Attachment A, NAVFAC Specification.pdf

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WO #1614003

NAVFAC

TWO 120/30 TON OVERHEAD ELECTRIC TRAVELING CRANES

at

STRATEGIC WEAPONS FACILITY ATLANTIC, KINGS BAY, GA

PREPARED BY:

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

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TABLE OF CONTENTS

PART 1.0 GENERAL

1.1 REFERENCES

1.2 UNIT PRICES

1.3 SYSTEM DESCRIPTION

1.4 SUBMITTALS

1.5 QUALITY ASSURANCE

1.6 DELIVERY, STORAGE, AND HANDLING

1.7 PROJECT/SITE CONDITIONS

1.8 SEQUENCING AND SCHEDULING

1.9 CONTRACTOR REQUESTED ENGINEERING CHANGES

1.10 WARRANTY

1.11 MAINTENANCE

PART 2.0 PRODUCTS

2.1 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

2.8 TESTS, INSPECTIONS, AND VERIFICATIONS

PART 3.0 EXECUTION

3.1 EXAMINATION

3.2 PREPARATION

3.3 ERECTION

3.4 INSTALLATION

3.5 APPLICATION

3.6 FIELD QUALITY CONTROL

3.7 ADJUSTING AND CLEANING

3.8 DEMONSTRATION

3.9 PROTECTION

3.10 SCHEDULES

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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 NATIONAL STANDARDS INSTITUTE (ANSI)

A14.3 - Fixed Ladders – Safety Requirements ANSI/IEC 60529 –Degrees of Protection Provided by Enclosures (IP20)

AMERICAN GEAR MANUFACTURERS' ASSOCIATION (ANSI/AGMA)

2001 - Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth 2015 - Accuracy Classification System 6013 - Standard for Industrial Enclosed Gear Drives 6034 - Practice for Enclosed Cylindrical Worm Gear Speed Reducers and Gear

Motors 6035 - Design, Rating and Application of Industrial Globoidal Worm gearing

ASSOCIATION FOR IRON & STEEL TECHNOLOGY (AIST)

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

Service TR-13 - Guide for the Design and Construction of Mill Buildings

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

360 - Specification for Structural Steel Buildings 303 - Code of Standard Practice for Steel Buildings and Bridges

AMERICAN SOCIETY OF MECHANICAL ENGINEERS INTERNATIONAL

(ASME)

B1.1 - Unified Inch Screw Thread B4.1 - Positional Fits and Tolerance for Cylindrical Parts B17.1 - Keys and Keyseats B18.8.2 - Taper Pins, Dowel Pins, Straight Pins, Grooved Pins, and Spring Pins

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

Girder, Top Running Trolley Hoist) B30.10 - Hooks

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE/SEI)

7 - Minimum Design Load for Buildings and Other Structures

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AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

A27 - Mild to Medium Strength Carbon Steel Castings for General Application A36 - Structural Steel A148 - High Strength Steel Castings for Structural Purposes A194 - Standard Specification for Carbon and Alloy Steel Nuts for Bolts for

High Pressure and High Temperature Service A242 - Standard Specification for High-Strength Low-Alloy Structural Steel A275 - Magnetic Particle Exam of Steel Forgings A307 - Standard Specification for Carbon Steel Bolts and Studs, 60 000 psi

Tensile Strength A325 - Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength A388 - Standard Practice for Ultrasonic Examination of Steel Forgings A434 - Standard Specification for Steel Bars, Alloy, Hot-Wrought or Cold-Finished, Quenched and Tempered A490 - Standard Specification for Heat-Treated Steel Structural Bolts, 150 ksi

Minimum Tensile Strength A504 - Wrought Carbon Steel Wheels A521 - Standard Specification for Steel, Closed Impression Die Forgings for

General Industrial Use A536 - Standard Specification for Ductile Iron Castings A563 - Standard Specification for Carbon and Alloy Steel Nuts A572 - Standard Specification for High-Strength Low-Alloy Columbium-

Vanadium Structural Steel A588 - Standard Specification for High-Strength Low-Alloy Structural Steel, up to 50 ksi [345 MPa] Minimum Yield Point, with Atmospheric Corrosion Resistance

A992 - Standard Specification for Steel for Structural Shapes for Use in Building Framing

