Attachment 1 Crane Spec.doc

USCG-SFLC

BOAT HANDLING SYSTEM FOR 418’ WMSL CUTTERS

P-583-0627

REVISION No. 0 . CHANGE NO. 0 .

Attachment 1

AFT BOAT HANDLING SYSTEM

FOR 418’ WMSL CUTTERS

P-583-0627 ORIGINATED BY: Brian Beverly, Alion

DATE: 03/14/12

Surface Forces Logistics Center, Engineering Support Division INTERNAL REVIEWER: Mark Tilyou DATE: 03/14/12

PRODUCT LINE APPROVAL: Tim Robinson DATE: 03/16/12 .

TABLE OF CONTENTS

BOAT HANDLING SYSTEM 1FOR 418’ WMSL CUTTERS

31.0

SCOPE

2.0

APPLICABLE DOCUMENTS

3.0

GENERAL MINIMUM REQUIREMENTS FOR MARINE CRANES

4.0

QUALITY ASSURANCE AND SYSTEM TEST REQUIREMENTS

5.0

PRESERVATION, MARKING AND PACKING

6.0

NOTES

FIGURES

1.0 SCOPE

1.1 PURPOSE – This specification sets forth the minimum requirements for purchase of Marine Crane equipment for the U.S. Coast Guard to install on the 418 ft WMSL cutter class. The Coast Guard will be replacing the existing gantry crane system on each of these cutters with new cranes to transfer boats launched and recovered from the centerline stern notch to cradle systems port and starboard.

1.1.1 The Coast Guard intends to launch and recover a Long Range Interceptor (LRI) boat up to 35 feet in length and 11 feet in width using the stern notch, and to store it in a cradle on the port side of the cutter. This boat must be picked up with a two point lift, which shall require two cranes to be installed on the port side. The Coast Guard intends to launch and recover a Short Range Prosecutor (SRP) boat up to 29 feet in length and 9.5 feet in width using the stern notch, and to store it in a cradle on the starboard side of the cutter. This boat must be picked up with a single point lift. A single crane shall be installed on the starboard side. The actual boats may be smaller and weight less than the design requirements stated herein; the intent is to be prepared to support future replacement boats for the current boats. The dimensions and weights specified herein are the design requirements. The boats shall be identified as Large Boat and Small Boat.

It is highly recommended that the contractor perform a shipcheck of the vessels. See figures 1 and 2 for general guidance.

The Contractor shall provide all labor and material to provide marine crane equipment for the US Coast Guard to install on the 418’ Maritime Security Large (WMSL) cutter class. Any materials and components sub-contracted for shall be the responsibility of the Contractor. The marine crane system shall be provided as a factory assembled and tested system. The Government will install this crane under separate contract.

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 HPU.

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

- logistics information and materials, and

- warranty, technical and training services.

For the purpose of this specification the terms “davit” and “marine crane” may be used interchangeably as the service for which the equipment is to be provided may, on other vessels, be considered to be a crane.

For the purpose of this specification, the term threshold refers to a required feature or capability. The term objective refers to an optional, but desired, feature or capability that should be priced separately if proposed.

1.2 INITIAL INSTALLATION

The Coast Guard intends to install the first unit 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.

2.0 APPLICABLE DOCUMENTS

2.1 ORDER OF PRECEDENCE

The following documents form a part of this specification to the extent specified herein. 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 10. 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

COAST GUARD DOCUMENTS

COMDTINST M9085.1C, Naval Engineering Computer Aided Design Standards, 11/11

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

SFLC Standard Specification 0740, Welding and Allied Processes SFLC-D-000-0100 G, Bar Coding for USCG ELC Material, 3/12.

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

SFLC D-084-0481, Equipment Unit Preservation, Packaging and Marking Standard Requirements for USCG ELC Auxiliary Machinery Branch, 3/12 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, 4/06 USCG Drawing 750-WMSL-801-20, Rev -, Booklet of General Plans, 1/08

USCG Drawing 750-WMSL-583-001, Rev B, SMALL BOAT HANDLING ARRANGEMENTS, 11/03

USCG Technical Publication 7443 LRI Drawings

USCG Technical Publication 6212 SRP Drawings

MILITARY SPECIFICATIONS

MIL-STD-419E – Cleaning and Protecting Piping, Tubing, and Fittings for Hydraulic Power Transmission Equipment, 2010.

MIL-STD-1310H, Shipboard Bonding, Grounding and Other Techniques for Electromagnetic Compatibility and Safety, 2009.

MIL-STD-1399C Section 300B, Interface Standard for Shipboard Systems, Electric Power, Alternating Current, 2008.

DOD-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, 2007

MIL-C-24643C Amend 1 – Cables and Cords, Electric, Low Smoke, for Shipboard Use, General Specification for, 2011

MIL-V-24695B - Valve, Hose Assembly and Adapter, Vent and Test, Hydraulic Service, General Specification for, 2011

OTHER GOVERNMENT DOCUMENTS

Code of Federal Regulations (CFR 46), U.S. Coast Guard, Subchapters F and J

FED-STD-595B Colors Used In Government Procurement, 1/94

2.4 COMMERCIAL DOCUMENTS

AMERICAN GEAR MANUFACTURING ASSOCIATION (AGMA)

AGMA 6001-E08 - Design and Selection of Components for Enclosed Gear Drives.

