same location as the existing crane as referenced in USCG Drawings 400-WAGB-103-3, Booklet of General Plans 1/8 Scale (POLAR STAR) and 400-WAGB-103-14, Booklet of General Plans (POLAR SEA). The crane shall be designed so that it can be removed from the pedestal bearing for overhaul. The hydraulic power unit(s) and motor controllers (which will also power the anchor windlasses) shall fit within the deck space in the Deck Gear Storeroom (2-E-0-A). No modifications to the ship’s structure by the Coast Guard are intended other than removal of the existing crane equipment, strengthening of the existing deck structure to carry any additional weight if needed, and physical attachment of the new crane assemblies to the ship’s deck. Materials for the structure of the crane shall be identified in accordance with SAE-H1086 nomenclature.

The crane machinery shall be stowed in the folded (or knuckled) under position (for knuckle boom style) or in the retracted position (for the extending or telescopic style). No control cab shall be provided. The control station shall be installed inside of a weather tight enclosure with a weather tight cover that is attached to the crane base at a level accessible from the weather deck. The crane control and safety components shall be protected from the weather and from accumulation of ice and salt.

Structural interferences require the HPU reservoirs to be fabricated on-site, in situ, by the installing activity. The contractor shall design the reservoir, and provide drawings and instructions suitable for the government to contract for its fabrication. The contractor shall provide all HPU and reservoir accessory devices, for installation by the installing activity.

The installing activity shall be responsible for the installation of all piping and control wiring between the HPUs and cranes and shall provide all cut-out and damage control valves in the piping. The contractor shall provide all control valves.

A crane rest device, if provided, shall support the crane under equipment survival conditions. The rest shall be padded to permit relative movement between the ship structure and crane without damage. The rest shall not interfere with crane operations.

The crane shall have provisions for protected storage during periods of transit. The crane will be subject to severe icing conditions and green water spray.

3.3.3 Markings

The equipment to be delivered under this contract shall be clearly marked at the subassembly level with nameplates. These plates are to be manufactured to best commercial practice, stainless steel, and contain (at a minimum) sub-assembly name, contract number, date of manufacture, and contractor assigned crane unit serial number physically imprinted (vice only using paint or ink). In addition, nameplates shall be provided on the crane body with Working Load Limit (WLL), brake test load (designated in paragraph 3.3.12.2) and the dynamic test load (designated in paragraph 3.3.12.2) physically imprinted. In addition to the above requirements, an additional nameplate containing the Contractor’s name and address shall be permanently affixed to the crane boom pedestal. The plates shall be permanently affixed to their respective sub-assemblies in a position that is clearly visible after the crane is installed.

3.3.4 Hoisting, Lowering, and Slewing.

The crane shall be able to lift a load of cargo from the deck level, slew over the side of the vessel and lower the load to the pier and perform the same in reverse. The crane does not need the capability to slew 360 degrees. Due to the crane’s proximity to the bridge superstructure, the crane shall be limited to a slewing radius of 200 degrees (100 degrees port and starboard of the vessel centerline).

The control system shall be capable of supporting two simultaneous functions (i.e., hoisting and slewing) at rated load and speed. The crane shall be capable of operating at nominal slewing and hoisting speeds of 1 RPM and 100 ft/min respectively.

The crane shall be capable of extending or retracting between the minimum and maximum working radii within 60 seconds.

3.3.5 Control Station

A crane control cab mounted on the crane shall not be provided. A control station shall be provided for installation on the crane pedestal at a level accessible from the weather deck. The control station shall be installed in a watertight enclosure with a watertight cover. A tethered chestpack control shall also be provided to be plugged into the control station, giving the ability of a standing operator to observe the weather deck, full movement of the crane, and the position of the cargo load over the side of the vessel. All elements in the station shall be electrical; no hydraulic components shall be included in the control stand. ASTM F 1166, Standard Practice for Human Engineering Design for Marine Systems, Equipment and Facilities, 2007 shall be considered in the design of the operator’s control station.

The fixed control station shall provide visual indication that electric/control power is available to the control station, digital indication of hydraulic power available, digital indication of fluid temperature, and an Emergency Stop switch. HPU control shall not be provided in the weather.

