A5_Bridge_Crane_Specification_with_Attachments.pdf

ONE OVERHEAD ELECTRIC TRAVELING

BRIDGE CRANE

FOR

PUGET SOUND NAVAL SHIPYARD (PSNS)

PREPARED BY:

Code 713

Bldg. 448, PSNS

Bremerton Washington 98314

SPECIFICATION PREPARED BY:

Project Engineer: Travis Mays

Branch Head Supervisor: Dan Bowen

Contract Representative: Stacy Impey

Contracting:

Contract Number 2

TABLE OF CONTENTS

1. GENERAL

STANDARDS .....................................................................................................................................................3 1.1.

DEFINITIONS ....................................................................................................................................................5 1.2.

CONTRACTOR COMPLIANCE ............................................................................................................................6 1.3.

SUBMITTALS ....................................................................................................................................................6 1.4.

DRAWINGS .................................................................................................................................................... 12 1.5.

QUALITY ASSURANCE ................................................................................................................................... 13 1.6.

2. PRODUCTS

SYSTEM DESCRIPTION .................................................................................................................................. 19 2.1.

CRANE REQUIREMENTS ................................................................................................................................ 20 2.2.

PAINTING ...................................................................................................................................................... 36 2.3.

LETTERING, MARKINGS, AND LABEL PLATES ................................................................................................ 38 2.4.

UNIQUE IDENTIFIER TAG .............................................................................................................................. 38 2.5.

3. EXECUTION

SITE SPECIFIC REQUIREMENTS ..................................................................................................................... 39 3.1.

CONSTRUCTION PREPARATION .................................................................................................................... 39 3.2.

CRANE REMOVAL/INSTALLATION ................................................................................................................. 40 3.3.

TRAINING ...................................................................................................................................................... 40 3.4.

4. APPENDIX

APPENDIX (A) CRANE ENVELOPE DRAWING

APPENDIX (B) SHOP TEST PROCEDURE

APPENDIX (C) ACCEPTANCE TEST PROCEDURE

APPENDIX (D) BRAKE DATA SHEET

APPENDIX (E) PSNS SITE SPECIFIC REQUIREMENTS

Contract Number 3

1. GENERAL

STANDARDS 1.1.

If standards other than those listed below are used, proof of equivalence shall be provided. NEMA, 1.1.1.

OSHA, ASME, AWS, AISC, and NFPA rules shall govern.

Submit a certificate of compliance stating that the crane complies with the standards called out in 1.1.2.

this specification. (SUBMITTAL REQUIRED)

AMERICAN GEAR MANUFACTURERS’ ASSOCIATION (AGMA) 1.1.3.

2001 – Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical

Gear Teeth

6013 - Standard for Industrial Enclosed Gear Drives

6019 – Gearmotors Using Spur, Helical, Herringbone, Straight Bevel, or Spiral Bevel Gears

6034 - Practice for Enclosed Cylindrical Wormgear Speed Reducers and Gearmotors

6035 - Design, Rating and Application of Industrial Globoidal Wormgearing

ASSOCIATION FOR IRON & STEEL TECHNOLOGY (AIST) 1.1.4.

TR-06 - Specification for Electric Overhead Traveling Cranes for Steel Mill Service

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) 1.1.5.

B4.1 – Preferred Limits and Fits for Cylindrical Parts

B17.1 - Keys and Keyseats

AMERICAN SOCIETY OF MECHANICAL ENGINEERS INTERNATIONAL (ASME) 1.1.6.

B30.2 - Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top

Running Trolley Hoist)

B30.10 – Hooks

AMERICAN SOCIETY OF NONDESTRUCTIVE TESTING (ASNT) 1.1.7.

SNT-TC-1A – Personnel Qualification and Certification in Nondestructive Testing

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) 1.1.8.

A275 - Magnetic Particle Exam of Steel Forgings

A325 - Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum

Tensile Strength

A388 - Standard Practice for Ultrasonic Examination of Steel Forgings

Contract Number 4

A490 - Standard Specification for Heat-Treated Steel Structural Bolts, 150 ksi Minimum

Tensile Strength

A521 - Standard Specification for Steel, Closed Impression Die Forgings for General Industrial use

A1023/A - Standard Specification for Stranded Carbon Steel Wire Ropes for General Purposes

E94 - Standard Guide for Radiographic Examination

E164 - Recommended Practice of Ultrasonic Contact Examination of Weldments

E165 - Recommended Practice for Liquid Penetrant Inspection

E317 - Recommended Practices for Evaluating Performance Characteristics of Pulse-Echo

Ultrasonic Testing Systems

E543 - Standard Specification for agencies performing Nondestructive Testing

E709 – Standard Guide for Magnetic Particle Testing

F436 – Standard Specification for Hardened Steel Washers

F593 - Stainless Steel Bolts, Hex Cap Screws, and Studs

F594 - Stainless Steel Nuts

AMERICAN WELDING SOCIETY (AWS) 1.1.9.

A2.4 - Standard Symbols for Welding, Brazing, and Nondestructive Examination

D14.1 - Welding of Industrial and Mill Cranes and other Material Handling Equipment

CRANE MANUFACTURERS' ASSOCIATION OF AMERICA, INC (CMAA) 1.1.10.

70 - Specification for Top Running & Gantry Type Multiple Girder Electric Overhead

Traveling Cranes

ELECTRIFICATION AND CONTROLS MANUFACTURERS ASSOCIATION (ECMA) 1.1.11.

15 - Specification for Cable-less (Wireless) Controls

NATIONAL ELECTRICAL MANUFACTURERS' ASSOCIATION (NEMA) 1.1.12.

NEMA ICS 3 - Industrial Control and Systems: Medium Voltage Controllers Rated 2001 to

7200 Volts AC

NEMA ICS 8 - Industrial Control and Systems Crane and Hoist Controllers

NEMA MG 1 - Motors and Generators

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

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) 1.1.13.

NFPA 70 - National Electric Code

Contract Number 5

NFPA 70E – Standard for Electrical Safety in the Workplace

NAVAL SHIPS TECHNICAL MANUAL (NSTM) 1.1.14.

NSTM - Chp 61, Wire and Fiber Rope and Rigging

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) 1.1.15.

