Attach_A.pdf

HEAVY LIFT SPECIAL PURPOSE SERVICE PORTAL CRANES

for

U.S. NAVAL SHIPYARDS

PREPARED BY:

Navy Crane Center

Bldg. 491, Norfolk Naval Shipyard

Portsmouth, Virginia 23709-5000

Work Order # 1561544 Page 1 of 83

TABLE OF CONTENTS

PART 1 GENERAL

1.1 REFERENCES

1.2 UNIT PRICES

1.3 SYSTEM DESCRIPTION

1.3.1 Design Requirements

1.3.2 Performance Requirements

1.3.3 Capacity Sign

1.3.4 Unique Identifier Tag

1.3.5 Crane Delivery

1.4 SUBMITTALS

SD-01 Preconstruction Submittals SD-02 Drawings SD-03 Product Data SD-04 Samples SD-05 Design Data SD-06 Status, Test, and Inspection Reports SD-07 Certificates SD-08 Manufacturer’s Instructions SD-09 Manufacturer’s Field Reports SD-10 Operation and Maintenance Data SD-11 Closeout Submittals

1.5 QUALITY ASSURANCE

1.5.1 Qualifications

1.5.2 Regulatory Requirements

1.5.3 Post-Award Conference

1.5.4 Preliminary Design Review Conference

1.5.5 90% Design Review Conference

1.5.6 Pre-Installation Conference

1.5.7 Inspection Requirements and Responsibilities

1.6 DELIVERY, STORAGE, AND HANDLING

1.7 PROJECT/SITE CONDITIONS

1.7.1 Environmental Requirements

1.7.2 Existing Conditions

1.7.3 Government Furnished Equipment

1.8 SEQUENCING AND SCHEDULING

1.9 CONTRACTOR REQUESTED ENGINEERING CHANGES

1.10 WARRANTY

Work Order # 1561544 Page 2 of 83

1.11 MAINTENANCE

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Ductile Materials

2.2 MANUFACTURED UNITS

2.3 EQUIPMENT

2.3.1 Structural Design

2.3.2 Mechanical Design

2.3.3 Electrical Design

2.4 COMPONENTS

2.5 ACCESSORIES

2.6 MIXES

2.7 FABRICATION

2.7.1 Shop Assembly

2.7.2 Shop and Factory Finishing

2.7.3 Tolerances

2.8 TESTS, INSPECTIONS, AND VERIFICATIONS

2.8.1 Contractor’s Self -Test

2.8.2 Government Witnessed Shop Test and Inspection

2.8.3 Government Witnessed Field Test and Inspection

PART 3 EXECUTION

3.1 EXAMINATION

3.2 PREPARATION

3.3 ERECTION

3.4 INSTALLATION

3.5 APPLICATION

3.6 FIELD QUALITY CONTROL

3.6.1 Field Inspection and Test

3.6.2 Acceptance

3.7 ADJUSTING AND CLEANING

3.8 DEMONSTRATION

3.8.1 Training

3.9 PROTECTION

3.10 SCHEDULES

Work Order # 1561544 Page 3 of 83

PART 1 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 GEAR MANUFACTURERS' ASSOCIATION (ANSI/AGMA)

6013 Standard for Industrial Enclosed Gear Drives

2000 Gear Classification and Inspection Handbook Tolerances and Measuring Methods for Unassembled Spur and Helical Gears

6001 Design and Selection of Components for Enclosed Gear Drives

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

360 Specification for Structural Steel Buildings

303, Section 3 Code of Standard Practice for Steel Buildings and Bridges

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

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

AMERICAN PETROLEUM INSTITUTE (API)

2C Offshore Pedestal-mounted Cranes

ASSOCIATION OF IRON AND STEEL ENGINEERS (AISE)

11 Brake Standards for Mill Motors

AMERICAN SOCIETY OF CIVIL ENGINEERS/STRUCTURAL ENGINEERING INSTITUTE

(ASCE/SEI)

7 Minimum Design Loads for Buildings and Other Structures

AMERICAN SOCIETY OF MECHANICAL ENGINEERS INTERNATIONAL (ASME)

B4.1 Preferred Limits and Fits for Cylindrical Parts

B17.1 Keys and Keyseats

B30.4 Portal, Tower, and Pedestal Cranes

BTH-1 Design of Below-the-Hook Lifting Devices

AMERICAN SOCIETY FOR QUALITY (ASQ)

9001 Quality Management Systems – Requirements

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

A27 Standard Specification for Steel Castings, Carbon, for General Application

A36 Structural Steel

A53 Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

A148 Standard Specification for Steel Castings, High Strength, for Structural Purposes

Work Order # 1561544 Page 4 of 83

A275 Standard Practice for Magnetic Particle Examination of Steel Forgings

A314 Standard Specification for Stainless Steel Billets and Bars for Forging

A434 Standard Specification for Steel Bars, Alloy, Hot-Wrought or Cold-Finished, Quenched and Tempered

A500 Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes

A504 Standard Specification for Wrought Carbon Steel Wheels

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

A536 Standard Specification for Ductile Iron Castings

A572 Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

A668 Standard Specification for Steel Forgings, Carbon and Alloy, General Industrial Use

A992 Standard Specification for Structural Steel Shapes

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

B26 Standard Specification for Aluminum Alloy Sand Castings

B108 Standard Specification for Aluminum Alloy Permanent Mold Castings

E543 Standard Specification for Agencies Performing Nondestructive Testing

E1444 Standard Practice for Magnetic Particle Testing

F436 Standard Specification for Hardened Steel Washers

F593 Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs

F594 Standard Specification for Stainless Steel Nuts

F1836M-15 Standard Specification for Stuffing Tubes, Nylon, and Packing Assemblies (Metric)

