Revision to Spec 41 22 13.15.pdf

P691 Aircraft Development and Maintenance Facility-Ph 2 eProject No. 1737036 Naval Air Station Patuxent River, MD

SECTION 41 22 13.15

BRIDGE CRANES, OVERHEAD ELECTRIC, UNDER RUNNING

THIS SECTION HAS BEEN DEVELOPED IN RESPONSE TO PPI-#222, #254, #255, #256,

#262, #257, #258 #259, #390, #391, #394, #397, #409, #429, #494, #498, #500, #501

PART 1 GENERAL

1.1 REFERENCES

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

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

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

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

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

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

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

ANSI/AGMA 6113 (2016B) Standard for Industrial Enclosed Gear Drives (Metric Edition)

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 360 (2016) Specification for Structural Steel Buildings

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

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

ASME B18.2.2 (2022) Nuts for General Applications:

Machine Screw Nuts, and Hex, Square, Hex Flange, and Coupling Nuts (Inch Series)

ASME B30.10 (2019) Hooks

ASME B30.16 (2017) Overhead Underhung and Stationary Hoists

ASME B30.17 (2020) Overhead and Gantry Cranes (Top

SECTION 41 22 13.15 Page 1

CUI

Running Bridge, Single Girder, Underhung Hoists)

ASME HST-1 (2012) Performance Standard for Electric Chain Hoists

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

AMERICAN SOCIETY OF SAFETY PROFESSIONALS (ASSP)

ASSP Z359 (2013) Fall Protection Code

AMERICAN WELDING SOCIETY (AWS)

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

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

ASTM INTERNATIONAL (ASTM)

ASTM A668/A668M (2021a) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM A931 (2008; R 2013) Standard Test Method for Tension Testing of Wire Ropes and Strand

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

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

ASTM F3125/F3125M (2019) Standard Specification for High Strength Structural Bolts and Assemblies, Steel and Alloy Steel, Heat Treated, Inch Dimensions 120 ksi and 150 ksi Minimum Tensile Strength, and Metric Dimensions 830 MPa and 1040 MPa Minimum Tensile Strength

CRANE MANUFACTURERS ASSOCIATION OF AMERICA (CMAA)

CMAA 74 (2015) Specifications for Single Girder Cranes

MATERIAL HANDLING INDUSTRY OF AMERICA (MHI)

MHI MH27.1 (2009) Specifications for Underhung Cranes and Monorail Systems

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2020) Enclosures for Electrical Equipment

SECTION 41 22 13.15 Page 2

(1000 Volts Maximum)

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

NEMA ICS 5 (2017) Industrial Control and Systems:

Control Circuit and Pilot Devices

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

NEMA ICS 8 (2011) Crane and Hoist Controllers

NEMA MG 1 (2016) Motors and Generators - Revision 1: 2018; Includes 2021 Updates to Parts 0, 1, 7, 12, 30, and 31

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2020; ERTA 20-1 2020; ERTA 20-2 2020; TIA

20-1; TIA 20-2; TIA 20-3; TIA 20-4)

National Electrical Code

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

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

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

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

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

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

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

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

29 CFR 1910 Occupational Safety and Health Standards

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

29 CFR 1910.179 Overhead and Gantry Cranes

29 CFR 1910.306 Specific Purpose Equipment and Installations

UNDERWRITERS LABORATORIES (UL)

UL 943 (2016; Reprint Feb 2018) UL Standard for Safety Ground-Fault Circuit-Interrupters

UL 1004-1 (2012; Reprint Nov 2020) UL Standard for

SECTION 41 22 13.15 Page 3

Safety Rotating Electrical Machines - General Requirements

1.2 DEFINITIONS

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

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

c. Dead Loads: The loads on a structure which remain in a fixed position relative to the structure.

d. Girder: The principal horizontal beam of the crane bridge. It is supported by the crane end trucks. Normally the crane trolley mounted hoist is suspended from the girder below the crane.

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

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

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

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

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

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

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

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

m. Operating Environments:

SECTION 41 22 13.15 Page 4

(1) General Purpose Service: This applies to most cranes and are, in large measure, the manufacturers' standard designs. Cranes should be classified as General Purpose Service if they are operating in routine environments.

(2) Ordnance/Explosives Handling: Cranes handling palletized or unpackaged ammunition, missiles, torpedoes, and other types of ordnance. Minimum requirement of CMAA service class D ( PPI #222, #259, #391, & #498) .

