60021-Proc_Spec_225_Crane_and_ATON_ICCS_-18Feb16.doc

REVISION NO__ (-) . CHANGE NO. 0 .

USCG SFLC – 225’ WLB Crane and Integrated Crane Control System

REVISION: (-)

ATTACHMENT J.1

225-WLB MMA

CRANE

AND

INTEGRATED CRANE CONTROL SYSTEM

PROCUREMENT SPECIFICATION

DATE: 02/02/2016

COMMAND/DIVISION: Engineering Services Division, NAME Branch, ISVS and Auxiliary Machinery Sections

41.0

SCOPE

41.1 Purpose:

41.2 Scope:

52.0

APPLICABLE DOCUMENTS

52.1 General

52.2 Government Documents

72.3 Commercial Documents

112.4 Order of Precedence

123.0

REQUIREMENTS

123.1 General

143.2 Design Standards.

143.3 Environmental

153.4 Crane Functions

163.5 Structure

223.6 Access

223.7 Plates

253.8 Coatings and Color

263.9 Lubrication

263.10 Hydraulic System

303.11 Electrical System

313.12 Control System

613.13 Technical Data (TD)

613.14 Integrated Logistics Support

753.15 Deviation from Specification

774.0

QUALITY ASSURANCE AND TESTING

774.1 Quality Assurance

784.2 Test Requirements

885.0

PRESERVATION, MARKING AND PACKING

885.1 Preservation, Packaging and Marking Plan

885.2 Crane and ICCS Unit Packaging

885.3 Parts

885.4 Freight / Shipping Container

896.0

NOTES

896.1 Government and Commercial Document Sources

Appendix A - Crane Controls…………………………………………….………………….….……..92 Appendix - Glossary ……………………………………………………………………….…..……..96

1.0 SCOPE

Purpose:

1.1.1 This specification covers the design, manufacture, testing, inspection, preservation, and packaging for a Pedestal Mounted, Telescoping Boom Crane, with an PLC-based integrated crane control system (ICCS). In addition to providing control to the crane, the ICCS will provide control of Aids to Navigation (ATON) deck equipment. The complete system is for replacement of the existing crane system on the 225 ft WLB class (A and B) buoy tending cutters.

Scope:

1.1.2 This specification covers Integrated Logistics Support for the crane and ICCS, including a Design and Interface Report, Provisioning Technical Documentation, Maintenance Recommendations, Recommended Spare Parts, Technical Publications and Drawings. For follow-on or “Production” crane systems, Logistics Support will generally be limited to logistics support for changes or modifications from the Prototype crane installation which might occur.

1.1.3 Installation of the crane and ICCS will be accomplished by an Installing Activity (outside of this contract) based on technical and interface data provided by the Vendor. Limited on-site technical support to the Installation Activity and Commissioning (final adjustments) of the systems to ensure that the equipment is installed and functions correctly shall be provided by the Vendor.

1.1.4 The crane and ICCS shall be designed for on-board and off-board movement of rated load at sea, in sea states identified herein.

2.0 APPLICABLE DOCUMENTS

2.1 General

2.1.1 The following documents form a part of this Specification to the extent specified herein. The documents listed are by title and effective date, unless otherwise documented. Commercial documents may be listed in the Department of Defense Index of Specifications and Standards (DODISS). To obtain the referenced documents, see Section 6.1

2.2 Government Documents

2.2.1 Military and Federal Specifications

DOD-STD-1399C Section 301A, Rev A, Interface Standard for Shipboard Systems Ship Motion and Attitude, 1986.

MIL-DTL-15024F, Rev F, Plates, Tags and Bands for Identification of Equipment, General Specifications for, 1997.

MIL-DTL-24643, Rev C, Cables, Electrical, Low Smoke Halogen-Free, For Shipboard Use, General Specification, 2011.

MIL-DTL-24695, Rev C, Valve, Hose Assembly, and Adapter, Vent and Test Hydraulic Service, General Specification for, 2012.

MIL-PRF-18458, Rev C, Grease, Wire Rope – Exposed Gear, 2007.

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

MIL-STD-1310, Rev H, Shipboard Bonding, Grounding and Other Techniques for Electromagnetic Compatibility and Safety, 2013.

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

MIL-STD-2003, Rev A, Electric Plant Installation Standard Methods for Surface Ships and Submarines (Series, sections 1-5), 2009.

MIL-STD-38784, Rev A, Standard Practice for Manuals, Technical: General Style and Format Requirements, 2011.

DI-SESS-81495A, Rev A, Failure Modes, Effects, and Criticality Analysis Report, (Data Item Description), 2014.

DI-IPSC-81434A, Rev A, Interface Requirements Specification (IRS), (Data Item Description), 2013.

DI-GRDQ-81224, Functional Flow Diagram, (Data Item Description), 1991.

DI-IPSC-81435A, Rev A, Software Design Description (SDD), (Data Item Description), 1999.

DI-NDTI-80809B, Rev B, Test Inspection Report, (Data Item Description), 2014.

DI-SESS-81927, Failure Analysis and Corrective Action Report, 2013.

FED-STD 595C, Colors for Government Procurement, 2008.

2.2.2 Code of Federal Regulations (CFR)

Title 29 CFR, 1910, Occupational Safety and Health Standards (OSHA), (2014).

Title 46 (Shipping), Subchapter F – Mechanical, (2013).

Title 46 (Shipping), Subchapter J – Electrical, (2013).

2.2.3 USCG Specifications and Standards.

COMDTINST 9085.1C, Naval Engineering Computer Aided Design Standards, 2011.

COMDTINST M10360.3D, Coatings and Color Manual, 1/2014 SFLC Technical Standard TS 085, Engineering Drawings, 6/11/2013.

SFLC Technical Standard TS 085-1, Illustrated Parts Breakdown (IPB), 7/17/2013.

SFLC Technical Standard TS 305, Electrical and Electronic Designating and Marking, 3/17/2014.

SFLC Specification D-085-482, Drawings for Auxiliary Machinery, 2006 edition.

SFLC Specification D-086-483, Technical Publication Requirements for Auxiliary Machinery, 2006 edition.

SFLC Standard Specification 0740, Welding and Allied Processes, 2014.