AMERICAN WELDING SOCIETY (AWS)

D1.1 Structural Welding Code Steel

D1.3 Structural Welding Code – Sheet Steel

QC1 Specification for AWS Certification of Welding Inspectors

DEFENSE FEDERAL ACQUISITION REGULATIONS (DFAR)

DFARS 252.211-7003 Item Identification and Valuation

FEDERAL AVIATION ADMINISTRATION (FAA)

AC 70/7460-1K Obstruction, Marking and Lighting

FEDERAL SPECIFICATION

RR-W-410 Wire Rope and Strand

INTERNATIONAL ORGANIZATION FOR STANDIZATION (ISO)

4301-1 Cranes and Lifting Appliances – Classification – Part 1: General

Work Order # 1561544 Page 5 of 83

4406:1999 Hydraulic Fluid Power – Fluids – Method for coding the level of contamination by solid particles

9001 Quality Management Systems – Requirements

10816-Parts 1-5 Mechanical Vibration Evaluation of machine vibration by measurements on non-rotating parts

15408 Common Criteria for Information Technology Security Evaluation

MILITARY STANDARD (MIL-STD)

2035A Nondestructive Testing Acceptance Criteria

NATIONAL ELECTRICAL CONTRACTORS ASSOCIATION (NECA)

1-2015 Standard Practice of Good Workmanship in Electrical Contracting

NATIONAL ELECTRICAL MANUFACTURERS' ASSOCIATION (NEMA)

ICS 1 Industrial Control and Systems General Requirements

ICS 2 Industrial Control Devices, Controllers, and Assemblies

ICS 5 Industrial Control and Systems Control Circuit and Pilot Devices

ICS 8 Industrial Control and Systems Crane and Hoist Controllers

ICS 61800-2 Adjustable speed electrical Power Drive Systems Part 2: General requirements - Rating specifications for low voltage adjustable frequency a.c. power drive systems

MG 1 Motors and Generators

250 Enclosures for Electrical Equipment (1000 Volts Maximum)

NATIONAL ASSOCIATION OF CHAIN MANUFACTURERS (NACM)

RR-C-271 Chains and Attachments, Carbon and Alloy Steel

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

10 Standard for Portable Fire Extinguishers

12 Standard on Carbon Dioxide Extinguishing Systems

70 National Electric Code

70E Standard for Electrical Safety in the Workplace

NAVAL FACILITIES ENGINEERING COMMAND (NAVFAC)

P-307 Weight Handling Program Management

NAVSEA TECHNICAL PUBLICATION

T9074-AS-GIB-010/271 Change Notice 1 - Requirements for Nondestructive Testing Methods

NAVAL SHIPS TECHNICAL MANUAL (NSTM)

Chapter 613 Wire and Fiber Rope and Rigging

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

Title 29 CFR Part 1910.140 Personal fall protection systems

Title 29 CFR Part 1917 Maritime Terminals

Title 29 CFR Part 1926.1400 Cranes and Derricks in Construction

Work Order # 1561544 Page 6 of 83

Title 47 CFR Part 15 Radio Frequency Devices

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

Specification for Structural Joints Using High-Strength Bolts

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

J198 Windshield Wiper Systems – Trucks, Buses, and Multipurpose Vehicles

J429 Mechanical and Material Requirements for Externally Threaded Fasteners

J995 Mechanical and Material Requirements for Steel Nuts

J375 Radius-Of-Load or Boom Angle Indicating Systems

J159 Rated Capacity System

J516 Hydraulic Hose Fittings

J517 Hydraulic Hose

J1273 Recommended Practices for Hydraulic Hose

J2202 Automobile and Motor Coach Wiring

Z26.1 Safety Glazing Materials

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SP10 Near-White Blast Cleaning

WIRE ROPE TECHNICAL BOARD

Wire Rope Users Manual

Work Order # 1561544 Page 7 of 83

1.2 UNIT PRICES

See RFP Section B.

1.3 SYSTEM DESCRIPTION

The intent of this specification is to procure heavy lift portal cranes to be installed at Naval Shipyards.

The crane shall be a portal type with a rotating superstructure, luffing boom, main hoist and an auxiliary (aux) hoist designed to meet the dimensional and functional requirements of this specification. See Figure 1 in Appendix A for a depiction of the terminology used throughout this specification.

The crane shall be built to the design of a registered professional engineer. The crane shall be designed, fabricated, assembled, shop tested, delivered, installed, inspected, field tested, and made ready for use in accordance with this specification.

Basic dimensions related to crane design shall be in accordance with Table 1 in Appendix B. Existing ground rail dimensions and conditions are detailed in Appendix C.

1.3.1 Design Requirements

The design of the crane shall conform to 29 CFR 1917, 29 CFR 1926.1400, ASME B30.4, and other requirements specified herein. The crane shall be cab controlled, and designed to operate on an EPA and OSHA compliant onboard diesel engine-power system. The crane shall also be designed to operate on Shore Power without the use of an onboard diesel engine. The crane shall also be configured for hotel power. The crane shall comply with all applicable requirements (“shall” statements) and recommendations (“should” statements) of ASME B30.4 (all “should” statements shall be considered “shall” statements). The crane shall have minimum ISO 4301 group classifications of A6 for the crane as a whole and M7 for hoists, luff, rotate and travel.

