DRAFT_REPLACEMENT PSNS CIF CRANE SPECIFICATION_UPDATED.docx

BUILDING 7201 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: John Mullet Branch Head Supervisor: Stuart MacDiarmid Contracting Officer’s Representative: Ryan Harrison

TABLE OF CONTENTS

Contract Number 17

GENERAL

STANDARDS

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

Submit a certificate of compliance stating that the crane complies with the standards called out in this specification (SUBMITTAL REQUIRED) The most recent revision on the day the contract is awarded shall be used for all standards listed in this specification.

AMERICAN GEAR MANUFACTURERS’ ASSOCIATION (AGMA)

AGMA 2001-D04 – Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth AGMA ISO 1328-1-B14 – Cylindrical Gears – ISO System of Flank Tolerance Classification AGMA 6013-B16 – Standard for Industrial Enclosed Gear Drives AGMA 6034-C21 – Practice for Enclosed Cylindrical Wormgear Speed Reducers and Gearmotors AGMA 6035-A02 – Design, Rating and Application of Industrial Globoidal Wormgearing AGMA 6123-C16 – Design Manual for Enclosed Epicyclic Gear Drives

ASSOCIATION FOR IRON & STEEL TECHNOLOGY (AIST)

AIST TR-06 - Specification for Electric Overhead Traveling Cranes for Steel Mill Service AIST TR-11 – Brake Standards for Mill Motors

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI/ASC A14.3-2018 – Fixed Ladders ANSI/ASSP Z359 – Fall Protection & Arrest Standards ANSI 60529 – Degrees of Protection Provided by Enclosures (IP Code)

1.1.1 AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE)

ASCE/SEI 7-22 – Minimum Design Loads and Associated Criteria for Buildings and Other Structures

1.1.2 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B4.1 – Preferred Limits and Fits for Cylindrical Parts ASME B17.1 – Keys and Keyseats ASME B30.2 – Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist) ASME B30.20 – Below-the-Hook Lifting Devices ASME B30.30 – Ropes ASME BTH-1 – Design of Below-the-Hook Lifting Devices

AMERICAN SOCIETY OF NONDESTRUCTIVE TESTING (ASNT)

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

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A668– Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use ASTM A1023 – Standard Specification for Carbon Steel Wire Ropes for General Purposes ASTM E94 – Standard Guide for Radiographic Examination Using Industrial Radiographic Film ASTM E164 – Standard Practice for Contact Ultrasonic Testing of Weldments ASTM E543 – Standard Specification for Agencies Performing Nondestructive Testing ASTM E709 – Standard Guide for Magnetic Particle Testing ASTM F436 – Standard Specification for Hardened Steel Washers ASTM F3125 – Standard Specification for High Strength Structural Bolts and Assemblies

AMERICAN WELDING SOCIETY (AWS)

AWS A2.4 – Standard Symbols for Welding, Brazing, and Nondestructive Examination AWS D14.1 – Welding of Industrial and Mill Cranes and Other Material Handling Equipment

CRANE MANUFACTURERS' ASSOCIATION OF AMERICA, INC (CMAA)

CMAA 70 – Specification for Top Running Bridge and Gantry Type Multiple Girder Electric Overhead Traveling Cranes

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO/IEC 15408 – Information Security, Cybersecurity, and Privacy Protection – Evaluation Criteria for IT Security.

NATIONAL ELECTRIC CONTRACTORS’ ASSOCIATION (NECA)

NECA NEIS 1 – Good Workmanship in Electrical Construction NECA NEIS130 – Installing and Maintaining Wiring Devices NECA NEIS 230 – Selecting, Installing, and Maintaining Electric Motors and Motor Controllers (1000 Volts and Less)

NATIONAL ELECTRICAL MANUFACTURERS' ASSOCIATION (NEMA)

NEMA ICS 8 – Application Guide for Industrial Control and Systems Crane and Hoist Controllers ANSI/NEMA MG 00001-2024 – Motors and Generators ANSI/NEMA EN 10250-2024 – Enclosures for Electrical Equipment (1000 Volts Maximum)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 – National Electric Code NFPA 70E – Standard for Electrical Safety in the Workplace NFPA 79 – Electrical Standard for Industrial Machinery

NAVAL SHIPS TECHNICAL MANUAL (NSTM)

