Specification Section 41 22 13.55 .pdf

P197-Aircraft Maintenance Hangar & Parking Garage WON 1620400 MCAS Cherry Point

SECTION 41 22 13.55

BRIDGE CRANES, UNDER RUNNING, AIRCRAFT HANGAR

11/20

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 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 (2015) Nuts for General Applications:

Machine Screw Nuts, 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 (2015) Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung Hoists)

ASME HST-4 (2016) Performance Standard for Overhead Electric Wire Rope Hoists

SECTION 41 22 13.55 Page 1

AMERICAN SOCIETY OF SAFETY PROFESSIONALS (ASSP)

ASSP Z359 (2013) Fall Protection Code

AMERICAN WELDING SOCIETY (AWS)

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

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

ASTM INTERNATIONAL (ASTM)

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

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

ASTM A1023/A1023M (2019) Standard Specification for Stranded Carbon Steel Wire Ropes for General Purposes

ASTM E125 (1963; R 2013) Photographs for Magnetic Particle Indications on Ferrous Castings

ASTM E543 (2015) Standard Practice for Agencies Performing Non-Destructive Testing

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

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

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

CRANE MANUFACTURERS ASSOCIATION OF AMERICA (CMAA)

CMAA 70 (2015) Specifications for Double Girder Cranes

CMAA 74 (2015) Specifications for Single Girder Cranes

ELECTRIFICATION AND CONTROLS MANUFACTURERS ASSOCIATION (ECMA)

ECMA 15 (2018) Cable-less Controls for Electric Overhead Traveling Cranes

SECTION 41 22 13.55 Page 2

MATERIAL HANDLING INDUSTRY OF AMERICA (MHI)

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

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2018) Enclosures for Electrical Equipment (1000 Volts Maximum)

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

NEMA ICS 5 (2017) Industrial Control and Systems:

Control Circuit and Pilot Devices

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

NEMA ICS 8 (2011) Crane and Hoist Controllers

NEMA MG 1 (2018) Motors and Generators

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 S348 (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

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U.S. NAVAL SEA SYSTEMS COMMAND (NAVSEA)

NAVSEA T9074-AS-GIB-010/271 (1999; Notice 1) Requirements for Nondestructive Testing Methods

UNDERWRITERS LABORATORIES (UL)

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

UL 1004-1 (2012; Reprint Aug 2017) UL Standard for 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. Typically, for single girder cranes the trolley mounted hoist is suspended from the girder below the crane. For double girder cranes, the hoist can be mounted on top of the under running trolley.

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.

SECTION 41 22 13.55 Page 4

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. Hazardous (Explosive) Operating Environment: Cranes operating in hazardous environments as defined by the cognizant activity safety office must be equipped with electrical safety features that meet NFPA 70 Article 500. The activity safety office must identify the specific Class and Division, 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.

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

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

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

1.3 SYSTEM DESCRIPTION

The requirements for the crane runway system and rail supporting structures are specified in Section 05 12 00 STRUCTURAL STEEL, and must conform to AISC 360 .

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. Provide loaded hook coverage to the maximum extent possible in the Aircraft Maintenance Bay.

1.3.1.1 General

Include the following: Number of cranes 2, located in Hangar identified as module 1 & 2, with the capacity expressed in 5 tons , for each overhead electric traveling (OET) crane. Also clearly locate and identify each hoist and system components.

1.3.1.2 Classification

Provide under running, double girder bridge overhead electric traveling crane(s) (OET), with under running trolley mounted hoist, conforming to MHI MH27.1, CMAA 70, and CMAA 74 service class C for operation in an indoor environment, hazardous area service, meeting the requirements of ASME B30.16 and ASME B30.17 , with an ambient temperature range of 37 to 88 degrees Fahrenheit. This crane must operate in an NFPA 70 Class I , Division 2 , Group C hazardous area. Hazardous protection is required for the 20 feet above floor level. The crane span must be 95 feet with a

SECTION 41 22 13.55 Page 5 vertical lift of 29.5 feet and as specified herein.