Title 29 CFR, Part 1910.23, Walking-Working Surfaces

Title 29 CFR, Part 1910.27, Fixed Ladders

Title 29 CFR, Part 1910.66, Personal Fall Arrest System

Title 29 CFR, Part 1910.147, The Control of Hazardous Energy (lockout/tagout)

Title 29 CFR, Part 1910.179, Overhead and Gantry Cranes

Title 29 CFR, Part 1910.306, Specific Purpose Equipment and Installations

Title 29 CFR Part 1926.62, Safety and Health Regulations for Construction (Lead)

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC) 1.1.16.

Specification for Structural Joints Using High-Strength Bolts

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) 1.1.17.

SAE J429 - Mechanical and Material Requirements for Externally Threaded Fasteners

SAE J995 – Mechanical and Material Requirements for Steel Nuts

Society of Protective Coatings (SSPC) 1.1.18.

SSPC - SP 10, Near-White Metal Blast Cleaning

DEFINITIONS 1.2.

Words that are italicized throughout this specification are defined below: 1.2.1.

Angularity: Angle of shaft centerline measured from other shaft centerline.

Collision forces (CF): Defined per CMAA No. 70.

Control Circuit Type (Limit Switch): When activated this type of limit switch restricts the control operations of the crane.

End gap: Distance between the ends of two shafts after a coupling is installed.

Flex-Rigid Coupling: A coupling that allows for angularity but does not allow for offset.

Holding Brake: A brake that does not set on a moving shaft during normal operations, not including testing operations.

Joint Class I: Defined per section 6.9.1 of AWS D14.1.

Contract Number 6

Joint Class II: Defined per section 6.9.2 of AWS D14.1.

Load Bearing: Components are considered load bearing if they contribute to holding up a portion or all of the lifted load or dead weight of the crane.

Loss of Power Test: A test where the crane is lifting 100% load, and the power is removed from the hoist, bridge, or trolley when in operation, simulating a loss of power.

Offset: Vertical and horizontal distance between the center line of two shafts

Operating Wind loads (WLO): Defined per CMAA No. 70.

Primary Hoist Brake: Hoist brake closest to hoist motor that is located on high speed shaft.

Primary Welds: Defined per section 3 of AWS D14.1.

Rigid-rigid Coupling: A coupling that does not allow for any angularity or offset mis-alignment.

Flange-to-flange shaft connections are examples of rigid-rigid couplings.

Secondary Hoist Brake: Hoist brake that is furthest from motor located on the high speed shaft.

Secondary Welds: Defined per section 3 of AWS D14.1.

Spliced Connection: Is a connection of two structural members where the two members are treated as one continuous member.

Stored Wind Loads (WLS): Defined per CMAA No. 70.

CONTRACTOR COMPLIANCE 1.3.

The Contractor is required to read, understand, and comply with this entire specification. 1.3.1.

The Government will determine compliance with the requirements of this specification by 1.3.2.

reviewing and accepting the submittals shown in section 1.4.4, performing an on-site shop test, performing crane inspections, and witnessing the Contractor complete Appendix B and C.

SUBMITTALS 1.4.

The Contractor is required, per this specification, to provide a submittal to the Government anytime 1.4.1.

there is a SUBMITTAL REQUIRED designation after a sentence. The Government will review each submittal within the time period stated in the Submittal Summary Table (section 1.4.4), and either provide comments or accept the submittal. For convenience each occurrence is listed in the

Submittal Summary Table (section 1.4.4) along with the file format, location, due dates, and number of copies. The Contractor shall ensure that all submittals are entirely legible and suitable for reproduction.

The Government reserves the right to require changes to submittals, which may change the design, 1.4.2.

if the requirements of this specification are not met. Therefore, obtaining Government authorization on specific submittals, e.g., drawings, calculations, and catalogs cuts before starting fabrication is highly recommended.

Contract Number 7

All submittals shall be corrected and resubmitted by the Contractor within ten (10) working days of 1.4.3.

receipt of Government comments. The Government has ten (10) working days to return comments to the Contractor. If further comment rounds are required, both the Contractor and Government shall continue to reply within ten (10) days.

SUBMITTAL SUMMARY TABLE: 1.4.4.

SUBMITTAL

FILE

FORMAT

SPECIFICATION

SECTION

CONTRACTOR DUE

DATE

GOVERNMENT

DUE DATE

COPIES

TECHNICAL FORMS

Certificate of Compliance for

Standards Listed in this

Specification

.pdf 1.1.2 Prior to shop test

Review, comment, and submit within ten

(10) business days after date received

Catalog Cuts (Structural, Mechanical, and Electrical) .pdf 1.4.5.2

Prior to manufacturing of crane

Review, comment, and submit within ten

(10) business days after date received

Preliminary Drawings

(General, Structural, and

Electrical)

.pdf and .dxf or .dwg 1.5.1

Prior to manufacturing of crane

Review, comment, and submit within ten

(10) business days after date received

Final As-Built Drawings

(General, Structural, and

Electrical)

.pdf and .dxf or .dwg 1.5.1

Prior to acceptance of crane

Review, comment, and submit within twenty (20) business days after date received

Preliminary Maintenance, Technical, and Operations

Manual

.pdf 1.5.9.1 Ten (10) business days prior to crane delivery

Review, comment, and submit within ten

(10) business days after date received

Final Maintenance, Technical, and Operations Manuals

Hard copy and .pdf

1.5.9.1 After acceptance of crane

Review, comment, and submit within twenty (20) business days after date received

2 Hard

Copies, 1 pdf

Contractor Schedule .pdf 1.6.1.1

First submittal prior to post-award meeting (after first submission an updated schedule shall be submitted monthly at a minimum)

Continual Feedback and Communication

Regarding Schedule 1

Contractor Existing Rail

Survey Data and Contractor

Aligned Rail Survey Data

.pdf or xlsx 1.6.3.1

Submit rail survey ten (10) business days after completing survey. Submit aligned rail survey data

(10) business days after completing alignment.

