J1_Seed Project Specification.pdf

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Solicitation: N62470-22-R-9013

One (1) 50-Ton Overhead Electric Traveling Bridge Crane with Two (2) Top Running Trolleys

FOR

Portsmouth Naval Shipyard

Building 92

PREPARED BY:

NAVY CRANE CENTER

Bldg. 491, Norfolk Naval Shipyard

Portsmouth Virginia 23709-1044

Lead Design Engineer: Michael Albero

Project Manager: Jason Jordan

Contract Specialist: Mikel Outen

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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 and Identification Markings

1.3.4. Unique Identifier Tag

1.3.5. Crane Installation(s) and Removal(s)

1.4. SUBMITTALS

SD-01. Preconstruction Submittals SD-02. Drawings SD-03. Product Data SD-04. Samples SD-05. Design Data SD-06. Test 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. Pre-Installation Conference

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

1.11. MAINTENANCE

PART 2: PRODUCTS

2.1. MATERIALS

2.1.1. Ductile Material

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2.1.2. Structural Steel

2.1.3. Cast Steel

2.1.4. Ductile Cast Iron

2.1.5. Forged Steel

2.1.6. Steel Shafts

2.1.7. Aluminum Castings

2.1.8. Welding Materials for Crane

2.1.9. Welding Materials for Facilities

2.1.10. Stainless Steel Fasteners

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. Contractor's Scheduling of DCMA Inspections

PART 3: EXECUTION

3.1. EXAMINATION

3.2. PREPARATION

3.3. ERECTION

3.4. INSTALLATION AND REMOVAL

3.4.1. Contractor Representative

3.4.2. Crane Removal/Installation Plan

3.4.3. Crane Removal/Installation Requirements

3.5. APPLICATION

3.6. FIELD QUALITY CONTROL

3.6.1. Field Inspection and Test

3.6.2. Acceptance

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3.7. ADJUSTING AND CLEANING

3.8. DEMONSTRATION/TRAINING

3.9. PROTECTION

3.10. SCHEDULES

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PART 1: GENERAL

1.1. REFERENCES

The following documents, of the issue in effect on date of 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)

1328 - Accuracy Classification System 2001 - Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth 2015 - Accuracy Classification System

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

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

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI-ASC A14.3 - American National Standard for Ladders – Fixed – Safety Requirements B4.1 - Preferred Limits and Fits for Cylindrical Parts ANSI/IEC 60529 -Degrees of Protection Provided by Enclosures Z359 - Fall Protection Code

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE/SEI)

7 - Minimum Design Loads for Buildings and Other Structures

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

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

B30.10 - Hooks

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

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

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

A194 - Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both

A275 - Standard Practice for Magnetic Particle Examination of Steel Forgings A307 - Standard Specification for Carbon Steel Bolts, Studs, and Threaded Rod

60, 000 PSI Tensile Strength A434 - Standard Specification for Steel Bars, Alloy, Hot-Wrought or Cold-

Finished, Quenched and Tempered A504 - Standard Specification for Wrought Carbon Steel Wheels A536 - Standard Specification for Ductile Iron Castings A563 - Standard Specification for Carbon and Alloy Steel Nuts A668 - Standard Specification for Steel Forgings, Carbon and Alloy, for General

Industrial Use

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A992 - Standard Specification for Steel for Structural Shapes A1023 - 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 F436 - Standard Specification for Hardened Steel Washers Inch and Metric

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

Studs F594 - Standard Specification for Stainless Steel Nuts F3125 - Standard Specification for High Strength Structural Bolts, Steel and

Alloy Steel, Heat Treated, 120 ksi and 150 ksi Minimum Tensile Strength, Inch and Metric Dimensions

AMERICAN WELDING SOCIETY (AWS)

D1.1 - Structural Welding Code - Steel D14.1 - Specification for Welding of Industrial and Mill Cranes and Other

Material Handling Equipment

CRANE MANUFACTURERS ASSOCIATION OF AMERICA, INC (CMAA)

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

DEFENSE FEDERAL ACQUISITION REGULATIONS (DFAR)

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 STANDARDS ORGANIZATION (ISO)

4309 - Cranes, Wire Ropes, Care and Maintenance Inspection and Discard 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

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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, Subpart D - Walking-Working Surfaces 29 CFR Part 1910, Subpart I - Personal Protective Equipment 29 CFR Part 1910.179 - Overhead and Gantry Cranes