SFLC Standard Specification 6310, Requirements for Preservation of Ship Structures, 2012.

SFLC-D-000-0100 G, Bar Coding for USCG ELC Material, 03/12.

SFLC-D-083-0351, Data for Provisioning, 01/03/00.

SFLC-D-084-0481, Rev B, Engineering Change Equipment Unit, Preservation, Packaging and Marking, Standard Requirements, 04/20/12.

2.2.4 US Coast Guard Technical Publications

TP 3939-573-A, Rising Sheave Chain Stopper.

TP 3554-556-A, Hydraulic Power Units A Class.

TP-3554-556-B, Hydraulic Power Units B Class.

TP 3557-573-A, Crane, Buoy Model TB90-60 A Class.

TP 3557-573-C, Crane, Buoy Model EB-480-60-40 B Class.

TP 3558-573-A, Cross Deck Winch Model BMD-390.

TP 3558-573-B, Cross Deck Winch Model BMD-471.

TP 3558-573-C, Crane Control and Monitoring System – Model 0008RETR055.

TP-3498-573-A, Buoy Chain Winch Model CW-1.

2.2.5 USCG SFLC Drawings

225-WLB-573-001, Rev M, Buoy Handling System Arrangement.

225-WLB-556-058, Rev A, Mods to FWD HPU #1 & #2 Control Schematic & Elementary Wiring Diagram.

225-WLB-556-001, Rev K, Hydraulic System Diagram.

225B-WLB-556-001, Rev F, Hydraulic System Diagram.

225-WLB-601-1, Rev U, General Arrangements Inboard and Outboard Profiles.

225B-WLB-601-1, Rev L, General Arrangements Inboard and Outboard Profiles.

225-WLB-320-2, Rev M, Power System Deck Plan Frame 30 Forward.

225B-WLB-320-2, Rev J, Power System Deck Plan Frame 30 Forward, Hull Block 910 & 901.

SK-TB150512, Rev (-), ISVS 225 WLB Replacement Ship-Crane Interface Sketch.

2.3 Commercial Documents

2.3.1 American Bureau of Shipping (ABS)

ABS, Steel Vessel Rules, 2014.

2.3.2 American Gear Manufacturing Association (AGMA)

AGMA 915-1-A02, Inspection Practices – Part 1: Cylindrical Gears – Tangential Measurements, 2002.

AGMA 915-2-A05, Inspection Practices – Part 2: Cylindrical Gears – Radial Measurements, 2005.

AGMA 2015-1-A01, Accuracy Classification System – Tangential Measurements for Cylindrical Gears, 2001.

AGMA 2015-2-A06, Accuracy Classification System – Radial Measurements for Cylindrical Gears, 2006.

AGMA 6001-E08, Design and Selection of Components for Enclosed Gear Drives, 2008.

AGMA 6013-A06, Standard for Industrial Enclosed Gear Drives, 2006.

AGMA 6123-B06, Design Manual for Enclosed Epicyclic Metric Module Gear Drives, 2006.

AGMA 9005-E02, Industrial Gear Lubrication, 2002.

2.3.3 American National Standards Institute (ANSI)

ANSI/ASQC 9001, Quality Management Systems – Model for Quality Assurance in Design, Development, Production, Installation, and Servicing Requirements, 2008.

ANSI/ISO/IEC 17025, General Requirements for the Competence of Testing and Calibration Laboratories, 2005.

ANSI/NCSL Z540.3, Requirements for the Calibration of Measuring and Test Equipment, 2013.

ANSI/ISA 18.1-1992, Annunciator Sequences and Specifications, 1992.

2.3.4 American Petroleum Institute (API)

API-2C, Offshore Pedestal Mounted Cranes, 7th edition, 3/2012.

API-9A, Specification for Wire Rope, 26th edition, 5/2011.

2.3.5 American Society of Mechanical Engineers (ASME)

ASME B30.7 – Winches, 2011.

ASME B30.10 – Hooks, 2014.

ASME B30.26 – Rigging Hardware, 2013.

2.3.6 American Society of Testing and Materials (ASTM)

ASTM F1166, Standard Practice for Human Engineering Design for Marine Systems, Equipment, and Facilities, 2007.

ASTM F1836M-97, Standard Specification for Stuffing Tubes, Nylon, and Packing Assemblies, 2007.

ASTM F1837M-97, Standard Specification for Heat-Shrink Cable Entry Seals, 2007.

ASTM D3951-10, Standard Practice for Commercial Packaging, 2010.

ASTM A312, Standard Specification for Seamless and Welded Austenitic Stainless Steel Pipes, 2014.

2.3.7 American Society of Welding

AWS D1.1, Structural Welding Code, 2011.

2.3.8 International Electrotechnical Commission (IEC)

IEC 61131-3, System Hardware and Software Technical Requirements, Edition 3.0, 2013.

IEC 60945, Maritime Navigation and Radio Communication Equipment and Systems, 2002.

IEC-60529, Degrees of protection provided by enclosures (IP-Code), 2014.

2.3.9 Institute of Electrical and Electronic Engineers (IEEE) IEEE Standard 45, Recommended Practice and Electrical Installation on Shipboard, 2002.

IEEE Standard C37.24, Guide for Evaluating the Effect of Solar Radiation on Outdoor Metal-Enclosed Switchgear, 2003.

IEEE Standard 315, Graphic Symbols for Electrical and Electronics Diagrams, 1993.

2.3.10 Illuminating Engineering Society of North America (IESNA) LM-79, Electrical and Photometric Measurements of Solid-State Lighting Products, 2015.

2.3.11 International Maritime Organization (IMO)

IMO Resolution MEPC.107(49), Revised Guidelines and Specification for Pollution Prevention for Machinery Space Bilges of Ships, Adopted 18 July 2003.

IMO IB867E, IMO Code on Alerts and Indicators, 2009.

2.3.12 International Organization for Standardization (ISO)

ISO 4406, Hydraulic fluid power - Fluids - Method for coding the level of contamination by solid particles, 1999.

ISO 6022, Hydraulic fluid power – Mounting dimensions for single rod cylinders, 25 MPa (250 bar) series, 2006.

ISO 6682, Earth-moving machinery – Zones of comfort and reach for controls, 1986.