(3) Hazardous (Explosive) Environments: Cranes operating in hazardous environments as defined by the cognizant activity safety office must be equipped with electrical safety features that meet NEC Article 500. The activity safety office must identify the specific Class, Division, and Group, as well as the envelope that the hazard exists, to allow proper design and must list these in this section. Materials for mechanical components must be chosen to minimize the potential for sparking, typically bronze, stainless steel, or aluminum. Hazardous environments are split into two groups: minimum anti-spark protection and maximum anti-spark protection.

(a) Minimum Anti-Spark Protection is used when only the load block enters the explosive area.

(b) Maximum Anti-Spark Protection is used when the hazardous area envelops the entire crane.

1.3 SYSTEM DESCRIPTION

1.3.1 Crane Design Criteria

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

1.3.1.1 Classification

Provide under running bridge overhead electric traveling crane (OET), with under running trolley mounted hoist, conforming to CMAA 74 service class C for operation in an indoor environment, general purpose service, meeting the requirements of ASME B30.16 and ASME B30.17 , with an ambient temperature range of 40 to 90 degrees Fahrenheit . This crane must operate in an NEC Class I , Division II, Group D (PPI- #254, #257, #397, & #429) hazardous area. Hazardous protection is required for the full height of the crane. The crane girder must have to spans and vertical lift as indicated on the drawings .

The crane must be pendant controlled and operate in the spaces and within the loading conditions indicated. The pendant controller must be mounted on a separate festooned cable system from the trolley power supply. The crane must operate on 480 -volts AC, 60 Hz, three phase power source.

Maximum crane wheel loads (without impact) due to dead, trolley, and lifted loads, with the trolley in any position, must not cause a more severe loading condition in the runway support structure than that produced by the design wheel loads and spacing indicated.

SECTION 41 22 13.15 Page 5

1.3.1.2 Rated Capacity and Speeds

Provide crane with a rated capacity of 15,000 pounds . Lower load block or assembly of hook, swivel bearing sheaves, pins, and frame suspended by the hoisting ropes are not considered part of the rated capacity.

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

Rated Speeds feet/min

Description Minimum Maximum

Main Hoist 40 30

(PPI #258, #390,

#494)

Trolley 60 70

Bridge 100 120

1.4 VERIFICATION OF DIMENSIONS

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

Verify all dimensions of the building that relate to fabrication of the crane and notify the Contracting Officer of any discrepancy before finalizing the crane order.

1.5 SUBMITTALS

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are for information only. When used, a code following the "G" classification identifies the office that will review the submittal for the Government.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-02 Shop Drawings

Overhead Electric Crane System ; G

Complete Schematic Wiring Diagram ; G

Control System ; G

SD-03 Product Data

Gear Reducers ; G

Hoist Brakes ; G

Travel Brakes ; G

Couplings ; G

Load Block and Hook ; G

SECTION 41 22 13.15 Page 6

Hoist and Trolley Units ; G

Bridge End Trucks ; G

Crane Bridge Girder ; G

End Stops ; G

Bumpers ; G

Crane Runway System ; G

Motors ; G

Enclosures ; G

Circuit Breakers ; G

Disconnect Switch ; G

Contactors and Relays ; G

Fuses ; G

Variable Frequency Drives ; G

Limit Switches ; G

Resistors ; G

Pendant Push-Button Station ; G

Pendant Conductor System ; G

Crane Controllers ; G

Control Parameter Settings ; G

Warning Devices ; G

Runway Conductor System ; G

Bridge Conductor System ; G

Overload Protection ; G

Painting System ; G

Control System ; G

SD-05 Design Data

Load and Sizing Calculations ; G

SD-06 Test Reports

Hook Proof Test ; G

SECTION 41 22 13.15 Page 7

Post-Erection Inspection ; G

Operational Tests ; G

Hook Tram Measurement ; G

Load Tests ; G

SD-07 Certificates

Wire Rope ; G

Crane Runway System ; G

Loss of Power Test ; G

Coupling Alignment Verification Record ; G

Overload Test ; G

Brake Adjustment Record ; G

Compliance with Listed Standards ; G

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals ; G

1.6 QUALITY ASSURANCE

1.6.1 Manufacturer Qualification

Overhead Electric Crane System, including sub-system components manufactured by vendors, must be designed and manufactured by a company with a minimum of 10 years of specialized experience in designing and manufacturing the type of overhead crane required to meet requirements of the Contract Documents.