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

Specification for Structural Joints Using High-Strength Bolts

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC-PA1 - Shop, Field, and Maintenance Coating of Metals SSPC-PA2 - Procedure for Determining Conformance to Dry Coating Thickness

Requirements SSPC-SP1 - Solvent Cleaning SSPC-SP6 - Commercial Blast Cleaning

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

J429 - Mechanical and Material Requirements for Externally Threaded Fasteners

J995 - Mechanical and Material Requirements for Steel Nuts Z26.1 - Safety Glazing Materials for glazing Motor Vehicles and Motor Vehicle

Equipment Operating on Land Highways - Safety Standard

WIRE ROPE TECHNICAL BOARD

Wire Rope Users Manual

1.2. UNIT PRICES

Not applicable for this specification.

1.3. SYSTEM DESCRIPTION

The intent of this specification is to procure one 50T capacity top running double girder overhead electric traveling (OET) General Purpose Service bridge crane with two top running trolleys (denoted as East trolley and West trolley). The East trolley shall have one 25T capacity main hoist and one 5T capacity auxiliary hoist. The West trolley shall have one 25T capacity main hoist.

The crane shall be built to the design drawings of a registered professional engineer (PE). The crane shall be designed, fabricated, assembled, shop tested, delivered, installed, inspected, field tested, and made ready for use in accordance with this specification. The capacity, span, and hook travel shall be as follows:

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Crane Span Capacity Runway Hook Lift Appendix

West Trolley 94' 4.5" 25T 472 41' 2.5" A

East Trolley 94' 4.5" 25T/5T 472 41' 2.5" A

Note: Span and runway length are estimates and shall be verified by the Contractor. Hook lift is measured from finished floor.

Crane electrification shall be via an existing conductor bar system. Approzimately 20’ of new conductor bar system shall be added to the south end of the existing conductor bar system in order to extend to the south end of the building.

1.3.1. Design Requirements

The design of the crane shall conform to OSHA 29 CFR Part 1910.179, 29 CFR Part 1910.306, paragraph (b), ASME [B30.2/B30.17], CMAA No. 70, and other requirements as specified herein.

The crane shall be designed to operate on 480 VAC 3-phase, 60-Hertz system in an indoor environment with an ambient temperature range of 32°F to 104°F. The crane shall comply with all applicable requirements (“shall” statements) and recommendations (“should” statements) of CMAA No. 70 for Class C service (minimum) as well as ASME [B30.2/B30.17] (all “should” statements shall be considered “shall” statements).

Packaged hoists shall not be permitted. A packaged hoist is defined as a hoist where the components are mounted via c, d, or p-face flanges as opposed to base mounted and mass produced by established manufacturers of the crane industry.

The crane shall be designed to operate in the space, and match the runway dimensions and rails shown on the sketches in Appendix A. Dimensions in the appendix 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 this specification and in Appendix A, and shall be met without requiring the bypass of any applicable limits. The crane’s maximum wheel load (without impact) due to dead load and the rated capacity live load, 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.

1.3.2. Performance Requirements

The rated speeds for both trolleys and hoists (plus or minus 10%), in feet per minute, shall be as a minimum:

Function Rated Speed Minimum Speed

Bridge Travel 250 fpm 25 fpm

Trolley Travel 125 fpm 12 fpm

Main Hoist 20 fpm 2 fpm

Aux Hoist 40 fpm 4 fpm

Note: The rated (maximum) speed tolerance is plus or minus 10%. The minimum speeds shall not exceed the values above.

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1.3.3. Capacity and Identification Markings

Provide capacity plate with permanent lettering securely attached on each side of the bridge. Each plate shall indicate the rated hoisting capacity of each hook in pound units. Beneath the rated capacity the following information shall be included:

Naval Facilities Engineering Command

Contract and Delivery Order Number (provided after contract award)

Manufacturer’s Name, Address, and Crane Serial Number

PNS Crane #406974

Voltage, Phase and Frequency of AC power supply

Provide cardinal direction indication letters on the bottom of the 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 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 Installation

The Contractor shall verify all crane envelope clearances and other building/crane interface features, including those identified in Appendix A prior to design of the crane.

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.

The Contractor shall follow the guidelines for the site specific installation in Section H.

1.3.6. Crane Removal

The Contractor shall remove and dispose of the existing bridge cranes #400119. 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 crane disassembly shall be contained and collected for disposal per local regulations.

