JC-1_SPECIFICATION.docx

MODERNIZATION OF CRAFT PORTAL CRANES

SERVICE LIFE EXTENSION PROGRAM (SLEP)

at

NORFOLK NAVAL SHIPYARD (NNSY)

PUGET SOUND NAVAL SHIPYARD & IMF (PSNSY)

PORTSMOUTH NAVAL SHIPYARD (PNSY)

PREPARED BY:

Navy Crane Center Bldg. 491, Norfolk Naval Shipyard Portsmouth Virginia 23709-5000

SPECIFICATION PREPARED BY:

TABLE OF CONTENTS

N62470-14-R-5001

PART 1.0 GENERAL

1.1 REFERENCES

The following documents, of the issue in effect on date of invitation for bids or request for proposal, form a part of this specification to the extent specified herein. In case of difference between the following documents and this specification, this specification shall govern to the extent of such difference. If standards other than those listed below are used, proof of equivalence shall be provided. NEMA, OSHA, ASME, AWS, AISC, and NFPA rules shall govern.

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS INTERNATIONAL (ASME)

AMERICAN SOCIETY OF NON-DESTRUCTIVE TESTING (ASNT)

Recommended Practice No. SNT-TC-1A Topical Outlines for Qualification of NDT Personnel

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

AMERICAN WELDING SOCIETY (AWS)

D1.1 - Structural Welding Code Steel

DEFENSE LOGISTIC AGENCY (DLA)

ENVIRONMENTAL PROTECTION AGENCY (EPA)

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS, INC. (IEEE)

IEEE 519 - Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 60529 - Degrees of Protection Provided by Enclosures

INTERNATIONAL STANDARDS ORGANIZATION (ISO)

NATIONAL ELECTRICAL MANUFACTURERS' ASSOCIATION (NEMA)

NATIONAL FIRE PROTECTION ASSOCIATION

NAVAL FACILITIES ENGINEERING COMMAND

NAVFAC P-307 - Management of Weight Handling Equipment

NAVAL SHIPS TECHNICAL COMMAND (NSTM)

Chapter 613 -Wire and Fiber Rope and Rigging

NAVSEA TECHNICAL PUBLICATION

T9074-AS-GIB-010/271 Requirements for Nondestructive Testing Methods

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

Title 29 CFR, Part 1910.27, Fixed Ladders Title 29 CFR, Part 1910.66, Appendix C, Personal Fall Arrest System 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, Occupational Exposure to Lead for Construction

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

Specification for Structural Joints Using High-Strength Bolts

SOCIETY OF AUTOMOTIVE ENGINEERS

SPANISH ASSOCIATION FOR STANDARDIZATION AND CERTIFICATION (AENOR)

EN13411 Part 8 - Terminations for steel wire ropes - Safety - Swage Terminals and Swaging

1.2 UNIT PRICES

See Section B and Section J, Attachment JB-1, Exhibit Line Items for use in the submission of pricing.

1.3 SYSTEM DESCRIPTION

The intent of this specification is to modernize fourteen 60/15 ton portal cranes at Norfolk Naval Shipyard (NNSY), Puget Sound Naval Shipyard & IMF (PSNSY), and Portsmouth Naval Shipyard (PNSY). The cranes to be modernized are as follows: ten cranes at NNSY (DC 29, DC 30, DC 31, DC 32, DC 35, DC 37, DC 39, DC 40, DC 41 and DC 43); three cranes at PSNSY (80, 81, and 82); and 1 crane at PNSY (PC 31). The modernization for all cranes will include replacing the existing DC drives, modifying the operator’s controls, replacing/modifying the electric control system, replacing the crane’s diesel engine generator set, adding a rail lubrication system (as an option), adding new limit switches, replacing of whip hoist wire rope and replacing outdoor conduit. Additionally, the addition of a caliper disc brake mounted on the drum and associated caliper disc brake control system will be required on the whip hoist on seven of the fourteen cranes. The modernization shall be performed in accordance with released design drawings developed by registered professional engineers. All cranes shall be inspected, field tested, and made ready for use in accordance with this specification. The cranes’ capacity, hook radii, hook travel, and hook speed are listed below.

Note: ‘Long boom’ indicates cranes that have a boom length 40’ longer than the ‘short boom’ cranes. DC 35, DC 37, DC 39, DC 40, DC 41 and DC 43 are the ‘long boom’ cranes and DC 29, DC 30, DC 31, DC 32, 80, 81, 82, and PC 31 are the ‘short boom’ cranes.