The crane must be radio controlled with pendant backup and operate in the spaces and within the loading conditions indicated. Provide a crane, including hooks and hoisting ropes, that in all operating configurations is able to clear the vertical lift fabric door maintenance catwalk. The crane must operate on 460-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.

1.3.1.3 Rated Speeds

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

Rated Speeds feet/minute

Description Minimum Maximum

Main Hoist 14 27

Trolley 50 80

Bridge 50 115

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" designation;

submittals not having a "G" designation are for Contractor Quality Control approval. Submittals with an "S" are for inclusion in the Sustainability eNotebook, in conformance with Section 01 33 29 SUSTAINABILITY REPORTING.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-02 Shop Drawings

Overhead Electric Crane System; G

Complete Schematic Wiring Diagram; G

Control System and Network Drawings; G

SD-03 Product Data

Hoist Brakes; G

SECTION 41 22 13.55 Page 6

Travel Brakes; G

Couplings; G

Load Block and Hook; G

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

Contactors and Relays; G

Fuses; G

Variable Frequency Drives; G

Limit Switches; G

Resistors; G

Radio Control System; G

Pendant Conductor System; G

Crane Controllers; G

Control Parameter Settings; G

Pilot Devices; G

Warning Devices; G

Floodlights; G

Runway Conductor System; G

Bridge Conductor System; G

Overload Protection; G

Load Indicating Device; G

Painting System; G

SECTION 41 22 13.55 Page 7

Control System and Network; G

SD-05 Design Data

Load and Sizing Calculations; G

SD-06 Test Reports

Hook Proof Test; G

Hook Non-Destructive Test (NDT); G

Post-Erection Inspection; G

Operational Tests; G

Hook Tram Measurement; G

Load Tests; G

SD-07 Certificates

Wire Rope; G

Crane Runway; G

Hazardous Material; G

Loss of Power Test; G

Coupling Alignment Verification Record; G

Overload Test; G

Brake Adjustment Record; G

Compliance with Listed Standards; G

Contractor Hazardous Environment; G

Hoist Manufacturer Hazardous Environment; G

Public Domain Software; G

Software and Services; G

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals, Data Package 3; G

SD-11 Closeout Submittals

Disabled Ports, Connectors, and Interfaces; G

Network-Capable Control Devices; G

Control System Access Control; G

SECTION 41 22 13.55 Page 8

Control System Account Management; G

Patch Management and Updates; G

Malware Detection and Protection; G

Wireless Technology Provisions; G

Control System Inventory; G

Evaluation Status of Hardware and Software; 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 ultrasonic testing. Reference allowable degree of discontinuities to ASTM E125, and relationship to service loads and stresses, critical configuration, location and type. All load 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 Hook Proof Test

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

1.6.2.3 Inspection of Hook Assembly

Inspect hook by a magnetic-particle type inspection and tested ultrasonically prior to delivery. Furnish documentation of hook inspection to Contracting Officer prior to field operational testing. As

SECTION 41 22 13.55 Page 9 part of the acceptance standard, linear indications greater than 1/16 inch are not allowed. Welding repairs of hook are not permitted. A hook showing linear indications, damage or deformation is not acceptable.

1.6.2.3.1 Hook Non-Destructive Test (NDT)

Magnetic-particle inspect the hook over the entire area in accordance with ASTM A275/A275M . Acceptance standard is no defects. A defect is defined as a linear indication that is greater than 1/16 inch long. For hooks of non-magnetic material, NDT shall be liquid penetrant (PT) method in accordance with ASTM E1417/E1417M . For PT testing of hooks containing stainless steels, titanium, or nickel based alloys, total halogens and Sulphur used in the NDT process shall be controlled as specified in

NAVSEA T9074-AS-GIB-010/271 .