A weatherproof machinery house shall enclose all machinery mounted on the superstructure. Travel truck systems shall be designed to enable the crane to operate on straight and curved track with “frogs” and switches at intersections.

The crane shall be capable of simultaneous main hoisting, rotating and luffing with rated load at rated speeds at the operating wind load. The crane shall also be capable of simultaneous traveling and rotating with the main hoist carrying the rated load at rated speeds at the operating wind load.

1.3.2 Performance Requirements

Crane performance requirements including loads, reaches, lifts, and speeds shall be in accordance with Tables 2 and 3 of Appendix B. All speeds are at rated load in operating wind unless otherwise noted.

1.3.3 Capacity Sign

Provide capacity plates that list the capacity in pounds with permanent lettering, visible from all sides of the crane. All lettering shall be of sufficient size to be easily read from the ground. The capacity plate shall contain the following information:

Rated capacity of the crane (in pounds) Naval Facilities Engineering Command Contract Number XXXX Manufacturer’s name, address and crane serial number Crane Number XXX The crane number(s) shall be: PC-38

Work Order # 1561544 Page 8 of 83

1.3.4 Unique Identifier Tag

In accordance with DFARS 252.211-7003, the Contractor shall assign a unique identifier to the crane.

The Unique Identification Tag shall be attached to the outside of the main electrical disconnect panel.

1.3.5 Crane Delivery

The Contractor shall field verify all crane envelope clearances and other crane interface features, including those identified in Appendices, prior to design of the crane.

The cranes shall be delivered as complete as possible for final assembly.

1.4 SUBMITTALS

The Contractor shall submit to the Contracting Officer all items of technical documentation listed hereinafter for the crane. Large electronic files (e.g. 5MB) shall be submitted via AMRDEC Safe (https://safe.amrdec.army.mil/safe/). 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. Review of crane design packages and installation plans will be tracked through ProjNet (https://www.projnet.org/).

For submittals that reference a Navy Crane Center form, all forms can be found at https://www.navfac.navy.mil/navfac_worldwide/specialty_centers/ncc.html under the “Downloads” page.

SD-01 Preconstruction Submittals

The Contractor shall submit a schedule which identifies key milestone events in the design, fabrication, and installation of cranes. At a minimum, the schedule shall include the following:

a. Post Award Conference

b. Initial General Arrangement and Design Submittals

c. Government Review of First Design Submittals

d. Second General Arrangement and Design Submittals

e. Government Review of Second Design Submittals

f. Third General Arrangement and Design Submittals

g. Government Review of Third Design Submittals

h. Fabrication Initiation

i. Fabrication Completion

j. On-Site Pre-Installation Conference

k. Government Witnessed Shop Test

l. Contractor Site Mobilization

m. New Crane Installation

n. Government Crane Inspection

o. Field Acceptance Test

p. Crane Acceptance

q. Contract Completion Date

Work Order # 1561544 Page 9 of 83 https://safe.amrdec.army.mil/safe/ https://www.projnet.org/ https://www.navfac.navy.mil/navfac_worldwide/specialty_centers/ncc.html

r. Receipt of Final O&M Manuals

s. Completion of Warranty

SD-02 Drawings

The Contractor shall submit the drawings listed below for approval. Initial drawing submittals (preliminary, 90%, and final) shall bear a complete title block with a permanent drawing number and a registered professional engineer’s original seal with a dated signature. Subsequent submittals shall bear a new revision number and engineer’s seal with a dated signature for each sheet that has been modified.

The Contractor shall provide design submittals in three phases throughout the process of developing the crane design.

The first submittal shall be a preliminary design. The preliminary design shall include the following :

general arrangements, preliminary crane stability, maximum wheel loads, selection of components for commonality, failsafe devices and features, provisions for removal of rotate bearing, ease of maintenance, and design factors utilized. The purpose of the initial submittal and review process is to identify and resolve problems early in the design phase. Review of the preliminary design shall take place at the Contractor’s facility as described in Section 1.5.4.

The second design submittals shall be a 90% design submittal. The 90% design submittal shall include drawings required in SD-02, product data required in SD-03, and design calculations required in SD-05.

Review of the 90% design submittal shall take place at Navy Crane Center during the two-day conference described in Section 1.5.5.

The third design submittal shall be the final 100% design submittal. The final 100% design submittal shall be approved by the Government. The Government review and approval process does not relieve the Professional Engineer from the responsibility for all aspects of the design of the crane.

Fabrication of a specific assembly may commence after all submittal components for that assembly are “Approved” by the Government. This approval does not relieve the Contractor of his responsibility to comply with contract requirements.

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. An index for all drawings shall be included.

Preliminary, 90%, and final design drawings shall be provided as a file viewable in Adobe Acrobat as a bookmarked portable document format (.pdf).

As-built drawings shall be provided in the following formats:

1. As an editable file in the file format of the program it was originally generated in.

2. As a file in the file format of .dxf or .dwg editable in Autocad 2010.

3. A separate copy viewable in Adobe Acrobat as a bookmarked portable document format (.pdf).

SD-02.G General Arrangement Drawings

The crane assembly and each major component shall be shown in plan, elevation, and side views. All major features of the crane shall be shown including: overall dimensions, clearances, hook reach and capacity, hook lifts, side-pull capabilities, wheel spacing, boom hinge and cab floor elevations, tie down arrangements, rotate bearing assembly arrangement, speeds, the wind speed above which the crane shall be placed in a stowed position, jacking points, maximum wheel loads, electrical power supply, and general locations of components such as: brakes, motors, gearboxes, and control panels. In addition, estimated weights and CGs shall be shown for the completely assembled crane.