The crane design must be accomplished by, or directly supervised by, a registered professional engineer (PE). PE licensing must be by a board or agency authorized to license and register professional engineers. The PE may be a Contractor's regular employee or a consultant. The PE's review and attestation of specification compliance and professional responsibility must be signified by his or her PE original seal and dated signature on the final drawings. The professional engineers must only undertake and perform work under this contract in the branch(s) of engineering in which they are licensed.

1.6.2 Pre-Delivery Inspections

Contractor is responsible for performance of quality control inspections, testing, and documentation. Submit all crane test data recorded on appropriate test record forms suitable for retention for the life of the crane.

1.6.2.1 Inspection of Steel Castings

Visually inspect and test load-carrying steel castings using the magnetic-particle inspection method or using ultrasonic testing. All load

SECTION 41 22 13.15 Page 8 bearing components, couplings, shafts, and gears, in the hoist drive train must be rolled or forged steel, except brake drums which may be ductile iron. Methods of repairing the discontinuities is subject to review by the Contracting Officer.

1.6.2.2 Inspection of Hook Assembly

Inspect hook by a magnetic-particle type inspection prior to delivery.

Furnish documentation of hook inspection to Contracting Officer prior to field operational testing. As part of the acceptance standard, linear indications are not allowed. Welding repairs of hook are not permitted.

A hook showing linear indications, damage or deformation is not acceptable.

1.6.2.3 Hook Proof Test

Proof test the load hook per ASME B30.10 . Perform the proof test prior to Hook NDT.

1.6.3 Drawings: Overhead Electric Crane System

a. Submit drawings showing the general arrangement of all components in plan, elevation, and end views. Show all major features of the crane including: hook approaches on all four sides, clearances and principal dimensions, assemblies of hoist, trolley and bridge drives, motor nameplate data, overcurrent protective device ratings, and electrical schematic drawings. Include weights and centers of gravity of major components.

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

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

d. Provide control system .

1.6.4 Design Data: Load and Sizing Calculations

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

1.6.5 Certificates

All certifications shall be dated and shall bear the original signature (above the printed name) of the authorized representative of the Contractor or the manufacturer of the items or equipment being certified.

SECTION 41 22 13.15 Page 9

Each certification shall clearly identify the crane, the drives, components, and location (as applicable) to which it applies:

a. Submit a Wire Rope Certification with the wire rope manufacturer's certification that the rope meets the published breaking strength or the actual breaking strength of a sample taken from the reel and tested. Certification shall be traceable to the hoist, crane, and reel.

b. Submit a Crane Runway System Certificate stating that the new crane will operate properly on the runway. For runways provided by Contractor, include statement certifying runway has been aligned in accordance with CMAA 74 or MHI MH27.1 , as applicable. If runway is existing and if the crane(s) cannot operate without restriction, the Contractor shall indicate crane limitations.

c. Submit a Loss of Power Test Certificate stating that a test may be performed in which power is removed from the crane while the hoist, bridge, and trolley are in operation to simulate a loss of power.

d. Submit a Certificate of the Coupling Alignment Verification Record .

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

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

g. Submit a Certificate of the Brake Adjustment Record . Provide a brake adjustment record and installation/maintenance manuals for each brake on the crane. Each brake measurement must have a tolerance traceable to the associated brake manual or documentation provided by the brake manufacturer, location of measurements, and the actual brake setting.

Changes made to settings of the brake, at any time, will void the record.

h. Submit a Certificate of Compliance with Listed Standards .

1.6.6 Welding Qualifications and Procedure

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

1.7 CRANE SAFETY

Comply with the mandatory and advisory safety requirements of ASME B30.10 , ASME B30.16 , ASME B30.17 , ASME HST-4 or ASME HST-1, 29 CFR 1910.147 , 29 CFR 1910.179 , 29 CFR 1910.306 , and all applicable provisions of 29 CFR 1910 and NFPA 70 . Where personal fall arrest anchorages are provided, design anchorages in accordance with ASSP Z359 .

SECTION 41 22 13.15 Page 10

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 General

Provide materials and equipment which are standard products of manufacturers regularly engaged in the fabrication of complete and totally functional cranes including necessary ancillary equipment. Material will be free from defects and imperfections that might affect the serviceability and appearance of the finished product. All material must be new and unused.

2.1.2 Nameplates

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

2.1.3 Capacity Marking

Mark the rated capacity in ton pounds units on each side of the crane on the bridge girder. Capacity marks must be large enough to be clearly visible from the floor. Individual hoist units must have their rated capacity clearly marked on their bottom block, and additionally labeled on the hoist body. Rated capacity must include all accessories below the hook, such as load bars, magnets, and grabs, as part of the load to be handled.