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

B26 - Aluminum Alloy Sand Castings B108 - Specification for Aluminum Alloy Permanent Mold Castings E543 - Standard Specification for agencies performing Nondestructive Testing F436 - Standard Specification for Hardened Steel Washers F593 - Stainless Steel Bolts, Hex Cap Screws, and Studs F594 - Stainless Steel Nuts

AMERICAN WELDING SOCIETY (AWS)

D1.1 - Structural Welding Code Steel D14.1 - Welding of Industrial and Mill Cranes and other Material Handling

Equipment

CRANE MANUFACTURERS' ASSOCIATION OF AMERICA, INC (CMAA)

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No. 70 - Specification for Top Running Bridge & Gantry Type Multiple Girder Electric Overhead Traveling Cranes

DEFENSE FEDERAL ACQUISITION REGULATIONS (DFAR)

DFARS 252.211-7003 Item Identification and Valuation

FEDERAL ACQUISTION REGULATIONS (FAR)

FAR Part 2 Definition of Words and Terms

FEDERAL SPECIFICATION

RR-W-410 - Wire Rope and Strand

INTERNATIONAL ORGANIZATION FOR STANDIZATION (ISO)

15408 Common Criteria for Information Technology Security Evaluation

NATIONAL ELECTRICAL CONTRACTORS ASSOCIATION (NECA)

1-2015 - Standard Practice of Good Workmanship in Electrical

Contracting

NATIONAL ELECTRICAL MANUFACTURERS' ASSOCIATION (NEMA)

ICS 8 - Industrial Control and Systems Crane and Hoist Controllers MG 1 - Motors and Generators 250 - Enclosures for Electrical Equipment (1000 Volts Maximum)

NATIONAL FIRE PROTECTION ASSOCIATION

NFPA 70 - National Electric Code NFPA 70E - Standard for Electrical Safety in the Workplace

NAVAL FACILITIES ENGINEERING COMMAND

NAVFAC P-307 Management of Weight Handling Equipment

NAVSEA TECHNICAL PUBLICATION

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

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

29 CFR, Part 1910.66, Appendix C - Personal Fall Arrest System 29 CFR, Part 1910.179 - Overhead and Gantry Cranes 29 CFR, Part 1910.306 - Specific Purpose Equipment and Installations Title 47 CFR Part 15 - Radio Frequency Devices 29 CFR, Part 1910.28 - Duty to have fall protection and falling object protection

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

Specification for Structural Joints Using High-Strength Bolts

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC-SP1 - Solvent Cleaning SSPC-SP2 - Hand Tool Cleaning SSPC-SP3 - Power Tool Cleaning

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SSPC-SP10 - Near-White Metal Blast Cleaning

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE J376 - Load Indicating Devices in Lifting Crane Service SAE J159 - Rated Capacity System SAE J429 - Mechanical and Material Requirements for Externally Threaded Fasteners SAE J995 - Mechanical and Material Requirements for Steel Nuts

UNITED FACILITIES GUIDE SPECIFICATIONS (UFGS)

UFGS-09 97 13.27 - Exterior Coating of Steel Structures

WIRE ROPE TECHNICAL BOARD

Wire Rope User’s Manual

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1.2 UNIT PRICES

Not applicable to this specification.

1.3 SYSTEM DESCRIPTION

The intent of this specification is to procure two (2) 120-ton double girder, outdoor cab operated overhead electric traveling (OET) ordnance handling cranes, each with a 30-ton auxiliary hoist, with a backup radio-controlled system. The north and south cranes, identified as 83-00509 and 83-00508 respectively, will share the same runway and will be installed in the Explosive Handling Wharf building No.1. The new cranes are identical, and this specification applies to both cranes.

The cranes shall be built to the design drawings of registered professional engineers, fabricated, assembled, shop tested, delivered, installed, inspected, field tested, and made ready for use in accordance with this specification. Each crane’s capacity, span, and hook travel shall be as follows:

Location Capacity (lbs.)

Main (Aux.)

Span (ft-in) Runway (ft) Hook Lift (ft-in) Main (Aux.)

EHW-1 240,000 (60,000) 189’-0” 520’-0” 113’-0” (118’-0”)

NOTE: Spans and runway lengths are estimates. Final values shall be verified by the contractor.