157-0 (short boom)

160-0 (max) 65-0 (min) Short Boom:

126-0 (max) 52-0 (min) 230-6 (long boom) 170-0 (short boom)

The existing portal cranes were designed by Amclyde and constructed by Craft. The cranes are controlled by five independent Rockwell Automation DC drive systems; three hoist drives (main hoist, whip hoist, boom hoist), a rotate drive, and a travel drive. These drives are controlled by five master switches located in the operator’s cab. As part of the hoisting system, there are primary and secondary electric brakes for all three hoist functions. Seven of the cranes (DC 29, DC 30, DC 31, 80, 81, 82, and PC 31) include hydraulic caliper disc brakes installed on the main hoist, which remain open at all times during crane operations unless a broken shaft is detected. The cranes are powered by an onboard diesel engine generator set which provides 480 VAC to the five DC drives. The Contractor shall remove all existing components that are not being reused.

Electrical schematics of the existing cranes have been provided in Appendix C. These drawings cannot be confirmed for accuracy or completeness and are for information only. Any information contained in the drawings must be confirmed by the Contractor.

1.3.1 Design and Performance Requirements

The design of the modernized cranes shall conform to NFPA 70, ASME B30.4, and other requirements specified herein. The crane shall comply with all applicable requirements (“shall” statements) and recommendations (“should” statements). After contract award, the Contractor shall perform an initial site visit to NNSY to observe the current operation of two of the portal cranes. The Government will operate each crane prior to initiating work, to demonstrate to the Contractor the electrical and operational characteristics of the existing crane components, which will be used for comparison of the new components to be installed on the crane. All new components installed (i.e. drives, caliper disc brake control, diesel generator, etc.) shall duplicate the functionality of the existing crane except where otherwise specified herein.

1.4 SUBMITTALS

The Contractor shall submit to the contracting officer all items of technical documentation listed hereinafter. The Contractor shall ensure that all submittals are entirely legible and suitable for reproduction. The content, number of copies, time of submission, and distribution shall be in accordance with Exhibit A of this specification and as specified below. Compliance with the requirements of this specification will be determined by a review of the design and construction submittals by the contracting officer and by field inspection. Submittals are listed as general items. Some items may not be applicable based on specific crane design.

SD-01 Preconstruction Submittals Contractor shall submit monthly status reports. The first page of the report shall contain the following identifying information: Title/Project Description, Reporting Period, Contract Number, Name and Title of Report Preparer, Security Classification (when required), and a Distribution Statement. The content of the report shall address the overall project status and the status of each milestone/task for each crane, for designs in process – indicate the percent complete and estimated submission dates, and for designs under review - indicate the level of Government review and projected approval dates. It shall also list and describe current Contractor Change Request Forms (CCRFs), describe outstanding problems and proposed resolutions indicating who has the next action, describe significant results from conferences and trips, list directives given from the Contracting Officer's representatives, list all contract modifications issued, provide a summary of work planned in the next month, and provide any necessary supporting documentation as an attached appendix. An updated milestone schedule shall be provided with every monthly status report. The Contractor shall submit a schedule which identifies key milestone events in the design, fabrication, and installation of each crane. At a minimum, the schedule shall include the following:

Post Award Conference Design Submittals (100% & Final) Government Review (100% & Final) Pre-Installation Conference Shop Test Receive materials required for upgrade Install materials required for upgrade Field Acceptance Test Crane Acceptance Completion of Warranty

SD-02 Drawings The Contractor shall submit for approval the drawings and catalog cuts listed below via ProjNet (www.projnet.org). After Navy Crane Center design approval and prior to shop inspection, the Contractor shall submit a complete set of final design drawings. Initial design drawings shall include certification of review by a professional engineer. Contractor shall provide new crane drawings for the complete electrical control system. Final and “As-built” drawings shall bear a complete title block with a permanent drawing number and a registered professional engineer’s original seal and dated signature. Drawings within each category (such as structural, mechanical, etc.) shall be numbered consecutively. Each assembly and subassembly drawing shall include an integral Bill of Materials or shall be followed by a consecutively numbered drawing with the applicable Bill of Materials. There shall be no proprietary notes on any drawing. All drawings shall be created for viewing in AutoCAD 2006 with a drawing file format of .dwg or .dxf., and a separate copy viewable in Adobe Acrobat as a bookmarked portable document file (.pdf). An index for all drawings shall be included. The Government shall have full rights to use, reproduce, “build-from”, modify, copy, and release all submitted information.