Inspect each hook and shank over the entire surface area by magnetic particle inspection.

a. Procedure: Conduct magnetic particle inspection in accordance with ASTM A275/A275M with the following restrictions: Do not use DC yokes (including switchable AC/DC yokes used in the DC mode) or permanent magnet yokes. Do not use automatic powder blowers or any other form of forced air other than from a hand-held bulb for the application or removal of dry magnetic particles. Remove arc strikes. Equipment ammeters must have an accuracy of plus or minus 5 percent of full scale (equipment ammeter accuracy other than that stated is acceptable provided the MT procedure states that a magnetic field indicator is used to establish and verify adequate field strength for all aspects of the inspection) For hooks of non-magnetic material, NDT shall be liquid penetrant (PT) method in accordance with ASTM E1417 or T9074-AS-GIB-010/271. For PT testing of hooks containing stainless steels, titanium, or nickel based alloys, total halogens, and Sulphur used in the NDT process shall be controlled as specified in

T9074-AS-GIB-010/271.

b. Acceptance Criteria: Defects found on the hook will result in rejection of defective items for use on furnished hoist. For this inspection, a defect is defined as a linear indication for which the largest dimension is greater than 1/16 inch.

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

Submit the (Level III examiner) approved procedures, technique sheets, and certification to the Contracting Officer with the test report.

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

SECTION 41 22 13.55 Page 10 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 and network drawings. Network diagram must show equipment locations, names, models, and IP addresses on network communications schematic for all Programmable Logic Controllers (PLCs), Remote Terminal Unit (RTU), Supervisory Controller, and Other Network-Capable Devices. In addition, the drawings shall consist of all software block, flow, and ladder diagrams.

1.6.4 Design Data: Load and Sizing Calculations

Submit complete list of equipment and materials, including manufacturer's descriptive data and technical literature, performance charts and curves, catalog cuts, and installation instructions. Submit discipline specific calculations reviewed, signed, and sealed by a registered professional engineer verifying the load cases, sizing of the bridge girder(s), end trucks, travel drives, motors, overcurrent protection, and conduit.

Provide a list of all codes and standards, design assumptions, equations, specified efficiencies, limits, factors of safety, component ratings, and sources of values used. Include free body diagrams or sketches of each load case.

1.6.5 Certificates

All certifications 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.

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 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 MHI MH27.1 . If runway is existing and if the crane(s) cannot operate without restriction, the Contractor shall indicate crane limitations.

SECTION 41 22 13.55 Page 11

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

d. 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.

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

Coupling alignment verification records are not required for couplings between components mounted via c, d, or p-face flanges.

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.

i. Provide a Contractor Hazardous Environment Certificate stating that the new crane and all associated components excluding the hoist are designed for operation in the hazardous environment specified in the Classification section.

k. Provide a Hoist Manufacturer Hazardous Environment Certificate from the hoist manufacturer stating that the hoist is designed for operation in the hazardous environment specified in the Classification section.

l. The Contractor shall provide a Public Domain Software Certificate declaring that public domain software (e.g., freeware, shareware) is not used in the system.

m. The Contractor shall provide a certificate stating that all Software and Services that are not required for operation and/or maintenance of the product have been removed. The software/services to be removed are identified in SOFTWARE AND SERVICES.

1.6.6 Welding Qualifications and Procedure

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

Welders and welding operators must be qualified in accordance with AWS D1.1/D1.1M or AWS D14.1/D14.1M .

SECTION 41 22 13.55 Page 12

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, 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 .

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 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 MHI MH27.1 . Structural

SECTION 41 22 13.55 Page 13 steel materials must conform to the standards permitted in MHI MH27.1 and AISC 360 . Skewing and other applicable lateral loads must be considered in the design.

2.2.1 Structural Connections

High-strength bolted structural connections must be designed and installed in accordance with RCSC S348. 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

MHI MH27.1 .

2.2.2 Crane Bridge Girder

Provide a bridge girder of patented track conforming to MHI MH27.1 .

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 the 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 MHI MH27.1 .