1.3.1 Design Requirements

The design of the cranes shall conform to CMAA No.70, 29 CFR 1910.179, 29 CFR 1910.306, paragraph (b), ASME B30.2, and other requirements specified herein. Each crane shall be equipped with a single top running motor-operated trolley including wire rope main and auxiliary hoists. Each crane shall be cab controlled with a radio remote back up and designed to operate on a 480 VAC, 3-phase, 60-Hertz system. The cranes shall comply with all applicable requirements (“shall” statements) and recommendations (“should” statements) of CMAA No. 70 for class D service (minimum) and ASME B30.2 (all “should” statements shall be considered “shall” statements).

The main hoist, auxiliary hoist, bridge, and trolley of the cranes shall each have a redundant drive, drivetrain, and motor.

The new runway electrification shall be furnished and installed by the government as part of a separate building refurbishment program. The cranes shall be designed to operate in the space, and match the runway dimensions and rails shown on the sketches in Appendix A-1. All crane dimensions in Appendix A-1 are approximate and shall be verified by the contractor. The hook work envelope shall be the maximum practical consistent with good design, but shall not be less than that indicated in Appendix A-1. Each crane’s maximum wheel loads (without impact) due to dead load and the rated capacity live loads, with the trolley in any position, shall not cause greater shear or moment in the runway girders than that produced by the design wheel loads and spacing shown in Appendix A-1. The contractor shall also verify all clearances and other building/crane interface, including those features shown in Appendix A-1.

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1.3.2 Performance Requirements

The rated speeds (plus or minus 10%), in feet per minute for both cranes shall be as follows:

Function Capacity (pounds) Rated Speed cab(fpm) / radio

(fpm)

* Minimum Speed (fpm)

Bridge 240,000 100 1 Trolley 240,000 50 0.75 Main Hoist 240,000 12 0.50 Aux Hoist 60,000 100 0.50

* The minimum speeds shall not exceed the values listed above. Minimum speeds shall also apply to redundant drive units.

1.3.3 Capacity Plate

Provide two capacity plates with permanent lettering, one for each side of the bridge.

Each plate shall indicate the rated hoisting capacity of the hooks in pound units and shall be securely attached to the bridge. Beneath the rated capacity the following information shall be included:

Naval Facilities Engineering Command Contract Number N62470-10-D-xxxx; DO xxx Manufacturer’s name and crane serial number Voltage of AC power supply and phase and frequency of AC power supply Crane Number

Provide cardinal direction indication letters centered on the bottom of a girder. The direction shall denote N-S-E-W and shall reflect the travel directions given on the controller. All lettering shall be of sufficient size to be easily read from the floor.

1.3.4 Unique Identifier Tags

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 Installation

The contractor shall field verify all crane envelope clearances and other building/crane interface features, including those identified in Appendix A-1, prior to design of the crane. The Contractor shall follow the guidelines for the site-specific installation in Section H. Installation of the new cranes shall be performed inside the building as there will be no provision for through-roof access. Upon installation, the contractor shall operate the crane so that a satisfactory Crane Operating Envelope (COE) check by the Government and the Contractor may be performed at the facility.

1.3.6 Crane Removal

The Contractor shall be responsible for the removal and disposal (with exceptions) of the two existing 120-ton bridge cranes prior to the installation of the new cranes. Removal of

WO #1614003 Page 9 of 71 the existing cranes shall be performed inside the building as there will be no provision for through-roof access. Exceptions to the disposal of the crane are all drives and motors, which shall remain the property of the government. Care shall be taken in the removal of these components as to keep components in working order for possible re-use. The contractor shall coordinate the removal effort with the activity as to minimize the time of impact to regular facility operations. The Contractor is responsible for disposal of all waste generated during crane removal.

The weight of the existing cranes components shall be verified by the Contractor. The Contractor shall ensure that the lifting and handling equipment to be used is sufficient for the actual weight of the crane to be removed.

The crane paint is suspected to be lead based. If the metal material is to be recycled, the paint is expected to be disposed intact with the metal material. The Contractor shall provide a specific lead removal program in the Accident Prevention Plan should cutting, grinding, burning or disturbing of the coating be required by the planned work. Lead based paint coating dislodged during the crane’s disassembly shall be contained and collected for disposal per local regulations. The crane wiring and crane brake pads are suspected to contain asbestos. These components shall be tested for verification and must be handled and disposed of appropriately. The Contractor shall take the necessary precaution and shall provide a specific hazardous material handling program in the Accident Prevention Plan. The Contractor shall adhere to all local, state, and federal regulations in the handling, transportation, and disposal of hazardous materials. The crane gearcases and brake controls will contain non-hazardous fluids that require appropriate disposal.