ISO 7181, Hydraulic fluid power – Cylinders – Bore and rod area ratios, (second edition) 1991.

ISO 7241-1, Hydraulic fluid power - Quick-action couplings - Part 1: Dimensions and requirements, 1987.

ISO 8136, Hydraulic fluid power - Single rod cylinders, 160 bar (16 MPa) medium series - Port dimensions, 1986.

ISO 8137, Hydraulic fluid power - Single rod cylinders, 250 bar (25 MPa) series - Port dimensions, 1986.

ISO 16889, Hydraulic fluid power - Filters - Multi-pass method for evaluating filtration performance of a filter element, 2008.

2.3.13 National Electrical Manufacturers Association (NEMA)

NEMA Standard 250, Enclosures for Electrical Equipment (1000 Volts Maximum), 2008.

NEMA Standard ICS 1, Industrial Control and Systems (series), 2003.

2.3.14 National Fluid Power Association (NFPA)

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, 2009.

NFPA/T3.9.22 R2-2000 (R2009), Pump/motor – Pressure rating supplement to NFPA/T2.6.1 R2-2000, Fluid power components – Method for verifying the fatigue and burst pressure ratings of the pressure containing envelope of a metal fluid power pump and motor, 2009.

2.3.15 Society of Automotive Engineers (SAE)

SAE J518/1_201301, Hydraulic Flanged Tube, Pipe, and Hose Connections, 4-Screw Flanged Connection Part 1: 3.5 MPa to 35 MPa (Code 61).

SAE J1780_199104, Hydraulic System Diagrams and Associated Tables for Marine Vehicles.

SAE J1782_201305, Ship Systems and Equipment - Hydraulic Systems - Noise Control.

SAE J1942_200907, Hoses and Hose Assemblies for Marine Applications.

SAE J1942/1_201012, Qualified Hoses for Marine Applications.

SAE J2270_200306, Ship Systems and Equipment--Threaded Fasteners--Inspection, Test, and Installation Requirements.

SAE J2280_199604, Ship Systems and Equipment--Fasteners--Selection and Identification Requirements.

SAE J2295_200605, Fastener Part Standard - Cap Screws, Hex Bolts, and Hex Nuts (Inch Dimensioned).

SAE J2321_200212, Ship Systems and Equipment-- General Specification for Filter Elements--Hydraulic and Lube Oil Service.

SAE J2333_201315, Ship Systems and Equipment - Hydraulic Systems - Filter Selection Parameters.

2.3.16 Society of Naval Architects and Marine Engineers (SNAME) T&R Bulletin 3-39, Guide for Shop and Installation Tests.

2.3.17 Underwriters Laboratory (UL)

UL 508, Industrial Control Panels, 2008.

2.4 Order of Precedence

2.4.1 In the event of a conflict between the text of this Specification and the references cited herein, this Specification takes precedence. The Vendor shall notify the Contracting Officer (KO) in writing for a resolution of any ambiguity or conflict found in these Specifications prior to proceeding with any work.

3.0 REQUIREMENTS

3.1 General

3.1.1 Summarized critical crane parameters are in Table 3.1-1.

Table 3.1-1 WLB-225 Buoy Crane Critical Requirements

Main

Anti-2 blocking required

Auxiliary (whip)

Anti-2 blocking required

3.1.2 The Vendor shall provide all labor and material to manufacturer and provide a new pedestal mounted, telescoping boom crane for installation on a USCG 225’ WLB Class cutter; the Coast Guard intends to replace the existing cranes on both the “A” and “B” sub-classes. The new crane shall be complete and ready for installation on the existing crane pedestal flange on the cutter. The crane neutral and stowage position shall be facing aft. The crane shall have a single load rating over its entire operational area.

3.1.3 The Vendor shall provide a crane furnished with a PLC- based integrated crane control system (ICCS) to control the crane and to control Buoy Deck Aids to Navigation (ATON) machinery and related Hydraulic Power Units (HPU). The ICCS’s PLC shall be configured to mount inside the crane pedestal, below the rotation ring. Control of the ICCS’s PLC shall be from a Buoy Deck Crane Operator’s chair and Human Machine Interface (HMI) in the Buoy Deck Control Booth. Control of the crane shall also be provided from a tethered control pack, for use only when the cutter is tied to a pier.

3.1.4 Major external interfaces to the crane and ICCS

3.1.4.a. Provision shall be made for lifting the crane for installation. Lifting points shall be at the center of gravity or arranged symmetrically around it.

Table 3.1.4-1 Interfaces

Structural

PLC

Shall fit through a 24 in x 36 in (corner radius=12.25 in) clear opening on the existing pedestal.

Shall be mounted to the inside of the existing pedestal.

Penetration must be added to the existing pedestal for tethered controller chest pack cabling. Chest pack connection to be installed by Installing Activity.

Interface to Cutter HPU’s and hydraulic system.

Chair must be mounted in the operator’s control booth.

Hydraulic

3.1.5 The Buoy Deck Crane Operator’s crane controls shall be located on the operator chair arms. See section 3.12.9 for Operator control and display requirements.

3.1.6 The crane will, after installation, be statically and dynamically tested.

3.1.7 All load bearing fasteners, bolts, nuts and hardware shall meet minimum requirements of ASTM 320-Grade L7 Alloy Steel. .

3.1.8 A warranty of the crane and ICCS will be required. See section 3.14.13 for warranty information.

3.2 Design Standards.

3.2.1 The crane and ICCS shall meet the requirements of 46 CFR (Shipping) Sub-Chapters F (Marine Engineering) and J (Electrical Engineering).

3.2.2 The crane shall meet API-2C standards for “off-board lift” and “on-board lift” of rated loads at sea.

3.2.2.a. Welding shall be performed, inspected with certified Non-Destructive Testing (NDT) in accordance with API-2C (AWS D1.1).

3.2.2.b. Hook block and/or overhauling ball assemblies, together with the hook, shall have sufficient weight to maintain tension on the wire rope, in operational sea states, without additional load.

3.2.3 The PLC shall meet IEC Standard 61131-3.

3.2.4 Electrical systems shall meet the requirements of IEEE Standard 45 and applicable ABS Steel Vessel Rules.

3.3 Environmental

3.3.1 General

3.3.1.a. Submergence: All portions of the crane exposed to the weather shall be capable of operating under temporary submergence.