AGMA 6010-F97-Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives

AGMA 6123-B06- Design Manual for Enclosed Epicyclic Gear Drives

AGMA 9005-E02 -Industrial Gear Lubrication

ASTM INTERNATIONAL

ASTM F1166-07 Standard Practice for Human Engineering Design for Marine Systems, Equipment and Facilities.

ASTM D3951-10 Standard for Commercial Packaging

ASTM D4174-89, Standard Practice for Cleaning, Flushing, and Purification of Petroleum Fluid Hydraulic Systems, 2005

AMERICAN PETROLEUM INSTITUTE (API)

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

API-9A Specification for Wire Rope, 2011

INSTITUTE OF ELECTRICAL AND ELECTRONIC ENGINEERS (IEEE)

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

INTERNATIONAL ELECTROTECHNICAL COMMISSION

IEC 61131-3 (2003) Programmable Controllers - Language

INTERNATIONAL MARITIME ORGANIZATION (IMO)

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

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, 1987

ISO 7181 - Hydraulic Fluid Power cylinders, 160 bar, 2001

ISO 8136 - Hydraulic Fluid Power – Single Rod Cylinders, 1994

ISO 8137 – Hydraulic Fluid Power – Cylinders, 250 bar, 1997

ISO 16889 – Fluid Power, Filter, Multi-pass Method for Evaluation, 2008

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG1, Motors and Generators, 2011.

NEMA Standard 250– Enclosures for Electrical Equipment, 2008

NEMA Standard ICS-1– Industrial Control and Systems (series), 2010

NATIONAL FLUID POWER ASSOCIATION (NFPA)

NFPA T-3.9.22 R1 – Fluid Power, Pressure Ratings for Pumps and Motors, 2009

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) INTERNATIONAL,

SAE H1086, Metals and Alloys in the Unified Numbering System, 2008

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, 2009

SAE-J1942-1, Qualified Hoses for Marine Applications, 2010

SAE J2321, Ship Systems and Equipment – General Specification for Filter Elements, 2002

SAE J2333, Ship Systems and Equipment – Filter Selection Parameters, 2004

SAE J2270, Ship Systems and Equipment – Threaded Fasteners – Inspection Test and Installation, 2003

SAE J2280, Ship Systems and Equipment – Standard for Selection and Identification Requirements, 1996

SAE J2295, Ship Systems and Equipment – Fastener Parts Standard – Cap Screws, Hex Bolts and Hex Nuts, 2006.

AMERICAN BUREAU OF SHIPPING –

ABS Rules For Certification Of Cargo Containers, 1998.

American National Standard Institute (ANSI)

ANSI/NCSL Z540-1, Calibration Laboratories and Measuring and Test Equipment - General Requirements, 2002.

British Defence Standard DEF STAN 61-12: 90/001, Cables, Special Purpose, Electrical (Digital Data Transmission)-Issue 2, 01/01/1988

British Standard (BS) BS 6883, Elastomer Insulated Cables for Fixed Wiring In Ships and On Mobile and Fixed Offshore Units - Requirements and Test Methods, 06/15/1999

British Standard (BS) EN12385, Steel Wire Ropes, Safety, 10/30/2002

Society of Naval Architects and Marine Engineers (SNAME) Reference for Pierson-Moskowitz Sea Spectrum

3.0 GENERAL MINIMUM REQUIREMENTS FOR MARINE CRANES

3.1 PERFORMANCE REQUIREMENTS:

3.1.1 The contractor shall provide two boat handling systems for installation on the stern of the cutter. The port side system shall consist of two folding boom cranes to transfer a Large dual point lift cutter-boat; the cranes shall be identified as Crane 2 (forward) and Crane 4 (aft). The starboard side system shall be a folding boom crane to handle a Small single point lift cutter-boat; the crane shall be identified as Crane 3.

3.1.2 All cranes shall stow below the glide slope of the flight deck when not in use. See Figure 2. When the crane is in use the glide slope restriction does not apply; boat handling operations will be suspended during flight deck operations.

3.1.3 Cranes 2 and 4 shall operate in parallel to lift and transfer a Large Boat weighing up to 25,666 lbs (combined crane ratings), 35 feet long by 11 feet wide with a two point lift, between the centerline boat notch and cradle 12 feet to port, using their main winches, rigging and hooks. A single operator shall operate both cranes together in parallel. The main rigging sheave heads shall be within 5 feet of the load to minimize boat sway during lifting operations. Each of the cranes shall individually have a rating of not less than 15,400 lbs (7 metric tons) to address a potential boat lifting imbalance of 40% / 60%. The cranes shall be capable of operating at rated capacity under Sea State 5 conditions.