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 ARL Safe-Support (https://safe-support@arl.army.mil).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 NAVCRANECEN 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 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 designs in process – indicate the percent complete and estimated submission dates, and for designs under review – indicate level of Government review and projected approval dates. It shall also https://safe-support@arl.army.mil https://www.navfac.navy.mil/navfac_worldwide/specialty_centers/ncc.html

WO #1614003 Page 10 of 71 list and describe current Contractor Change Request Forms (CCRF), 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 (CORs), 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 the crane. At minimum, the schedule shall include the following:

a. Post Award Conference

b. Initial General Arrangement and Design Submittals

c. Government Review of First Design

d. Second General Arrangement and Design Submittals

e. Government Review of Second Design

f. Third General Arrangement and Design Submittals

g. Government Review of Third Design

h. Fabrication Initiation

i. Fabrication Completion

j. On-Site Pre-Installation Conference

k. Government Witnessed Shop Test

l. Contractor Site Mobilization

m. Existing Crane Removal (if applicable)

n. New Crane Installation

o. Government Crane Inspection

p. Field Acceptance Test

q. Crane Acceptance

r. Contract Completion Date

s. Receipt of Final O&M Manuals

t. 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 test, the contractor shall submit a complete set of Final design drawings. Initial design drawings shall include certification of review by a professional engineer. Any subsequent drawing submittals satisfying a design review comment or Contractor initiated changes shall bear a new revision number for each sheet that has been modified.

Final and “As-built” drawings shall bear a complete title block with a permanent drawing number, 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. Bill of Materials to include model/part number, size, and serial numbers

WO #1614003 Page 11 of 71 of all major components. 3-D model(s) shall be submitted in accordance with section SD-

11.2 3-D Modeling following final Government acceptance of the crane.

There shall be no proprietary notes on any drawing. All drawings shall be created for viewing in AutoCAD 2010 with a drawing file format of .dwg or .dxf, and a separate copy viewable in Adobe Acrobat (.pdf). An index for all drawings, including applicable revisions, shall be included. Drawings shall be created and editable in AutoCAD 2010.

PDF images pasted into AutoCAD file format shall not be permitted.

SD-02. G General Arrangement Drawings Each crane assembly and each major component (e.g. girders, end trucks, trolley/hoist, cab, etc.) shall be shown in plan, elevation, end views, and in 3-D to demonstrate proper interface with the facility building and relation to other crane components. All major features of the crane shall be shown including: clearances, lifts, spans, wheel spacing, speeds, trolley gage, hook approaches on all sides, any loads that are applied to the facility (e.g. maximum wheel loads, actual ground loadings, bracing, etc.), electrical power supply, facility electrical disconnects, and general locations of components such as: brakes, motors, speed reducers, and control panels (including size). In addition, estimated weights shall be shown for the completely assembled crane and major components 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. The requirements of FAR 52.236-21 for shop drawings shall also be accounted for in the structural drawing submittals.

Other critical information that shall be provided on the structural design drawings includes the welded-joint configuration in accordance with AWS D1.1 and D14.1, 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 lift points (for components to be lifted by suspended rigging during crane installation) and approximate locations of center of gravity for each major component listed below shall be provided on the structural design drawings.

Dimensioned locations of 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. Girder Fabrication (including rail detail and trolley end stops)

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b. Bridge End Truck Fabrication

c. Trolley End Truck Fabrication

d. Trolley Fabrication

e. Walkway and Ladder Fabrication

f. Cab Fabrication (if applicable)

g. Lift Point Fabrication

h. Trolley and Bridge End Stop Fabrication – as applicable

i. Fall Protection Anchorage(s)

SD-02. M Mechanical Drawings

a. Mechanical drive arrangements (including assembled components)

b. Bolt torque values for coupling and base mounted component with information for the thread lubrication and/or washer types used. Torque values may be on a separate drawing that includes the mechanical arrangement and location of each bolt listed, or they may be listed on the drawing where the torqued bolts are shown.

c. Travel wheel dimensional and assembly including wheel material, wheel tread hardness, wheel to axle fit and assembly cross section details.

d. All sheave dimensional and assembly for top and equalizer sheaves including sheave material, sheave groove hardness and assembly cross section details.

e. Hook block dimensional and assembly including the block cross section and hook. If the hook is not a commercial product, a separate drawing for the hook shall be provided.

f. Drawings for any non-commercial components that require calculations in paragraph SD-05.M1 of this specification including each component material specification.

g. Means to manually verify the hoist brake holding torque in its de-energized state.

h. Reeving Diagram

i. Coupling and brake drum installation including locations, applicable shaft size, shaft engagement, bore, keyway and key details to verify required fit.

j. Lubrication information showing the location of lubrication points, type of lubricant to be used, quantity required and the frequency of lubrication.