Work Order # 1561544 Page 10 of 83

SD-02.S Structural Drawings

The structural design drawings shall be based upon consideration of the design loads and forces to be resisted by the structural steel in the completed project, and completed in accordance with AISC 303, Section 3, “Design Drawings and Specifications.”

The structural design drawings shall show the fabrication details, weldments, fastener joint details, Bill of Materials and location and size of all structural members. The fabrication details shall clearly show the size, section, material grade and location (dimensions) of all members; all geometry necessary for layout;

elevations; centers and offsets; camber requirements; and joining requirements between elements of built-up elements.

Other critical information that shall be provided on the structural design drawings includes the welded-joint configuration in accordance with AWS D1.1, and structural bolted-joint configuration in accordance with the RCSC “Specification for Structural Joints Using High-Strength Bolts.” All members required for fabrication shall be shown on drawings and shall be labeled to correspond with the Bill of Materials.

Dimensioned locations of lifting attachment points (for components to be lifted by suspended rigging) and approximate locations of center of gravity for each component requiring a lifting attachment per specification section 2.3.1.19 shall be provided on the structural design drawings.

Dimensioned locations of fall protection anchorages shall be provided on the structural design drawings.

Structural drawings shall be provided to verify design compliance with all design requirements specified in Specification Section 2.3.1. The following drawings shall be provided as a minimum:

a. Boom

b. Portal Base

c. A-Frame

d. Operator’s Cab

e. Machinery House including layout

f. Counterweight

g. Personnel Access (walkways, ladders, stairs)

h. Diesel Engine Compartment Layout, including Fuel Tank

i. Crane Load Chart in accordance with section 2.3.1.20.

SD-02.E Electrical Drawings

The drawings shall at a minimum include:

a. 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 cranes. All optional equipment not installed on the crane shall be removed from the schematic diagrams. Locations of contacts and coils shall be cross-referenced to each other within the schematic diagrams. For components with adjustable settings, settings shall be shown on the schematics.

b. Complete wiring diagrams depicting wire routing, conduit designations and layout, and conduit sizes. Wiring type, size, and temperature ratings shall be included on wiring diagrams.

c. Motor nameplate data (including all information called for in NFPA 70, Section 430.7)

d. Ratings, types, and required settings of over-current protective devices

Work Order # 1561544 Page 11 of 83

e. A comprehensive component material list showing all electrical components used on the crane. It shall include component designation, OEM name, and OEM part/model number.

f. Layout diagrams showing component placement in control panel enclosures and for operator’s cab

g. List of used symbols and designations

h. Grounding system, bonding methods, and lightning protection

i. Graphical limit switch diagrams for all limit switches showing the relationship of hoist hooks and boom positions to limit switch trip points. Limit switch contacts shall be clearly marked as either open or closed, as applicable, for all hoist and boom positions.

SD-02M Mechanical Drawings

a. Drive machinery arrangements for hoists, rotate, and travel drives (including assembled components)

b. Reeving Diagrams

c. Base mounted component and coupling bolt torque values. Torque tables shall be its own drawing page and shall include any lubrication and/or washer types used. This drawing page shall include the mechanical arrangement and location of each bolt listed.

d. Coupling installation drawings including: locations, applicable shaft engagement, allowable misalignment, bore, cylindrical fit, and key fit details.

e. Brake installation drawings including: locations, applicable shaft engagement, bore, cylindrical fit and key fit details.

f. Lubrication drawings showing all lubrication points, the type of lubrication used and the recommended lubrication frequency.

g. Hydraulic Systems Circuit Diagram and Schematic (if applicable) – This shall include the hydraulic power and control circuits for each system. All components shown on schematics shall have labels that correspond to the nameplates that will be on the system.

Hydraulic hosing/piping/tubing type, size, and pressure ratings shall be included on schematic diagrams

h. Wheels

i. Shaft and Axles

j. Hooks

k. Load Blocks, Sheave Nests and Sheaves

l. Rotate bearing assembly arrangement

m. Travel Equalizing System (including equalizer beams, gudgeons, gudgeon pins, travel trucks, truck float pins, etc.)

SD-02.C Control System and Network Drawings

a. Network diagram must show equipment locations, names, models, and IP addresses on network communications schematic for all PLC, RTU, Supervisory Controller, and Other Network-Capable Devices

b. Software block, flow, and ladder diagrams

Work Order # 1561544 Page 12 of 83

SD-03 Product Data

Manufacturer’s catalog data shall be provided for all standard commercial products/assemblies (as defined in section 2.4 of this contract) provided on 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. For electrical components catalog cuts shall identify the relevant Nationally Recognized Testing Laboratory (NRTL) listing for the product. Each catalog cut and each supplemental sheet shall clearly identify the item to which it applies. For each submittal, 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 for all standard commercial products/assemblies including those listed below:

SD-03.M Mechanical Product Data

SD-03.M1 Gearboxes including gear ratio and ratings

SD-03.M2 Brakes (including electrical information, installation/service manuals and all information required to set or adjust)

SD-03.M3 Diesel Engine

SD-03.M4 Diesel Engine Control System

SD-03.M5 Bearings and Bearing Housings

SD-03.M6 Couplings

SD-03.M7 Load Blocks

SD-03.M8 Control Valves

SD-03.M9 Filters

SD-03.M10 Hydraulic Motors, Pumps and Cylinders

SD-03.M11 Wire Rope and End Fittings

SD-03.M12 Lubrication (including OEM technical specifications and MSDS)