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 ASME B30.17 . 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.

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

SECTION 41 22 13.55 Page 14 structural supports indicated on the drawings. Provide runway and support structure for underrunning crane of patented track girders conforming to MHI MH27.1 .

b. 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.

c. Runway support structure must be designed, fabricated, and installed such that runway rails meet the alignment tolerances of MHI MH27.1 .

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 Service Platform

Service platform not required. Service will be performed from man lift in hangar bay.

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.

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 SAE J429 Grade 5 fasteners, ASTM F436/F436M washers, and SAE J995 Grade 5 nuts. SAE J429 Grade 8 fasteners and SAE J995 Grade 8 nuts may be substituted for J429 Grade 5 fasteners and pre-loaded to their full installation torques only when so prescribed by the component manufacturer. All mechanical fasteners must be lubricated unless otherwise specified by the component OEM. Mechanical fastener installation torque should correspond to approximately 67 percent of the SAE J429 Grade 5 fastener material yield strength, except in applications where component manufacturers prescribe specific fastener torque requirements.

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.

2.3.2 Hoist

Provide hoist conforming to ASME B30.16 , ASME B30.17 , and CMAA 74, double

SECTION 41 22 13.55 Page 15 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 H3 or better.

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. Contact surfaces of the drop stops shall be constructed of non-sparking material.

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.

b. For cranes with two electro-mechanical or thruster brakes, designate each brake as primary or secondary with the primary brake being the brake mounted closer to the motor. Provide the primary brake with a non-time delayed setting and secondary brake with an adjustable setting time delay, set between one to three seconds after the primary brake in any stopping condition. Do not use an uninterruptible power supply (UPS) to create the secondary brake time delay.

c. Electro-mechanical or thruster brakes must be adjustable to 50 percent of its rated capacity, and must have an externally accessible means of manual release. On drives where the brakes are utilized as holding brakes only, torque adjustment is not required. The brakes must be equipped with a manual self-return to ON brake release and designed to permit inspection and adjustment without disassembly of the brake.

Brakes shall not be double face mounted.

2.3.2.2 Load Block and Hook

The load block must be constructed of non-sparking materials and designed to prevent metal-to-metal contact of moving parts. This may be accomplished by covering the exposed surfaces of the block with thin bronze, stainless steel, or aluminum covers attached with similar fasteners. 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. Standard commercial blocks may be used at their published ratings when their published design factors are 5.0 or greater.

Provide an unpainted single barbed hook of non-sparking material with a minimum material longitudinal elongation of 16 percent in 2 inches.

Bronze or copper 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 a hook nut secured to the hook with a commercial standard removable and reusable means. 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

SECTION 41 22 13.55 Page 16

360 degrees when supporting the test load up to 125 percent of the rated capacity. The Hook shall be a standard commercial product with a published design factor of 5.0 or greater.

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.

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. Provide stainless steel hoist ropes.

c. 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. Do not paint, coat, or galvanize the surface of the drum which comes in contact with wire rope.

2.3.2.5 Sheaves

Provide sheaves mounted within the load block constructed of non-sparking metals. Upper nest sheaves are to be forged steel, machine ground to contour and heat treated to a minimum hardness of 320 BHN in the rope contact area. Provide sheaves sized IAW HST-4 for the minimum pitch diameters of running and equalizer sheaves.

2.3.3 Drives

Provide travel assemblies with at least half 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

Acceleration and deceleration must meet the requirements specified in CMAA 70 and CMAA 74. Provide bridge travel limit switches.

2.3.3.2 Trolley Drives

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

SECTION 41 22 13.55 Page 17

2.3.4 Travel Brakes

Spring set brakes must be provided with an externally accessible means to manually release the brake. The brakes must be equipped with a manual self-return to ON brake 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 or non-freecoasting mechanical drive 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 an end-mounted electro-mechanical brake conforming to the requirements of CMAA 74 or 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. Electro-mechanical brakes must be sized in accordance with ASME B30.17 .