3.3.1.b. Equipment enclosures on the weather-deck shall be rated IP 67 or better.

3.3.1.c. Humidity: The crane and ICCS shall be capable of operating up to 100% humidity and under icing conditions.

3.3.2 Ship Motion

3.3.2.a. Survival: The crane and ICCS shall be designed to survive without damage up to Sea State 8 storm environmental conditions in accordance with (IAW) DOD-STD-1399C Section 301A, with the crane parked on the cutter centerline, facing aft and unloaded.

3.3.2.b. Operational: The crane and ICCS shall be designed to operate up to Sea State 4 acceleration conditions IAW DOD-STD-1399C Section 301A, with the boom tip ten (10) feet outboard of the centerline of the buoy port (frame 37.5), and the crane luffed so that the crane hook is thirty (30) feet above the water.

3.3.3 List and Trim

3.3.3.a. The crane and ICCS shall be capable of operating with 9.86° list athwart ship. 5.00° static list plus 4.86° dynamic list (total 9.86° athwart ship) and 3.03° pitch.

3.3.3.b. The crane and ICCS shall be capable of operating with 5° static list plus 7.02° dynamic list (total 12.02° athwart ship) plus 0.0° pitch.

3.3.4 Temperature Limits

3.3.4.a. Ambient: The crane and ICCS shall be capable of surviving, without damage, full temperature soaking exposure to ambient temperatures from -40° F to 125° F. Outdoor enclosures subjected to sunlight exposure shall minimize the effects of solar radiation. IEEE C37.24 can be used as guidance to reduce the effects of solar load.

3.3.4.b. The crane and ICCS shall be capable of operating under ambient temperatures from -20° F to 125° F, plus effects of solar load.

3.3.4.c. The crane PLC shall be located in the crane pedestal. The crane pedestal is a naturally ventilated compartment, without heat or air conditioning services. The compartment is subject to the cutter’s outside ambient temperatures.

3.3.4.d. The Buoy Deck Control Booth is a naturally ventilated compartment, with internal heating and air conditioning services which operates only when the compartment is occupied. Control system components of the Crane and ICCS in the booth are subject to full ambient temperatures and shall not depend on heating or air conditioning services for full rated electrical and electronic equipment operation.

3.3.4.e. Seawater: The crane shall be capable of operating with seawater temperatures of 28° F minimum to 95° F maximum, including seawater spray icing.

3.4 Crane Functions

3.4.1 Luff

3.4.1.a. The crane shall operate at boom luff elevations of -10 degrees (below horizontal) to not less than 80 degrees (above horizontal), under rated load in operational sea states at 1.0 deg/sec.

3.4.2 Extend

3.4.2.a. The crane shall have an extending boom which can operate at nominal crane boom tip extensions of 40 feet to not less than 60 feet, and all extensions between.

3.4.2.b. The crane boom shall extend and retract continuously under rated load in operational sea states.

3.4.2.c. The crane shall extend and retract at a rate of not less than 30 fpm.

3.4.2.d. The crane shall decelerate and stop when approaching the extension limit positions to structural impacts or collision avoidance set-points.

3.4.3 Slew

3.4.3.a. The crane shall rotate + 210 degrees from 0 degrees and return (420 degrees total), stop to stop, under rated load in operational sea states. “Zero” (0) orientation and normal stowage shall be centerline facing AFT.

3.4.3.b. The crane shall slew at a maximum rate of one 1.0 rpm. The crane neutral / stowage position shall be horizontal, facing aft, with the boom retracted.

3.4.3.c. The crane shall stow against the luffing cylinders, over the fore-deck without a cradle or boom rest for not less than 8 hours, at zero degrees.

3.4.3.d. The crane shall decelerate and stop when approaching the slew limit positions to structural impacts or collision avoidance set-points.

3.4.4 Lift

3.4.4.a. The crane shall have both a main and auxiliary (whip) lift.

3.4.4.b. The main lift shall be two part rigging.

3.4.4.c. The auxiliary lift shall have single part rigging.

3.4.4.d. The main and auxiliary winches shall each have a bare drum hoist/lower speed of zero to 60 fpm, under full load and operational sea states.

3.4.4.e. Constant tension winch systems shall not be used.

3.4.5 Operations

3.4.5.a. The crane shall be able to launch and recover ATONs at sea in the operational sea state.

3.4.5.b. The crane shall support dock-side operations for load-out and on-load operations.

3.5 Structure

3.5.1 General

3.5.1.a. The Vendor shall provide a Material Documentation Report to the Contracting Officer and the COR (See Section 3.14.8.a).

3.5.2 Lift Ratings

3.5.2.a. The crane shall have a “posted” API-2C “Off-board” lift rating under the operational sea state (See Section 3.3.2.b).

3.5.2.b. The crane shall have both a main lift with an “Off-board” rating of 40,000 lbs, and an auxiliary lift with an “off-board” rating of 10,000 lbs.

3.5.2.c. At all radii, the crane shall have a “posted” API-2C “On-Board” lift rating under the same operational sea states rating of 40,000 lbs (main) and 10,000 lbs (auxiliary).

3.5.3 Rotation Bearing

3.5.3.a. The existing crane is mounted on top of a Rotek ™ A22-105E series bearing, with ring gear, bolted to a structural foundation flange. The replacement crane shall provide a new pedestal bearing and ring gear or equivalent, which shall bolt directly to the existing pedestal foundation flange.

3.5.4 Slewing Drive

3.5.4.a. The Slewing Drive system shall use hydraulic motors and brakes.

3.5.4.b. Installed parking brake systems shall be wet-type (oil filled).

3.5.4.c. Parking brake assemblies shall be fitted with a manual hydraulic release feature which will release all of the slewing brakes together.

3.5.4.d. The active and braking loads shall be balanced across the drives.

3.5.4.e. This hydraulic release feature shall be supported by a portable, hydraulic hand pump assembly with reservoir (See section 3.5.10.d). Vendor shall provide Stainless steel quick disconnect fittings.

3.5.4.f. The Vendor shall provide a means for alignment and adjustment of each hydraulic motor, gear reducer, pinion drive assembly to properly align and engage with the ring gear. Specific instructions shall be provided in the technical manual (See Section 3.14.8).