The control station shall provide audible and visual indication that an alarm condition has occurred; the audible indication shall have a temporary silencing feature. A space reservation 4 inches by 4 inches by 4 inches deep shall be provided in the control station panel for field installation of sound power telephone connections within the protected area. The fixed control station shall have a marine grade plug system for the tethered controls.

The fixed control station shall provide on/off and dimming control of the white and blue floodlights on the crane, and both white and blue lighting on the console. The capability to dim digital display devices shall be provided.

A tethered chest pack control unit shall be provided for routine operation of the crane. The chest pack shall have finger function control switches for crane functions (lift, slew, articulation, extension) arranged in accordance with API-2C requirements. The controls shall be arranged with a hand rest/protective bar on which to rest the hands during operation, and to prevent inadvertent operation of the switches. The chest pack shall also have an Emergency Stop switch and digital readout of the hook load. A hook system shall provide temporary stowage on the crane column. The chest pack shall be unplugged for inside stowage when not in use. The chest pack and harness support system shall be suitable for use over cold weather clothing.

The console shall have flight operations compliant lighting provision; console lighting shall be able to be made to not interfere with night vision goggles. This shall include a switch or switches to select console light on, off, white or night vision goggle compliant blue, to adjust brightness of the control station console lighting and an on/off switch for the white floodlight. Any electronic controls beyond the switches, gauges, alarms and lights above shall be installed below decks in a NEMA 12 enclosure, in accordance with NEMA 250.

The enclosure for the control panel for the crane shall be weather tight and shall have a hinged, 316 stainless steel weather tight cover, which shall further protect the exposed control console switches, handles and working components from the weather when the console is not in use. All cable penetrations to the control panel shall be run through the deck within the watertight base of the console or crane. The console shall allow for access to all controls for maintenance or replacement. When opened for use, the cover shall hinge out of the way, latch fully open or in a position to shade the panel from direct sunlight, and shall be prevented from accidental closure from seaway motions. When closed the cover shall be secured by a latch.

3.3.6 Hook

The hook block and load hook shall be conform to API 2C, section 7.5.

3.3.7 Winch and Rigging

3.3.7.1. Winch -

Winch drum shall have a D:d ratio of not less than 18:1 per API 2C, section 8.1.2.1. The winch shall stow the working portion of the wire rope in no more than 3 layers of wire on the drum. The drum shall be fitted with a LeBustm grooved sleeve. The winch shall be fitted with a spring set hydraulic drum release system rated for at least 150% of the WLL of the crane. Provision shall be made for the change of lubricant with minimal spillage or clean-up. The winch shall be underslung on the crane boom for protection for the weather.

A secondary or auxiliary winch is not required.

3.3.7.2. Sheaves

Sheave assemblies shall meet API-2C, section 7.4. Sheave pin assemblies shall be stainless steel, and shall incorporate stainless steel grease fittings and internal grease distribution paths positioned so that all pins can be easily lubricated by personnel standing on a deck, platform or access ladder. The crane head sheave or crane head shall pivot or flag not less than 30 degrees to the left and right of vertical to the boom tip, to permit the wire rope to trail up to 30 degrees forward or aft of vertical.

3.3.7.3. Wire

Wire rope shall meet the requirements of API-2C, section 7.2 and API-9A, except that galvanized or stainless steel wire shall not be provided. The wire shall be fitted with a closed swaged socket eye similar to Crosby Group S502 series or equal. The use of “field attachable” poured socket fittings will be permitted for repairs only. Sufficient wire rope shall be provided on the winch to fully extend the boom, slew athwartships and luff so that the wire rope is against the hull. The hook shall reach the keel line of the cutter, with at least 3 wraps of wire rope remaining on the drum, plus an additional re-termination allowance of 20 feet. Wire shall be pressure lubricated after assembly with MIL-PRF-18458 wire rope lubricant, with particular attention to lubrication of the wire rope in way of the swaged fitting. To ensure sufficient lubricant in the fitting area, supplementary aerosol type lubricants can to be used in this area only. The wire rope and attached closed swaged socket shall be pull tested to twice the rated breaking strength of the weakest link after assembly, assuming a design factor of safety of at least 6.0, and provided with a certificate of pull test. The certificate shall be attached to the wire rope.