3.1.3.1 A Large Boat recovery position is shown in Figure 1. The boat may not be recovered to exactly the same position each time; the cranes shall be capable of servicing a boat up to 1 foot forward to 2 feet aft of the position shown. To accomplish this, both Crane 2 and Crane 4 main rigging shall have a working radius at rated load in Sea State 5 of not less than 22 feet.

3.1.3.2 Secondarily, Crane #2 shall be able to transfer cargo weighing at least 2,200 lbs between the pier (at full extension) and the aft corner of the flight deck with a working radius of 28 feet in Sea State 1. Over the flight deck, the crane shall be able to position the auxiliary hook at least 6 feet above the flight deck. Reach over the flight deck shall be not less than 4 feet. Crane structure and rigging for cargo handling shall not interfere with main winch operations, or with stowage of the cranes.

3.1.3.3 Secondarily, Crane #4 shall be able to service areas aft of the crane and over the stern with a working rating of at least 2,200 lbs under Sea State 1 conditions.

3.1.3.4 The Coast Guard is concerned with the slewing and luffing sensitivity for small movements during Large Boat transfer operations; a separate slow speed slewing control and slow speed luffing control shall be provided.

3.1.3.5 The Coast Guard is concerned with the coordinated lateral movement of the cranes during Large Boat transfer operations; separate controls for parallel operation shall be provided. Provision shall be made for the adjustment of an individual crane’s position while the system is aligned for parallel control.

3.1.3.6 The Coast Guard is concerned that Cranes #2 and #4 shall not interfere with maintenance and access to the Large Boat, or with other cutter operations on the aft deck. Cranes #2 and #4 shall be identical, stow facing each other, and stow with minimum shadow print to minimize interference with other fantail operations. When stowed, the cranes shall not project more than 36 inches to the inboard (boat stowage) side of the crane centerlines. A narrower stowage profile is an objective.

3.1.4 Crane 3 shall transfer a Small Boat weighing up to 8,800 lbs (4 metric tons), up to 29 feet in length and 9.5 feet wide with single point lift between the centerline notch and cradle 12 feet to starboard using the main winch, rigging and hook. The main rigging sheave head shall be within 5 feet of the load to minimize boat sway during lifting operations. No personnel shall be on board the boat during transfer operations. The crane shall be capable of operating at rated capacity under Sea State 5 conditions.

3.1.4.1 A Small Boat recovery position is shown in Figure 1. The boat may not be recovered to exactly the same position each time; the crane shall be capable of servicing the boat up to 1 foot forward to 2 feet aft of the position shown. To accomplish this, the main rigging on Crane 3 shall have a working radius at rated load in Sea State 5 of not less than 25 feet.

3.1.4.2 The Coast Guard is concerned with the slewing and luffing sensitivity for small movement during Small Boat transfer operation; a separate slow speed slewing control and slow speed luffing control shall be provided.

3.1.4.3 Crane 3 shall transfer a Small Boast weighing up to 9,500 lbs (with a 3 person crew on board) with single point lift between the cradle and a launch position to starboard, overboard, under Sea State 1 conditions. This is a threshold emergency launch capability. The crane and main rigging shall have an operating radius with this loading condition of not less than 15 feet, which will reach a point 8 feet outboard of maximum beam.

3.1.4.4 As an objective, it is desirable for Crane 3 to be able to transfer a Small Boat weighing up to 9,500 lbs (with a 3 person crew on board) with single point lift between the cradle and a launch position starboard, overboard, under Sea State 3 conditions. This operation shall require a Constant Tension feature on the crane, a SOLAS off-load release hook, and a retractable boat boom system for the sea painter. The Contractor shall provide a separately priced option for providing this Objective capability on Crane 3.

3.1.4.5 Secondarily, Crane #3 shall be able to transfer cargo weighing at least 2,200 lbs between the pier (at full extension) and the aft corner of the flight deck with working radius of 28 feet in Sea State 1. Over the flight deck, the crane shall be able to position the hook at least 6 feet above the flight deck. Reach over the flight deck shall be not less than 4 feet. Crane structure and rigging for cargo handling shall not interfere with main winch operations, or with stowage of the cranes.

3.1.4.6 The cranes shall meet API-2C except as modified herein.

3.1.4.7 The Coast Guard is concerned that Crane #3 shall not interfere with maintenance and access to the Small Boat, or with other cutter operations on the aft deck. Crane #3 shall stow fore/aft with minimum shadow print to minimize interference with other fantail operations.

3.1.5 Cargo handling operations shall be supported by auxiliary winches, auxiliary wire rigging and cargo hooks.

3.1.6 The Contractor shall provide a statement of fact from ABS or other member of IACS that the cranes meet the requirements herein; that the component fabrication and welding meet the requirements herein; and that the factory testing meets the requirements herein.