3.5.4.g. Change of oil shall not require removal of the gearbox or other components.

3.5.4.h. Vendor shall provide drain plugs.

3.5.4.h(i) The drain plugs shall be piped as necessary to accessible locations.

3.5.4.h(ii) Gearboxes fitted with breather ports shall prevent intrusion of moisture / humidity and water.

3.5.4.i. The Vendor shall provide lubricant, lubrication schedule and lubricant condemnation recommendations in the Technical Publication and Integrated Logistics Support documentation. Commercial marine grade lubricants shall be used.

3.5.4.j. Gearing shall comply with the requirements of the AGMA specifications, or equivalent.

3.5.5 Rigging System

3.5.5.a. Hoist Winches 3.5.5.a(i) Hoist winches shall be self-contained, hydraulic, commercial marine grade winch assemblies complete with gearbox, dynamic brake, and spring set / hydraulic release parking brake. The winches shall meet API-2C and ASME B30.7 requirements. The winch brakes shall support the design wire loading requirements, and shall permit conduction of 150% of wire WLL Modified Static / Brake Tests.

3.5.5.a(ii) Winch parking brakes shall be fitted with a remote hydraulic release feature, which shall be extended so that personnel standing on the crane base can remotely release the parking brake with the crane in any alignment. This hydraulic release feature shall be supported by a portable, removable hydraulic hand pump assembly with reservoir (See section 3.5.10), for stowage in a protected compartment. Stainless steel quick disconnect fittings shall be provided.

3.5.5.a(iii) Fleet angle shall not exceed +/-1.5 degrees.

3.5.5.a(iv) Winch drums shall be fitted with a LEBUS™ shell or grooving.

3.5.5.a(v) With crane retracted and parked, and hooks raised, the wire rope shall be contained on 4 full level wraps or less. Drum cheek plates shall permit at least one additional wrap of wire rope.

3.5.5.a(vi) Winches shall be furnished with lifting eyes.

3.5.5.b. Assemblies 3.5.5.b(i) The main hoist shall utilize two-part rigging. The wire rope shall be high strength, compacted strand, 1.0 inch diameter, Dyform18 ™ or CushionPac18™ or equivalent18 x 19 strand IWRC wire rope with rotation resistant properties. The wire rope shall not be galvanized.

3.5.5.b(ii) Wire rope shall have a WLL design factor of at least 5:1 on the rated breaking strength of the rope.

3.5.5.b(iii) Main Wire rope assembly of 300 ft (+ 3ft/-0 ft.) in length shall be provided.

3.5.5.b(iv) The auxiliary hoist shall utilize single part rigging. The wire rope shall be high strength, XIPS (EIPS) Grade, ¾ inch diameter, Right Regular Lay, 6X36 class, IWRC, General Purpose wire rope. The wire shall not be galvanized.

3.5.5.b(v) Auxiliary Wire rope assembly of 200 ft (+ 3ft/-0 ft.) in length shall be provided.

3.5.5.b(vi) Wire ropes shall terminate with a poured open spelter socket assembly, Crosby Group G-416 or equivalent with the second end seized. The wire rope and attached socket shall be pull tested to 200% of the WLL of the wire. A dated and signed pull test certificate shall be provided, and shall be attached to the coiled wire rope which is shipped. An example of an initial certificate and wire data shall be provided in the Technical Publication.

3.5.5.b(vii) Wire rope shall be pressure lubricated after assembly with DynaGuard™, or DynaGuard Blue™, or equivalent wire rope lubricant.

3.5.5.c. Sheaves 3.5.5.c(i) Sheaves shall meet API-2C requirements, and shall be roll forged.

3.5.5.c(ii) Sheaves shall be furnished with roller type bearings with inner races. Bearings shall be configured for the application of grease through grease fittings and grease passages in the sheave pins.

3.5.5.c(iii) Grease seals shall be provided.

3.5.5.c(iv) Sheaves shall be furnished with a lifting hole in web.

3.5.5.c(v) All sheaves shall be fitted with guards.

3.5.5.c(vi) Crane head sheaves shall pivot or flag up to + 45 degrees from vertical.

3.5.5.c(vii) Sheaves shall be fully painted as separate assemblies. The wearing surfaces of sheaves shall be double coated with modified inorganic zinc undercoating; no top color coat is required.

3.5.5.d. Hook Block / Overhauling Ball Assemblies.

3.5.5.d(i) Hook Block and Overhauling Ball assembles shall meet the requirements of ASME B30.26.

3.5.5.d(ii) Hook block assemblies shall be furnished with stainless steel grab handles bolted to both sides of block.

3.5.5.d(iii) Hook block and overhauling ball assemblies shall be configured to make positive contact with anti-two-block switch actuator arm/weight.

3.5.5.d(iv) Grease fittings on sheave pins shall be located to prevent damage.

3.5.5.d(iv)(A) Load Hooks.

3.5.5.d(iv)(B) Hooks shall be of alloy steel, and shall meet the requirements of ASME B30.10.

3.5.5.d(iv)(C) Hook material shall be suitable for low temperature operations 3.5.5.d(iv)(D) Load hooks shall be supported in the hook block/overhaul ball by a thrust bearing to allowing full rotation.

3.5.5.d(iv)(E) Thrust bearing shall be greaseable by an accessible lube fitting.

3.5.5.d(iv)(F) Load hooks shall be provided with permanent marks (such as punch marks) for checking hook throat spread. Initial as furnished dimension between marks shall be provided with the crane documentation.

3.5.5.d(iv)(G) Hooks shall be furnished with a self-closing, safety latch mechanism. Hook safety latch hardware (pins, springs, etc.) shall be constructed of corrosion resistant material for marine environment.

3.5.5.d(iv)(H) Hook block assemblies shall be painted.

3.5.5.d(iv)(I) Hooks shall be pull tested to 200% of rated capacity and furnished with a pull test certificate from the hook manufacturer.

3.5.5.d(iv)(J) The certificate shall be wired to the hook.

3.5.6 Pins & Shafts

3.5.6.a. All load bearing pins shall be installed with replaceable bushings on both sides of the pin and shall be lubricated prior to installation.