2.1.4 Safety Warnings

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

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

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

2.2 STRUCTURAL REQUIREMENTS

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

2.2.1 Structural Connections

High-strength bolted structural connections must be designed and installed

SECTION 41 22 13.15 Page 11 in accordance with RCSC A348. Bolts must be of ASTM F3125/F3125M Grade A325/A325M or Grade A490/A490M material. Galvanized bolts are not acceptable.

Welded connections for the crane must be performed in accordance with AWS D14.1/D14.1M . Welded connections to the building must be performed in accordance with AWS D1.1/D1.1M . Allowable stress values must comply with

CMAA 74.

2.2.2 Crane Bridge Girder

Provide a bridge girder of rolled steel shape conforming to CMAA 74 or patented track conforming to MHI MH27.1 , as applicable. For ordnance handling cranes, the bridge girder must be of patented track (PPI #222, #259, #391, & #498) . Intermittent ("skip") welds on bridge girder elements (e.g. web and flange interfaces) are prohibited. If the girder is notched to fit over the end trucks, reinforce the girder ends with vertical and horizontal stiffeners. Splices in the unsupported length of the girder are prohibited.

For patented track girder, submit manufacturer's standard published tables that verify the crane bridge girder is sized in compliance with all specification requirements. When standard published tables are not available, provide calculations for the strength design and deflection of the bridge. Patented track girder must be of welded steel construction and fabricated by a manufacturer regularly engaged in the production of this type of beam.

2.2.3 Bridge End Trucks

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

2.2.4 End Stops and Bumpers

Fit bridge girders with structural steel end stops. Locate stops to permit maximum trolley travel. Fit bridge end trucks and trolley frames with shock-absorbing bumpers capable of decelerating and stopping the bridge and trolley within the limits stated by 29 CFR 1910 and CMAA 74 or MHI MH27.1 , as applicable. Ensure bumpers and end stops conform to ASME B30.17 . Bumpers must fully engage end stops. Mount bumpers so that there is no direct shear on mounting bolts (if any) upon impact. Bumpers must provide adequate clearance between the crane and surrounding structure when compressed to preclude damaging equipment. When more than one crane is located and operated on the same runway, bumpers shall be provided on their adjacent ends or on one end of one crane. Fit the other end of the end-truck with a structural steel stop to engage the bumpers of the adjacent crane. Ensure bridge bumpers are properly aligned with runway end stops. Metal to metal contact at the bumper to end stop connection is not permitted.

2.2.5 Crane Runway System

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

SECTION 41 22 13.15 Page 12 conforming to CMAA 74 or patented track girders conforming to

MHI MH27.1 .

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

c. For patented track girders, perform splices as necessary in accordance with the manufacturer's recommendations and requirements. Align ends of lower T-section to minimize the horizontal gap on the running surface to not greater than 1/16 inch and not greater than a vertical difference of 1/32 inch for the wheel running surface alignment for a smooth crossing by the wheels. Splice assemblies must be from the same manufacturer as the patented track and located under structural support members. Submit manufacturer's standard published tables that verify the crane runway track is sized in compliance with all specification requirements. When standard published tables are not available, provide calculations for the strength design and deflection of the beams.

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

2.2.6 Additional Provisions for Outside Service

Seal weld structural members on outdoor cranes. Provide crane bridges with parking brakes which will sufficiently hold the crane against a wind pressure of 5 psf for in-service conditions. Provide crane bridge with manually-operated pin locks at each rail, designed to securely anchor the crane against a wind pressure of 30 psf for out-of-service conditions.

Design members to prevent the collection of water on crane.

2.3 MECHANICAL REQUIREMENTS

Provide steel shafts, gears, keys, and couplings. Cast iron and aluminum used to support components of the hoist power transmission train must be ductile. Gray cast iron load bearing parts are prohibited.

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

2.3.1 Threaded Fasteners

Fasten base-mounted and flange-mounted components and all mechanical connections subjected to calculable loads with lubricated SAE J429 Grade 5 fasteners, ASTM F436/F436M washers, and SAE J995 Grade 5 nuts. Match bolt and nut threads. Oversize tapping is not permitted. Bolt and nut threads must conform to ASME B18.2.2 and ASME B1.1 . Bolts and screws may be installed into tapped holes provided that adequate thread engagement is provided to develop the full designed connection strength.