3.2 ENVIRONMENTAL CONDITIONS

3.2.1 Ship Motions

The cranes shall be designed to withstand the following survival accelerations interface data while in the stowed position on a 418’ WMSL cutter under Sea State 8 (Pierce-Moskowitcz Scale):

Acceleration Factor Magnitude Direction

Ax

0.49g

Parallel to centerplane

Ay

1.26g

Perpendicular to centerplane

Az

2.43g

Perpendicular to baseplane

The contractor shall be responsible to provide with the system any stowage brackets needed for support of the cranes in order to meet the above requirements and to include the necessary bracket placement in their recommended installation sketch.

The cranes shall be designed to transfer the cutter-boat under Sea State 5 (Pierce-Moskowitcz Scale). The following operational interface acceleration data has been calculated for the extended crane head on a 418’ WMSL cutter and shall be applied to the design of the crane. Boom tip is kept near the minimum height.

Acceleration Factor Magnitude Direction

Ax

0.10g

Parallel to centerplane

Ay

0.35g

Perpendicular to centerplane

Az

1.41g

Perpendicular to baseplane

3.2.2 Temperature Limits.

The cranes shall be designed to launch and retrieve the cutter-boat under temperature operating limits of -40 degrees F to +125 degrees F ambient air temperature plus solar gain. The latter results in an equivalent equipment surface temperature of 140 degrees F for weatherdeck equipment. 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.

The hydraulic power unit, motor controller, and crane control panel shall be suitable for installation in the steering gear compartment. This compartment has mechanical ventilation, is heated and cooled, and contains other electro-hydraulic equipment.

Salt-water cooling systems shall be designed to operate with 28 to 95 degree F seawater.

3.2.3 List and Trim

The cranes shall be designed to perform all functions at Safe Working Load (SWL) against a permanent list of 15 degrees and permanent trim of 5 degrees.

In a stowed condition the crane shall survive the cutter rolling 45 degrees single amplitude and pitching 10 degrees single amplitude, which may occur simultaneously.

3.3 MARINE CRANE REQUIREMENTS

3.3.1 Cranes 2 and 4 and their main rigging shall each have a nominal rating of not less than 15,400 lbs (7 metric tons) (25,667 x 0.6) at an outreach of 22 feet under Sea State 5 conditions. Structural ratings shall incorporate Sea State 5 Operating condition accelerations; the structure shall be based on a design load of not less than 21,714 lbs (15,400 x 1.41). The cranes shall have a slew rate of zero to 6 degrees per second (one rpm) when operated independently, and slew at a rate of zero to 0.5 degrees per second (0.167 rpm) when operated together for Boat Handling operations; separate slow speed slew controls shall be provided. The cranes shall have a lifting speed of zero to 60 fpm. The cranes shall have variable speed luffing and extension controls, as required. Separate slewing, luffing and extension controls shall be provided for parallel operation during Boat Transfer operations.

3.3.2 Cranes 2 and 4 and their main rigging shall be designed to accept the following loading condition: With the cutter deck and crane tilted 15 degrees (down) to starboard, and the crane heads oriented over the boat lifting points in the stern notch, a vertical load downward of not less than 21,714 lbs downward (15,400 x 1.41), a horizontal load aft of 1,540 lbs (15,400 x 0.10), and a horizontal load port or starboard of 5,390 lbs (15,400 x 0.35). These stresses shall be translated back into the crane structure. The crane structure shall also be subject to the same operational acceleration factors. Stress levels shall not exceed API-2C allowable stress limits.

3.3.3 Cranes 2 and 4 and their auxiliary rigging shall be designed to accept the following loading condition under Sea State 1: With the crane extended to full radius to port, the application of the cargo rating x 1.1 downward. These stresses shall be translated back into the crane structure. The crane structure shall also be subject to an acceleration factor of 1.1. Stress levels shall not exceed API-2C allowable stress limits.

3.3.4 Cranes 2 and 4 will be mounted on foundations 20 foot 6 inches apart, as shown on Figure 1.

3.3.5 Crane 3 and its main rigging shall have a nominal rating of not less than 8,800 lbs (4 metric tons) at an outreach of not less than 25 feet under Sea State 5 conditions. Structural ratings shall incorporate Sea State 5 Operating condition accelerations; the structure shall be based on a design load of not less than 12,408 lbs (8,800 x 1.41). The crane shall have a slew rate of zero to 6 degrees per second (one rpm) when in cargo operations, and a slew at a rate of zero to 0.5 degrees per second (0.167 rpm) when operated for Boat Handling operations; separate slow speed slew control shall be provided. The crane shall have a lifting speed of zero to 60 fpm. The cranes shall have variable speed luffing and extension controls, as required.

3.3.6 Crane 3 and its main rigging shall be designed to accept the following loading condition: With the cutter deck and crane tilted 15 degrees (down) to port, and the crane head oriented over the boat lifting point in the stern notch, a vertical load downward of not less than 12,408 lbs downward (8,800 x 1.41), a horizontal load aft of 880 lbs (8,800 x 0.10), and a horizontal load port or starboard of 3,080 lbs (8,800 x 0.35). These stresses shall be translated back into the crane structure. The crane structure shall also be subject to the same operational acceleration factors. Stress levels shall not exceed API-2C allowable stress limits.