The Contractor is responsible for disposal of all waste generated during crane removal. The Contractor shall coordinate this effort with the Government.

The Contractor shall estimate the weights of the cranes’ components prior to removal.

Fluids from the crane’s gear boxes and brake controls are considered non-hazardous and shall not require special handling and disposal.

1.4. SUBMITTALS

The Contractor shall submit to the Contracting Officer all items of technical documentation listed hereinafter for the cranes. Large electronic files (maximum size of 8 GB) shall be submitted via DoD SAFE File Transfer (https://safe.apps.mil/). The Contractor shall ensure that all submittals (including lift plans, certificates, etc.) are entirely legible and suitable for reproduction, and shall indicate the current revision of each submittal. The content, number of copies, time of submission, and distribution shall be in accordance with Exhibit A of this specification and as specified below.

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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://ncc.navfac.navy.mil/ 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 list and describe current Request for Information (RFI) Forms, 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 Initial Design

d. Final General Arrangement and Design Submittals

e. Government Review of Final Design

f. Fabrication Initiation

g. Fabrication Completion

h. Pre-Installation Conference

i. Government-Witnessed Shop Test

j. Mobilization Start

k. Existing Crane Removal (if applicable)

l. New Crane Installation

m. Field Inspection & Acceptance Test

n. Crane Acceptance

o. Contract Completion Date

p. Receipt of Final Operation and Maintenance Manuals

q. Completion of Warranty

SD-01.1 Post-Award Conference Minutes

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The Contractor shall prepare meeting minutes for the post-award conference as described in section

1.5.3 of this specification for review and approval by the Government.

SD-01.2 Pre-Installation Conference Minutes

The Contractor shall prepare meeting minutes for the pre-installation conference described in section 1.5.4 of this specification for review and approval by the Government.

SD-02. Drawings

The Contractor shall submit the drawings and data listed below for approval. All drawings shall bear a complete title block with a permanent drawing number, a registered professional engineer’s original seal and dated signature. 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. Changes shall be clearly identified (using change triangles, cloud method, or similar). Contractor initiated changes shall also be reflected in a Summary of Contractor Initiated Changes document, listing the drawing number and updated revision, the item(s) that have been changed since the previous design submittal, and a brief description of the contractor’s justification for the change. Each assembly and subassembly drawing shall include an integral Bill of Materials or shall be followed by a consecutively numbered drawing with the applicable Bill of Materials.

There shall be no proprietary notes on any drawing. All drawings shall be created for viewing in AutoCAD 2016 with a drawing file format of .dwg or .dxf, and a separate copy viewable in Adobe Acrobat (.pdf). Drawings within each category (such as structural, mechanical, etc.) shall be numbered consecutively. Discipline-specific submittals shall be identified by the letters "G" for general arrangement, "S" for structural, "M" for mechanical, "E" for electrical, and "C" for control system and network. The submittal shall be ordered in a similar fashion to the list provided below.

After Navy Crane Center design approval and prior to shop test, the contractor shall submit a complete set of final design drawings.

An index for all drawings, including applicable revisions, shall be included.

SD-02.G General Arrangement Drawings

General arrangement drawings shall be provided for the crane assembly and each major component (e.g. girders, end trucks, trolley/hoist, etc.) and shall show components in plan, elevation, and end views to demonstrate proper interface with the facility building and relation to other crane components, other cranes on the same rail system, and the lower rail system. 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, 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.

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.

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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), estimated weight, 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 Section 2.3.1. The following drawings shall be provided as a minimum:

SD-02.S1. Girder fabrication (including rail detail and trolley end stops)

SD-02.S2. Bridge end truck fabrication

SD-02.S3. Trolley end truck fabrication

SD-02.S4. Trolley fabrication

SD-02.S5. Walkway and ladder fabrication

SD-02.S6. Cab fabrication

SD-02.S7. Lift point fabrication

SD-02.S8. End stop fabrication (trolley and bridge)

SD-02.S9. Fall protection anchorage(s)

SD-02.S10 Drawings for any modified commercial products or non-commercial components requiring calculations per Section SD-05.S.

SD-02.S11 Runway and Runway Support Structure

SD-02.M Mechanical Drawings

The mechanical design drawings shall at a minimum include:

SD-02.M1. Mechanical drive arrangements (including assembled components)

SD-02.M2. Bolt torque values for couplings and base mounted components 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. Fasteners utilizing helical spring lockwashers shall be tightened until the lockwasher is fully compressed.