SD-02.S Structural Drawings Structural drawings shall be provided for any modification to, addition to, or removal from the existing structure. These drawings shall be in accordance with the AISC 360 requirements for design drawings.

Structural drawings shall be provided for the following as a minimum:

1. Engine Room Layout Machinery House Layout Modification Details SD-02.E Electrical Drawings The drawings shall at a minimum include:

1. Complete schematic diagram with narrative of any special description of operation. All components shown on schematics shall have labels that correspond to the nameplates that will be on the crane. Wiring type, size, and temperature ratings shall be included on schematic diagrams and material list(s). All optional equipment not installed on the crane shall not appear on the schematic diagrams.

Motor nameplate data (including all information called for in NFPA 70, Section 430.7) Rating, types, and allowable settings of over-current protective devices.

Schematics of all electrical systems shall be provided, including complete assembly and layout drawings. In addition, comprehensive bill of materials listing showing all electrical components used on the crane. The machinery house layout drawings shall include locations for all electrical equipment on the crane, including control panel enclosures, motors, brakes, limit switches, conduits, and conductor systems.

Layout diagrams showing component placement in control panel enclosures Operator’s console arrangement Schematic showing crane rail lubrication system (if required) Load Moment Indicator (LMI) system SD-02.M Mechanical Drawings The drawings shall at a minimum include:

1. Hoist Caliper Disc Brake Installation Drawings including hydraulic schematics Rail Lubricator Installation Drawings (if required) Whip Hoist Headache Ball Drawing Diesel engine installation drawing (skid) SD-03 Product Data (Required only for new equipment/components) Manufacturer’s catalog data shall be provided for all major components of the crane. The catalog cuts shall be marked-up or supplemented with additional sheets to clearly identify the model or size, selected options, features, and/or modifications to demonstrate compliance with specification requirements. Catalog cuts which show modifications beyond the standard options and all supplemental pages, shall bear original signatures and dates of the equipment manufacturer’s authorized representative. Each catalog cut and each supplemental sheet shall clearly identify the item to which it applies. All catalog cuts shall be submitted in one file viewable in Adobe Acrobat and bookmarked as to the location of each catalog cut. In accordance with Exhibit A, the Contractor shall submit, for approval, the catalog cuts listed below:

SD-03.M Mechanical Product Data

SD-03.E Electrical Product Data

SD-04 Samples Not applicable to this specification.

SD-05 Design Data Calculations shall demonstrate compliance with all design requirements. Design data and calculations will not be approved if their evaluation/review is dependent on data or information not previously approved. All variables shall be listed and defined at the beginning of each calculation section. The Contractor as a minimum shall electronically submit for approval the calculations listed below.

SD-05.E Electrical Calculations

SD-05.M Mechanical Calculations

For each crane, the Contractor shall submit a report documenting the speeds, performance, and any other applicable information recorded during witnessing of the government post-award crane demonstration (para. 1.5.4.1) or the pre-work crane demonstration (para. 1.5.4.2). Additionally, for each crane, the Contractor shall document all electrical deficiencies and mechanical/structural deficiencies related to electrical components that are uncovered at the post-award crane inspection (para. 1.5.4.1) or the pre-work crane inspection (para. 1.5.4.2) that are outside the scope of the maintenance and repairs required by this contract. Reports of these deficiencies shall contain a detailed cost estimate, with labor and material costs, to repair deficiencies. Deficiency, as defined here, is any defect or problem that can or will prevent safe operation of the crane or a violation of NFPA 70, ASME B30.4, or OSHA requirements.

SD-06.2 Post-Work Inspection Report For each crane, the Contractor shall document in a single report all electrical deficiencies and mechanical/structural deficiencies related to electrical components that are uncovered during the course of the modernization that are outside the scope of this contract. The report shall contain a detailed cost estimate, with labor and material costs, to repair the deficiencies. Deficiency, as defined here, is any defect or problem that can or will prevent safe operation of the crane or a violation of NFPA 70, ASME B30.4, or OSHA requirements.

SD-07 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, drives, components, and location (as applicable) to which it applies.

SD-07.1 Wire Rope The Contractor shall provide the wire rope manufacturer’s certification that the new whip hoist wire rope meets the published breaking strength of samples taken from reels and tested. Certification shall be traceable to the hoist, crane, and reel.

SD-07.2 Periodic Overload Testing The Contractor shall certify crane components purchased and/or modified by this contract are capable of being load tested semi-annually up to and not exceeding 131.25% of the rated capacity without any detrimental effects.