Review, comment, and submit within five (5) business days after date received for both rail survey data and rail alignment survey data

Contract Number 8

SUBMITTAL

FILE

FORMAT

SPECIFICATION

SECTION

CONTRACTOR DUE

DATE

GOVERNMENT

DUE DATE

COPIES

Crane Envelope Drawing .pdf, .xlsx, .dxf or .dwg

1.6.4.1 Prior to manufacturing of

crane

Review, comment, and submit within five (5) business days after date received

Preliminary Calculations

(Structural, Mechanical, and

Electrical)

.pdf 1.6.14.1 Prior to manufacturing of crane

Review, comment, and submit within ten

(10) business days

Final Calculations (Structural, Mechanical, and Electrical) .pdf 1.6.14.1 Prior to crane delivery

Review, comment, and submit within ten

(10) business days after date received

NDT Qualification Report .pdf 1.6.16.1 Prior to performing any

NDT

Review, comment, and submit within two (1) business days after date received

Weld NDT Reports .pdf 1.6.16.2 Prior to shop test meeting

Review, comment, and submit within five (5) business days after date received

Overload Test Certificate .pdf 2.2.1 Prior to crane delivery Acceptance upon

Receipt

Loss of Power Test Certificate .pdf 2.2.4 Prior to crane delivery Acceptance upon

Receipt

Hazardous Material Certificate

.pdf

2.2.6.4.1

Prior to shop test meeting

Review, comment, and submit within one (1) business days

Trolley and Bridge Wheel

Specification Sheet .pdf 2.2.8.5.3

Provide report after completion of wheel sample

Review, comment, and submit within five (5) business days after date received

Seismic Analysis Report .pdf 2.2.8.6.1 Prior to manufacturing of crane

Review, comment, and submit within five (5) business days after date received

Coupling Alignment Certificate .pdf 2.2.9.3.4 Prior to acceptance of crane

Review, comment, and submit within five (5) business days after date received

Hook and Hook Nut Proof Test

Certificate .pdf 2.2.9.7.1 Prior to crane delivery

Review, comment, and submit within two (2) business days

Contract Number 9

FILE

FORMAT

SPECIFICATION

SECTION

CONTRACTOR DUE

DATE

GOVERNMENT

DUE DATE

COPIES

Wire Rope Braking Strength and Specification Certificate

.pdf 2.2.9.8.2 Prior to crane delivery Review, comment, and submit within two (2) business days after date received

Wire Rope End Connection

Proof Test Certificate .pdf 2.2.9.8.4 Prior to crane delivery

Review, comment, and submit within two (2) business days after date received

Brake Setting Certificate .pdf 2.2.9.16.4 Prior to crane delivery

Review, comment, and submit within two (2) business days after date received

Lubrication MSDS .pdf 2.2.9.19.1

Prior to applying lubrication or filling gearbox

Review, comment, and submit within five (5) business days after date received

Removal and Installation

Lifting Plans .pdf 3.2.4.1

Forty (40) business days prior to crane delivery

Review, comment, and submit within twenty (20) business days after date received

Lead Work Plan .pdf 3.3.4

Ten (10) business days prior to crane delivery (if applicable)

Review, comment, and submit within two (2) business days after date received

APPENDIX (E) FORMS

DD Form 1494 Application for

Equipment Frequency

Allocation (Attachment 17)

.pdf 2.2.10.9.15, 3.1.2.10

Forty (40) business days prior to shop test meeting

NA

Contractor Hazardous

Material Inventory (CHMI)

(Attachment 1)

Hard Copy or

.pdf 3.1.2.1

Ten (10) business days prior to crane delivery

NA

TBD

Solid Waste Tracking Sheet

(SWTS) (Attachment 3)

Hard Copy or

.pdf 3.1.2.2

Filled out when disposing of waste at Contractor determined disposal facility

NA

TBD

Contractor’s Monthly Project

Waste Summary Report

(CMPWSR) (Attachment 4)

Hard Copy or

.pdf 3.1.2.3

Monthly during on-site work

NA

TBD

Personal Information for

Visitor Request (Attachment 6)

Hard Copy or

.pdf 3.1.2.4

Ten (10) business days prior to coming to PSNS

NA

TBD

AIS Survey (Attachment 7) Hard Copy or

.pdf 3.1.2.5

Twenty (20) business days prior to bringing a laptop into the CIA

NA

TBD

Contract Number 10

FILE

FORMAT

SPECIFICATION

SECTION

CONTRACTOR DUE

DATE

GOVERNMENT

DUE DATE

COPIES

Radio Operations Request

(Attachment 8)

Hard Copy or

.pdf 3.1.2.6

Ten (10) business days prior to coming to PSNS with a radio

NA

TBD

Vehicle Pass Request for

Access to the Controlled

Industrial Area (CIA)

(Attachment 12)

Hard Copy or

.pdf 3.1.2.7

Twenty (20) business days prior to bringing a vehicle into the CIA at PSNS

Foreign Interest Determination

(Attachment 13)

Hard Copy or

.pdf 3.1.2.8

Twenty business days prior to coming to PSNS

NA

TBD

Certificate of Compliance

Form (Attachment 16)

Hard Copy or

.pdf 3.1.2.9

Prior to use of crane/lifting and handling equipment at

PSNS

Government will fill out form on-site with

Contractor

TBD

Contractor Operator License Hard Copy or

.pdf 9.4, Appendix E

Submit License(s) prior to operating equipment such as fork lift, ariel work platform, crane, and other types of equipment

CATALOG CUTS: 1.4.5.

Catalog cuts for all commercially available components shall be provided as a submittal to 1.4.5.1.

the Government. The catalog cuts shall be marked to clearly display what component and component options are used on the crane, e.g., part number, model, and load rating.

The Contractor shall submit for approval all applicable component catalog cuts listed below 1.4.5.2.

and any other commercially available components not listed. If components below are fabricated by the Contractor then design drawings will need to be submitted in place of catalog cuts.

(SUBMITTALS REQUIRED)

STRUCTURAL CATALOG CUTS 1.4.5.3.

1.4.5.3.1 End trucks (including drive units)

1.4.5.3.2 Product information for all paint used on the crane

1.4.5.3.3 Trolley end stops

1.4.5.3.4 Trolley rails

1.4.5.3.5 Commercial lifting attachment points

1.4.5.3.6 Manufacture’s installation instructions for swing gates

MECHANICAL CATALOG CUTS 1.4.5.4.