3.3.7.4. Anti-Two-Block

The crane shall be fitted with an anti-two-block mechanism to prevent the wire rope and end fittings from being drawn into contact with the load sheave in any working position, from rated speed. The anti-two-block device shall be fail safe, and shall utilize a proximity switch or transducer-based switch system. When the system is triggered, crane functions which would reduce the effective wire length shall be blocked. Crane functions which would extend the effective wire length shall not be impeded. The system shall self-reset upon removal of the interference. In the Level-Luffing mode, the winch shall automatically pay out sufficient for the crane to continue operation without interruption from the anti-two-block device.

3.3.7.5. Load Management System

The main and auxiliary rigging systems shall be fitted with load cells and a digital display system. The load cell range shall be to 200% of the rated load. The system shall have an adjustable alarm feature set to alarm at 125% of the rated load and an electronic averaging feature to display the average load at one second intervals. Use of wireless radio frequency based components will require submission of frequency spectrum data and approval by USCG-HQ prior to use. Failure of such devices shall cause the crane to be non-operable.

3.3.8 Rotation Bearing

The rotation bearing shall be bolted to both the mounting flange on the crane column, and to the marine crane flange. The equipment shall be arranged to permit easy access to all bearing bolting for torque validation. The bearing shall be provided with multiple grease fittings to ensure complete lubrication can be accomplished without excessive rotation.

3.3.9 Pins And Fasteners

All bearing pins shall be of a 316 Grade Stainless Steel, and shall be fitted with stainless steel zirc fittings and grease distribution grooves.

All bolts used for mounting of the crane to the vessel shall be provided with the crane.

All non-load bearing fasteners, bolts, nuts and hardware shall meet minimum requirements of Grade 316 Stainless Steel.

3.3.10 Emergency Operation Upon Loss of Electric Power or Hydraulic Pressure.

Provision shall be made for manual cranking of the lift winch. A removable hand crank shall be provided and a bracket shall be installed for stowage of the hand crank when not in use. An extension socket shall be provided so that the manual crank drive may also be powered by a cutter’s ½ inch drive pneumatic wrench. The hydraulics shall have a manual release to release the brakes securing the crane from slewing motion and to lower the load from the slewed position. A portable hand pump shall be provided to power the brake release and the slewing motor in an emergency. The hand pump shall be removable via a quick disconnect fitting for stowage out of the weather.

3.3.11 Electrical

Electric motors and associated equipment shall meet the design, performance, application and installation requirements of IEEE-STD-45, 46 CFR, Subchapter J, and National Electric Manufacturer's Association (NEMA) standards MG1 and ICS. Current carrying elements of motors shall not be made of aluminum.

All motors shall be equipped with anti-condensation heaters and factory-sealed pre-lubricated bearings. All motors shall be rated for continuous duty. The motor for the HPUs shall have a soft start feature. The motor shall be located below decks and shall be rated for 90 degrees F temperature rise.

The crane system shall be designed to operate on 450vac, 3phase, 60Hertz, ungrounded ship service power. Electrical equipment shall operate on an ungrounded electrical system.

The Cutter's ship service distribution system maintains the system characteristics of Type 1 power as defined in MIL-STD-1399, Section 300A. The Crane system shall operate within the constraints specified by this standard.

Exterior connection boxes and wiring fittings shall be made of brass or bronze. Fasteners such as bolts, nuts and pins shall be the same material as the connection box.

Equipment bonding and grounding shall be provided in accordance with MIL-STD-1310G.

Motor control circuits shall operate on 120 volts or less and power for motor control circuits shall be obtained from control transformers integral to the motor controllers.

Motor control circuits shall be designed so that any grounding in the control or power circuits will not start the motor or by-pass any shutdown provisions.

All power and control cables shall be installed from the bottom of the controllers or junction boxes. Cable penetrations exposed to the weather shall be waterproof per NEMA standards. Electrical cabling exposed to possible damage shall be protected in conduit per IEEE-STD-45, 2002, 25.4 Cable protection.