SD-07.3 Hazardous Material The Contractor shall certify that the crane components purchased and/or modified by this contract do not contain asbestos, lead paint, Polychlorinated Biphenyl’s (PCB’s), or elemental mercury, and that Chromates have been avoided where feasible.

SD-07.4 Loss of Power Test The Contractor shall certify that when hoisting a test load, a loss of power test, can be performed without any detrimental effects to the electronic control system.

SD-07.5 Welding Certifications If welding is required, the Contractor shall provide a certificate stating that all welders, welding operators, weld inspector(s) and welding procedure (qualification) meet the requirements of AWS D 1.1 for all work performed on this crane.

SD-07.6 Design Review by Professional Engineer The Contractor shall provide a certificate stating that the design has been reviewed by a professional engineer. The certificate shall indicate the name, state of licensure and license number of the professional engineer.

SD-07.7 EPA Emission Certification The Contractor shall submit certification that the provided diesel engine meets the applicable EPA Tier Level requirements.

SD-07.8 Coupling Alignments (if applicable) Contractor shall submit coupling alignment data records with certification that the alignment of all shafting connected by means of flexible couplings are within manufacturer's installation tolerances. The coupling alignments shall be made using laser alignment equipment. The data records shall be taken after the coupling's final installation and after installation of shear bars or dowel pins in all base-mounted components. Coupling alignments shall be verified by the Contractor after crane component installation. The coupling alignment data record(s) shall be submitted on the official form titled, “Shaft/Coupling Alignment Record Form,” which can be found on the NCC website.

SD-08 Manufacturer’s Instructions SD-08.1 Shop Test Procedure Not applicable to this specification. A shop test procedure is not required to be submitted, however the Government will be given an opportunity to perform a shop inspection of the equipment required for the crane modernizations at the Contractor’s facility in accordance with para. 2.8.1.

SD-08.2 Removal and Installation Plan The Contractor shall submit a plan detailing the logistics involved in crane mobilization to the site and installation and removal of the components on the existing crane. The plan shall include, as a minimum, lifting configurations, lay-down areas, removal, installation, and transport through the activity. This plan shall also include details on removal and reinstallation of existing crane components (roof hatches, etc.) that are required for accessing the equipment necessary for the crane modernization. There is not a roof access in the crane’s diesel engine room. The entire roof may be removed for diesel gen-set replacement. A detailed lifting and handling plan meeting the minimum requirements shown in Appendix A shall be submitted by the Contractor, for review and acceptance by the Government. The construction crane and rigging gear shall comply with OSHA requirements and any local requirements.

NOTE: On-site changes of the plan are not allowed without Government review and acceptance.

SD-08.3 Field Test Procedure The Contractor shall develop and submit a field test procedure that will demonstrate operation, performance, and safety of the modernized cranes. This test shall be based on the pre-work inspection report and shall prove the functionality of the crane matches the functionality of the crane prior to modernization. The test procedure shall be submitted and approved prior to conducting the field test. This test shall, at minimum, include:

1. All demonstrations performed by the government at the post-award crane demonstration (para 1.5.4) including tests with no load, 50% load, 100% load, and 125% load.

A procedure to test the diesel engine safety system warnings and alarms.

Inspections necessary to verify safety of the crane (including verification of whip hoist caliper disc brake settings) that must be performed prior to beginning of load testing.

A procedure to test the whip hoist caliper disc brake system (if applicable) to demonstrate that it will meet the capacity and operational characteristics specified. The drive trains need not be disconnected for these tests.

SD-08.4 Accident Prevention Plan (APP) The APP shall be prepared in accordance with Appendix B, Exhibit A, and Exhibit B and shall be submitted for review and acceptance by the Contracting Officer. Installation of the crane components cannot proceed prior to the review and acceptance of the APP by the Contracting Officer.

SD-08.5 Training Course Outline The Contractor shall prepare and submit to the Contracting Officer for approval, a training course outline. The outline shall contain enough detail for the Government to determine that all topics are adequately covered as prescribed in section 3.8 of this specification.

SD-09 Manufacturer’s Field Reports SD-09.1 Brake Adjustment Records The Contractor shall provide a brake adjustment record for the new caliper disc brake installed on the whip hoist. The brake adjustment record shall be submitted on the official form titled “Brake Adjustment Record Form,” which can be found on the NCC website. Each brake measurement shall have a tolerance traceable to the associated brake manual or documentation provided by the brake manufacturer and an actual brake setting. Changes made to settings of the brake, at any time, will void this record.