1.4.5.4.1 Speed reducers (including gear ratio, HP rating, speed ratings, service factors)

1.4.5.4.2 Brakes (including electrical information)

Contract Number 11

1.4.5.4.3 Bearings (lubrication instructions, load ratings)

1.4.5.4.4 Couplings (acceptable offset, angularity, and end gap values as applicable)

1.4.5.4.5 Load blocks and hooks

1.4.5.4.6 Wheels

1.4.5.4.7 Sheaves

1.4.5.4.8 Bumpers

1.4.5.4.9 Wire rope and end fittings

ELECTRICAL CATALOG CUTS 1.4.5.5.

1.4.5.5.1 Variable Frequency Drive Controllers (including dynamic braking resistors and line reactor selection/isolation transformers)

1.4.5.5.2 Motors

1.4.5.5.3 Encoders

1.4.5.5.4 Electrical Enclosures

1.4.5.5.5 Runway Electrification and Collectors

1.4.5.5.6 Limit Switches

1.4.5.5.7 Bridge-to-Trolley Electrification

1.4.5.5.8 Warning Devices

1.4.5.5.9 Disconnect Switches

1.4.5.5.10 Contactors and Relays

1.4.5.5.11 Wireless Transmitters (Operator Controllers)

1.4.5.5.12 Wireless Receiver

1.4.5.5.13 Auxiliary Devices (Floodlight, Horn, etc.)

1.4.5.5.14 Circuit Breakers

1.4.5.5.15 Fuses

Contract Number 12

DRAWINGS 1.5.

Provide a preliminary drawing package to the Government for review (SUBMITTAL 1.5.1.

REQUIRED). Provide a final design drawing package that complies with all requirements listed in section 1.5 (SUBMITTAL REQUIRED). The preliminary and final design drawing packages shall include all general arrangement drawings, structural drawings, electrical schematics, and electrical wiring diagrams.

Drawings that use foreign language and nomenclature shall include corresponding English 1.5.2.

equivalents. Metric units may be used for drawings, but they shall include conversions to English units on the drawings.

All drawings shall have a complete title block that includes the crane number (107-B-904), and the 1.5.3.

signature and seal of a registered Professional Engineer that directly oversees the work. There shall be no proprietary notes on any of the drawings.

Each revision shall be tracked and marked on the drawing. 1.5.4.

All drawings must be provided in PDF format and in a .dwg or .dxf file format. 1.5.5.

GENERAL ARRANGEMENT DRAWINGS 1.5.6.

Provide general arrangements drawings that show all assemblies in plan, elevation, and side 1.5.6.1.

views. These drawings shall show all mechanical components and assemblies, e.g., hoist assembly, trolley and bridge drivetrains, building clearances, and principal dimensions that include tolerances.

Provide general arrangement drawings that show major components in plan, elevation, and 1.5.6.2.

end views. All major features of the crane shall be shown including: clearances, lifts, spans, wheel spacing, rated speeds, trolley gage, hook approaches on all sides, maximum wheel loads, electrical power supply, and general locations of components, e.g., brakes, motors, speed reducers, electrical enclosures (including size). The component information such as size, part number, gear ratio, power rating, and RPM shall be included on the drawings.

Include weights of all components and maximum bridge wheel loads (without impact), wheel 1.5.6.3.

spacing, and show the location of the center of gravity of the trolley and bridge assemblies.

STRUCTURAL DRAWINGS 1.5.7.

Provide a complete drawing package detailing all fabricated components and structural 1.5.7.1.

assemblies/weldments, include tolerances, camber requirements, weld call outs per AWS A2.4, material type and the standard associated with the material type, e.g., ASTM A36.

ELECTRICAL SCHEMATICS 1.5.8.

Provide all electrical schematics and wiring diagrams for all electrical components and 1.5.8.1.

drives. The schematics and wiring diagrams shall have sufficient detail that show; wire sizes, types and sizes of protective devices, all installed electrical components and connections, settings and permissible adjustment ranges for tunable/adjustable devices, motor rated current, motor horsepower, and detailed parts lists of all electrical components.

Contract Number 13

Provide general crane electrification detail drawings that include the interface between the 1.5.8.2.

existing building electrical panel; fused disconnect switch installation; and insulated runway conductor installation.

Provide motor nameplate data and overcurrent device ratings. 1.5.8.3.

OPERATIONS AND MAINTENANCE/TECHNICAL DATA 1.5.9.

The Contractor shall submit a preliminary copy of the crane’s operations and 1.5.9.1.

maintenance/technical manuals to the Government for review. The Contractor shall submit final copies of the operations and maintenance/technical manuals once all Government comments have been addressed. (SUBMITTAL REQUIRED)

The operations and maintenance/technical manual may be combined into one manual or may 1.5.9.2.

be separated out into multiple manuals; however, a detailed table of contents is required.

OPERATIONS MANUAL 1.5.9.3.

1.5.9.3.1 The body of the operations manual shall include detailed crane operating and safety instructions including specific starting/stopping instructions.

MAINTENANCE/TECHNICAL MANUAL 1.5.9.4.

1.5.9.4.1 The maintenance/technical manual shall include detailed written procedures necessary to maintain the crane, all catalog cuts, a recommended spare parts list, and the final as-built crane drawing package.

1.5.9.4.2 The maintenance/technical manual shall include detailed maintenance procedures, and manufacturer’s installation and maintenance manuals for commercial components. If applicable, the manuals shall include alignment, adjustment, and calibration instructions.

1.5.9.4.3 Provide preventative maintenance instructions including location of lubrication points, type of lubricant used, and the frequency of lubrication.

1.5.9.4.4 Provide part numbers and all available information for all Contractor-designed parts, purchased sub-assemblies and components. The information shall be broken down to the smallest replacement part.

1.5.9.4.5 The maintenance/technical manual shall include all of the crane’s final as-built programming, i.e., ladder logic diagrams, software flow diagrams, parameter listings, or any other type of machine controlling software code that is used in the Contractor’s design.

Ladder logic and software flow diagrams shall include comments explaining the function of each unique software task/operation. The maintenance/technical manual shall include the

Contractor’s recommended methods for tuning the motion controlling electronics to achieve optimal performance; and include a functional description of each subsystem and how each subsystem interfaces to the rest of the crane.