SD-03.M13 Rotate Bearing

SD-03.M14 Travel Trucks (including Drive Units)

SD-03.E Electrical Product Data

SD-03.E1 Variable Frequency Drives

SD-03.E2 Motors

SD-03.E3 Electrical Enclosures

SD-03.E4 Hotel Power Components

SD-03.E5 Shore Power Components

SD-03.E6 Limit Switches

SD-03.E7 Encoders/Resolvers

SD-03.E8 Operator Controls

SD-03.E9 Warning and Pilot Devices

Work Order # 1561544 Page 13 of 83

SD-03.E10 Disconnect Switches & Power Distribution Switchgear

SD-03.E11 Fuses and Circuit breakers

SD-03.E12 Generator

SD-03.E13 PLCs

SD-03.E14 Lighting

SD-03.E15 Slip Rings

SD-03.E16 Transformers

SD-03.E17 Capacity Overload Protection System

SD-03.E18 Load Indicating System

SD-03.E19 Contactors

SD-03.E20 Control Relays

SD-03.E21 Computer

SD-03.E22 Line/Load Reactors

SD-03.E23 Networking Components

SD-03.E24 Sensors

SD-03.E25 Conductors for conductor types not listed within NFPA 70 (including Listing and ampacity information)

SD-03.S Structural Product Data

SD-03.S1 Painting System

SD-03.S2 Bumpers

SD-03.C Control System and Network Product Data

Ensure the following is provided in the product data for PLC, RTU, Supervisory Controller, or other network-capable (whether networked or not upon delivery) control devices as applicable:

(a) Hardware list (Hardware list must include the following for each device):

i. Manufacturer,

ii. Model,

iii. Location,

iv. Key technical ratings (e.g. memory),

v. Serial number,

vi. MAC addresses,

vii. IP addresses.

(b) Software List (Software list must include the following for each device):

i. Manufacturer,

ii. Version/subversion,

iii. Location/device,

iv. Used network ports/protocols/services.

(c) List and discussion of all security features of Vendor hardware and software.

SD-04 Samples

Not applicable to this specification.

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SD-05 Design Data

The Contractor shall submit the calculations listed below for approval. The initial submittal shall bear a descriptive title and the date. Subsequent submittals shall bear a new revision number and date. All calculations shall have a registered professional engineer’s original seal with dated signature. These calculations shall demonstrate compliance with all design requirements of this specification. Calculations will not be approved if their evaluation/review is dependent on data or information not previously approved.

Drawings/Calculations shall include complete information so that they may be approved without reference to detail (shop) drawings. All references and assumptions used in the calculations shall be clearly stated within the calculation submittals.

Preliminary calculations shall be provided as a file viewable in Adobe Acrobat as a bookmarked portable document format (.pdf).

All final calculations shall be provided in the following formats:

1. As editable files in the file format of the program it was originally generated in, and

2. As a file viewable in Adobe Acrobat as a bookmarked portable document format (.pdf).

SD-05.S Structural Calculations

SD-05.S1 Calculations verifying the adequacy of structural components for the load combinations of section 2.3.1.2 of this specification.

SD-05.S2 Calculations verifying the adequacy of structural components for fatigue in accordance with section 2.3.1.3 of this specification.

SD-05.S3 Calculations verifying the stability of the crane in accordance with section 2.3.1.4 of this specification.

SD-05.S4 Wheel load calculations for the crane in accordance with section 2.3.1.5 of this specification.

SD-05.S5 Calculations verifying the adequacy of the storm secure system in accordance with sections 2.3.1.2 and 2.3.1.11 of this specification.

SD-05.S6 Calculations verifying structural response of cranes during shipping in accordance with section 1.6 of this specification.

SD-05.S7 Calculations verifying stresses in cranes and loads applied to the pier due to loading and unloading of the cranes in accordance with section 1.6 of this specification.

SD-05.S8 Travel truck system float calculations to ensure the cranes’ capability of negotiating the minimum radius rail curve (section 2.3.1.13).

SD-05.S9 Lifting attachment calculations in accordance with section 2.3.1.19.

SD-05.S10 Computer Analyses in accordance with section 2.3.1.22.

SD-05.M Mechanical Calculations

SD-05.M1 Wire rope line pull and sizing calculations in accordance with section 2.3.2.6 of this specification.

SD-05.M2 Calculations verifying brake sizing and selections in accordance with section 2.3.2.10

SD-05.M3 Main, Aux, and Boom Hoist Calculations

The Contractor shall perform analysis, or provide technical documentation from component OEM’s, to demonstrate adequacy of the selected hoist mechanical drive train components, and hoist frame structural frame members, considering duty cycles

Work Order # 1561544 Page 15 of 83 consistent with ISO 4301 group classification M7. Mechanical component selections and ratings, and structural component designs, shall account for an annual load testing at 125% (+5/-0%) of rated capacity load. The analysis shall consider normal primary and secondary brake operation (as defined in Section 2.3.2.10.1).

As a minimum, the following hoist drive train mechanical and structural components shall be evaluated (as applicable): brakes, gearbox, external pinion gear, drum mounted bull gear, drum stub shafts, shaft couplings, all shaft key/keyseat connections, wire rope drum, drum bearings, pinion stand bearings, reducer bearings, drum bearing foundations, pinion stand foundation, gearbox foundation, and all brake foundations.