SD-02.M3. Travel wheel dimensional and assembly including wheel material, wheel tread hardness, wheel to axle fit, and assembly cross section details.

SD-02.M4. Sheave dimensional and assembly for top and equalizer sheaves including sheave material, sheave groove hardness, and assembly cross section details.

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SD-02.M5. 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.

SD-02.M6. Drawings for any non-commercial components that require calculations in paragraph SD-05.M1 of this specification including each component material specification.

SD-02.M7. Reeving Diagram

SD-02.M8. Coupling and brake drum installation including: locations, applicable shaft engagement, and bore and key details.

SD-02.M9. 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 crane(s), including control panel enclosures, radio/pendant control panel enclosures, motors, brakes, limit switches, conduits, disconnects, and conductor systems. The drawings shall at a minimum include:

SD-02.E1 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.

SD-02.E2 Motor nameplate data (including all information called for in NFPA 70, Section 430.7 (A) items 1 through 7).

SD-02.E3 Rating and types of over-current protective devices.

SD-02.E4 A comprehensive component material list showing all electrical components used on the crane.

SD-02.E5 Layout diagrams showing component placement in control panel enclosures.

SD-02.E6 Festoon layout drawings showing festoon cables used, carrier system, and cable loop depth

SD-02.E7 Carrier system layout drawings showing carrier system details including conductors

SD-02.E8 Complete assembly (wiring) diagrams showing all conductor routings and terminations

SD-02.C Control System and Network Drawings

SD-02.C1 Complete schematic diagram with narrative of any special description of operation. All components shown on schematics shall have labels that

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SD-02.C2 Software block, flow, and ladder diagrams.

SD-03. Product Data

Manufacturer’s product data shall be provided for all major standard commercial components (as defined by section 2.4 of this specification) used on the cranes. The product data sheets 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.

Product data sheets which show modifications beyond the standard options and all supplemental pages, shall bear original signatures and dates of the equipment manufacturer’s authorized technical representative. Each product data sheet and each supplemental sheet shall clearly identify the item to which it applies. All product data sheets shall be submitted in one file viewable in Adobe Acrobat and bookmarked as to the location of each product data sheet. The Contractor shall submit for approval the product data sheets listed below in accordance with Exhibit A. Discipline-specific submittals shall be identified by the letters "S" for structural, "M" for mechanical, "E" for electrical, and "C" for control system and network. The submittal shall be ordered in a similar fashion to the list provided below.

SD-03.S Structural Product Data

SD-03.S1. End trucks (including drive units) and girder to end truck connection

SD-03.S2. Bridge rails and associated hardware (e.g. clips, splice bars)

SD-03.S3. End stops

SD-03.S4. Bumpers

SD-03.S5. Lift point(s)

SD-03.S6. Swing gates or swing gate components

SD-03.S7. Fall protection anchorage(s) (if off-the-shelf product)

SD-03.S8. Cab (if off-the-shelf product)

SD-03.S9. 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

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SD-03.M5. Load blocks and hooks

SD-03.M6. Wheels and sheaves

SD-03.M7. Wire rope

SD-03.E Electrical Product Data

SD-03.E1 Variable Frequency Drives (including Dynamic Braking Resistor and Reactor/Transformer 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 (if applicable)

SD-03.E12 Circuit Breakers

SD-03.C Control System and Network Product Data

SD-03.C1 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.

SD-03.C2 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.

SD-03.C3 List and discussion of all security features of Contractor hardware and software.

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SD-04. Samples

Not applicable for this specification.

SD-05. Design Data and Calculations

The Contractor shall submit the design data and calculations listed below for approval. The submittal shall be indexed and provided in a searchable document. Design data and calculations will not be approved if their evaluation/review is dependent on data or information not previously approved. The calculations shall demonstrate compliance with all design requirements of this specification. 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. The submittal shall bear a registered professional engineer's original seal with dated signature. Each revision of the submittal shall be resealed and include a revision number for each sheet that has been modified.

Discipline-specific submittals shall be identified by the letters "S" for structural, "M" for mechanical, and "E" for electrical. The submittal shall be ordered in a similar fashion to the list provided below.