SD-02. E Electrical Drawings These drawings shall show the layout of electrical equipment on the cranes, including control panel enclosures, motors, brakes, limit switches, conduits, disconnects, and conductor systems. These drawings shall also 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 crane. Wiring type, size, and temperature ratings shall be included on schematic diagrams. 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, final settings shall be shown on the schematics.

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b. Motor nameplate data (including all information listed in NFPA 70, Section

430.7 (A) items 1 through 7).

c. Rating and types of over-current protective devices

d. A comprehensive component material list showing all electrical components used on the crane.

e. Layout diagrams showing component placement in control panel enclosures.

f. Cable tray system layout drawings showing cable tray system details including conductors.

SD-02.C Control System and Network Drawings

a. Network diagram must show interconnection cabling, 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 SD-03 Product Data The contractor shall submit the product data listed below for approval. Manufacturer’s catalog product data shall be provided for all major components of the cranes(s). The product data catalog cuts shall be marked-up or supplemented with additional sheets to clearly identify the model or size, serial number, selected options, features, and/or modifications to demonstrate compliance with specification requirements. Product data 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 product data catalog cuts shall be submitted in one file viewable in Adobe Acrobat and bookmarked as to the location of each product catalog cut. The Contractor shall submit for approval the products catalog cuts listed below (as applicable) in accordance with Exhibit A.

SD-03. S Structural Product Data

SD-03. S1 End Trucks (including Drive Units) including girder to end truck connection

SD-03. S2 Trolley Rails SD-03. S3 Trolley Frame (if packaged) SD-03. S4 Painting System SD-03. S5 End Stops SD-03. S6 Lift Point(s) SD-03. S7 Bumpers SD-03. S8 Swing Gates or Swing Gate Components SD-03. S9 Fall Protection Anchorage(s) SD-03. S10 Cab (if packaged) SD-03. S11 Bolted rail clips

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SD-03. S12 Painting System including completion of NCC Form: Coating System Summary Form

SD-03. M Mechanical Product Data SD-03.M1 Speed Reducers including gear ratio SD-03.M2 Brakes (including electrical information, installation/service manuals and all information required to set or adjust) SD-03.M3 Bearings and Bearing Housings SD-03.M4 Couplings SD-03.M5 Hooks including hook material, type and catalog identification SD-03.M6 Wheels and Sheaves

SD-03. E Electrical Product Data SD-03. E1 Variable Frequency Drives (including Dynamic Braking Resistor and

Reactor selection) SD-03. E2 Motors and Encoders (if applicable) SD-03. E3 Electrical Enclosures SD-03. E4 Runway Electrification (including Collectors if applicable) SD-03. E5 Limit Switches SD-03. E6 Bridge-to-Trolley Electrification SD-03. E7 Warning and Pilot Devices SD-03. E8 Disconnect Switches SD-03. E9 Contactors and Relays SD-03. E10 Operator Controllers SD-03. E11 Lighting / Heating / Air Conditioning/Air filtration SD-03. E12 Circuit Breakers and Fuses SD-03. E13 Load Indication System SD-03.E14 Collision Avoidance System

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),

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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.

SD-05 Design Data These calculations shall demonstrate compliance with all design requirements of this specification. 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; variables shall be in accordance with required references and/or drawings.

SD-05. S Structural Calculations

SD-05. S1 Calculations verifying load cases in accordance with Section 3 of CMAA No.70 and section 2.3.1.1 of this specification for any non-commercial items.

SD-05. S2 Calculations verifying girder design in accordance with Section 3 of CMAA No.70 and section 2.3.1.1 of this specification for any non-commercial items.

SD-05. S3 Calculations verifying bridge and trolley end truck design in accordance with Section 3 of CMAA No.70 and section 2.3.1.1 of this specification for any non-commercial items.

SD-05. S4 Calculations verifying trolley design in accordance with Section 3 of CMAA No.70 and section 2.3.1.1 of this specification for any non-commercial items

SD-05. S5 Calculation verifying compliance with maximum allowable wheel loading and spacing as specified in Appendix A-1.