SECTION 41 22 13.15 Page 13

2.3.2 Hoist

Provide hoist conforming to ASME B30.16 , ASME B30.17 , and CMAA 74 service class D or better, double reeved, except as modified and supplemented in this section. Standard commercial hoist and trolley units (packaged hoists) must be electric wire rope hoist conforming to ASME HST-4 Duty Class H4 or better. For custom hoist shafts, the fatigue design factor must be a minimum of 1.5.

Configure trolley such that the trolley frame contacts the trolley stops and prevents the trolley from dropping more than one inch in the event of an axle or wheel failure.

2.3.2.1 Hoist Brakes

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

2.3.2.2 Load Block and Hook

a. The load block must be constructed of steel non-sparking materials and designed to prevent metal-to-metal contact of moving parts. The block must be fully enclosed, concealing the sheaves and wire ropes, except for wire rope slots and drain holes. The design must preclude the wire rope from being cut, pinched, crushed, or chafed in case of two-blocking. The block must be clearly marked with the capacity in pounds on both sides. The load block sheaves must be constructed of non-sparking materials. An insulated link must be provided on each hook block per the requirements of NAVSEA OP-5. Standard commercial blocks may be used at their published ratings when their published design factors are 5.0 or greater.

b. Provide an unpainted single barbed forged steel hook complying with ASTM A668/A668M and which conforms to ASME B30.10 . Provide an unpainted single barbed hook of non-sparking material with a minimum material longitudinal elongation of 16 percent in 2 inches. Bronze clad hooks are prohibited. Hook dimensions must be as shown on the drawings. Fit hook with a safety latch designed to preclude inadvertent displacement of slings from the hook saddle. The hook and hook nut must be removable without unreeving of the hoist or disassembly of the block. Provide hook nut with a removable type set screw or other similar fastener, installed in a plane parallel to the longitudinal axis of the hook shank. Do not weld hook nut. Uniquely mark the hook in a permanent fashion that is traceable to the NDT certification. The nut must be marked to match the hook. The hook nut must be of non-sparking materials. Hook must be free to rotate through 360 degrees when supporting the test load up to 125 percent of the rated capacity. Upper hooks of hook suspended hoists shall be of non-sparking materials.

2.3.2.3 Wire Ropes

a. Wire rope must conform to ASTM A1023/A1023M and be tested as required by ASTM A931. The wire rope must be in a double reeved configuration with the equalizing method perpendicular to the running sheaves.

SECTION 41 22 13.15 Page 14

Provide wire rope with a minimum design factor of 5 to 1 based on the load experienced at rated capacity and minimum breaking strength of the wire rope.

b. Hoisting rope end connections, other than drum connections, must be speltered sockets with forged steel terminals or swaged fittings installed in a fashion that provides 100 percent of the breaking strength of the wire rope. Anchor hoisting rope ends on the drum by means of swaged fittings or by clamping with hoisting rope ends neatly and securely seized with corrosion resistant wire. Provide proof of Wire Rope breaking strength. Wedge sockets or aluminum swages are not permitted on wire rope end connections.

2.3.2.4 Drum

Provide drum made of steel. Design the drum such that all hoisting rope is wound in a single layer and so that not less than two dead wraps of hoisting rope remain on each anchorage when the hook is in its extreme low position. Drum grooving must be machined right and left hand beginning at the ends and grooving toward the center of the drum. Minimum drum groove depth must be 0.375 times the rope diameter.

Provide minimum drum groove pitch either 1.14 times the rope diameter, or the rope diameter plus 1/8 inch , whichever is smaller. Minimum drum pitch diameter must be 16 times the rope diameter. Do not paint, coat or galvanize the surface of the drum which comes in contact with wire rope.

2.3.2.5 Sheaves

Provide steel sheaves (PPI #500) . Machine or grind the grooves to contour and rim toughen, flame, or induction harden to not less than 320 BHN.

Minimum pitch diameters must be 16 times the rope diameter for running sheaves and no less than 12 times the rope diameter for equalizer sheaves. Provide sheave groove depth of not less than 1.5 times the hoisting rope diameter. Do not paint wire rope contact surfaces of sheaves.

2.3.3 Drives

Provide travel assemblies with at least one quarter of all wheels driven for the crane and a minimum of one driven wheel on each side of the flange. No 3-bearing shaft configurations are allowed. The travel drive arrangement will be the contractor's design of choice.

2.3.3.1 Bridge Drives

Outdoor cranes must have half of the total wheels driven. Acceleration and deceleration must meet the requirements specified in CMAA 74. Provide bridge travel limit switches.