SD-05.S Structural Calculations

SD-05.S1. Calculations verifying load cases in accordance with Section 3 of CMAA No.

70 and this specification for any non-commercial items.

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

SD-05.S4. Calculations verifying trolley design in accordance with Section 3 of CMAA No. 70 and 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.

SD-05.S6. Calculations verifying design of end stops and bumpers in accordance with this specification.

SD-05.S7. Calculations verifying design of structural connections in accordance with this specification.

SD-05.S8. Calculations verifying the design of lift points in accordance with this specification for any non-commercial items.

SD-05.S9. Calculations verifying the design and installation of fall protection anchorages in accordance with this specification.

SD-05.S10. Calculations verifying the design of the operator’s cab in accordance of Section 3.8 of CMAA No. 70.

SD-05.M Mechanical Calculations

SD-05.M1. Calculations verifying compliance with Section 4 of CMAA 70 for any non-commercial items.

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SD-05.M2. Calculations verifying brake selections and settings.

SD-05.M3. Calculations verifying coupling selections.

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 fills calculations (using tables from NFPA 70, Chapter 9 or manufacturer’s data sheets). Grounding conductors shall be included in the calculations.

SD-05.E4 Protective device coordination study showing proper coordination for any overcurrent devices that have the same rating as another overcurrent device upstream. This study shall include all devices from the line side of the primary facility overcurrent device.

SD-05.E5 Lighting calculations demonstrating specified illumination level. (if applicable)

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

SD-06. Test Reports

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

SD-06.1. Hook Non-Destructive Test (NDT) Report

For custom designed and non-ferrous hooks requiring proof testing per SD-07.7, proof testing shall be performed prior to hook NDT.

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 approval signature of a SNT-TC-1A qualified Level III examiner stating they are independent of the vendor.

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SD-06.1.3. Prior to performing any operational testing of the crane, the hook 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-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 criteria 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-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 hoist, 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. Crane Runway Rail

Contractor shall provide a certificate stating that the new crane will operate properly on the runway; if the crane(s) cannot operate without restriction, the contractor shall indicate crane limitations.

SD-07.3. Hazardous Material

The Contractor shall certify that the crane contains no asbestos, lead paint, Polychlorinated Biphenyls (PCBs), chromates, elemental mercury, or other toxic or noxious industrial materials.

SD-07.4. Loss of Power Test

The Contractor shall certify that the hoist loss of power tests as identified in Appendix C can be performed without any detrimental effects to the electronic control system.

SD-07.5. Coupling Alignments (Not applicable for coupling between components mounted via c, d, or p-face flanges)

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. 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)

NAVFAC WO 1728653 Page 19 of 58 REV 0 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.

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 of the hook 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.

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 D14.1 for all work performed in manufacturing the 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 D1.1 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 copy of the completed self-test, recorded on the approved shop test document verifying the Contractor’s self-test has been completed in accordance with Section 2.8.1 of this specification.

SD-07.9. Public Domain Software

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

SD-07.10. Software and Services

The Contractor shall provide a certificate stating that all software and services not required for operation and/or maintenance of the product has been removed. If removal is not technically feasible, then disable software not required for the operation and/or maintenance of the product.

Configure the product to allow the ability to re-enable ports and/or services if they are disabled by software. The removal of software or services shall not impede the primary function of the product.

If software that is not required cannot be removed or disabled, document a specific explanation and provide risk mitigating recommendations and/or specific technical justification. The software/service to be removed and/or disabled shall include, but not be limited to:

a. Cameras

b. Games

c. Device drivers for product components not procured/delivered

d. Messaging services (e.g., email, instant messenger, peer-to-peer file sharing)

e. Source code

f. Software compilers in user workstations and servers

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g. Software compilers for programming languages that are not used in the control system

h. Unused networking and communications protocols

i. Unused administrative utilities, diagnostics, network management, and system management functions

j. Backups of files, databases, and programs used only during system development

k. All unused data and configuration files

l. Remove and/or disable, through software, physical disconnection, or engineered barriers, all services and/or ports in the procured product not required for normal operation, emergency operations, or troubleshooting. This shall include communication ports and physical input/output ports (e.g., USB docking ports, video ports, and serial ports).

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 by the Government prior to conducting the shop test. As a minimum, the test procedure shall conform to those requirements specified in Appendix B.