NSTM - Chap 613, Wire and Fiber Rope and Rigging

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

Title 29 CFR, Part 1910 Subpart D, Walking-Working Surfaces Title 29 CFR, Part 1910.140, Personal Fall Protection Systems 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)

AISC 348 – RCSC Specification for Structural Joints Using High-Strength Bolts

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE J429 – Mechanical and Material Requirements for Externally Threaded Fasteners SAE J995 – Mechanical and Material Requirements for Steel Nuts

SOCIETY OF PROTECTIVE COATINGS (SSPC)

SSPC AMPP SP 10 - Near-White Metal Blast Cleaning

UNDERWRITERS LABORATORIES (UL)

UL 60947-4 – Low Voltage Switchgear and Controlgear

WIRE ROPE TECHNICAL BOARD

Wire Rope User’s Manual

DEFINITIONS

Words that are italicized throughout this specification are defined below:

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.

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 125% 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 Primary Hoist Brake: Hoist brake closest to hoist motor that is located on the 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 misalignment. 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.

CONTRACTOR COMPLIANCE

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

The Government will determine compliance with the requirements of this specification by reviewing and accepting the submittals shown in section 1.4.3, attending an on-site shop test (Appendix B), performing crane inspections, and witnessing the Contractor complete the Acceptance Test (Appendix C).

SUBMITTALS

The Contractor is required, per this specification, to provide a submittal to the Government anytime 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 1.4.3), and either provide comments or accept the submittal. For convenience each occurrence is listed in the Submittal Summary Table (section 1.4.3) 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. All digital files must be text searchable. All PDF files must be less than 500MB in size.

A complete design submittal (e.g., catalog cuts, calculations, drawings/schematics) must be submitted before the Government will begin its review. The Government reserves the right to require changes to submittals, which may change the design, if the requirements of this specification are not met. Any fabrication work performed prior to obtaining design approval is at the Contractor’s risk. Design approval from the Government will be given upon satisfactory completion of the Final Design Submittal.

SUBMITTAL SUMMARY TABLE:

TECHNICAL FORMS

post crane installation

CATALOG CUTS:

Catalog cuts for all commercially available components shall be provided as a submittal to 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 preliminary and final catalog cuts listed below, and any other commercially available components not listed in their respective design submittals. 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

End trucks (including drive units).

Product information for all paint used on the crane.

Trolley end stops.

Bridge rails and associated hardware (e.g. clips, splice bars) Commercial lifting attachment points, fall protection anchorage(s) and ADD anchor points.

Swing gates, including manufacturer’s installation instructions.

MECHANICAL CATALOG CUTS

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

Brakes (including electrical information, installation, servicing and adjusting).

Bearings and housings (including lubrication instructions, load ratings).

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

Load blocks and hooks.

Wheels.

Sheaves.

Bumpers (including bumper compression and the resulting force based on the total kinetic energy absorbed).

Wire rope and end fittings.

ELECTRICAL CATALOG CUTS

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

Motors (to include all NEC Article 430.7 nameplate data).

Encoders.

Electrical Enclosures.

Collector Shoes and Assembly.

Limit Switches.

Bridge-to-Trolley Electrification.

Warning Devices.

Disconnect Switches.

Contactors and Relays.

Master Switches.

Auxiliary Devices (Floodlight, Horn, etc.).

Circuit Breakers.

Fuses.

NETWORKED CONTROL SYSTEM AND NETWORK PRODUCT DATA

Networked control system and network product data for equipment installed on the crane shall include the following devices Crane Supervisory Controller, Programmable Logic Controller/Relay (PLC/PLR) Remote Terminal Unit (RTU) Human Machine Interface (HMI) Motor Drive Interface Terminal Network Communication Module Network Router Network Switch/Hub Other network-capable device, whether it is networked or not upon delivery, as applicable.

For each device, as applicable, provide the following data:

Device Manufacturer.

Device Model.

Device (relative) Location.

Key Technical Ratings (e.g. memory, capacity, format, compatibility, etc.).

Serial Number.

Unique Network Identifier/Address.

Provide each of the following pieces of data for software used on the crane:

Manufacturer.

Version/Sub-Version.

Associated device (relative) location.

Used network ports/protocols/services.

Descriptions of all security features associated to vendor hardware and software.