SD-09.2 Shop Test Deficient Items List Upon completion of the government inspection of the equipment required for crane modernization, a list of deficient items will be compiled and attached to the “Navy Crane Center Post Shop Test Sign Off Sheet,” NCC Form 08-002, and signed by the Contractor, Navy Crane Center Representative, and activity representative (if applicable) and forwarded to the Contracting Officer.

SD-09.3 Field Test Record The Contractor shall follow the approved field test procedure that will demonstrate operation, capacity, and safety of the crane. Any deviations to the field test required by the Contractor must be approved by the Government. Upon successful completion of all testing, the Contractor shall submit records of all test data.

SD-10 Operation and Maintenance Data The Contractor shall submit the crane’s operation and maintenance manual to the Government for review. The operation and maintenance manuals shall include a table of contents, operation instructions, maintenance information, parts information, drawing list, all drawings, catalog cuts, and calculations.

Operation instructions shall include Contractor’s detailed written procedures as well as crane operating and safety instructions including special precautions for starting/stopping.

Maintenance information shall include recommended maintenance procedures, preventative maintenance, manufacturer’s installation and maintenance manuals (for purchased components), lubrication instructions, and maintenance and programming instructions for the drives. Lubrication instructions shall include the location of lubrication points, type of lubricant to be used, amount of lubrication to be used, and the frequency of lubrication, which shall agree with the lubrication drawing provided. Maintenance instructions shall include alignment, adjustment, and calibration instructions for commercial components and parts lists. Programming instructions shall include a complete listing of all control system parameters with an explanation of their functions.

Parts information shall include a recommended spare parts list, all information on all Contractor-designed parts, and all purchased sub-assemblies and components including the manufacturer’s part number. The information shall be broken-out to the smallest replacement part.

SD-11 Closeout Submittals SD-11.1 Drawings on CD-ROM The Contractor shall provide the crane’s as-built drawings on CDs viewable in AutoCAD 2006. The file shall be in .dwg or .dxf format and a separate copy in a bookmarked .pdf. The as-built drawings shall be submitted to the Government following final Government acceptance of the crane. The CDs shall include an index of the drawings.

SD-11.2 Operation and Maintenance Manuals The Contractor shall provide the operation and maintenance manuals for updated and/or new components following final Government acceptance. The manuals shall be in the form of a bookmarked .pdf that can be modified by the Government in the future when changes are required.

SD-11.3 Control System Parameter Record After each crane has passed the final field test, the Contractor shall complete a control system parameter record for each crane and provide the crane parameter file downloaded from each drive at time of acceptance, if applicable. The record shall include the contract number, Contractor’s name and address, date, all control system parameters, crane number, and their final settings. Each control system parameter shall be designated as either used or unused. This applies to all systems that have software as applicable such as Diesel Generator, LMI, Control System, HMI, etc.

SD-11.4 Product Data Catalog cuts shall be submitted electronically, in .pdf format, as one unit with a cover sheet containing a title block and index sheet identifying individual catalog cuts. Ensure each page is numbered and identified to allow proper filing if separated. Linked book marking is acceptable vice page numbering for the .pdf file. The minimum sections for indexing shall be the sections noted in paragraph SD-03.

SD-11.5 Property Transfer Verification After each crane has passed the final field test, the Contractor shall transfer possession of all small items associated with the operation and maintenance of the crane, including but not limited to keys, control software, computer cabling, remote controls, etc. The property shall be given to the point of contact of the supported command. The Contractor shall prepare and submit an itemized dated invoice showing the quantity and description of items transferred with a signature and date from the recipient.

1.5 QUALITY ASSURANCE

1.5.1 Qualifications

Crane design shall be accomplished by, or directly supervised by, registered professional engineers (PE). Each PE may be the Contractor's regular employee or consultant. Each PE's review and attestation of specification compliance and professional responsibility shall be signified by the PE's original seal, and dated signature on the as-built drawing and calculations. The PE’s shall only undertake and perform work under this contract only in the branch(es) of engineering in which they are licensed. Licensing shall be by a board or agency authorized to license and register professional engineers in the U.S. or Canada.

1.5.2 Regulatory Requirements

All crane functions and components shall comply with all Occupational Safety and Health Administration (OSHA) and other listed references in this specification.

1.5.3 Post-Award Conference

The Contractor shall attend a post-award conference that will be held at NNSY. This conference will cover design submissions, shipping, site mobilization, assembly dates, Exhibit A submissions, the APP, the crane installation plan, roles and responsibilities of the entities involved, and the overall schedule. Meeting minutes shall be prepared by the Contractor and reviewed by the Government.