3.3.7 Crane 3 and its auxiliary rigging shall be designed to accept the following loading condition under Sea State 1: With the crane extended to full radius to starboard, the application of the cargo rating x 1.1 downward. These stresses shall be translated back into the crane structure. The crane structure shall also be subject to an acceleration factor of 1.1. Stress levels shall not exceed API-2C allowable stress limits.

3.3.8 Threshold Boat Launch. Crane 3 and its main rigging shall be designed to accept the following loading condition: With the cutter and crane tilted 15 degrees (down) to starboard, the crane head oriented athwart ship at 15 foot radius (boat ready to launch into the water) the application of an acceleration factor of 1.1 downward to the boom tip. These stresses shall be translated back into the crane structure. The crane structure shall also be subjected to an acceleration factor of 1.1. Stress levels shall not exceed API-2C allowable stress limits.

3.3.9 Objective Boat Launch. If this option is exercised, Crane 3 and its main rigging shall be designed to accept the following loading condition: With the cutter and crane tilted 15 degrees (down) to starboard, the crane head oriented athwart ship at 15 foot radius (boat ready to go into the water) the application of an acceleration factor of 1.25 downward to the boom tip. These stresses shall be translated back into the crane structure. The cane structure shall also be subjected to an acceleration factor of 1.25. Stress levels shall not exceed API-2C allowable stress limits.

The cranes shall be fitted with encoder based Anti-2-Block and minimum wire wrap / loose end protection devices. Wireless anti-2-block devices shall not be provided. The contractor shall establish safety zones and illustrated instructions in the technical publication for adjustment.

All cranes shall stow below the glide slope of the flight deck when not in use. See attached figures.

All cranes shall fold and stow fore/aft with minimum shadow print to minimize interference with other fantail operations. The cranes in stowage shall not interfere with access to the boats for maintenance. The contractor shall provide deck mounted support brackets for support of crane boom in storage.

Note: The position of a boat (returning from the sea) in the notch is variable. The cranes shall be capable of recovering a boat between 1 foot forward and 2 feet aft of the position shown.

Crane cabs shall not be provided.

The Contractor shall provide crane pedestals for structural installation down to the 2nd deck level.

The port cranes shall stow facing each other, eccentric to the right of the opposing crane.

3.4 Control Station

Pedestal mounted control consoles shall be provided for 1) Cranes 2 and 4 together, and 2) Crane 3. Control console components shall be identical to the extent practical. 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, 2005 shall be considered in the design of the operator’s console. Controls in the weather shall be operable by personnel with cold weather mittens.

Touch screen virtual controls shall not be provided for crane functional controls. Functional and system on/off controls shall be met with switches, pushbuttons, joysticks or finger levers as appropriate. Flat panel displays may be provided on the weather deck for display of information, and virtual controls may be provided for selection or adjustment of that data or for diagnostic analysis systems. An anti-glare feature shall be provided to permit use during direct sunlight.

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 a three position selector switch to select Off, Blue, or White floodlights. Any electronic controls beyond the switches, gauges, alarms and lights shall be installed below decks in a NEMA 12 enclosure, in accordance with NEMA 250.

The enclosures for the control consoles shall be watertight and shall have a hinged, 316 stainless steel weathertight 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. 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.

Port and Starboard Control Consoles shall provide at least the control listed herein. Alternative console arrangements may be proposed, provided that boat transfer controls are separate and distinct from individual crane controls, and individual crane controls remain accessible for adjustment purposes while using boat transfer controls.

3.4.1 PORT CRANE (Cranes 2 and 4) CONTROL REQUIREMENTS:

The console shall be logically divided into 6 parts: Crane Nr. 2 functional controls (upper left); Functional Displays (upper center); Crane Nr. 4 functional controls (upper right); Crane and Hydraulic Power Control (lower left); Boat Transfer functional controls (lower center); and reserved (lower right).

CRANE AND HYDRAULIC POWER CONTROL (LL): Within this section, independent power control shall be provided for each crane, and power control shall be provided for the common hydraulic power unit. This section shall provide at least the following:

Visual indication (white) that power is available to the console.

On/Off control of Crane Nr. 2; visual indication (blue) when crane is powered.

On/Off control of Crane Nr. 4; visual indication (blue) when crane is powered.

On/Off control of the hydraulic kidney /cooling loop pump motor, if provided; visual indication (green) shall indicate the pump motor is on.

On/Off control of the Hydraulic Power Unit hydraulic pump; visual indication (green) when the pump is on.

On/Off control of the HPU electric heater; visual indication (blue) when the heater is on.

Audible and visual alarms (amber) that HPU maintenance is required. Visual indication shall be solid. An audible alarm silencing feature shall silence the audible alarm. The visual indication remains solid until the issue is resolved. Alarms shall be consolidated.