2.3.3.2 Trolley Drives

Provide a motor-driven trolley arrangement. Provide trolley travel limit switches.

2.3.4 Travel Brakes

Provide brakes with an externally accessible means to manually release the brake. The brakes must be equipped with a manual self-return to ON brake

SECTION 41 22 13.15 Page 15 release and designed to permit inspection and adjustment without disassembly of the brake.

2.3.4.1 Bridge Brake

Provide bridge drive with an end-mounted electro-mechanical brake conforming to the requirements of CMAA 74 capable of stopping the motion of the bridge within a distance in feet equal to 10 percent of the full load speed in feet per minute when traveling at full speed with a full load. Provide brakes with a minimum torque rating per CMAA 74 according to the applicable environment, but not sized larger than 150 percent of the drive motor rated torque.

2.3.4.2 Trolley Brake

Provide trolley drive with a non-coasting mechanical drive capable of stopping the trolley within a distance in feet equal to 10 percent of the rated speed in feet per minute when traveling at rated speed with rated load. The electro-mechanical brakes must have a minimum torque rating per CMAA 74 according to the applicable environment, but not be sized larger than 150 percent of the motor torque.

2.3.5 Gearing

Provide gearing of the enclosed gear reducers type. Provide steel spur, helical, or herringbone type gears and pinions only. Gearing must conform to ANSI/AGMA 2001 and AGMA 908. Internal and external gear dimensional tolerances must conform to the applicable AGMA standard for tooth geometry and tolerances. Open-type gearing is not acceptable, except for final drives.

2.3.5.1 Gear Reducers

Gear reducers must be standard items of manufacturers regularly engaged in the design and manufacture of gear reducers for Class D and E cranes.

Gear reducers must be designed, manufactured, and rated in accordance with ANSI/AGMA 6113 ( ANSI/AGMA 6013 ) (for trolley drives only), as applicable.

Except for final reduction, the gear reduction units must be fully enclosed in oil-tight housing.

2.3.5.2 Open Gearing

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

2.3.6 Bearings

All bearings, except those subject only to small rocker motion, must be anti-friction type. Provide permanently lubricated and sealed bearings or provide grease lubricated bearings with means for relubrication through easily accessible lubrication fittings.

Fit all connections subject only to small rocking motion with manufacturer's standard bronze alloy bushings in the pivot pin bore, as applicable. Provide means for relubrication of grease lubricated bushings through easily accessible lubrication fittings or provide oil impregnated

SECTION 41 22 13.15 Page 16 type bushings.

2.3.7 Couplings

Chain and continuous sleeve type couplings must not be used. Spline couplings are acceptable as installed on c, d, or p-face assemblies.

Conventional couplings must not be loaded in the radial direction. Brake wheel or brake disc couplings (if used) must be compatible with the required coupling type. Flexible couplings must not be relied upon to compensate for inaccurate alignment. Ends of coupled shafts must be aligned within the recommended installation criteria of the coupling manufacturer.

2.3.8 Wheels

a. Top running trolley and bridge travel wheels are to be straight tread, double flanged, and sized in accordance with CMAA 74 recommendations for wheel sizing and flange to rail head clearances. Wheel material must be of rolled-to-shape or roll-forged steel. Provide steel wheels with a minimum tread hardness of 320 BHN.

b. Under running wheels are to be flanged or provided with side guide rollers. Provide wheel sizing and flange-to-rail head clearances in accordance with MHI MH27.1 and CMAA 74 recommendations, as applicable. Wheel material is to be steel or ductile cast iron.

Minimum tread hardness for underhung wheels that run on patented track is 375 BHN. Minimum tread hardness for wheels running on structural shapes is 320 BHN. Wheels are to be made of forged steel (PPI #262, #394, #409, & #501) . Provide wheels of non-sparking material. The minimum tread hardness for bronze wheels is 225 BHN.

2.3.9 Drip Pans

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

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

c. Provide drip pans fitted around the shank of the hook and extending outward to encompass all possible points of lubrication drips from the load block or wire rope and must be easily removable without disassembly of the hook or load block and shall not interfere with the crane structure during testing of the upper limits.

2.4 ELECTRICAL REQUIREMENTS

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

SECTION 41 22 13.15 Page 17

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

2.4.1 Motors

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

All motors must have a minimum of a 60 minute duty rating and be Totally Enclosed Non Ventilated (TENV), Totally Enclosed Fan Cooled (TEFC), or Totally Enclosed Blower Cooled (TEBC). Provide inverter duty motors for Open Loop Variable Frequency Drives (VFD). Provide motors with a minimum of Class F insulation. Provide motor overload protection utilizing a thermal sensitive device embedded in its windings. Provide motors painted to manufacturer's standard for "wash-down" service. Motors located outdoors must be furnished with anti-condensation heaters that remain energized when the mainline contactor is deenergized.