The Contractor shall perform an initial site visit to NNSY to observe the current operation of two of the portal cranes, one with a caliper disc brake, and one without. The Government will operate the cranes to demonstrate to the Contractor the electrical and operational characteristics of the existing drive units for comparison against the new drive installations. This demonstration will include operation specifically for the broken shaft detection system if necessary. For the crane with a caliper disc brake, the demonstration will be conducted with no load, 100% load, and 125% load. For the crane without a caliper disc brake, the demonstration will be conducted with no load. Additionally, the Contractor shall operationally check and may inspect all electrical components of the crane. This demonstration and inspection can be coordinated to be held at the same time as the Post-Award Conference.

1.5.4.2 Pre-Work Crane Demonstrations and Inspections

After completion of the initial post-award crane demonstration and inspection, all subsequent cranes that will be modernized will be required to perform a pre-work crane demonstration to demonstrate satisfactory operation of the crane to the Contractor before any work commences. The Government will operate the cranes with no load during the pre-work crane demonstration. Additionally, the Contractor shall operationally check and inspect all electrical components of each crane before any work commences.

1.5.5 Pre-Installation Conference

Prior to each crane modernization, the Contractor shall attend a Government conducted pre-installation conference that will be held at the installation site. This conference will allow the Contractor and any Sub-contractors, the Navy Crane Center, and local command the ability to review any necessary precautions to insure a safe and accurate installation. A draft of the Crane Installation Plan should be available at the pre-installation conference. Meeting minutes will be prepared by the Contractor and submitted for review and approval to the Government in accordance with Exhibit A.

1.5.6 Government Furnished Equipment

The government will provide certified test weights, rigging gear, operators and riggers at the facility for acceptance testing of this delivery order and for post award demonstrations. The Government shall be notified a minimum of 5 business days prior to testing. This time is required to ensure the test weights and rigging gear are on-site when needed.

1.5.7 Diagnostic Fault Indication Test Plan

For each diagnostic fault that is not part of the standard drive platform (provided automatically to all drive purchasers) or that involves accessible code, the Contractor shall submit a test plan detailing its procedure for test/verification of functionality on the crane. Examples of hardware component inputs to be verified include those that are specific to this crane (i.e. not included in the normal OEM system package) and stop the drive or provide separate output or indication (i.e. buzzer or light, etc), Additionally, the indicative fault messages associated with the diagnostic fault shall be documented. Diagnostic faults that are disabled or which do not have accessible programming code, are not required to be tested.

1.6 DELIVERY, STORAGE AND HANDLING

Not applicable for this specification.

1.7 PROJECT/SITE CONDITIONS

1.7.1 Environmental Requirements

The drives shall be designed to operate in an indoor environment with an ambient temperature of -20° to 122° F and up to 90% humidity.

1.7.2 Existing Conditions

Prior to each mobilization, the site shall be inspected by the Contractor, a facility representative, and a NCC representative to document the condition of all existing construction and record any existing damage. A “Pre/Post Installation Site Inspection Checklist,” NCC form 11-001, shall be initiated at that time. Upon completion of the work, the Contractor, a facility representative, and a NCC representative shall determine the extent of any damage that may have occurred as a result of work performed under this contract. During this final inspection the NCC Form 11-001 shall be completed. Any damage as a result of the crane component installation and/or testing shall be the responsibility of the Contractor under this contract.

1.8 SEQUENCING AND SCHEDULING

Contractor shall provide sequencing and scheduling to be coordinated with the installation sites via NAVCRANECEN. The Contractor will provide a minimum of thirty days notice prior to any mobilization.

1.9 CONTRACTOR REQUESTED ENGINEERING CHANGES

All Contractor requested engineering changes must be submitted to the Government on the “Contractor Change Request Form,” NCC Form 07-001. The “Contractor Change Request Form Cost Worksheet,” NCC Form 07-001A, needs to be attached to any engineering changes. The forms are available at https://portal.navfac.navy.mil/ncc under the “downloads” page. The worksheet shall compare the cost of equipment as specified in the contract with the cost of the proposed change. CCRFs shall be disapproved if submitted without the “Contractor Change Request Form Cost Worksheet.”

1.10 WARRANTY

See section I of the contract for warranty information.

1.11 MAINTENANCE

Not applicable to this specification.

PART 2 PRODUCTS

2.1 MATERIALS

Material shall be free from defects and imperfections that might affect the serviceability and appearance of the finished product. All material shall be new and unused.