The mechanical hoist design calculations shall take into account all hoist speeds and lifts.

SD-05.M4 Wheel load and sizing calculations in accordance with section 2.3.2.17

SD-05.M5 Travel Drive Calculations

The Contractor shall perform analysis, or provide technical documentation from component OEM’s, to demonstrate adequacy of the selected travel mechanical drive train components, and truck structural members, considering duty cycles consistent with ISO 4301 group classification M7. Mechanical component selections and ratings, and structural component designs, shall account for an annual load testing at 125% (+5/-0%) of rated capacity load. The analysis shall consider required brake operation (as defined in Section 2.3.2.10.2).

As a minimum, the following travel drive train mechanical and structural components shall be evaluated (as applicable): brakes, gearbox, shaft couplings, all shaft key/keyseat connections, brake foundations, and gearbox foundations.

SD-05.M6 Rotate Drive Calculations

The Contractor shall perform analysis, or provide technical documentation from component OEM’s, to demonstrate adequacy of the selected rotate mechanical drive train components, and associated structural members, considering duty cycles consistent with ISO 4301 group classification M7. Mechanical component selections and ratings, and structural component designs, shall account for an annual load testing at 125% (+5/-0%) of rated capacity load. The analysis shall consider required brake operation (as defined in Section 2.3.2.10.3).

As a minimum, the following rotate drive train mechanical and structural components shall be evaluated (as applicable): brakes, gearbox, external pinion gear, shaft couplings, all shaft key/keyseat connections, pinion support bearings, pinion foundation, gearbox foundation, and all brake foundations.

SD-05.M7 Shaft calculations, including fatigue and bearing life in accordance with sections 2.3.2.1 and 2.3.2.15

SD-05.M8 Calculations verifying acceptability of all mechanical and structural components for side load case in accordance with section 2.3.1.2.5.

SD-05.E Electrical Calculations

SD-05.E1 Motor sizing in accordance with Section 2.3.3.2 of this specification

SD-05.E2 Wire sizing and overcurrent protection

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SD-05.E3 Conduit fill calculations (using tables from NFPA 70, Chapter 9 or manufacturer’s data sheets)

SD-05.E4 Protective device coordination study showing proper coordination between the overcurrent devices installed.

SD-05.E5 Diesel Engine and Generator Sizing

SD-05.E6 Arc flash energy calculations for each electrical control panel showing proper data necessary for appropriate arc flash labels per NFPA 70E Flash Calculations

SD-05.E7 Load Balance Calculation

SD-05.E8 Power-off Brake Delay Calculation and verification

SD-05.DB Hoist Wire Rope Drum Caliper Disc Brake Calculations

SD-05.DB.1 Caliper Disc Brake Setting on Intact Drive Train

The Contractor shall perform analysis, or provide technical documentation from component OEM’s, to demonstrate adequacy of mechanical and structural components in the event of emergency drum brake setting on an intact hoist drive train. This load condition is considered an extraordinary, infrequent load condition.

The calculations and technical documentation shall demonstrate acceptability of each component. The analysis shall consider the caliper disc brake conditions that produce the maximum torque, including:

minimum air gap, maximum friction coefficient, and minimum setting reaction time. The analysis will account for impacts in the drive train caused by the load path reversal when the drum brake sets in the lowering direction.

As a minimum, the following hoist drive train mechanical and structural components shall be evaluated (as applicable): gearbox, external pinion gear, drum mounted bull gear, drum stub shafts, shaft to shaft couplings, all shaft key/keyseat connections, wire rope drum, drum bearings, pinion stand bearings, reducer bearings, drum bearing foundations, pinion stand foundation, gearbox foundation, and all brake foundations. As a minimum, the following load cases shall be considered:

a. Test load, full speed raising

b. Test load, full speed lowering

c. No load, full speed raising

d. No load, full speed lowering

For each load case above, consider:

a. Emergency drum brake sets only, with applicable dynamic braking

b. All brakes set simultaneously (emergency drum brake, primary brake, secondary brake, and applicable dynamic braking)

c. Location of line pull on drum

SD-05.DB.2 Caliper Disc Brake Setting on Broken Drive Train

The Contractor shall perform analysis to demonstrate the hoist caliper disc brake will safely stop and hold a rated capacity load considering a drive train failure, which separates the primary and secondary brakes from the load. This load condition is considered an extraordinary, infrequent load condition. Mechanical and structural components shall be analyzed to demonstrate adequacy when the emergency brake applies due to a broken drive train.

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As a minimum, the following load cases shall be considered:

a. 100% load, full speed raising

b. 100% load, full speed lowering

For each load case above, consider:

a. Drive train failure at gearbox input shaft locations (motor to gearbox coupling, input shaft pinion)

b. Drive train failure at output shaft location (separating gearbox from external pinion gear)

c. Location of line pull on drum

SD-06 Status, Test, and Inspection Reports

The following reports, outlines, and plans shall be submitted in accordance with Exhibit A.

SD-06.1 Status

The Contractor shall submit monthly status reports with updated project schedules.

SD-06.2 Hook Non-Destructive Test (NDT) Reports

SD-06.2.1 The Contractor shall provide a certification that the NDT vendor meets the requirements of ASTM E543. The certification shall be current, within one year of the date the NDT was performed.