DRAWINGS

ALL DRAWINGS

Provide a preliminary drawing package to the Government for review (SUBMITTAL 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/mechanical drawings, and electrical drawings.

Drawings that use foreign language and nomenclature shall include corresponding English equivalents. Metric units may be used for drawings, but they shall include conversions to English units on the drawings. Whenever units have been converted on a drawing, the converted unit shall be displayed in parentheses as a reference value next to the original, designed-to unit.

All drawings shall have a complete title block that includes the crane number, and the signature and seal of a registered Professional Engineer that directly oversees the work. There shall be no proprietary notes on any of the drawings.

All drawings shall have a comprehensive and complete bill of materials for the given drawing.

Each revision shall be tracked and marked on the drawing. An index of drawings shall be included that tracks current revisions of drawings.

All drawings must be provided in PDF format during the design review phase and in PDF and either DWG or DXF for final as-built drawings. These files shall be compatible with AutoCAD 2023.

GENERAL ARRANGEMENT DRAWINGS

Provide general arrangement drawings that show all assemblies in plan, elevation, and side views. These drawings shall show all mechanical components and assemblies, e.g., hoist assemblies, trolley and bridge drivetrains, building clearances, and principal dimensions that include tolerances.

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

Include weights of all components and maximum bridge wheel loads (with 100% load and without impact), wheel spacing, and show the location of the center of gravity of the trolley and bridge assemblies.

STRUCTURAL/MECHANICAL DRAWINGS

Provide a complete drawing package clearly detailing all fabricated components and structural assemblies/weldments, include tolerances, size and location (dimensions), camber requirements, weld call outs per AWS A2.4, material type and the standard associated with the material type, e.g., ASTM A36. For structural fasteners, include size and type of fastener, associated hardware and joint type for RCSC Specification for Structural Joints Using High-Strength Bolts.

Wheels and shafts (excluding motor and gearbox) machining details including material type, hardness and ultimate and yield strength. Gearbox assembly/setup drawings including any backlash limits, bearing size and type, shim stacks or preload requirements.

Reeving diagram including wire rope specification to include diameter, construction, material, length and terminations. Sheave assemblies including machining details, dimensions, material type and hardness.

Component bolt torque values shall be provided for installed fasteners with consideration for any lubrication and washers type. A general table may be used however, any special torques shall be called out on the applicable drawing.

Coupling & brake installation drawings including: locations, applicable shaft engagement, allowable misalignment, and bore and key details.

Wire rope drum assembly drawing with bearing size and type, alignment criteria and material type.

Hook block assembly drawing with bearing size, load ratings, part numbers and material type.

Lubrication drawing detailing the location of lubrication points, type of lubricant used, quantity and frequency of lubrication.

Joining/assembly details (including girder to endtruck, cab, etc.).

Dimensioned locations of lift points, estimated weight and approximate locations of center of gravity for each major component.

Dimensioned locations of fall protection anchorages (if applicable).

ELECTRICAL DRAWINGS

Provide electrical schematics, layout drawings and wiring diagrams for all electrical components and drives.

Schematics shall show all electrical components and wired connections including rating and type of protective devices and grounding. All devices with adjustable set points shall have the range and desired set point shown.

All electrical components shall list power requirements except control circuits.

The wiring diagram shall show all electrical component device placement, wiring size, wiring type, wiring color.

The wiring diagram shall include a bill of materials listing schematic designator, OEM name, and part number for all electrical components.

Schematics shall show overcurrent device ratings next to the applicable device.

Schematics shall show motor nameplate data called for in items (2), (4), (5), (6), and (7) of NFPA 70 Article 430.7(A).

Provide a comprehensive and complete drive parameter listing and all custom programming associated with the crane.

CONTROL SYSTEM AND NETWORK DRAWINGS

Network diagram must show interconnecting cabling, equipment locations, names, models, and unique network identification on network communications schematic for all network-capable devices.

Software logic graphical diagram (e.g. flow or block diagram, ladder-logic diagram, etc.).

Ladder logic and/or software flow/block diagrams shall include comments explaining the function of each unique software task or operation.

Network variable cross-reference list (or table) for all variables spanning multiple network protocols shall be provided in a drawing format. This list or table shall provide variable names and register addresses used in each communication protocol and each variable shall be correlated to the hardware/device served.