3.5.6.b. Threaded pins shall be installed with anti-seize compound on the threads.

3.5.6.c. Pins and shafts shall be 17-4 PH.

3.5.7 Fasteners

3.5.7.a. All structural Fasteners materials shall be ASTM 320 - Grade L7 Alloy Steel , non structural fasteners shall be CRES 316L or Monel suitable for use in a marine environment.

3.5.7.b. Fastener designation shall be in accordance with SAE J2295.

3.5.7.c. A complete set of new turret mounting bolts shall be provided for the installation of the crane onboard.

3.5.8 Telescoping Boom

3.5.8.a. Inner and outer boom alignment shall be maintained at all times.

3.5.8.b. The internal and external boom sections shall be fabricated without twist. Manufacturer and constructor tolerance inspections shall ensure that the alignment of the two boom sections shall not bind or waiver during extension and retraction under load.

3.5.8.c. The boom system shall be provided with alignment and wear pucks or slides which ride on unpainted stainless steel strips. Contact with a significant percentage of the pucks or slides shall be maintained over the entire length of extension.

3.5.8.c(i) The pucks shall be replaceable and easily shimmed or adjustable from outside of the boom. The objective is to minimize wander of the boom tip.

3.5.8.c(i)(A) At full extension, the boom tip alignment shall not shift more than +/- 1.5 inch, under the external application of nominal 500 lb shifting horizontal loads. The shift at partial extensions shall be less than at full extension.

3.5.8.c(ii) The pucks or slides shall be drilled and machined for distribution of lubricant. Provision shall be made for lubrication, which shall be included in the maintenance schedule.

3.5.8.c(iii) The Vendor shall define the installation tolerance levels of the wear puck / slides to the stainless strips.

3.5.8.d. The boom system shall telescope using an internal hydraulic cylinder. The cylinder shall be accessible for routine maintenance without unshipping the boom. The lubrication points (i.e. pins) shall be accessible from outside the boom.

3.5.8.e. The counterbalance / load hold valve and related fittings shall be accessible for maintenance and emergency cylinder recovery.

3.5.9 Luffing & Boom Extension Cylinders

3.5.9.a. Hydraulic cylinders shall meet 46 CFR and ABS requirements, and rated for marine service. Cylinder rod corrosion protection shall be provided with double chrome plated over corrosion resistant steel rods.

3.5.9.b. Cylinders shall conform to dimensional standards of ISO 6022 or its equivalent. Bore and area ratios shall comply with ISO 7181.

3.5.9.c. Cylinder rod wiper and seal systems shall be a cartridge type that is field replaceable.

3.5.9.d. Cylinders shall be fitted with hydraulic cushions at both ends to reduce structural impact loading on the cylinder ends.

3.5.9.e. Cylinders shall be equipped with dual direction counterbalance / load hold valves for safe operation, to maintain crane positions, and to lock the cylinder in case of hydraulic hose failure.

3.5.9.e(i) Counterbalance valves shall be mounted at the highest possible location on cylinders to act as an air trap.

3.5.9.e(ii) Counterbalance valve manifolds shall be fitted with Schroeder 1215 series stainless steel test fittings (or equal) for bleeding air.

3.5.9.f. Counterbalance valves shall be fitted with a hydraulic pressure over-ride capability to release the counterbalance valve, if required, to permit “recovery” of the crane to a position for repair or come-home transit.

3.5.9.f(i) The system shall utilize the Emergency Brake Release portable hydraulic hand pump with sump, plugged into installed stainless steel quick disconnect fittings.

3.5.9.f(ii) Hydraulic tubing supporting emergency release of counterbalance valves shall not be pressurized and subject to fluid baking and to contaminant settling.

3.5.9.f(iii) Maintenance recommendations shall be provided in the Technical Publication for these tubing / hoses. Assembly instructions shall include scheduled “demonstrations”, and flushing.

3.5.9.g. Cylinders shall be arranged with rods retracted when stowed to minimize rod corrosion.

3.5.9.h. Equipment arrangements shall stow with as minimal rod exposed.

3.5.9.i. Hydraulic cylinder control shall be smooth and variable speed in both directions.

3.5.10 Portable Brake Release System

3.5.10.a. The crane shall be furnished with an portable brake release system to permit manual (or emergency) release of the winch holding/parking brakes and cylinder load/hold valves for the various motions to permit the manual maneuvering of the crane to allow lowering of the load in the case of a power failure.

3.5.10.a(i) Note: Hydraulic tubing supporting emergency brake release is not pressurized and subject to fluid baking and to contaminant settling.

3.5.10.b. All components of the emergency brake release systems shall be of stainless steel construction with Monel trim and shall be specifically designed for marine crane service.

3.5.10.c. The emergency brake release systems shall be furnished with isolation valves to permit selective actuation of specific brakes and to isolate pressure during connection of the pump hose.

3.5.10.d. The hand pump for the emergency brake release systems shall be self-contained with an oil sump adequately sized for this application. The pump shall be connected to the system via a hydraulic hose with stainless steel quick disconnect fittings to allow removal of the pump from the system for stowage below decks. Hose length shall be sufficient to permit the hand pump to be placed on adjacent walkway/deck for operation.

3.5.10.d(i) The hand pump shall be provided with the crane system.

3.6 Access

3.6.1 General

3.6.1.a. Maintenance access meeting ASTM F1166 ergonomic requirements for 5th percentile female through 95th percentile male personnel shall be provided to all areas of the crane.

3.6.1.b. Crane walkways shall be provided for maintenance access to all serviceable and replaceable components on the crane unless accessible from the deck. Walkways shall be of open grating construction with full handrail protection.

3.6.1.c. When necessary for maintenance access, sections of grating shall be hinged to provide access. Raised grating shall have provisions to hold open grating in place.

3.6.1.d. At personnel access points, automatic safety closure devices shall be provided in railings.

3.6.1.e. A retractable boarding ladder or other means to access the crane walkways shall be provided.

3.6.1.e(i) The ladder shall stow in the up position to permit slewing of the crane without creating a safety hazard for personnel on the deck and to prevent damage to deck mounted devices and handrails.

3.6.1.e(ii) A positive locking device, operable from the fore-deck deck by a 5th percentile female, shall be provided to prevent the ladder from drifting down.