The crane arm shall have a 200 watt white flood light and a 200 watt light with a blue lens to illuminate the cargo load during night operations. Lights shall be gimbaled or otherwise made to direct downwards from any crane arm aspect and shall be made to be manually adjustable by the ship’s crew. The lights shall be operated from a power switch on the operator’s console to select Off, Blue light, or White light, and shall have a dimming feature.

All controller panels shall be NEMA Standard 250 Type 4X and shall be fitted with stainless steel latching devices.

All indicator lights shall be able to be dimmed. One dimming control located on the operator’s console shall be provided to facilitate dimming all indicator lights.

Any electrical equipment located on the weather deck or exposed to severe moisture and icing conditions shall be watertight. Any motors located on deck or exposed to the weather shall be Totally Enclosed Fan Cooled (TEFC). All interconnection cable on the boat crane shall meet MIL-C-24643, including watertight rating.

3.3.12 System Test Requirements.

The contractor shall notify the contracting officer (KO) of all tests at least 14 calendar days prior to the event. The Coast Guard reserves the right to witness any or all of these tests. The contractor shall retain records of all tests and submit them to the contracting officer. A report on the following tests shall be submitted which shall include description of test setup and procedure, photographs from two adjacent sides, documentation of weights used, logs of times for start and finish and any measurements taken during the test. Testing shall meet the requirements as identified below, based on the required WLL.

3.3.12.1. First Article Testing

The following tests shall be performed on the first crane constructed under this contract in addition to the other Factory Testing listed below. During the first article testing, the crane system shall not require adjustment or biasing of pressure settings or control limits and the system shall not operate in an overload condition.

a. Tilting Platform Test: While the crane is mounted on a tilting platform simulating the crane mounted in its normal aspect on the cutter with the cutter heeled 15 degrees to port and 10 degree trim the cranes shall demonstrate full operation to lift, slew, lower, hold, and launch the full WLL, and perform all those functions in reverse. Performing this at rated speeds is not required however movements shall be at no less than half the rated speeds.

b. Static load test: External application of 220% of WLL at a 5 degree aft angle to the crane arm and holding the weight for 5 minutes. Deflection measurements (forward, vertical, and horizontal) shall be recorded. Upon release, the crane shall return to the original position with no permanent deformities or deflection.

In the event of significant modifications to the structural or mechanical elements over the life of the contract the Coast Guard may require new First Article testing as above.

3.3.12.2. Factory Testing

Factory testing shall apply to all units manufactured. During the factory testing, the crane system shall not require adjustment or biasing of pressure settings or control limits and the system shall not operate in an overload condition. The manufacturer shall include a table of calculated cable drum revolutions per minute for the winch to equate to hoist speeds as part of the required test plan. In addition to the operational tests indicated in API 2C, section 6.3, the following tests shall be performed:

a. Operational test: Conduct operational test of the crane with no load on the crane, luff boom from lowest level to full height and return. Slew crane from positive stop to positive stop. Lower and raise hook until the two block alarm sounds.

b. Brake test: Conduct by limited lifting (grunt) of a weight equivalent to 150% of WLL to a height sufficient to complete the test, stopping with the brake holding the load, allowing a controlled release of the brake load, brief freefall of about 10 feet, and resetting the brake. The load shall be stopped in a distance of no more than 3 feet after resetting the brake. There is no specified speed for this test.

c. Dynamic test: Conduct by lifting 125% of WLL, and breasting and slewing the load over the entire range of motion of the crane. Speeds shall be not less than one half of the rated speed.

d. Slewing speed test: At WLL, record luffing speeds over the full range of movement in both directions using normal operating parameters. The crane shall slew in its normal operation range at a nominal rate of 1 rpm (minimum 0.95 rpm).

e. Extension/ luffing test: The crane shall be capable of moving the hook from minimum working radius position with the crane boom extensions (if applicable) fully retracted, to the maximum working radius position within a nominal 60 seconds (maximum 65 seconds).

f. Luffing creep test: Under static load of 100% of WLL hydraulic cylinders shall have a measured drift tolerance or creep not exceeding .25 inch (6.35 mm) in 2 hours.