2.1.1 Ductile Material

All non-redundant components directly supporting the load shall be of ductile materials. These components include, but are not limited to all motor frames and end bells, flanged adapters, and brake wheels and discs. For the purpose of this specification, ductile is defined as having a minimum elongation of 5% in 2 inches. Furthermore, all shafts, keys, gears, torque carrying coupling components (with the exception of limit switches, other indicators, and diesel engine to generator couplings), load block components, and brake components (shoe levers, armatures, pull rods, torque springs, and bases) shall be steel.

2.1.2 Welding Materials

Welding materials for the crane shall conform to AWS D1.1.

2.2 MANUFACTURED UNITS

Not applicable for this specification.

2.3 EQUIPMENT

2.3.1 Modernization Design

General scope of modernization is as follows:

1. Remove the existing drives and control panel backplanes on each of the five crane functions, including the thyristor (SCR) boxes, field supplies, and any other equipment not required for the new drive system.

Remove the existing operator master switches/pedestals, and operator’s chair.

Provide and install new control panel backplanes, DC drives, field power supplies, resistor banks, breakers, overcurrent devices, line contactors and any other equipment, wiring, conduit, or hardware necessary for the new drive installation.

Provide and install new operator’s chair, with new integrated master switches.

All indicator lights in the operator’s cab shall be replaced.

Existing bypass key switches shall be relocated and re-used while maintaining their function unless identified here-in to be replaced.

Provide and install new main line contactor (retain existing main line contactor enclosure).

Provide and install new power transfer switches in the machinery house for main power and auxiliary power.

Remove non-working equipment and unnecessary equipment from the operator’s cab as defined by this specification.

Provide and install two (2) new maintained capacity overload bypass key-switches for the main hoist and whip hoist on the control panel door.

Remove existing hoist and rotate motor mechanical overspeed switches.

All hoist tachometer generators shall be removed.

Provide and install new motor encoders on each hoist function and rotate function. Utilize these encoders for motor feedback.

Provide and install new main distribution panel breakers (line side of isolation transformers).

Provide and install new crane monitoring system with remote diagnostic display.

For cranes with main hoist caliper disc brakes, provide and install new control panel with the incorporation of broken shaft detection.

Provide and install new caliper disc brakes for the whip hoists on selected cranes. The controls for this new caliper disc brake shall be integrated into the new control system.

Provide and install new hoist limit switches.

For cranes with a manual spud lock, reconfigure such that it is controlled electrically from the operator’s cabin using a selector switch. For cranes with an electrically controlled spud lock, update these connections with new.

Provide and install new LMI system for the main and whip hoists.

Provide and install new mis-spool limit switch on the main and whip hoist functions on selected cranes Provide and install new unbalanced load limit switch on the main hoist on selected cranes.

Integrate new controls into existing crane such that all functionality (not changed by this specification) of the crane, safety devices, limit switches, etc. are maintained.

Adjust the new drives and associated control equipment required to make the crane’s function operate properly and in accordance with the initial operational tests.

Provide the Government with a laptop computers with the diagnostic software loaded. Include all interface cables, portable storage case, and documentation required to communicate with the new drive units.

Provide and install new diesel engine/generator, generator circuit breaker, voltage regulator, electric starting system and any other equipment, wiring, conduit, or hardware necessary for the installation.

Provide and install new crane rail lubrication system (if applicable).

Provide and install new outdoor conduit on the crane gantry.

Provide and install new whip hoist wire rope.

Provide and install new whip hoist headache ball.

Remove air compressor and all associated pneumatic components Provide and install new outdoor sound powered phones stations

2.3.1.1 Overall Modernization Electrical Design Criteria

The electrical design of the crane shall conform to NFPA 70, NEMA ICS 8, ASME B30.4, and other requirements specified herein. The existing 800A main distribution breaker (located in a panel across from the main contactor panel in the machinery house) shall be replaced. Each drive mechanism shall be provided with a new separate and independent drive unit with a circuit breaker branch circuit protection device capable of being locked in the open position. The new control system shall be designed to operate on 480 VAC, 3phase, 60Hertz diesel generator power. All control circuits shall be fed from a single phase, air cooled, double-wound transformer. Contactors and relays shall not be definite purpose. If IEC contactors are used, the application cannot exceed the contactor manufacturer’s AC3 rating for the contactor. All contactors and relays shall have appropriate MOVs or R-C surge absorbers installed across the respective device’s coil. As much as practical, power and control cables shall not be mixed in the same conduit in order to prevent interference. Power cables and low voltage signal cables shall not be mixed in the same conduit. Existing transformers may be reused. All control components, including, but not limited to, circuit breakers, fuses, contactors, and relays shall be replaced.