1.5.9.4.6 The Contractor shall provide all physical and electronic means to calibrate, tune, adjust, and/or modify all parameters that control the operation of the machine.

QUALITY ASSURANCE 1.6.

CONTRACTOR SCHEDULE 1.6.1.

Contract Number 14

The Contractor shall submit a preliminary schedule that details key events in the design, 1.6.1.1.

fabrication, and installation of the crane. The schedule shall be updated and submitted, at a minimum, monthly throughout the duration of the contract (SUBMITTAL REQUIRED). At a minimum the schedule shall include the information below (the order of events shown below is not fixed):

1.6.1.1.1 Post-Award Meeting

1.6.1.1.2 Rail Survey, Rail Alignment, Crane Envelope, and Dimension Verification

1.6.1.1.3 Preliminary Drawings and Calculation Submittals

1.6.1.1.4 Government Review of Initial Design

1.6.1.1.5 Start of Fabrication

1.6.1.1.6 Shop Test Meeting

1.6.1.1.7 Completion of Fabrication

1.6.1.1.8 Pre-Installation Meeting

1.6.1.1.9 Final Drawings and Calculation Submittals

1.6.1.1.10 Government Review of Final Design

1.6.1.1.11 Crane Delivery

1.6.1.1.12 Existing Crane Removal

1.6.1.1.13 New Crane Installation

1.6.1.1.14 Acceptance Test

1.6.1.1.15 Crane Acceptance

1.6.1.1.16 Completion of Warranty

CONTRACTOR VERIFICATION AND POST-AWARD MEETING (CONTRACTOR AT PSNS) 1.6.2.

The Contractor shall meet with the Government at PSNS after the contract has been awarded. 1.6.2.1.

This meeting will be used to discuss the contract and any other questions that arise.

The Contractor shall verify, on-site all electrification information necessary to install new 1.6.2.2.

runway conductors/grounding, conduit, and wiring from the crane to the building control panel

(see section 2.2.10.5 for requirements). The Contractor may also gather information necessary to perform the runway rail survey/alignment and the crane envelope survey.

EXISTING RUNWAY RAIL SURVEY AND ALIGNMENT 1.6.3.

The current runway rail does not meet the requirements of CMAA No. 70. The Contractor 1.6.3.1.

shall survey and align the existing runway rails per Table 1.4.2-1 of CMAA No. 70. The

Contractor shall provide a report showing the existing runway rail alignment and the rail alignment after the rails have been aligned. (SUBMITTAL REQUIRED)

Contract Number 15

When the Contractor realigns the existing crane rail they shall space all rail clips a maximum 1.6.3.2.

of 48 inches apart. The Contractor will need to provide additional clips since the current rail clip spacing is 52 inches.

The Contractor shall perform the runway rail survey and alignment prior to starting the 1.6.3.3.

design of the crane.

CRANE ENVELOPE SURVEY 1.6.4.

The Contractor shall verify all crane envelope clearances and other building/runway features, 1.6.4.1.

prior to designing the crane and shall submit a crane envelope drawing similar to the one shown in Appendix (A). The purpose of Appendix (A) is to provide an example crane envelope and should not be used to design the crane. (SUBMITTAL REQUIRED)

CONTRACTOR TESTING 1.6.5.

The Contractor prior to the Shop Test Meeting (see section 1.6.6), shall test the operations of 1.6.5.1.

the crane under a no load condition. The Contractor shall perform a detailed inspection of the crane and its components and test all possible functions of the assembled crane. Once the

Contractor successfully tests and inspects the crane, the Contractor shall notify the Government to schedule the Shop Test Meeting.

SHOP TEST MEETING (GOVERNMENT AT CONTRACTOR’S FACILITY) 1.6.6.

The Contractor shall allow the Government to come to the Contractor’s facility and 1.6.6.1.

participate in a Shop Test Meeting. This meeting will cover the submittals that the Contractor is responsible for providing to the Government, shop testing, shipping, site mobilization, erection dates, crane installation plan, roles and responsibilities of the entities involved, and the overall schedule.

The Contractor shall be available to operate the crane, participate in the shop test, complete 1.6.6.2.

the shop test shown in Appendix (B), and answer any questions that arise. All contract violations found during the shop test will be recorded by the Government on a punch list. The Government will conduct an out-brief with the Contractor and will go over every punch list item with the

Contractor before leaving the Contractors facility. All punch list items shall be resolved by the

Contractor prior to shipping the crane to PSNS.

The crane shall not be shipped to PSNS until the Government accepts the Contractor’s 1.6.6.3.

request to ship.

PRE-INSTALLATION MEETING (TELECONFERENCE OR CONTRACTOR AT PSNS) 1.6.7.

The Contractor shall attend a Government conducted pre-installation conference that will 1.6.7.1.

either be a teleconference or will be held at the installation site. This conference will provide the

Contractor/Sub-Contractors, and the Government the ability to review all aspects of the crane installation to ensure accuracy and safety.

GOVERNMENT INSPECTION 1.6.8.

Once the Contractor has installed, tuned, tested and is ready for acceptance testing, the 1.6.8.1.

Contractor shall allow the Government to conduct a 3-5 day inspection of the crane prior to acceptance. The Contractor shall be available to operate the crane at the request of the inspectors during this 3-5 day period.

Contract Number 16

All items that are found during the Government inspection that do not meet the requirements 1.6.8.2.

of this contract shall be written on the punch list and corrected by the Contractor prior to acceptance testing. After the corrections have been made, the Government has one day to re-inspect the crane to ensure all the corrections have been made.

FIELD ACCEPTANCE TEST 1.6.9.

The Acceptance Test, shown in Appendix (C), shall be satisfactorily completed after the 1.6.9.1.

crane is installed inside building 107 at PSNS by the Contractor. The Government will provide all test weights and rigging gear. If the crane fails to complete an item listed in Appendix (C) the test shall be repeated until the test is passed. The Government may, if necessary, request additional tests to determine that the crane meets the requirements of this specification.

The Government shall have one regular work day to conduct a final inspection after the Field 1.6.9.2.

Acceptance Testing is completed.

ACCEPTANCE 1.6.10.