3.6.1.e(iii) The ladder shall be furnished with a proximity sensor to verify when the ladder is fully retracted / stowed.

3.6.1.e(iv) The ladder position shall be interlocked with the crane control system; the crane shall be inoperable unless the ladder is retracted.

3.6.1.f. Personnel safety anchor points shall be provided for attachment of 29 CFR 1910 series OSHA personnel safety harnesses for working aloft on the crane platform, particularly at sea. The anchor points shall support multiple persons at 220 lbs each using D-ring type harness straps.

3.7 Plates

3.7.1 General

3.7.1.a. The crane body may be fitted on each side with a manufacturer’s decal and/or emblem not to exceed lettering of 2 ½ inch height, or a total of 100 square inches. Advertisement decals, emblems or ratings shall not be used.

3.7.1.b. A stainless steel builder’s plate, which shall include at least the manufacturer’s name, address, government contract number, manufacturer’s model number, date of fabrication (equipment delivery/acceptance) and a manufacturer’s serial number shall be provided on the back (spine) or one side of the crane.

3.7.1.b(i) Lettering shall not exceed ¾ inch in height, and shall be back-filled with black enamel, and sealed with clear coat.

3.7.1.b(ii) The builder’s plate shall be drilled and installed with threaded fasteners or rivets.

3.7.1.c. A stainless steel rating plate with the API Monogram applied shall be provided for field installation on the crane pedestal.

3.7.1.c(i) The plate shall identify load ratings at sea of 40,000 and 10,000 lbs, and the test loads required for dynamic and modified static / brake tests.

3.7.1.c(ii) Text shall not exceed ¾ inch in height and shall be backfilled with black enamel and sealed with clear coat.

3.7.1.c(iii) The plate shall be drilled for installation with threaded fasteners or rivets.

3.7.1.c(iv) A printed copy of this plate shall also be in an appendix to the Technical Publication.

Manufacturer’s Name

Crane Model # and Crane Serial # Effective Date

Rated Load

- Crane Op Area at Pier

On-Load Rating

- Buoy Dk Service Area at SS 4

Off-Load Rating

- Buoy Port Service Area at SS 4

TEST LOADS

3.7.1.d. A stainless steel Test Data Plate shall be provided by the manufacturer for field installation on the crane pedestal.

3.7.1.d(i) The plate shall coordinate with the Rating Plate, and shall have blocks for field engraving of test dates and facility.

3.7.1.d(ii) Text shall not exceed ½ inch in height. Text shall be back-filled with enamel, and sealed with clear coat.

3.7.1.d(iii) The plate shall be drilled for installation with threaded fasteners or rivets. It is intended that this plate would be replaced every two years.

3.7.1.d(iv) A printed copy of this plate shall be in an appendix to the Technical Publication.

TEST DATA PLATE

Mod Static/ Brake Test

Dynamic Test

Rated Load Test

2nd Yr Annual Test – Rated Load

3.7.1.e. A three-part Working Load Limit (WLL), stainless steel engraved graphic plate shall be provided for installation in the Buoy Deck Control Booth; printed copies shall be in the Technical Publication.

3.7.1.e(i) The plate (with 3 sections) shall show an arrangement of the crane over the buoy deck or working areas.

3.7.1.e(ii) The engravings shall be back-filled with enamel paint in multiple colors, and sealed with clear coat.

3.7.1.e(iii) The plates shall be drilled for attachment with threaded fasteners or rivets.

3.7.1.e(iv) One part shall highlight the Buoy Port Work Areas. Text shall identify the “Off-Load” Working Load Limits (main and auxiliary) in operational sea states, and acceleration design factors.

3.7.1.e(v) One part shall highlight the Buoy Deck Work Area. Text shall identify the “On-Load” Working Load Limits (main and auxiliary) in operational sea states, and acceleration design factors.

3.7.1.e(vi) One part shall highlight the full reach of the crane. Text shall identify the Working Load Limits (main and auxiliary), when tied to a pier. A footnote shall indicate that maximum load (main) at full extended outreach port and starboard may be “subject to cutter stability limitations”.

3.7.1.f. A Testing Instructions graphic shall be provided in the Technical Publication. The Testing Instructions shall specify the crane position / extension, instructions and limitations for conducting the 125% Dynamic Load test and 150% Modified Static Load / Brake test with the crane head beginning over the Buoy Port Service Areas.

3.7.1.g. The control cabinet, the chair, the control console and other equipment provided (beyond the crane) shall each be fitted with a stainless steel or engraved plastic serial number plate, which shall include the manufacturers name and the system serial number.

3.7.1.g(i) Lettering shall be black against white or metal, and nominal 1/4 to 3/8 inch in height.

3.7.1.g(ii) The plates shall be drilled and attached with threaded fasteners or rivets.

3.7.1.h. Identification / Functional Label Plates shall be provided and installed for each valve, major component (e.g. slewing drive #3), sensor, and piping connection.

3.7.1.h(i) Label plates shall also be provided to identify normal fluid levels. The plates shall be stainless steel or engraved plastic plates, which shall be drilled and attached with threaded fasteners or rivets.

3.7.1.h(ii) Lettering shall be black against white or metal, and nominal1/4 to 3/8 inch in height.

3.7.1.h(iii) The plates shall be permanently affixed to their respective sub-assemblies in a position that is clearly visible after the crane is installed.

3.8 Coatings and Color

3.8.1 The crane assembly and control components shall be coated in accordance with, SFLC Standard Specification 6310. The coating system shall be an approved polysiloxane multi-coat system over an enriched inorganic zinc primer base.

3.8.2 All non-painted surfaces shall be 316L stainless steel unless otherwise noted.

3.8.3 The crane and all components exposed to the weather shall be colored SPAR (Fed Std 595 #10371)

3.8.4 Machinery or cabinets for inside installation, and equipment for installation in the Buoy Deck Control Booth shall be colored GRAY (Fed Std 595 #26307)

3.8.5 Crane hooks shall be colored YELLOW (Fed Std 595 #13538). Head block and headache ball assemblies shall be striped YELLOW (Fed Std 595 #13538) and BLACK (Fed Std 595 #17038) on a 45 degree angle; suggested stripe width 2 to 3 inches.