The existing control panels may be reused, however, new backplanes for these control panels shall be provided for the new DC drives and controls. The panels shall be designed with appropriate heating and/or cooling accessories to maintain a climate within the panel that provides an appropriate internal temperature environment for proper operation of the drives. The panels shall be designed such that there shall not be any condensation inside the control panels. This shall include, at a minimum, panel heaters which can be run when hotel power is hooked up to the crane.

In addition to the diesel engine generator, the existing cranes can be powered via a shore power connection at the ground level. The crane also can be connected to hotel power to power ancillary loads when the crane is not in operation. The shore power transfer switch and the hotel power transfer switch (located in the machinery house next to the main contactor and main distribution panel), as well as associated interlocks and enclosures shall be replaced. Maintain existing circuit configurations and phasing. There is an internal breaker in the hotel power switch that shall be retained and relocated if required to provide computer and auxiliary power. Both the hotel power transfer switch and the shore power transfer switch shall include indicator lamps to validate proper voltage and phase rotation/voltage level Indoor enclosures shall be NEMA type 12 as defined by NEMA Standards Publication Number 250. All enclosures shall be metallic and be UL or CSA listed. All control panels shall have an interior light for each 3 foot of enclosure width with a door switch to turn lights off when doors are closed. All electrical components shall be industrial grade and located so they are easily accessible for inspection and maintenance.

Outdoor sound powered phones stations shall be replaced with new, ensuring new stations operate with existing indoor stations.

Components in all panels shall be selected and installed such that the control system enclosures are NFPA 70E arc flash hazard/risk category 0. Individual components shall comply with IP20 “finger safe” standards of IEC 60529. Appropriate shields shall be placed over components that cannot meet category 0 or IP20 standards and allow the panel doors to be open with the drives in operation.

All electrical components removed from the crane shall be turned over to the Government. These components include, but are not limited to, backplanes, contactors, drives, switches, master switches, circuit breakers, etc.

2.3.1.2 Overall Modernization Structural Design Criteria

The Contractor shall be responsible for modifications to the crane structure, including but not limited to, foundations, platform structures, and structural supports, to accommodate the brake retrofit work. Structural design, materials, fabrication, and installation shall be in accordance with the allowable stress design of the AISC 360. The allowable stresses shall not exceed 85% of the allowable stresses listed in the AISC 360. Stresses in welds shall not exceed the allowable stresses listed in AWS D1.1. Structural bolted connections shall be designed and installed in accordance with RCSC Specification for Structural Joints Using High Strength Bolts.

Weight shall be permanently installed by the Contractor as needed to restore the center of gravity of each rotate structure of each crane after the retrofit to within 0.10 feet of the existing value. The amount and location of the weight shall be verified by calculations. Weight shall be ferrous metals and bolted or welded in position.

2.3.2 Wiring System

Existing wiring may be reused unless otherwise specified. The existing wiring color scheme for the identification of conductors (i.e. AC power, DC power, etc.) shall be maintained. Unless otherwise specified, interconnecting wiring shall be of copper stranded construction complying with Table 310-13 of NFPA 70. 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 shall have, with the exception of types SA and FEPB, insulation shown in NEC Table 610-14(a) for 125°C maximum temperature. Motor branch circuit conductors shall be sized as to have an ampacity not less than 150% of the motor full load current rating. Conductors shall be selected and de-rated based on maximum ambient temperature. Continuous loads such as utility, heating, lighting, and air conditioning shall be multiplied by 2.25 to determine ampacity in order to permit application of NEC 610-14 (e) for crane supply conductors.

A separate grounding wire, sized in accordance with Section 250-122 of NFPA 70, shall be routed with all ungrounded conductors. All wiring shall be numbered or tagged at all connection points. Power conductors which are shielded shall be labeled as to the conductor size. All unused conduit openings shall be plugged. All conductors shall terminate on terminal blocks; there shall be no splices, with the following exceptions:

1. Encoder and master switch potentiometer signal conductors shall have a continuous run from the device to the drive. If the length of cable required between a drive and its respective encoder is longer than 300 feet, fiber optic cable shall be used. All subject signal cables shall be shielded.

Motor and brake connections may be made using split-bolts or lugged and connected with nuts, bolts, flat washers and lock washers in lieu of installing a terminal block in the motor connection box. No wire-nuts shall be permitted.

Cables used outside shall be a flexible, sunlight and UV resistant, fine…