OPERATIONS AND MAINTENANCE/TECHNICAL DATA

The Contractor shall submit a preliminary copy of the crane’s operations and maintenance/technical manuals to the Government for review (SUBMITTAL REQUIRED). 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 be separated out into multiple manuals. A detailed table of contents is required and all pages shall be individually numbered in a manner that corresponds to the table of contents.

The operation and maintenance manuals shall be tailored to the crane and include a coversheet indicating the revision number, table of contents, operation instructions, maintenance information, parts information, drawing list, all drawings, product data, and calculations.

OPERATIONS MANUAL:

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

The operation manual shall be specific to the crane and include Contractor’s detailed written procedures as well as crane operating and safety instructions including any special precautions for starting/stopping, to include any provisions for entering and exiting long term storage.

MAINTENANCE / TECHNICAL MANUAL:

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.

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.

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

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.

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 various levels of performance, while staying within crane design allowances and/or limitations; and include a functional description of each subsystem and how each subsystem interfaces to the rest of the crane.

QUALITY ASSURANCE

CONTRACTOR SCHEDULE

The Contractor shall submit a preliminary schedule that details key events in the design, 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):

Post-Award Meeting Crane Envelope and Dimension Verification Preliminary Drawings and Calculation Submittals Government Review of Initial Design Final Drawings and Calculation Submittals Government Review of Final Design Start of Fabrication Shop Test Meeting Completion of Fabrication Pre-Installation Meeting Crane Delivery Existing Crane Removal New Crane Installation Post Installation Government Inspection Acceptance Test Crane Acceptance Completion of Warranty

CONTRACTOR VERIFICATION AND POST-AWARD MEETING (CONTRACTOR AT PSNS OR VIRTUAL)

The Contractor shall meet with the Government at PSNS after the contract has been awarded. This meeting will be used to discuss the contract and any other questions that arise.

1.1.2.1 The Contractor shall verify, on-site all electrification information necessary to install new runway conductors/grounding, conduit, and wiring from the crane to the building control panel (see section 2.2.10.8 for requirements).

CRANE ENVELOPE & RAIL ALIGNMENT SURVEY

1.1.2.2 The Contractor shall verify all crane envelope clearances, hook approaches, hook heights, spans, other building/runway features, and existing rail end stops, prior to designing the crane and shall submit a crane envelope drawing similar to the one shown in Appendix (A). The location and dimensions of the boarding platform shall also be included in this survey, see section 2.2.6.2.1. The purpose of Appendix (A) is to provide an example crane envelope and should not be used to design the crane. (SUBMITTAL REQUIRED) The Contractor shall review and validate existing rail survey provided by the Government, by independently surveying the rails and confirm crane span, straightness, elevation and rail-to-rail elevation comply with CMAA #70 for the proposed crane service class, capacity and runway length. Any runway rail discrepancies beyond CMAA #70 tolerances shall be identified and submitted to the government with a corrective work plan, and be fully corrected by the contractor and re-surveyed to demonstrate compliance prior to completion of crane design. Interaction between the existing crane and runway shall not be used to achieve required tolerances. The Contractor’s final certified survey report shall be included in the Rail Alignment Survey submittal package. (SUBMITTAL REQUIRED)

CONTRACTOR TESTING

Prior to the Shop Test and Inspection (see section 1.6.5), the Contractor shall test the operations of 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. The crane is to be fully assembled during the test and inspection, unless otherwise approved by the Government. The crane shall not be reeved. Once the Contractor successfully tests and inspects the crane, the Contractor shall provide a copy of the completed self-test, recorded on the shop test procedure verifying the Contractor’s self-test has been completed (SUBMITTAL REQUIRED). The Contractor shall then work with the Government to schedule the Shop Test and Inspection.

SHOP TEST AND INSPECTION (GOVERNMENT AT CONTRACTOR’S FACILITY)

The Contractor shall allow the Government to come to the Contractor’s facility and participate in a crane inspection and Shop Test. 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 shop test shall occur after the Government approves the final design submittal of the crane. Sufficient time shall be provided to allow the Government to thoroughly inspect the crane prior to the start of the shop test. The Contractor shall establish the specific energy control requirements and lockout/tagout (LO/TO) procedures in accordance with 29 CFR Part 1910.147 to ensure all hazardous energy will be secured prior to the start of the inspection. The Contractor shall advise the Government of the anticipated shop test two weeks prior to the beginning of the Government-witnessed shop test.