g. Emergency hand hoisting: At 110% WLL; the hand hoist shall be operated to demonstrate the ability to hoist the load.

h. Winch hoist test: With WLL suspended; demonstrate variable speed, measure and record fast and slow hoist under power. Minimum fast hoist speed shall be 100 ft/min.

i. Hydrostatic test: The hydraulic system shall be hydrostatically tested at 150% of working pressure for 5 minutes in each direction. The system shall be examined for leaks including all flexible hoses, fittings, tubing, cylinders, and power pack.

j. Hydraulic oil analysis test: An oil sample shall be taken at the completion of testing and shall meet the requirements established IAW section 3.5.2.1 of this specification.

k. Motors and Controllers: These tests shall be performed in accordance with the requirements of IEEE-STD-45. All electrical components shall pass an operational test.

l. Motors and Pumps: Motors and pumps shall be bench tested for at least 30 minutes in no flow conditions and at least 30 minutes in variable flow conditions. Pump heaters and controllers shall not overheat.

3.3.12.3. Installation Testing

The installing activity may request the contractor to provide technical services for shipboard testing of each crane system provided to the Coast Guard. The installation activity will provide the labor and equipment for these tests. Tests will consist of Routine Service Life Tests and demonstration of full operation of the unit. This testing shall be completed as a part of the Commissioning Services under paragraph 3.7.5.

3.3.12.4. Routine Service Life Testing

Over the service life of the cutter, the Coast Guard intends to perform operational tests on a routine basis in order to ensure continued equipment operability. The crane design shall provide the cutter the ability to perform the following self-tests, without adjustment or biasing of pressure settings or control limits, and without systems operating in an overload condition:

m. Brake test: Conduct by limited lifting of a weight equivalent to 150% of WLL, holding the load and a controlled release of the load.

n. Dynamic test: Conduct by lifting 125% of WLL, and lifting and breasting the load over the entire range of motion of the crane.

3.3.12.5. Resistance to Marine Environment.

The crane system shall be preserved per Commandant Instruction M10360.3C, Coatings And Color Manual, Appendix A, under 'Machinery, Deck' Option II that requires a Zinc Rich Primer, Epoxy MidCoat, and Polysiloxane topcoat (Note that due to a recent change in M10360.3C, App C, Para E. CG Approved Coatings/Materials, the International brand polysiloxane system using Interfine 979 is no longer permitted). The topcoat color shall be Spar, FED-STD-595B color # 10371.

All purchased, factory pre-painted components for installation on the weather deck, shall be recoated per M10360.3C above unless the original coating treatment is specifically accepted by the Contracting Officer in advance. Component factory grade enamel paint systems are not acceptable.

Wear surfaces such as winch drums shall be coated with Inorganic Zinc primer as defined in M10360.3C, Appendix C.

All exposed metal surfaces shall be made of 316 Grade Stainless Steel material or otherwise coated in a manner to prevent corrosion from a saltwater environment.

3.4 AFT MARINE CRANES REQUIREMENTS

3.4.1 Certification.

The cranes shall be certified to API Specification 2C under the Minimum Purchaser-Defined Requirements sheet, Attachment 4, and as further detailed herein (Should the contractor consider there is any disagreement between that document and this specification they should contact the Contracting Officer for clarification, it is intended to be a restatement of these specifications). It shall have a Safe Working Load (SWL) of 30,000 lbs. in all positions There are several lifting cases which shall be met, each of which could be a limiting factor in the design of the crane.

Lifting cases which must be met are:

· The longest reach with break bulk or containerized cargo (30,000 lbs) suspended is 70 feet.

· The pick point radius with the Landing Craft Vehicle Personnel (LCVP) (26,000 lbs) suspended is 25 feet.

· The pick point radius with the Arctic Survey Boat (ASB) (25,000 lbs) suspended is 27 feet.

· The minimum lift radius of the cranes shall be at most 25 feet to the pick point of the LCVP located on deck.

The marine crane system shall not be rated for handling of personnel within the context of API-2C.

The Contractor shall prepare calculations to document compliance with API-2C and other equipment performance requirements herein and include same in the Design and Interface Report required by 3.6.1. In the calculation of structural and mechanical loads and stresses, see 3.2.1 Ship Motions.