SD-06.2.2 The Contractor shall submit for review the NDT vendor’s procedures, including technique sheets specific to the types, shapes, and size of the parts being examined (e.g., shank hook, eye hook, duplex hook, eye pin, swivel eye bar). For the magnetic particle method, the procedures shall adequately describe the orientation of the hooks, swivel eye bar, or eye pins with the magnetizing equipment. Procedures must be reviewed and bear the signature of an SNT-TC-1A qualified Level III examiner stating they are independent of the vendor.

SD-06.2.3 Hook NDT

For each hoist, the hook, hook eye pin (as applicable) or hook swivel eye bar (as applicable) shall be inspected by the magnetic particle method over their entire surface area in accordance with NAVSEA Technical Publication T9074-AS-GIB-010/271.

ASTM A275 may be used with the following restrictions: DC yokes (including switchable AC/DC yokes used in the DC mode) and permanent magnet yokes shall not be used; automatic powder blowers or any other form of forced air other than from a handheld bulb shall not be used for the application or removal of dry magnetic particles;

arc strikes shall be removed; and equipment ammeters shall have an accuracy of ± 5% of full scale (equipment ammeter accuracy other than that stated is acceptable provided the magnetic particle method procedure states that a magnetic field indicator is used to establish and verify adequate field strength for all aspects of the inspection). If NDT cannot be performed on surfaces inside holes, those surfaces shall be visually inspected to the maximum extent practical. Acceptance criterion shall be no linear indications greater than 1/16 inch. An NDT report shall be provided for each hook, hook eye pin, or hook swivel eye bar as applicable. The NDT report shall be provided to the Government and shall be traceable to the unique ID number of the hook and eye pin or swivel eye bar (as applicable.

SD-06.3 Additional NDT Reports

SD-06.3.1 Welds

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As a minimum, the Contractor shall perform the following non-destructive test (NDT) for welds to mechanical and structural components. A test record shall be provided for each weld NDT, including visual inspections. The test records shall contain, as a minimum, the test/inspection procedure used, the acceptance criteria, identification of the welds tested, the test results, and signature of the qualified person performing the test. The Government will perform random review of weld NDT records. The Government will report all deficiencies found to the Contractor for resolution.

a. For all welds on the crane, perform visual inspection per the requirements and acceptance criteria specified in AWS D1.1 for cyclically loaded connections.

b. For all welds to mechanical and structural components considered in the design calculations to support the hook loads, perform magnetic particle inspection, per the requirements and acceptance criteria specified in AWS D1.1, to the extent specified below:

1. Flange to web joint fillet welds and web butt welds: spot test at least 20% of the length of each weld. When a spot test identifies a defect requiring repair, inspect two adjacent locations. If defects are found in either adjacent location, inspect the entire length of the weld in that joint.

2. Tubular T, Y, and K Joint welds on the boom structure: Inspect the full length of each weld.

c. For all welds to mechanical and structural components considered in the design calculations to support the hook loads, perform ultrasonic inspection, per the requirements and acceptance criteria specified in AWS D1.1, to the extent specified below:

1. For full penetration groove welds in tension: inspect the full length of each weld.

2. For full penetration groove welds in compression or shear: For welds less than 6 inches in length, spot test at least 20% of all the welds. For welds longer than 6 inches, spot test at least 20% of the length of the weld. When any spot test shows defects that require repair, inspect two adjacent locations. If either adjacent location shows defects, inspect the entire length of weld, or the entire group of welds less than 6 inches long in a specific weldment.

d. For all welds to mechanical and structural components considered in the design calculations to support the hook loads, perform radiographic inspection, per the requirements and acceptance criteria specified in AWS D1.1, to the extent specified below:

1. Butt Joint welds in tension: Spot test 10% of the length of each weld. When any spot test shows defects that require repair, inspect two adjacent locations. If either adjacent location shows defects, inspect the entire length of weld in that joint.

SD-06.3.2 Steel Forgings

All steel forgings listed below shall be magnetic particle inspected in accordance with ASTM E1444 or ASTM A275. The acceptance criteria is that there shall be no cracks, and there shall be no linear indications greater than 1/8 inch long, whose length is greater than three times it’s width. A test record shall be provided for all steel forging NDTs.

The test records shall contain, as a minimum, the test/inspection procedure used, the acceptance criteria, identification of forging tested, the test results, and signature of the qualified person performing the test. The Government will perform random review of forging NDT records. The Government will report all deficiencies found to the Contractor for resolution.

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a. Boom hinge pins

b. Hoist drive train shafts (other than shafting integral to commercial OEM components)

c. Travel Equalizing System Pins

d. All other forgings for which failure could cause uncontrolled, unintended, or unsafe movement of the load.

SD-06.3.3 Steel Castings

All steel castings that are considered in the design calculations to support the hook loads shall be magnetic particle inspected in accordance with ASTM E1444. Acceptance criteria shall be in accordance with MIL-STD-2035A, Section 6.3, Class 2. A test record shall be provided for all steel casting NDTs. The test records shall contain, as a minimum, the test/inspection procedure used, the acceptance criteria, identification of casting tested, the test results, and signature of the qualified person performing the test.

The Government will perform random review of casting NDT records. The Government will report all deficiencies found to the Contractor for resolution.

SD-06.3.4 Iron Castings

All iron castings shall be magnetic particle inspected in accordance with ASTM E1444.

Acceptance criteria shall be in accordance with MIL-STD-2035A, Section 6.3, Class 2.

A test record shall be provided for all iron casting NDTs. The test records shall contain, as a minimum, the test/inspection procedure used, the acceptance criteria, identification of casting tested, the test results, and signature of the qualified person performing the test.