Audible and visual alarms (red) of eminent HPU equipment failure; visual indication shall be solid. An audible alarm silencing feature shall silence the audible alarm. The visual indication remains solid until the issue is resolved. Alarms shall be consolidated.

Dimming controls for all panel lights.

Emergency Stop Switch (one switch stops both cranes and HPU)

CRANE CONTROLS (UL & UR): These sections shall be used when moving between stowage and the boat transfer position, and when functioning as a crane for general weight handling. Controls shall meet API-2C layout recommendations. At least the following controls shall be provided, unique to Crane Nr. 2 and Crane Nr. 4:

Finger switch slewing control at high speed.

Finger switch slewing control at slow speed.

Finger switch main winch control in both directions.

Finger switch auxiliary winch control in both directions.

Finger switch control of each luffing element at both full and slow speeds.

Finger switch control of each extension element (as required)

(Note: Finger switches are shorter and have less movement then joysticks.)

On/Off control of the crane boom tip light.

On/Off control of the crane instrumentation.

BOAT TRANSFER controls (LC): This section shall be used for boat transfer operations and operates both cranes in parallel. Special attention shall be paid to parallel operation of the cranes. Controls shall meet API-2C layout recommendations. At least the following controls shall be provided:

Joystick slewing control at slow speed (only).

Joystick winch control.

Joystick luffing control for each luffing element at slow speed (only).

Joystick control of each extension element (as required).

Note: Minor movements / adjustments of an individual crane will be accomplished on the Crane Control sections.

FUNCTIONAL DISPLAYS (UC): Displays shall be visible during daylight and under night lighting conditions (blue). The displays and sensors shall be for data indication only; the sensors shall not be connected to the crane functional controls. An anti-glare feature shall be provided to permit use during direct sunlight. At least the following shall be displayed continuously when the console is active:

Digital display of hydraulic pressure.

Digital display of the slewing angle of Crane Nr. 2;

Digital display of Crane Nr. 2 extension / position.

Digital display of Crane Nr. 2 load.

Digital display of the slewing angle of Crane Nr. 4

Digital display of Crane Nr. 4 extension / position.

Digital display of Crane Nr. 4 load.

On/Off control of any wireless sensor elements. When turned off, no wireless sensor element shall radiate a signal, and display of that function shall be blank.

RESERVED (LR): This section shall be reserved for future potential installation of vessel communication equipment (telephone / headset, etc.) The console face shall be suitable for placement and use of a 5 inch x 7 inch note pad with clipboard.

3.4.2 STARBOARD (CRANE NR. 3) CONTROL REQUIREMENTS:

The console shall be logically divided into 4 parts: Crane and Hydraulic Power Unit Control (UL), Functional Displays (UR), Crane Controls (LL), and Reserved (LR).

CRANE AND HYDRAULIC POWER UNIT CONTROL (UL): Within this section, power control shall be provided for the crane and hydraulic power unit. This section shall provide at least the following:

Visual indication (white) that power is available to the console.

On/Off control of Crane Nr. 3; visual indication (blue) when crane is powered.

On/Off control of the hydraulic kidney / cooling loop pump motor, if provided; visual indication (green) shall indicate the pump motor is on.

On/Off control of the Hydraulic Power Unit hydraulic pump; visual indication (green) when the pump is on.

On/Off control of the HPU electric heater; visual indication (blue) when the heater is on.

Audible and visual alarms (amber) that HPU maintenance is required; visual indication shall initially blink. An audible alarm silencing feature shall silence the audible alarm and change the visual alarm to solid. Alarms shall be consolidated.

Audible and visual alarms (red) of eminent HPU equipment failure; visual indication shall initially blink. An audible alarm silencing feature shall silence the audible alarm and change the visual alarm to solid. Alarms shall be consolidated.

Dimming controls for all panel lights.

Emergency Stop Switch.

CRANE Nr. 3 CONTROLS (LL): Controls shall meet API-2C layout recommendations. At least the following controls shall be provided:

Joystick slewing control at full and slow speeds.

Joystick main winch control.

Joystick auxiliary winch control.

Joystick luffing control for each element at full and slow speeds.

Joystick extension control (as required.)

On/Off control of the Crane Nr. 3 boom tip light.

On/Off control of the Crane Nr. 3 instrumentation.

If Constant Tension feature is provided, Joystick control and release of the feature.

FUNCTIONAL DISPLAYS (UR): Display shall be visible during daylight and under night lighting conditions (blue). The displays and sensors shall be for data indication only; the sensors shall not be connected to the crane control functions. An anti-glare feature shall be provided to permit use during direct sunlight. At least the following shall be displayed continuously when the console is active:

Digital display of hydraulic pressure.

Digital display of slewing angle.

Digital display of crane extension / position.

Digital display of the load.

On/off control of any wireless sensor elements. When turned off, no wireless sensor element shall radiate a signal, and display of that function shall be blank.

RESERVED (LR): This section shall be reserved for future potential installation of vessel communication equipment (telephone / headset, etc.). The console face shall be suitable for placement and use of 5 inch by 7 inch note pad w/ clipboard.