3.4.2 Crane System Layout and Design

The crane shall be a knuckle boom configuration. The location of the crane machinery shall be in the same location as the existing crane as referenced in USCG Drawings 400-WAGB-103-3, Booklet of General Plans 1/8 Scale (POLAR STAR) and 400-WAGB-103-14, Booklet of General Plans (POLAR SEA). The crane shall be designed so that it can be removed from the pedestal bearing for overhaul. The hydraulic power units and motor controllers shall fit within the deck space in the Hydraulic System Power Room No. 2 (3-143-5-Q). The Hydraulic System Power Room No. 2 is currently occupied by the hydraulic power units and reservoir for the existing centralized hydraulic system. No modifications to the ship’s structure by the Coast Guard are intended other than removal of the existing crane equipment, strengthening of the existing deck structure to carry any additional weight if needed, and physical attachment of the new crane assemblies to the ship’s deck. Materials for the structure of the crane shall be identified in accordance with SAE-H1086 nomenclature.

The crane control and safety components shall be protected from the weather and from accumulation of ice and salt.

Structural interferences require the HPU reservoirs to be fabricated on-site, in-situ, by the Installing Activity. The contractor shall design the reservoir, and provide drawings and instructions suitable for the government to contract for its fabrication. The Contractor shall provide all HPU and reservoir accessory devices, for installation by the Installing Activity.

The Installing Activity shall be responsible for the installation of all piping and control wiring between the HPUs and cranes. The Installing Activity shall provide all cut-out and damage control valves in the piping. The Contractor shall provide all control valves.

The existing fixed boom cranes have crane rests on the top of the helicopter hangar. The crane machinery shall be stowed in the folded (or knuckled) under position. Crane rest devices, if required and provided for the new cranes, shall support the cranes under equipment survival conditions. The rests shall be padded to permit relative movement between the ship structure and crane without damage.

The crane shall have provisions for protected storage during periods of transit. The crane will be subject to severe icing conditions in an arctic environment.

3.4.3 Markings

The equipment to be delivered under this contract shall be clearly marked at the subassembly level with nameplates. These plates are to be manufactured to best commercial practice, stainless steel, and contain (at a minimum) sub-assembly name, contract number, date of manufacture, and contractor assigned crane unit serial number physically imprinted (vice only using paint or ink). In addition, nameplates shall be provided on the crane body with the Working Load Limit, brake test load (designated in paragraph 3.4.12.2) and the dynamic test load (designated in paragraph 3.4.12.2) physically imprinted. In addition to the above requirements, an additional nameplate containing the Contractor’s name and address shall be permanently affixed to the crane boom pedestal. The plates shall be permanently affixed to their respective sub-assemblies in a position that is clearly visible after the crane is installed.

3.4.4 Hoisting, Lowering. And Slewing.

The cranes shall be able to lift a load of cargo from the deck level or in the aft cargo hold, slew over the side of the vessel and lower the load to the pier and perform the same in reverse. The cranes shall be able to launch and retrieve from the water, a LCVP (on the port side) and an ASB (on the starboard side). The cranes shall also be able to service a cargo hatch on the flight deck and a storage container that is located on the starboard side of the vessel.

The cranes do not need the capability to slew 360 degrees. Due to the proximity to the helicopter hangar, each aft crane shall be limited to a slewing radius of 270 degrees (from the pointing forward position, slewed out over the side of the vessel, back toward the centerline of the vessel).

The control system shall be capable of supporting two simultaneous functions (i.e., hoisting and slewing) at rated load and speed. The crane shall be capable of operating at nominal slewing and hoisting speeds of 1 RPM and 100 ft/min respectively.

The crane shall be capable of extending or retracting between the minimum and maximum working radii within 60 seconds.

3.4.5 Control Cab

A weather tight control cab shall be provided on a platform alongside the turret at a height off of the deck that allows the operator to observe the flight deck, full movement of the crane, and the position of the load (cargo, LCVP, ASB, etc) over the deck or side of the vessel. All electrical and mechanical operating controls shall be housed inside.