Final Government acceptance of the crane shall take place only after the following 1.6.10.1.

conditions are met:

1.6.10.1.1 Contractor receives Government approval for all tests, inspections, and verification that all submittals have been received and are acceptable.

1.6.10.1.2 The crane meets all contract requirements.

1.6.10.1.3 The crane passes a final inspection by the Government.

1.6.10.1.4 All punch list items have been corrected or a method of resolution has been determined. Outstanding punch list items not corrected prior to the Government's acceptance shall be carried as warranty items, which shall be corrected by the Contractor.

CONFERENCE CALLS 1.6.11.

The Contractor shall support all teleconferences at the Government’s request. 1.6.11.1.

GOVERNMENT INSPECTIONS 1.6.12.

The Government may perform both scheduled and unscheduled inspections of material, 1.6.12.1.

workmanship, and documentation throughout the life of the contract. If the Government determines there is a problem with quality then they will submit a written notification to the

Contractor and they shall respond to each identified problem within ten day(s) of receiving the notification.

MANUFACTURER QUALIFICATIONS 1.6.13.

The overhead electric crane system, including sub-system components manufactured by 1.6.13.1.

vendors, shall be designed and manufactured by a company with experience in designing this type of crane or system and can meet the requirements of this specification.

CALCULATIONS 1.6.14.

Contract Number 17

The Contractor shall provide preliminary and final structural, mechanical, and electrical 1.6.14.1.

calculations to the Government that validate that the design complies with the requirements in section 1.6.14, CMAA No. 70, and all other applicable requirements in this specification

(SUBMITTAL REQUIRED). Design calculations shall be provided for custom items, and sizing calculations shall be provided for commercial items.

Design calculations that use foreign language and nomenclature shall include English 1.6.14.2.

equivalent nomenclature. Metric units may be used for calculations, but they shall include conversions to English units. In the case of calculations, only the initial inputs and final results need to be converted.

All calculation submittals shall be labeled with the crane number 107-B-904. 1.6.14.3.

All Finite Element Analysis (FEA) that is provided as a submittal shall come with hand 1.6.14.4.

calculations that verify the FEA model and a write-up that details the designers assumptions and explains the thought process behind the model.

STRUCTURAL CALCULATIONS 1.6.14.5.

1.6.14.5.1 Operating Wind loads and Stored Wind Loads (WLO and WLS) shall be neglected since the crane will be indoors. Collision forces (CF) due to the crane impacting the bridge and trolley end stops shall be accounted for; however, calculations from two cranes colliding may be neglected since there are no other active cranes on the rail.

1.6.14.5.2 Calculations verifying compliance with a maximum allowable wheel loading of 15kips are required. The wheel loading is restricted to 15kips for all loading including (125% -

5%/+0%) test load with the trolley in any position.

1.6.14.5.3 Calculations verifying the design of trolley and bridge bumpers per AIST TR-06 and the design of the trolley end stops per ASME B30.2 shall be provided to the Government.

1.6.14.5.4 Calculations shall be provided that verify all lifting attachment points.

1.6.14.5.5 Perform a seismic analysis per the requirements of section 2.2.8.6.

MECHANICAL CALCULATIONS 1.6.14.6.

1.6.14.6.1 The calculations shall address overstressing the drivetrain and reducers during a situation where both the primary and secondary brakes set at the same time without the drive controls stopping the load. The calculations shall address the worst case scenarios regarding hoist up/down, no load/max load, and slow speed/rated speed.

1.6.14.6.2 The thermal capacity of the trolley, bridge, and hoist brakes shall be addressed for a loss of power situation where the brakes set on a moving shaft.

ELECTRICAL CALCULATION 1.6.14.7.

1.6.14.7.1 Conduit fill calculations (using tables from NFPA 70 or manufacturer’s data sheets).

Grounding conductors shall be included in the calculations.

1.6.14.7.2 Protective device coordination study showing proper coordination for any overcurrent devices that have the same rating as another overcurrent device upstream. This study shall include all devices from the line side of the primary facility overcurrent device.

Contract Number 18

1.6.14.7.3 Provide arc flash energy calculations for each electrical enclosure showing proper data necessary for appropriate arc flash labels per NFPA 70E Flash Calculations.

1.6.14.7.4 Wire sizing calculations for all power circuit conductors. Wire sizing shall meet the requirements of NFPA 70.

1.6.14.7.5 Provide component and device sizing calculations.

WELDING 1.6.15.

Welded or fabricated items (not including commercially purchased components) shall be per 1.6.15.1.

AWS D14.1.

Workmanship regarding welds shall be performed per Section 7 of AWS D14.1. 1.6.15.2.

All weld repairs for primary and secondary welds shall be per section 12 of AWS D14.1. 1.6.15.3.

NON-DESTRUCTIVE TESTING (NDT) 1.6.16.

The Contractor shall provide a certificate with qualification data showing that the inspector 1.6.16.1.

performing NDT on the crane is qualified as a level 3 examiner per ASNT-SNT-TC-1A or ASTM

E543. (SUBMITTAL REQUIRED)

All NDT performed per the NDT Table section 1.6.16.3, including visual inspection, shall 1.6.16.2.

be fully documented, and submitted to the Government. (SUBMITTAL REQUIRED). At a minimum, the test document shall provide the acceptance criteria used, identification of the weld or component that was tested, test results, and the individual who performed the test/inspection.

NDT TABLE 1.6.16.3.

DESCRIPTION EXAMINATION METHOD

*All Joint Class I and II welds that are considered Primary Welds (Section 10.8.1 of AWS D14.1)

V, MT, UT

All Lifting Attachment Welds V, MT

*All Secondary Welds (Section 10.6 of AWS

D14.1) V

Hook and Eye Pin or Swivel Eye Bar V, (MT performed by Government)

*See section 1.2 for definitions regarding joint class, primary welds, and secondary welds

Radiographic examination can be used in place of ultrasonic examination and magnetic 1.6.16.1.

particle examination can be used in placed of liquid penetrant examination.

VISUAL EXAMINATION (V): 1.6.16.2.

1.6.16.2.1 Acceptance criteria for a Visual Examination shall be per section 7, 10.6, and 10.7 of

AWS D14.1 and any other applicable standards included in these sections.

MAGNETIC PARTICLE TESTING (MT): 1.6.16.3.