3.4.3 COMMON CONTROL REQUIREMENTS.

E-STOP SWITCHES: Mushroom type, waterproof, Emergency Stop switches shall be provided; one on the port console, one for the starboard console, three for installation by the installing activity for the port cranes / HPU, three for installation by the installing activity for the starboard crane / HPU, and one on each Chest-Pack. The loose switches shall be provided with waterproof J boxes. Switch color shall be red. These switches shall be protected from inadvertent use with a lift-to-access bezel. These switches shall be wired in series, and activation shall cause all power to be lifted from the hydraulic power unit and all power to be lifted from the crane(s) on that side of the cutter. After use, power to the cranes and to the hydraulic power unit must be manually restored.

CHEST PACKS – Three weatherproof tethered Chest Packs shall be provided for plug-in attachment directly to the cranes; the packs shall be identical. These controls are intended for use when the cranes are used for other than Boat Transfer operations. When plugged into the cranes, the Crane Control sections of the console shall be deactivated.

Chest-packs shall have a cushioned pad to rest on the user’s abs or waist. The chest packs shall be provided with an adjustable support strap for use by 5th percentile female to 95th percentile male personnel.

Control layout shall meet API-2C recommendations. The Chest-Packs shall provide the following:

Visual indication (white) of power available to the chest-pack.

On/Off switch control of the chest-pack functions.

Finger lever controls for all lift, luff and slew functions.

Emergency Stop button.

Hand or wrist rest positions.

Switches shall be protected from inadvertent operation.

The tether cord shall be at least 8m / 26 ft in length. The cord shall be selected for weather deck use, shall be scuff resistant, and shall be independently replaceable from the chest-pack. The plug shall attach upward into the mating plug on the crane, and shall be protected from dripping water and horizontal spray. A waterproof, tethered, threaded plug and cap shall be provided to protect the plug when not in use.

The chest packs shall include soft carrying / stowage cases, including coiled tether cord.

CHEST PACK CONTROL ATTACHMENT – Waterproof plugs and receptacles shall be provided for the tethered connections. A connection point shall be provided on each crane.

The connection shall be vertical on bottom of the case and shall protect the plugs from dripping water and horizontal spray. Waterproof, tethered, threaded plugs and caps shall be provided to protect the plugs and receptacles when not in use.

When a chest-pack is plugged in, the console control of the same functions shall become inactive.

If a fault occurs in the main console, the chest-pack shall be capable of electrically controlling crane functions.

EMERGENCY MANUAL CONTROL - Provision shall be made for the manual control of hydraulic control valves on each crane for emergency and maintenance use. The hydraulic control valves, solenoids and handles shall be protected from the weather by a stainless steel cover or access panel door.

Emergency Operation upon Loss of Electric Power or Hydraulic Pressure. - The hydraulics shall have a manual release feature to release the brakes securing the crane in a controlled manner. A portable hand pump shall be provided to power the brake release in an emergency. The hand pump shall be removable via a quick disconnect fitting for stowage out of the weather. The hand pump shall be stowed with the HPU.

3.4.4 HYDRAULIC POWER UNIT CONTROLS: A Hydraulic Power Unit / Motor Controller panel shall be provided with each HPU for installation in a Steering Gear room. The panels shall provide the following:

· Local / Remote control selection. Selection of remote enables remote controls and remote indicators but does not disable local indications. Selection of local control disables all remote controls.

· Visual indication (white) that electric power is available to the panel.

· On/Off control of the hydraulic pump motor.

· Emergency Stop button.

· Digital hydraulic oil discharge pressure.

· Digital HPU cooling water temperature indication.

· On/Off control of the hydraulic kidney / cooling loop pump motor, if provided; visual indication (green) shall indicate the pump motor is on.

· On/Off control of the hydraulic reservoir heating element, and visual indication (blue) that the heating element is active.

· Audible and visual alarms (amber) that HPU maintenance is required; Visual indication shall initially blink. An audible alarm silence feature shall silence the audible alarm and change the visual alarm to solid. Alarms shall be consolidated.

· Audible and visual alarms (red) of eminent HPU equipment failure; Visual indication shall initially blink. An audible alarm silence feature shall silence the audible alarm and change the visual alarm to solid. Alarms shall be consolidated.

· Digital Service hour meter for the hydraulic pump(s).

3.4.5 LABEL PLATES – Engraved permanent label plates shall be provided and installed on all panels. The plates shall provide white lettering on a high contract background. The plates shall be affixed with threaded fasteners.

3.4.6 WIRELESS SENSORS: Frequency radiation from wireless sensors is a shipboard issue with regard to frequencies used, conflict with communication equipment on board, and emission of noise when not in use. Use of wireless sensors is strongly discouraged. However if provided, they shall not continuously emit radio waves, and shall function in an advisory capacity only. The cranes shall be fully functional w/o these sensors.