The Government will perform random review of casting NDT records. The Government will report all deficiencies found to the Contractor for resolution.

SD-06.3.5 Travel Wheel NDT

a. Hardness Testing of Test Wheel. An additional test wheel shall be manufactured and heat treated using the identical process used for all crane travel wheels. The test wheel shall be destructively tested by sectioning to demonstrate the degree and depth of hardening.

The test wheel shall have a cross section of the rim removed and hardness readings shall be measured to demonstrate the specified hardness depth and gradient, as required in section 2.3.2.17 of this specification, has been achieved. A test wheel report shall be provided, showing as sketch of the wheel rim and all hardness measurement readings.

b. Surface Hardness of Finished Wheels. The surface hardness of all wheels, at the tread and flange areas, shall be measured and recorded. The hardness measurements shall verify the surface hardness meets the requirement of section 2.3.2.17 of this specification.

A test report shall be provided documenting the surface hardness of each travel wheel.

c. Non-Destructive Testing. After heat treating and machining, all of the wheels shall be magnetic particle and ultrasonically tested. Magnetic particle inspection shall be performed after final machining. Ultrasonic inspection may be performed after rough machining. Ultrasonic inspection and acceptance criteria shall be in accordance with ASTM A504. The full rim surface, including all three surfaces of each wheel flange and the tread surface, shall be magnetic particle inspected in accordance with ASTM A275.

The acceptance criteria shall be no linear indications greater than 1/16 inch.

d. Material Certification. A certificate for each heat of material used for the wheel forgings shall be provided. The certification shall as a minimum include chemistry, and core properties for each heat of material after final heat treating.

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e. A test record/report shall be provided for travel wheel tests and documentation required above. The Government will perform random review of all wheel test records and reports. The Government will report all deficiencies found to the Contractor for resolution.

SD-06.4 Inspection Reports and Documentation

SD-06.4.1 Inspection Plan and Inspection Specification Reports for Parts and Assemblies

The Contractor shall submit their Inspection Plan, which shall identify all components (commercial-off-the-shelf or custom fabricated) and assemblies that will be inspected, and have an associated Inspection Specification Report, to document the parts or assemblies meet design requirements, tolerances, and purchase requirements. Inspection Specification Reports shall be generated for all parts and assemblies identified on the Inspection Plan. The Government will perform random review of completed Inspection Specification Reports. The Government will report all deficiencies found to the Contractor for resolution.

SD-06.4.2 Installation of High Strength Fasteners in Structural Connections

The Contractor shall complete a structural bolt tightening record for each structural connection. The bolt tightening record shall include the tightening process used, the pretension calibration/verification method, the connection location or drawing reference, the number of fasteners in the connection, the size type and grade of each fastener (bolt, nut, and washer), and the sequence of tightening. The Government will perform random review of completed structural bolt tightening records. The Government will report all deficiencies found to the Contractor for resolution.

SD-06.4.3 Installation of High Strength Fasteners in Mechanical Connections

The Contractor shall have procedures for tightening of high strength fasteners in mechanical connections. As a minimum the procedure shall identify the tightening process and torque values/tables based on the mechanical fastener size and grade, the lubricant used, and the calibration process for the equipment. For commercial assemblies, OEM fastener tightening procedures shall be used. The Contractor shall complete a mechanical bolt tightening record for all mechanical fasteners in joints that directly support lifting or movement of loads. The records shall identify the tightening procedure, number of fasteners in the connection, the size type and grade of each fastener (bolt, nut of washer), and the sequence of tightening. The Government will perform random review of completed mechanical bolt tightening records. The Government will report all deficiencies found to the Contractor for resolution.

SD-06.4.4 Lubrication

The Contractor shall complete a lubrication record for components on the crane that require lubrication. The lubrication record shall include the lubrication process (lubrication chart), the component lubricated, the type and amount of lubricant used, and the method of application.

SD-06.4.5 Open Gear Mesh Alignment

The Contractor shall complete a gear mesh alignment record for each open gear set. The record shall include the location of the gear set, the allowable gear contact pattern (loaded and unloaded), the measured gear contact pattern (loaded and unloaded), the allowable gear tooth backlash, and the measured gear tooth backlash. The Government will perform random review of all open gear mesh alignment records. The Government will report all deficiencies found to the Contractor for resolution.

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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, hoist, the drives, components, and location (as applicable) to which it applies.

SD-07.1 Wire Rope

The Contractor shall provide certification of the actual wire rope breaking strength, taken from a sample of wire rope from the same reel for each reel of wire rope used. The certification shall be traceable to the hoist, crane and reel.

SD-07.2 Wire Rope End Fitting

The Contractor shall provide documentation that the wire rope end fitting meets the requirements in Paragraph 2.3.2.6.1, including the results of the Charpy testing, for the wire rope end fitting, as applicable.

SD-07.3 EPA Emission Certification

The Contractor shall submit certification that the provided diesel engine meets the applicable EPA Tier Level provided in 2.3.3.26.

SD-07.4 Hazardous Material

The Contractor shall certify that the crane contains no asbestos, lead paint, Polychlorinated Biphenyl’s (PCB’s), elemental mercury, or chromates.

SD-07.5 Loss of Power Test

The Contractor shall certify that when lowering a test load a loss of power test can be performed without any detrimental effects to the crane and the drive control systems.

SD-07.6 Coupling Alignments

The Contractor shall generate a shaft coupling alignment report to document proper alignment for all shaft couplings.