The Contractor shall be available to operate the crane, perform the shop test, complete the shop test shown in Appendix (B) (SUBMITTAL REQUIRED), and answer any questions that arise. All contract violations found during the shop test and inspection 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 Contractor’s 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 request to ship (SUBMITTAL REQUIRED). The request to ship shall include details of how the crane will be shipped to the site, along with all submittals required in Appendix E.

PRE-INSTALLATION MEETING (TELECONFERENCE OR CONTRACTOR AT PSNS)

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

Once the Contractor has installed, tuned, and tested the crane to verify it is ready for acceptance testing, the Contractor shall allow the Government to conduct a 3 – 5-day inspection prior to field acceptance testing. The Contractor shall be available to operate the crane at the request of the inspectors during this 3 – 5-day period. The Government shall be given a 2-day notice that the crane is ready for inspection before the 3 – 5-day period begins. All references to “days” in this section are considered working days (M – F) excluding federal holidays.

All items that are found during the Government inspection that do not meet the requirements 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 two (2) days to re-inspect the crane to ensure all the corrections have been made.

FIELD ACCEPTANCE TEST

The Acceptance Test, shown in Appendix (C) (SUBMITTAL REQUIRED), shall be satisfactorily completed after the crane is installed inside Building 7201 at Bangor Trident Repair Facility 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 after repairs/adjustments have been made until the test is passed. Any repairs that would affect an already tested component will require retesting of the previously tested component. 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 Acceptance Testing is completed.

After the crane has passed the field acceptance test, the contractor shall complete a control system parameter record, including authorized parameter range tolerances, for the crane and provide the crane parameter file downloaded from the crane at a time of acceptance, if applicable. The record shall include the contract number, contractor's name and address, date, all control system parameters and their final settings. Each control system parameter shall be designated as either used or unused. A copy of the parameter file records shall be provided to the Government on CD. (SUBMITTAL REQUIRED)

ACCEPTANCE

Final Government acceptance of the crane shall take place only after the following conditions are met:

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

The crane meets all contract requirements.

The crane passes a final inspection by the Government.

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

The Contractor shall support 30-minute weekly teleconferences at the Government’s request including the Contractor project manager and lead engineer.

GOVERNMENT INSPECTIONS

The Government may perform scheduled inspections of material, 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

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

The Contractor shall provide preliminary (SUBMITTAL REQUIRED) and final (SUBMITTAL REQUIRED) structural, mechanical, and electrical calculations to the Government that validate that the design complies with the requirements in section 1.6.13, CMAA No. 70, and all other applicable requirements in this specification. Design calculations shall be provided for custom items, and sizing calculations shall be provided for commercial items. Calculations shall be stamped and signed by a PE. The stamp and signature shall be original or otherwise comply with the applicable rules or regulations pertaining to their reproduction.

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

Any Finite Element Analysis (FEA) that is provided as a submittal shall come with hand calculations that verify the FEA model and a write-up that details the designer’s assumptions and explains the thought process behind the model.

All calculations shall utilize the following guidance for structuring of calculation packages and good housekeeping guidance:

Software Packages For programs that utilize FEA analysis software, results shall be provided in one of the following options: STAAD Pro Connect Edition V22 Update 8, FEMAP V12.0, MSC Apex 2023.3, Excel document, or .CSV file format.

For programs performing Arc Flash Analysis, results shall be provided in one of the following options: SKM Powertools V11, Excel document, or .CSV file format.

File Structure, Type, and Size Calculation submittals shall be in a Mathcad Prime 10 compatible format that is editable.

Final submittals shall include an editable Mathcad Prime 10 compatible file and a word searchable PDF.

If Excel or other data tables are used, include these tables as an Excel compatible file (not a PDF).

PDF files in excess of 20 pages must include bookmarks for ease of file navigation.

PDF files shall be less than 500MB in size. Documentation exceeding this size shall be broken up into sequentially labeled packages that break in logical locations (i.e., between calculation sections, not in the middle of a calculation).

Layout and Formatting Consistent formatting shall be employed between each calculation package (electrical, mechanical, structural, etc). This shall include relevant section headers, descriptions of section calculation goals, and summaries of section calculation findings.

All sources used within the calculation package must be cited.