Contract Number 19

1.6.16.3.1 Welds that are subjected to magnetic particle testing shall first undergo a visual examination per sections 7, 10.6, and 10.7 of AWS D14.1.

1.6.16.3.2 All magnetic particle testing shall be performed per ASTM E709.

1.6.16.3.3 Acceptance criteria shall be per section 10.16.4 of AWS D14.1. A length of 20% of the weld shall be randomly selected for MT; if a sample shows defects, two adjacent locations shall be inspected. The entire length of weld is required to be inspected if either of the sample locations show defects.

RADIOGRAPHY EXAMINATIONS (R): 1.6.16.4.

1.6.16.4.1 Welds that are subjected to radiography examination shall first undergo a visual examination per sections 7, 10.6, and 10.7 of AWS D14.1.

1.6.16.4.2 All radiography examinations shall be conducted per ASTM E94.

1.6.16.4.3 Acceptance criteria for Radiographed welds shall be per section 10.11 of AWS D14.1 and any applicable standards included in this section.

ULTRASONIC EXAMINATIONS (U): 1.6.16.5.

1.6.16.5.1 Welds that are subjected to ultrasonic examination shall first undergo a visual examination per sections 7, 10.6, and 10.7 of AWS D14.1.

1.6.16.5.2 All ultrasonic examinations shall be conducted per section 10.13 and 10.14 of AWS

D14.1 and ASTM E164/E317.

1.6.16.5.3 Acceptance criteria for ultrasonic examinations shall be per section 10.15 of AWS

D14.1 and any applicable standards included in this section. A length of 20% of the weld shall be randomly selected for UT; if a spot shows defects, two adjacent locations shall be inspected. The entire length of weld is required to be inspected if either of the spot locations show defects.

LIQUID PENETRANT EXAMINATION (LP): 1.6.16.6.

1.6.16.6.1 Welds that are subjected to a liquid penetrant examination shall first undergo a visual examination per sections 7, 10.6, and 10.7 of AWS D14.1.

1.6.16.6.2 All liquid penetrant examinations shall be conducted per ASTM E165.

1.6.16.6.3 Acceptance criteria for liquid penetrant examinations shall be conducted per section

10.6 and 10.7 of AWS D14.1.

2. PRODUCTS

SYSTEM DESCRIPTION 2.1.

Contract Number 20

The intent of this specification is to procure one double girder, wireless (radio) controlled, top 2.1.1.

running, overhead electric traveling crane with a single hoist. This crane will replace an existing crane

(USN# 100704). The crane shall be installed in the shipping bay of Building 107 at Puget Sound

Naval Shipyard (PSNS) in Bremerton Washington. The crane shall be built to the design drawings of a registered Professional Engineer. The crane shall be designed, fabricated, assembled, shop tested, delivered, installed, inspected, field tested, and made ready for use per this specification.

The crane’s capacity, span, and hook travel shall be as follows: 2.1.2.

Location Capacity (lbs.) Span (ft-in) Runway (ft) Hook Lift (ft)

B107 Shipping Bay 10,000 minimum *82’-8” 377’ 24’ Minimum

*Span and runway dimensions are approximate. Final values shall be verified by the Contractor per section 1.6.4.1

CRANE REQUIREMENTS 2.2.

The Contractor shall maximize the capacity of the crane while not exceeding a maximum wheel 2.2.1.

loading of 15 kips per wheel. The crane capacity shall be a minimum of 10,000lbs. The bridge wheel spacing (center to center distance) shall be a minimum of 11.7ft. The crane shall be designed for periodic load testing of (125% -5%/+0%) of rated capacity and the wheel loading shall not exceed

15kips during this test. The Contractor shall provide an overload test certificate stating that the crane can be periodically load tested to (125% -5%/+0%) of rated load. (SUBMITTAL REQUIRED)

The crane shall be designed as a Class C service crane per CMAA No. 70. The crane shall be 2.2.2.

designed per the requirements of this specification, CMAA No. 70, ASME B30.2, and all other standards called out in this specification.

The crane shall be designed to operate within the allowable crane envelope, runway dimensions, 2.2.3.

and rail size, making sure to account for the full range of motion of wheel float. The crane hook envelope shall be maximized where practical, but it shall not exceed the on-site crane envelope measurements taken by the Contractor, see section 1.6.4.1. The allowable clearance between the sides of the crane and the building shall be a minimum of 2 inches when the crane is centered on the rails and 3 inches between the highest point of the crane and the lowest overhead obstruction when the crane is unloaded.

The crane shall be designed to endure a reoccurring Loss of Power Test. The Contractor shall 2.2.4.

provide a certificate stating that a Loss of Power Test can be performed. (SUBMITTAL

REQUIRED)

The crane noise level shall not exceed 70db while operating the crane at any rated load and speed. 2.2.5.

The noise measurement shall be taken as close to the trolley as possible while standing on one of the bridge girder walkways.

CRANE SAFETY REQIUREMENTS 2.2.6.

The crane shall comply with the mandatory and advisory safety requirements of CMAA No. 2.2.6.1.

70, OSHA 29 CFR 1910.147, 1910.179, 1910.306, paragraph (b) of ASME B30.2, and all applicable provisions of 29 CFR 1910 and NFPA 70.

CRANE ACCESS 2.2.6.2.

2.2.6.2.1 The crane shall be designed to be accessed from the West side of the bay between building columns 83 and 84.

Contract Number 21

FALL HAZARDS 2.2.6.3.

2.2.6.3.1 The crane shall have OSHA approved fall arrest tie off points in locations where there is a potential fall hazard. All fall arrest points shall be designed to support 5,000lbs minimum or designed as a fall arrest system which maintains a design factor of at least 2 under the supervision of a Qualified Person per 29 CFR 1910.66. All fall protection attachment points shall be marked as a fall arrest anchorage point.

HAZARDOUS MATERIAL 2.2.6.4.

2.2.6.4.1 The crane shall not contain any asbestos, lead, cadmium, chromium, polychlorinated biphenyl (PCB) or elemental mercury. The Contractor shall submit a hazardous material certificate that states that the crane does not contain any of the above listed hazardous materials. (SUBMITTAL REQUIRED)

PERFORMANCE REQUIREMENTS 2.2.7.