SD-08.2. Crane Removal/Installation Plan

The contractor shall submit a plan detailing the logistics involved in crane mobilization to the site and installation of the new crane(s) and removal of the exisiting crane(s), as applicable. The plan shall include, as a minimum, lifting configurations, lay-down areas, installation, and transport through the activity. A detailed lifting and handling plan 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 (as applicable).

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, Exhibit A, and Exhibit B, and shall be submitted for review and comment by the Contracting Officer. Installation of the cranes cannot proceed prior to the review and acceptance of the APP by the Contracting Officer.

SD-08.4. Training Course Outline

Not applicable for 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

NAVFAC WO 1728653 Page 21 of 58 REV 0 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 Government witnessed 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,” and signed by the Contractor, NAVCRANECEN representative, and activity representative (if applicable) and forwarded to the Contracting Officer.

SD-09.3. Shop Test Record

Upon successful completion of the shop test for the crane, 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 cranes. Any deviations to the field test required by the Contractor must be approved by the Contracting Officer. 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 be tailored to the crane and include a coversheet indicating the revision number, table of contents, operation instructions, maintenance information, parts information, drawing list, all drawings, catalog cuts, and calculations.

Operation instructions shall be specific to the crane and 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 and the adjustable parameter list of Appendix F.

SD-11. Closeout Submittals

SD-11.1. As-Built Drawings and Calculations

The Contractor shall provide the crane’s as-built drawings on CDs viewable in AutoCAD 2016.

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 cranes. The CDs shall include the crane's final calculation package in a bookmarked .pdf and also an index of the drawings and calculations. The Contractor shall provide two hard copies of the as-built drawings.

SD-11.2. Operation and Maintenance Manuals

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The Contactor shall provide the operation and maintenance manuals on CDs and hard copies following final Government acceptance of the manuals. The manuals shall be a bookmarked and indexed .pdf document. The Contractor shall provide three hard copies of the manuals.

SD-11.3. Control System Parameter Record

After the crane has passed the final field test, the contractor shall provide the following and this applies to all systems that have software such as the Drives, the Load Indicator Devise (LID), Control Systems, HMI’s, etc.:

1. A PDF of the control system record containing the crane parameter file downloaded from each drive or device. The record shall include the contract number, Contractor's name and address, date, crane number, and all programming and/or control system parameters and their final settings. Each control system parameter shall be designated as either used or unused.

2. The actual parameter file downloaded from the drive. The parameter file shall clearly indicate the date it was downloaded and which function the crane parameter file corresponds to.

SD-11.4. Frequency Allocation Application

Not applicable for this specification.

SD-11.5. List of Parameters and Crane OEM's Approved Crane Range

After the crane has passed the final field test, the Contractor shall submit Appendix F for each electronic drive to document the crane designed parameter ranges in which each parameter can be safely tuned by the end user. The design parameter range, determined by the Contractor, shall be the applicable portion of the drive’s default range for each parameter. The Contractor must provide justification for each range of each parameter on the list. When necessary, the justification shall include appropriate calculations.

SD-11.6. Property Transfer Verification

After the crane has passed the final field tests, the Contractor shall transfer possession of all small items associated with the operation and maintenance of the cranes, including but not limited to keys, software, computer cabling, remote controls, etc. The property shall be given to the point of contact at the supported command. The Contractor shall prepare and submit an itemized dated invoice showing the quantity and description of items transferred with a signature and date from the recipient. The Property Transfer form will be provided by the Government.

SD-11.7. Disabled Ports, Connectors, and Interfaces

Provide disclosure of any known methods for bypassing computer authentication in the product, often referred to as backdoors, and provide written documentation that all such backdoors created have been permanently deleted from the system.

Provide summary documentation of the procured product's security features and security-focused instructions on product maintenance, support, and reconfiguration of default settings.

Provide documentation showing all disabled ports, connectors, and interfaces for all network-capable devices.

SD-11.8. Network-Capable Devices

For every PLC, RTU, Supervisory Controller, or other network-capable (whether networked or not upon delivery) control device, deliver the following on CD/DVD:

(a) Original firmware

(b) Original firmware hash

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(c) SOP for application of firmware updates/patches

(d) POC or website for firmware updates/patches

(e) Count of interfaces and types

(f) Protocols in use, per interface

(g) Configuration file

(h) SOP for configuration

SD-11.9. Engineering Workstation

Not applicable to this specification.

SD-11.10. Control System Access Control

The Contractor shall document…