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 integral components of standard hoists or hoist/trolley units of manufacturers regularly engaged in the design and manufacture of hoists or hoist/trolley units for cranes of the selected Service Class. Gear reducers must be standard commercial products and conform to ANSI/AGMA 6113 ( ANSI/AGMA 6013 ) (for travel drives only), as applicable. Except for final reduction, the gear reduction units must be fully enclosed in oil-tight housing. Gearing must be designed to AGMA standards and operate in an oil bath. Operation must be smooth and quiet.

2.3.5.2 Open Gearing

Open gears must be enclosed with safety guards, where feasible, with cover openings for inspection and access for grease lubrication.

2.3.6 Wheels

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. Wheel material is to be steel or ductile cast iron. Wheels from plate steel or hollow stamped are not allowed. Minimum tread hardness for underhung wheels that run on patented track is 375 BHN.

SECTION 41 22 13.55 Page 18

2.3.7 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

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

b. All electrical components must be industrial grade, commercially available and comply with established national or internationally recognized approving organizations such as Underwriters Laboratories (UL) and Canadian Standards Association (CSA). All electrical components installed or operated in hazardous areas including but not limited to enclosures, junction boxes, disconnects, and electrification must be designed and rated for the NFPA 70 Hazardous Classifications specified in Classification section.

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

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

POWER TO LIGHTING, RECEPTACLES, AND ANCILLARY EQUIPMENT".

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

SECTION 41 22 13.55 Page 19 individual disconnects, with lockout feature, capable of being locked in the open position for bridge lights and receptacles.

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

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

Aluminum connectors are allowed if they are rated for use with copper conductors (marked "AL/CU"). All conductors connected to or routed above resistors must have insulation shown in NFPA 70 Table 610.14(a) for 257 degrees F. Motor branch circuit conductors must be sized as to have an ampacity not less than 150 percent of the motor full load current rating and to be no smaller than 12 AWG. Conductors must be selected and de-rated based on maximum ambient temperature.

Continuous loads such as utility, heating, lighting, and air conditioning must be multiplied by 2.25 to determine ampacity in order to permit application of NFPA 70 610.14 (A) for crane supply conductors. Wire-nuts are not permitted on splices. However, connections for lighting ballasts may be made using wire-nuts (if applicable).

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

g. When fiber optic cable is utilized, inspections and performance checks must be accomplished upon completion of on-site installation to ensure cable cleanliness and proper signal integrity. Testing and verification must be conducted by a knowledgeable fiber optics technician using specialized, calibrated equipment. Cables must be tested for signal loss/attenuation. The fiber optic system must also be tested using an Optical Time Domain Reflectometer (OTDR). Final attenuation and OTDR readings from each fiber optic cable run, including spares, must be documented as a baseline for future reference. All spare fiber optic cables must have protective covers over their ends to maintain cleanliness while not in use. When fiber optic cable is utilized the drive OEM's recommendations for encoders and optical to digital converters must be followed. All system components utilized for this purpose must have known compatibility prior to integration.

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

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

SECTION 41 22 13.55 Page 20

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. Motors that operate a particular function (e.g. travel, bridge, rotate) shall be identical (i.e.

nameplate ratings, mfg., etc)

2.4.2 Controls

a. Provide static reversing, variable frequency drives (VFD) for the bridge, trolley and hoist electric controls. The hoist controller must enable the drive motor to develop full torque continuously at zero speed. 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.

Provide speed control which is infinitely variable for each function, controlled via radio control system. 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 controllers.

b. . Energize a yellow/amber light/indicator while in slow speed mode.

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. The hoist control system may utilize overspeed up to 120hz, unloaded only, if the drivetrain equipment has all been balanced and is rated for the resulting speed.

d. The use of definite purpose contactors is prohibited. If IEC contactors are used, the application cannot exceed the contactor manufacturer's AC3 ratings for the contactor at a minimum.

e. On hoist function roll-up…