SD-05. S6 Calculations verifying design of end stops in accordance with AIST TR- 13 and all bumpers in accordance with the dynamic requirements of

AIST TR-06.

SD-05. S7 Calculations determining the wind speed that will cause the crane to drive through the brake with the brakes set and the wind speed that will cause the crane to slide on the rail with the brakes set.

SD05. S8 Calculations verifying fall protection anchorages comply with design requirements in section 1.5.2.

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SD-05. S9 Calculations verifying the design of all Installation of Lift Points used for Crane Installation / Removal in accordance with section per 2.3.1.9 of this specification.

SD-05. S10 Calculations verifying design of structural connections per section 2.3.1.2.

SD-05. S11 Calculations verifying operator’s cab design in accordance with this specification and section 3.8 of CMAA No.70.

SD-05. M Mechanical Calculations SD-05. M1 Calculations verifying compliance with Section 4 of CMAA No.70 for any non-commercial items SD-05. M2 Calculations verifying brake selections SD-05. M3 Calculations verifying coupling selections SD-05. M4 Hoist Brake Setting Calculations The Contractor shall submit calculations verifying the hoist drive train and structural components are designed to withstand the setting of the hoist brakes under each possible load case described in SD-05.M4.1 & SD-05.M4.2. The calculations and technical documentation shall demonstrate acceptability of each component. The analysis shall be performed based on each brake’s maximum torque. The analysis shall account for impacts in the drive train caused by the load path reversal. Calculations shall consider the maximum delay time of the broken shaft detection system (BSDS).

At a minimum, the following hoist drive train and structural components shall be evaluated: internal gearbox gears, gearbox shafts, gearbox bearings, drum stub shafts, shaft to shaft couplings, all shaft key/keyseat connections, wire rope drum, drum bearings and couplings, pinion stand bearings and foundation, gearbox foundation, and all brake foundations.

SD-05.M4.1 For each load case listed below; consider both the condition in which only the drum brake sets, as well as the condition in which all brakes set simultaneously - primary brake and secondary brake (wire rope drum brake). Calculations shall also consider the location of line pull on the drum. These conditions apply to the brakes setting on an intact drive train.

a. Test load, full speed raising

b. Test load, full speed lowering

c. No load, full speed raising

d. No load, full speed lowering

SD-05.M4.2 For each load case listed below; consider the condition in which drive train failure occurs at the gearbox input shaft location as well as the gearbox output shaft location. The contractor shall perform analysis to demonstrate the wire rope drum brake will independently stop and hold a rated capacity load. Hoist frame structural

WO #1614003 Page 17 of 71 components shall be analyzed to demonstrate adequacy when the emergency brake applies due to a broken drive train. Calculations shall also consider the location of line pull on the drum.

a. 100% load, full speed raising

b. 100% load, full speed lowering

SD-05. E Electrical Calculations SD-05. E1 Minimum required horsepower for each drive motor. For the bridge drive the minimum acceleration time to rated speed shall be 4 seconds.

For the trolley drive the minimum acceleration time to rated speed shall be 3 seconds. Calculations are not required for packaged hoists, but packaged hoists shall still meet acceleration and deceleration requirements for trolley and bridge drives and CMAA sizing calculations for hoist drives. All motor horsepower calculations may be performed with the allowable 10% speed reduction, however no additional latitude in selecting the nearest rated horsepower under the calculated value is allowed.

SD-05. E2 Overcurrent protection 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 for any overcurrent devices that have the same rating as another overcurrent device upstream

SD-05. E5 Lighting calculations demonstrating specified illumination level.

SD-06 Hook Non-Destructive Test (NDT) Reports

SD-06.1.1 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-06.1.2 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-06.1.3 Prior to performing any operational testing of the crane, the hook, the threaded stud used for connecting the insulated link to the hook trunnion, and eye pin or 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-

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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.

For hooks of non-magnetic material, NDT shall be liquid penetrant (PT) method in accordance with ASTM E 1417 or T9074-AS-GIB- 010/271. For PT testing of hooks containing stainless steels, titanium, or nickel-based alloys, total halogens, and sulphur used in the NDT process shall be controlled as specified in T9074-AS-

GIB-010/271.