2.4.2 Controls

a. Provide static reversing, variable frequency drives (VFD) for the bridge, trolley and hoist electric controls. VFD controllers must meet NEMA ICS 8 , Part 8 and at a minimum, provide under-voltage protection, electronic instantaneous over current protection, DC bus over voltage protection, and be able to withstand output line to line shorts without component failure. Select bridge and trolley drives such that the continuous rating of the controller is not less than the motor full load current. Select hoist drives such that the continuous rating of the controller is not less than 125 percent 100 percent of the motor full load current. All hoist drives must have a motor over-torque limit to lock out the hoist and prevent gross overload of the associated hoist. Provide dynamic braking for each electric drive that is sized per VFD manufacturer's requirements. Submit VFD Control Parameter Settings .

b. Provide speed control which is infinitely variable for each function, controlled via pendant pushbutton station. Provide controls designed such that the maximum speed of each function will be limited to 25 percent of rated speed when a slow speed switch is actuated on the controller.

c. The hoist, trolley, and bridge brakes must set after the associated controller decelerates the drive motor to a controlled stop. The hoist, trolley, and bridge, controllers must be sized to provide sufficient starting torque to initiate motion of that crane drive mechanism from standstill with 0 to 125 percent of rated load on the hook. The hoist controller must prove torque before release of the brakes and enable the drive motor to develop full torque continuously at zero speed. Motors must operate smoothly at all speeds without torque pulsations and must only be energized within the frequency range of 50-60 Hz at rated speed.

d. Provide the bridge and trolley motor control systems with a drift point between OFF and the first speed control point in each direction.

e. The use of definite purpose contactors is prohibited. If IEC contactors are used, the application cannot exceed the contactor

SECTION 41 22 13.15 Page 18 manufacturer's AC3 ratings for the contactor at a minimum.

f . On hoist function roll-up must be less than 1/8 inch measured at the hook block and roll-back must not occur over the entire load range.

g. Use of Uninterruptible Power Supplies (UPS) is prohibited. Feed control circuits from a single phase, air cooled, double wound transformer with a grounded metal screen between the primary and secondary windings of the transformer.

h. Provide a main line contactor. Energization of the main line contactor must be controlled by the POWER-OFF/POWER-ON switch/pushbutton on all controllers. Upon actuation of the POWER-OFF pushbutton; power to all drive motors, brakes, and controls must be removed. The mainline contactor must not be able to be energize while the POWER-OFF pushbutton is actuated. The POWER-OFF pushbutton circuitry must be independent of all controls or any other electronic devices.

2.4.3 Protection

Protection must not be less than that required by NEMA ICS 3 , NEMA ICS 8 , CMAA 74, NFPA 70 , UL 1004-1 , UL 943 , 29 CFR 1910.147 , 29 CFR 1910.179 , 29 CFR 1910.306 and all applicable provisions of 29 CFR 1910 . Provide disconnect switch or enclosed type circuit breaker readily accessible to the crane operator for the crane disconnect. Provide an On/Off button that removes power from the motors, brakes and control circuit on all operator control stations. Provide for lockout/tagout of all hazardous energy sources. Provide product data for all circuit breakers and fuses .

2.4.4 Resistors

Provide resistors with natural convection cooling sized as recommended by the VFD OEM and fabricated of corrosion resistant metal; the use of "wire wound" type resistors is prohibited for segments of 8 ohms or less. Mount resistors in substantial, ventilated enclosures constructed entirely of non-combustible materials. When mounted outdoors provide stainless steel resistor enclosures. Provide resistors with terminals fitted in the coolest position in the enclosure.

2.4.5 Transients and Harmonics Protection

a. Provide contactors and relays with appropriate Metal Oxide Varistors (MOV) or resistor-capacitor (R-C) surge absorbers installed across the respective coil.

b. Provide transient protection for electronic drive controllers that is either internal to the drive or via an MOV connected line-to-ground close to the line terminals of the drive.

c. Provide line reactors rated for continuous duty operation based upon the motor nameplate amperes. With motors of 50 horsepower or greater, harmonics protection must be provided by an isolations transformer or as recommended by the VFD OEM. For a drive motor branch circuit that exceeds 150 feet in length, a reactor must also be connected in series with the controller load (output) terminals to provide standing wave protection or as otherwise recommended by the VFD or motor OEM.