3.4.7 DIGITAL DISPLAYS: Displays shall be not less than ¾ inch in height.

Temperature shall be selectively displayed in degrees F or degrees C.

Slewing angles shall normally reference forward as zero; a feature shall be provided to reset the zero indication for repeat reference. Slewing angles shall display in increments of 0.1 degree movements.

Crane extension / position shall reference the lateral distance of the hook from the crane; a feature shall be provided to reset the distance zero indication for repeat reference. Extension / position shall selectively display in ft/in or in meters.

Loads shall be selectively displayed in lbs or kilograms. Accuracy shall be to 100 lbs or better.

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 6.2. In the calculation of structural and mechanical loads and stresses, see 3.1.2 Ship Motions. The calculations shall also document the moments imparted to ship structure by the crane under boat handling conditions at sea.

The crane machinery in the stowed and mission loading positions shall not project into the flight path area which starts aft of the aft most projection of the flight deck nets and rises towards the stern at an 8 degree angle, Figure 1. The control station shall be installed in the location of the existing control station as shown in the drawing and provide visibility to the boat in the water at the position to be retrieved, boat loading area, and the deck area of the cradle.

3.5 Detailed Requirements

3.5.1 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, contractor assigned crane unit serial number, Safe Working Load, brake test load (designated in paragraph 4.9.1) and the dynamic test load (designated in paragraph 4.9.2) physically imprinted (vice only using paint or ink). 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.

3.5.2 Commonality of Parts

Parts used on Cranes 2, 3 and 4 shall be common to the extent reasonable and practicable. Hydraulic system components, including valves, valve controllers, filters, pumps, motors, and slewing gears, shall be common to the extent reasonable and practical.

3.5.3. Hook

3.5.3.1. Hooks shall be marine grade alloy steel assemblies. They shall be fitted with self-closing latch mechanisms. Hooks shall be of sufficient strength to meet the specific design requirements of 3.1 and 3.3.

3.5.3.2. If Crane Nr. 3 requires a SOLAS offload release hook, the hook assembly shall be SOLAS approved by a Classification Society or by regulatory body. The hook shall have a mechanism with wire rope/lanyard release. The hook shall be fitted with handles suitable for grasp of the hook with mittened hands in accordance with ASTM F1166. The release lanyard shall extend to a point 200 to 300 mm (8 to 12) inches below the level of the actual hook and shall be terminated with a nylon (or equivalent) ball between 50 to 75 mm (2 to 3) inches in diameter and with a thimble and swaged wire clip. The top of the thimble and the wire clip shall be recessed into the nylon ball to minimize points of snag. Provision shall be made for an attachment of additional lanyards (rope) for tag lines. The hook shall be of sufficient strength to meet the design requirements of 3.1 and 3.2.

3.5.3.3. All hooks shall be pull tested to 200% of design strength and provided with a pull test certificate.

3.5.4 Winch and Rigging

3.5.4.1 Winch - Winch drum shall have a D:d ratio of 18:1 per API 2C 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. Winch shall be fitted with a spring set hydraulic drum release system rated for at least 150% of the SWL. Provision shall be made for the change of lubricant with minimal spillage or clean-up.

3.5.4.2 Sheaves - Sheave assemblies shall meet API-2C 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.

3.5.4.3 Swivel - A modified marine grade 8 ton swivel unit shall be provided. The swivel shall be machined from steel, and shall be zinc plated for corrosion resistance. The swivel shall be fitted with angular contact bearings, and shall be fitted with a pressure lubrication fitting. The swivel unit end fittings shall interface with the wire rope fitting, and with the cargo hook; this may require special machining. The swivel shall have a marine service rating, with a design factor of safety of 6.0, and shall be pull tested to twice the rating. The pull test certificate shall be attached to the swivel.

3.5.4.4 Wire – Wire rope shall be 6x37 classification wire with independent wire rope core and meet the requirements of API-2C 7.2 and API-9A. CRES or galvanized wire shall not be provided. The wire shall be fitted with an open or closed swaged socket eye similar to Crosby Group S502 series or equal (carbon steel, spherodize annealed, with swaged socket rated at 100% efficiency of the catalog strength of the rope and a means to visually verify swaging prior to physical gauging). Wire rope on Crane Nr 2, 3, and 4 shall have a design factor of 5. If the objective boat launch requirements for Crane Nr. 3 are met, the wire rope for Crane Nr. 3 shall have a design factor of not less than 6. 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 10 feet below the keel line of the cutter, with at least 3 wraps of wire rope remaining on the drum. Wire shall be pressure lubricated after assembly with DynaGuard, DynaGuard Blue, or 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 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.

3.5.5 Pins and Fasteners

All bearing pins shall be of a 316 Grade Stainless Steel, and shall be fitted with stainless steel zerk 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.

3.5.6. 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.

3.5.7 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. Electric motor frames and cases shall be steel, and shall be coated with marine grade paint system meeting paragraph 3.6.

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 HPU shall have a soft start feature. The motor shall be located below decks and shall be rated for 50 degrees C 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.