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. 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-06.1.4 In addition to the magnetic particle inspection, a through volume inspection of the forging shall be carried out in accordance with ASTM A388, Supplementary Requirement S1:

Reference block calibration shall be performed using at least three holes, spaced to approximate minimum, mean, and maximum thickness as tested, and shall be used to generate a distance amplitude correction (DAC) curve. The following hole sizes apply:

1. 1/16 in. flat bottom holes (FBH) for thicknesses less than

1.5 in.

2. 1/8 in. FBH for thicknesses of 1.5-6 in., inclusive

3. ¼ in. FBH for thicknesses over 6 in.

Reporting criteria include:

1. All indications exceeding the DAC curve

2. Two or more indications separated by ½ in. or less

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

WO #1614003 Page 19 of 71 equipment being certified. Each certification shall clearly identify the crane, the 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 rope meets the published breaking strength, or the actual breaking strength of a sample taken from the reel and tested. Certification shall be traceable to the hoist, crane and reel.

SD-07.2 Periodic Overload Testing The crane will be subjected to periodic overload testing (125% (-5% / +0%) of rated capacities). The crane contractor shall certify that the crane is capable of the above testing and that it is permitted, and will have no detrimental effect on the crane.

SD-07.3 Crane Runway Rail The Contractor shall provide a certificate stating that the new crane will operate on the existing runway rail without restrictions; if the crane(s) cannot operate without restriction, the contractor shall identify areas of the runway that require correction for crane operation without restriction and indicate crane limitations if runway remains in the existing condition.

SD-07.4 Hazardous Material The contractor shall certify that the crane contains no asbestos, lead paint, Polychlorinated Biphenyl’s (PCB’s), or elemental mercury. Chromates should be avoided where feasible.

SD-07.5 Coupling Alignments The Contractor shall submit coupling alignment data records with certification that the alignment of all shafting connected by means of flexible couplings are within the manufacturer's installation tolerances or within the applicable values in the table listed in paragraph 2.3.2.14, whichever is more restrictive. The shaft alignments shall be made using laser alignment equipment. Barrel couplings may be aligned using lasers or the OEM recommended method. The data records shall be taken after the coupling's final installation. Coupling alignments shall be verified by the Contractor and witnessed by the Government after crane installation. Barrel coupling alignment data record(s) shall be submitted on the official NAVCRANECEN form titled “Drum Barrel Alignment Data Sheet” located on the NAVCRANECEN website. All other coupling alignment data record(s) shall be submitted on the official NAVCRANECEN form titled “Shaft/Coupling Alignment Record Form” located on the NAVCRANECEN website.

A copy of the laser alignment computer generated printout shall be supplied in addition to the NCC data record forms.

SD-07.6 Hook and Hook Nut Proof Test Only applies to custom designed and non-ferrous hooks.

The Contractor shall submit certification that the hook and hook nut has been proof tested based on the rated capacity of the hoist it is installed on and satisfies the acceptance criteria of ASME B30.10.

The proof test shall be performed prior to the Hook NDT specified in SD-06.1.

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SD-07.7 Welding Certifications 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 14.1 for all work performed in manufacturing this crane.

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 in installing/welding parts supporting the crane at/to building interfaces.

SD-07.8 Contractor’s Self-Test The Contractor shall provide a certificate stating that the Contractor’s self-test has been completed in accordance with Section 2.8.1 of this specification.

SD-07.9 Radio Frequency (R.F.) Insulating Link Test The Contractor shall provide a certified test report showing results of the test required below for each insulated link.

1. The link shall be subjected to proof load of two times the rated capacity of the hoist or 400,000 pounds whichever is smaller. Application of the proof load shall be for two minutes. After releasing the proof load, the link shall be examined to determine that surface ruptures or defects which would interfere with serviceability had not develop and that elongation had not occurred. No permanent deformation or elongation shall occur as result of the test.

2. The link shall be subject to 100 kilovolts. Voltage shall be applied between the two ends of the link for one minute with no sign of failure or other evidence of electrical breakdown. Maximum leakage current of 1,500 microamperes at 100 kilovolts AC and prevailing atmospheric conditions will be allowed.

3. The link shall be subject to a R.F. test demonstrating the effectiveness of the link in attenuating R.F. signals from 5 kilohertz to 100 megahertz. A minimum attenuation ratio of 50:1 is required when measured with one of the metal ends grounded, in the range of 50 kilohertz to 50 megahertz.

SD-07.10 Public Domain Software The Contractor shall provide a declaration that public domain software (e.g., freeware, shareware) is not used in the system.