Comments shall be used thoroughly and frequently throughout the calculation so that it is demonstrably obvious what the purpose of each step, or set of steps as appropriate, of the calculation is intending to accomplish.

Page numbers in the format of {Page #} out of {Total # of Pages} shall be included on every page.

Variables and Data When practicable, do not overwrite variables.

All unused variables shall be removed from the calculation package and each calculation section.

All input data shall clearly note where the information is obtained from, such as catalogue cut title, page number, and table/figure number.

For each new calculation section, all data inputs shall be re-displayed for clarity Equations and Functions For all equations utilized within the calculations, reference info to verify the accuracy of the equation shall be provided. If the equation has been sufficiently modified from its original version for use within the calculation (ie, through substitutions, values going towards zero, rearranging of values, etc), such that it took several steps to accomplish the modification and/or the steps are not immediately obvious, then the derivation of the utilized equation shall be included either within the calculation, or in a referenced appendix.

For any calculation that calls an external or user-defined function to perform parts of the calculation, that function shall be labeled, defined, and fully derived within an appendix attached to the calculation package.

STRUCTURAL CALCULATIONS

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 (Whiting Handbook estimate) with a rated bridge speed of 90 ft/min. The crane shall be designed for all other applicable CMAA No. 70 load cases as required by section 2.2.8.1.2.

Calculations are required for verifying the design and sizing of the girders, end trucks, welds and bolt sizes.

Calculations verifying the design of trolley frame shall be provided in accordance with CMAA No. 70 for any non-commercial items.

Calculations verifying the design of structural connections in accordance with this specification.

Calculations shall be provided that verify all lifting attachment points for the trolley and the bridge. Custom designed attachments shall be designed to Category B, Service Class 0 criteria of ASME BTH-1. All lifting attachment points shall meet ASME B30.20 provisions that apply to the marking, construction, installation, inspection, and testing. If requested by the government, load testing per ASME B30.20 of the lifting attachments shall be performed and witness by the government.

Perform a seismic analysis per the requirements of section 2.2.8.7.

MECHANICAL CALCULATIONS

Calculations are required for sizing of couplings, brakes, sheaves, wheels, end stops, bumpers, gear reducers, drum, wire rope, and bearing life.

Fatigue calculations shall be provided for any custom design shafts. The calculations shall address the stresses and fatigue induced by the OEM allowed misalignment of couplings in addition to all other applied forces.

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 test load. The calculations shall be performed for the following load cases and identify the worst one: hoist up/down, no-load/max load, and slow-speed/rated speed. This load case is considered a momentary peak load. The stress due to this load case shall not exceed the component OEM’s peak load rating or for custom designed components, 75% of the yield strength of the material.

Any non-commercial mechanical components shall be analyzed to show compliance with CMAA No. 70.

ELECTRICAL CALCULATIONS

Provide conduit fill calculations (using tables from NFPA 70 or manufacturer’s data sheets). Grounding conductors shall be included in the calculations.

Protective device coordination study showing proper coordination. This study shall include all devices from the line side of the primary facility overcurrent device. A bolted fault current of 6.95kA is available at the existing crane primary facility floor disconnect switch.

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

Provide wire sizing calculations for all power circuit conductors.

Provide component and device sizing calculations for transformers, reactors, resistors, electronic drives, and control panel environmental controls.

Provide an analysis of the temperature inside the electrical enclosures shall be conducted to ensure that the OEM recommended climate of the components inside is being maintained.

Provide motor sizing calculations per CMAA No. 70.

Provide lighting calculations to verify floodlights comply with section 2.2.13.7.1 of this specification.

Provide sizing calculations to verify the size of fuses in the new floor-level fused disconnect switch, per NEC 610.14(E).

WELDING

Welders shall be qualified per AWS D14.1 section 9. (SUBMITTAL REQUIRED) Welded or fabricated items (not including commercially purchased components) shall be per AWS D14.1.

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

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

NON-DESTRUCTIVE TESTING (NDT)

The Contractor shall provide a certificate with qualification data showing that the inspector performing NDT on the crane is qualified as a level 2 examiner per ASNT-SNT-TC-1A (SUBMITTAL REQUIRED).

All NDT performed per the NDT Table section 1.6.15.8 including visual inspection, shall 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.

Radiographic examination can be used in place of ultrasonic examination.

VISUAL EXAMINATION (V):

All welds shall first undergo a visual examination.