3.8.6 The wear tread of sheaves, the ring gear of the bearing, and other wear component areas, as appropriate, shall be double coated with enriched inorganic zinc based primer, without a top color coating.

3.8.7 Emergency Stop devices shall be colored RED (Fed Std 595 #11105).

3.8.8 The vertical ladder shall be colored SPAR (Fed Std 595 #10371). Portions of the ladder which may be considered a safety hazard shall be top coated with yellow and black enamel striping, or topped with an equivalent commercial vinyl striping product.

3.8.9 Grade 316L, or equal, corrosion resistant stainless steel cabinets, components and hardware suitable for a marine environment need not be painted.

3.8.10 Portable components intended for inside stowage may retain an appropriate OEM coating system, provided that the coating system is marine grade and either a multi-coat epoxy, polysiloxane coating system, or appropriate powder coating. If painting is required, they shall be colored GREY (Fed Std 595 #26307).

3.8.11 Fully plumbed cylinders shall be fully painted as separate assemblies in accordance with SFLC Standard specification 6310.

3.9 Lubrication

3.9.1 The Vendor shall provide lubricant, lubrication schedule and lubricant condemnation recommendations in the Technical Publication and Integrated Logistics support documentation. Commercial marine grade lubricants shall be used.

3.9.2 The Vendor shall coordinate the use of a minimum number of lubricants.

3.9.3 Provision shall be made for the lubrication of all bearings, bushings, pins, etc. on the crane by personnel standing on structure or platforms, or within ergonomic reach. Fittings which are “hidden” from view shall be avoided if possible. Grease fittings shall be stainless steel or monel, and be fitted with a spring loaded internal ball. Where multiple points requiring grease lubrication are in the same vicinity and access is limited, “ganged” grease fittings with stainless steel tubing extensions, or grease lubricant distribution systems shall be provided.

3.9.3.a. In the selection of grease for distribution through tubing, greases which harden under environmental “baking” conditions shall be avoided.

3.9.3.b. More manifolds with fewer but shorter lines are preferred over fewer larger manifolds with longer lines piped to them.

3.9.3.c. Manifolds shall be readily accessible from decks, crane walkways and inside the crane pedestal.

3.10 Hydraulic System

3.10.1 General

3.10.1.a. The crane shall be powered by the cutter’s existing pressure compensated, central hydraulic system which is capable of providing 211 gpm at 2500 psig.

3.10.1.b. Hydraulic fluid used in the central hydraulic system is Mobil DTE-10M. All components on crane’s hydraulic system shall be compatible with this fluid.

3.10.1.c. The crane hydraulic control system shall provide for full variable speed control (creep to rated speed, in both directions) of all individual lift, luff, extend and slew functions at rated load under operational sea states.

3.10.1.d. The crane hydraulic system shall not allow boom creep under any load.

3.10.1.e. The existing filtering system mounted in the crane pedestal is fitted with Schroeder model KZ3 elements, or equivalent. Hydraulic return lines to the reservoir(s) are also filtered.

3.10.1.f. The crane system shall operate with a target hydraulic particulate contamination level of ISO 4406 Code 17/14/12 and a target water content level of 0.05% by weight. This contamination limit level shall be clearly identified on the hydraulic system diagram, and in the technical publication.

3.10.1.g. Hydraulic systems shall be cleaned during fabrication and assembly to ISO 4406 Code 16/14/11 or better. Provisions shall be made to maintain this cleanliness through delivery and installation.

3.10.1.h. The Vendor shall flush all piping, hoses and equipment per MIL STD 419D to achieve and maintain the required cleanliness level.

3.10.1.i. All points of hydraulic interface shall be capped or plugged immediately after flushing to prevent contamination and to prepare for shipping.

3.10.2 Piping

3.10.2.a. All piping materials, design and fabrication shall comply with CFR Title 46 (Shipping).

3.10.2.b. Hydraulic piping, tubing, and fittings shall be seamless stainless steel with a design factor of at least 4.0. Stainless steel shall be in accordance with ASTM A312.

3.10.2.c. The use of materials containing cadmium is prohibited.

3.10.2.d. Piping design and installation shall provide sufficient flexibility to absorb stresses on the piping imposed by the crane’s structural flexing and thermal gradients from minimum ambient temperatures to maximum ambient temperatures and full operating temperature conditions and to absorb the full range of motion permitted by the crane.

3.10.2.e. Piping shall not be pre-stressed during installation.

3.10.2.f. Piping shall be supported with isolation type hangers.

3.10.2.g. Equipment interfaces and take-down joints for maintenance purposes shall be fitted with flange type connections with O-ring seal or SAE straight thread type connections with O-ring seal. National Pipe Connections or British Standard Pipe (BSPP) tapered threaded connections shall not be used.

3.10.2.h. The hydraulic oil return line in the crane turret shall be designed to prevent the formation of air pockets.

3.10.2.i. Interface of piping to drive unit hydraulic motors shall be accomplished with hydraulic tubing and flexible hydraulic hoses.

3.10.2.j. Tubing bends shall be used to the maximum extent possible in lieu of elbow fittings. For fittings 2 inch and smaller, standard radius tees and elbows shall be used. For fittings larger than 2 inch, standard tees and long radius elbows shall be used.

3.10.3 Hoses

3.10.3.a. All hoses shall be in accordance with SAE J1942 and SAE J1942/1.

3.10.3.b. All hose assemblies (with fittings attached) shall be proof load tested to 150% of their pressure rating.

3.10.3.c. All hoses shall be equipped with stainless steel or Monel fittings.

3.10.3.d. Skived hoses shall be sealed on ends to prevent water entry into the hose layers and reinforcing material.

3.10.3.e. Hose fittings shall be SAE J518/1 flanged connections (code 61 or code 62, split flange) or SAE Straight Thread O-Ring Boss type fittings.

3.10.3.f. Hoses shall not exceed 36 inches in length except as necessary to support the movement or articulation of equipment.

3.10.3.g. Hoses shall have a service life of at least 8 years.

3.10.3.h. Hoses exposed to the weather shall have a weatherproof cover intended for marine service in direct sunlight that is resistant to ultraviolet light degradation.

3.10.3.i. Hose covers shall be easily removable for…