SD-08 Manufacturer’s Instructions SD-08.1 Shop Test Procedure The contractor shall develop and submit a shop test procedure that will demonstrate operation, performance, and safety of the crane. The test procedure shall be submitted and approved prior to conducting the shop test. As a minimum, the test procedure shall conform to those requirements specified in Appendix B of this specification.

SD-08.2 Crane Removal and Installation Plan The contractor shall submit a plan detailing the logistics involved in crane mobilization to the site and installation of the new crane. The contractor shall also submit a plan detailing the logistics involved in removal of the existing crane. The plans shall include, as a

WO #1614003 Page 21 of 71 minimum, lifting configurations, lay-down areas, installation, and transport through the activity. Detailed lifting and handling plans meeting the minimum requirements shown in Appendix D and NAVFAC P-307 Section 11.1 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. Lifts of all major components for crane removal and installation are considered to be critical lifts and include any lifts performed by equipment such as forklifts and jacks. Actual locations of center of gravity and location of lifting points for completely assembled crane and for each major component (girders, hoist/trolleys, and end trucks) shall be provided with the crane installation and removal plans.

NOTE: On site changes of the plan are not allowed without Government approval.

SD-08.3 Accident Prevention Plan (APP) The APP shall be prepared in accordance with Appendix E (Safety), and Exhibit A and B and shall be submitted for review and comment by the Contracting Officer. Installation of the crane cannot proceed prior to the review and acceptance of the APP by the Contracting Officer.

SD-08.4 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 and installation/maintenance manuals for each brake on the crane. The brake adjustment record shall be submitted on the applicable brake record form located on the NAVCRANECEN website. Each brake measurement shall have a tolerance traceable to the associated brake manual or documentation provided by the brake manufacturer, location of measurements, and the actual brake setting. Changes made to settings of the brake, at any time, will void the record.

SD-09.2 Shop Test Deficient Items List Upon completion of the shop test and inspection of the crane, a list of deficient items will be compiled and attached to the “Navy Crane Center Post Shop Test Sign Off Sheet,” signed by the attendees and forwarded to the Contracting Officer.”

SD-09.3 Shop Test Record Upon successful completion of the shop test for the cranes, the contractor shall submit records of all test data.

SD-09.4 Field Test Record The contractor shall follow the test procedure found in Appendix C that will demonstrate operation, capacity, and safety of the crane. Any deviations to the field test required by the

WO #1614003 Page 22 of 71 crane 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, 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. Within these sections the following information shall also be included:

a. Software program listings and functional descriptions.

b. Restoration procedures shall be provided, specifically, guidance on restoring vendor software & hardware including guidance to help determine priority for restoration.

c. Startup & Shutdown Procedures detailing system initialization, shutdown/aborts designed to ensure secure system state.

d. Testing equipment, including software and hardware, necessary for testing and communicating/troubleshooting all systems provided with the crane (e.g. engine/generator, control system, LID, etc.).

SD-11 Closeout Submittals SD-11.1 Drawings on CD-ROM The Contractor shall provide the crane’s as-built drawings on CDs viewable and editable in AutoCAD 2010. 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 3-D Modeling The Contractor shall provide a 3-D model(s) of the completed cranes and major subassemblies of the crane. The Contractor shall also provide the crane’s 3-D model(s) on

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CD’s viewable and editable in Autodesk Inventor software. The 3-D model(s) shall be submitted to the Government following final Government acceptance of the crane.

SD-11.3 Operation and Maintenance Manuals The Contactor shall provide the operation and maintenance manuals on CDs and three (3) hard copies following final Government acceptance of the manuals. The manuals shall be a bookmarked and indexed .pdf document.

SD-11.4 Control System Parameter Record After the crane has passed the final field test, the contractor shall complete a control system parameter record for the crane and provide the crane parameter file downloaded from the crane at time of acceptance, if applicable. The record shall include the contract number, contractor’s name and address, date, all control system parameters and their final settings. Each control system parameter shall be designated as either used or unused.

SD-11.5 Product Data Catalog cuts shall be submitted electronically, in .pdf format, as one unit with a cover sheet containing a title block and an index sheet identifying each catalog cut. Ensure each page is numbered and identified to allow proper filing if separated. Linked bookmarking is acceptable vice page numbering for the .pdf file. The minimum sections for indexing shall be the sections noted in paragraph SD-03.

SD-11.6 Frequency…