SECTION 41 22 13.15 Page 19

2.4.6 Limit Switches

a. Limit switches must be rated for the NEC Hazardous Classifications specified in the Classification section of this specification.

b. Provide primary upper and lower geared limit switches. Geared limits must allow reversing direction to back out of the limit without resetting. The lower limit switch must be set such that there are a minimum of two wraps of rope on the hoist drum.

c. Provide a backup mechanical hook block activated upper limit switch wired independent of the directional controllers and the primary upper limit switch that removes power from the hoist motor, hoist brake and hoist controls conforming to NEMA ICS 5 . The backup limit must require hoist resetting prior to operation of the hoist in any direction.

d. Travel limit switches must be provided for the bridge and trolley motion to slow the crane to 25 percent of its rated speed 10 feet before the bridge end stops and 5 feet from the trolley end stops.

Limit switches must be mounted rigidly in a manner so as to protect the switch from misalignment or damage. The target/trip arm must be large enough to provide interception given a misalignment were to occur.

2.4.7 Operator Controls

a. Provide crane equipped with a pendant pushbutton station.

b. Operator controls must be rated for the NEC Hazardous Classifications specified in the Classification section of this specification.

2.4.7.1 Pendant Pushbutton Station

The cranes must be controlled from a pendant pushbutton station suspended from an independent festooned messenger track system, operating the length of the bridge. Provide multiconductor flexible cords for pendant pushbutton stations with No. 16 AWG minimum conductors. Provide a method of strain relief to protect the electrical conductors from damage. Locate the pendant pushbutton station 4 feet above the finished floor.

Pushbutton pendant station must have its elements legibly marked and arranged vertically, in order, in accordance with CMAA 74. Provide one speed pendant pushbuttons for control of the hoist bridge and trolley.

Provide pendant pushbuttons for control that spring return to the OFF position. Voltage in the pendant pushbutton station must not exceed 150 Volts AC or 300 Volts DC. The pendant must be rated for the NEC Hazardous Classifications specified in the Crane Design Criteria "Classification" Section.

2.4.7.1.1 Pendant Conductor System

Provide a festoon type pendant conductor system. The festoon cables must be flat cables suspended from carriers riding on an I-beam or C-track.

The pendant controller must be capable of traveling the entire length of the bridge and move independently of the trolley. Festoon loops must not extend below the high hook position.

SECTION 41 22 13.15 Page 20

2.4.8 Electrification Systems

2.4.8.1 Runway Conductor System

a. Provide a rigid runway Conductor Bar System for the runway conductor system, including all necessary cables and hardware to the crane from a wall or column mounted disconnect switch. Provide electrification system with three power conductors and an equipment grounding conductor. UV resistant. Steel (non-stainless) conductor bars are prohibited. The crane must be grounded through the runway electrification system. The grounded conductors must be a minimum of 70 square millimeters. Provide runway conductors sized for simultaneous motions of the hoist, bridge, trolley mechanisms and any ancillary loads. If there is any way the hook block or wire rope can swing into the runway electrification, provide a guard installed to prevent contact.

b. Provide two Collector Shoes (tandem design) for each conductor; each collector shoe must be rated for not less than the runway conductor sizing, so as to provide redundancy.

2.4.8.2 Bridge Conductor System

a. Provide Festoon System for the bridge conductor system utilizing cables suspended from carriers riding on an I-beam or C-track.

Conductors must be fabricated from copper. A minimum of 20 percent of the festoon control circuit conductors for each electrification system must be spares at the time of crane acceptance. The trolley is required to be grounded through this conductor system. The grounded conductors must be a minimum of 2/0 AWG. Festooned cable loops must not extend low enough to come into contact with any obstructions.

2.4.9 Overload Protection

a. Provide a capacity overload protective device for all hoist systems using VFD drive capacity overload protection (separate from torque limiting feature of the VFD). Hoist capacity overload protection must be adjustable between 80 and 150 percent of hoist capacity. Provide a keyed override or other means to disable the hoist capacity overload protection when performing a load test. If a non-adjustable slip clutch is utilized, the OEM factory setting is acceptable and must be identified.

2.4.10 Enclosures

a. Provide enclosures for control panels, controls, and brakes in accordance with NEMA 250 and NEMA ICS 6 , Classification Type 7 indoor Class I hazardous . Provide enclosures with listed drains to prevent accumulation of water within the enclosure.