The crane shall have a speed range that matches the values in the Performance Requirement 2.2.7.1.

Table section 2.2.7.2.

PERFORMANCE REQUIREMENT TABLE 2.2.7.2.

Function Capacity (lbs) Rated Speed (fpm) +/-10% *Minimum Speed (fpm) +/-10%

Bridge 10,000 minimum 170 2

Trolley 10,000 minimum 80 1

Hoist 10,000 minimum 35 .5

* The slowest speeds shall not exceed the values listed in the minimum speed column.

STRUCTURAL REQUIREMENTS 2.2.8.

STANDARDS 2.2.8.1.

2.2.8.1.1 The structural design of this crane shall conform to CMAA No. 70, OSHA 29 CRF

1910.27, 1910.179, ASME B30.2, and all other standards that are included within these standards.

BRIDGE GIRDERS 2.2.8.2.

2.2.8.2.1 Single web bridge girders may be used; however, lateral torsional buckling shall be accounted for in the structural calculations and stiffeners shall be added to properly transfer the load when necessary.

2.2.8.2.2 Spliced connections shall be kept to a minimum and all spliced connections shall be placed in areas of low stress.

2.2.8.2.3 If the bridge girders are notched to fit over the end truck the girders shall be reinforced at the notches with vertical diaphragms and horizontal stiffeners.

LIFTING ATTACHMENT POINTS 2.2.8.3.

Contract Number 22

2.2.8.3.1 All lifting points shall be designed to withstand the stresses from rigging sling angles of

45 degrees measured from horizontal, see Figure 1 Padeye Orientation.

2.2.8.3.2 Orientation of all padeye lift points shall be orientated so that the applied load will be in plane of the padeye face within +/- 5 degrees, see Figure 1 Padeye Orientation.

2.2.8.3.3 All lifting configurations shall be designed such that any group of two legs in the configuration can carry the entire weight of the load.

2.2.8.3.4 Major sections of the crane, e.g, bridge girders, end trucks, and trolleys shall be designed with attachment points, e.g., lifting lugs, padeyes, safety hoist rings, or equivalent attachments points (Government approval is required to use equivalent attachment points).

2.2.8.3.5 The crane shall be designed with attachment points, e.g. (lifting lugs, padeyes, safety hoist rings, or a Government approved equivalent) that allow the entire bridge assembly to be lifted and attachment points that allow the entire trolley to be lifted.

2.2.8.3.6 All lift points shall be in a common horizontal plane that is located above the CG. The crane shall be able to be lifted level within 3 degrees.

2.2.8.3.7 If lifting attachments are welded on, these welds are considered primary welds per this specification and are required to undergo NDT per the NDT Table section 1.6.16.3.

WALKWAYS, HANDRAILS, AND LADDERS 2.2.8.4.

2.2.8.4.1 The crane shall have a full length walkway along each girder and a crossover walkway across an end truck or trolley. The main walkways shall conform to OSHA 29 CRF 1910.23.

All ladders shall conform to OSHA 29 CRF 1910.27.

2.2.8.4.2 Personnel shall be able to walk across the end truck without needing fall protection when the trolley is positioned at the furthest end position; meaning that OSHA approved hand rails are required on each end of the crane and all gaps shall be less than 12 inches between the trolley and end truck. The trolley shall serve as a guarded edge when the trolley is located in its furthest East or West position.

2.2.8.4.3 The trolley shall have OSHA approved handrails and toe boards around the perimeter of the trolley. If the crane envelope limits the handrail height on the trolley then handrails shall be omitted, and approved fall protection points shall be designed and located on the trolley, see section 2.2.6.3.1.

Figure 1: Padeye Orientation

Contract Number 23

2.2.8.4.4 The main walkway, where the electrical enclosures are located, shall be designed such that fall protection is not needed to walk along the walkway. The walkway may be lowered to accommodate for the OSHA approved handrail height (42+/-3in) or the bridge girder shall be

18 inches wide and the top surface of the bridge girder to the walkway shall be a minimum of

30 inches to qualify as an OSHA approved handrail. It is an option to lower the walkway to reduce the height of the girder needed to achieve the 30inch requirement. If the 30 and 18 inch requirements are not possible to achieve without greatly oversizing the girders then an approved fall arrest system shall be designed and located on the bridge walkway so that personnel can attach their fall protection clip to the cable and walk the full length of the walkway.

2.2.8.4.5 Swing gates shall be provided at all locations where personnel will access the crane and where they will access the trolley.

2.2.8.4.6 The bridge walkways shall have OSHA approved toe boards.

WHEELS 2.2.8.5.

2.2.8.5.1 The trolley and bridge wheels shall be made out of a material that meets ASTM A668 class G-N. The trolley and bridge wheel hardness, diameter, and rim width shall comply with

Table 3.4 of AIST TR No. 6. The bridge wheels shall be designed to run on the existing

ASCE 60 bridge rail. The wheels shall not be fabricated from plate steel and shall not be hollow stamped construction.

2.2.8.5.2 The trolley and bridge wheels shall be forged, have double flanges, and the treads shall be machined.

2.2.8.5.3 The Contractor shall provide the Government with a test sample report for the trolley and bridge wheels. This report shall provide a hardness profile of a sample wheel that matches the material and manufacturing/heat treating process that is used for the wheels. The wheel sample shall undergo MT or PT to ensure the wheels are not cracked (SUBMITTAL

REQUIRED). If the trolley and bridge wheel material, manufacturing, or heat treating process differ than two submittals are required.

2.2.8.5.4 The crane’s maximum bridge wheel load (without impact) due to dead load and the rated capacity live loads, with the trolley in any position, shall not exceed (15kip per wheel).

2.2.8.5.5 All bridge wheels shall be tapered treads or they shall all be straight treads. All trolley wheels shall have straight treads.

2.2.8.5.6 The wheel shall be designed so that the wheel/axle bearing assembly can be removed without having to jack the end truck more than 3 inches.

SEISMIC FORCES 2.2.8.6.

2.2.8.6.1 Seismic forces shall be analyzed per section 13 of ASCE 7 and all sections referenced in section 13. (SUBMITTAL REQUIRED)

2.2.8.6.2 Importance Factor shall be Ip=1…