Section C-1 Specification Updated 7 July 2022.pdf

Department of Homeland Security (DHS)

United States Coast Guard (USCG)

175 (WLM) MAJOR MAINTENANCE

AVAILABILITY (MMA)

Attachment C-1

TECHNICAL SPECIFICATION:

ATON CRANE, INTEGRATED CONTROLS, &

CENTRAL HYDRAULIC SYSTEM SETS

July 7, 2022

Attachment C-1: TECHNICAL SPECIFICATION: 175 WLM MMA ATON CRANE, INTEGRATED CONTROLS, & CENTRAL HYDRAULIC SYSTEM

Table of Contents

1.0 Applicable Information

1.1 Guidance for Information

1.2 References

1.3 Standards and Specifications

1.4 USCG Drawings

2.0 Components, Parts, and Accessories

2.1 Components

2.2 Parts and Accessories

3.0 General Requirements

3.1 Operational Requirements

3.2 Operating Conditions

3.3 Marine Use

3.4 Vibration

3.5 Cybersecurity

4.0 ATON Crane Set

4.1 General Requirements

4.2 Crane Functions

4.3 Structure

4.4 Access

4.5 Plates

4.6 Coatings and Color

4.7 Lubrication

5.0 Central Hydraulic System Set

5.1 General Requirements

5.2 Piping

5.3 Hoses

5.4 Hydraulic Valves

5.5 Gages

6.0 Integrated Controls Set

6.1 General Requirements

6.2 Instrumentation

6.3 Crane Controls

6.4 Deck Machinery Controls

6.5 Limits, Alerts, Alarms

6.6 Operator Control Interfaces

7.0 Electrical System

7.1 General Requirements

7.2 Electrical System

7.3 Enclosures

7.4 Lighting (Boom Tip)

8.0 Crane Calculations

9.0 Shipping

10.0 Supply

1. Applicable Information

1.1. Guidance for Information

1.1.1. References and drawings listed below can be provided upon request.

1.1.2. Unless otherwise specified, technical publications and drawings are applicable to 175 WLM Cutters.

1.1.3. Order of Precedence - In the event of a conflict between the text of this SOW and the references and requirements cited herein, this SOW takes precedence. The Contractor must notify the Contracting

Officer (KO) and Contracting Officers Representative (COR) in writing for a resolution of any ambiguity or conflict found in the SOW, Technical Specifications, and references prior to proceeding with any work.

1.2. References

SFLC Standard Specification 0850, General Requirements for Drawing Preparation, 2020

SFLC Standard Specification 6310, Requirements for Preservation of Ship Structures, 2020.

1.3. Standards and Specification

MIL-DTL-15024F, Rev G, Plates, Tags and Bands for Identification of Equipment, General Specifications for, 2018.

MIL-DTL-24643, Rev C, Cables, Electrical, Low Smoke Halogen-Free, For Shipboard Use, General

Specification, 2011.

MIL-DTL-24695, Rev C, Valve, Hose Assembly, and Adapter, Vent and Test Hydraulic Service, General

Specification for, 2017.

MIL-STD-1399C Section 300B, Rev B, Interface Standard for Shipboard Systems, Electric Power, Alternating Current, 2008.

DI-SESS-81495A, Rev A, Failure Modes, Effects, and Criticality Analysis Report, (Data Item

Description), 2014.

Code of Federal Regulations, Title 29 CFR, 1910, Occupational Safety and Health Standards (OSHA), (2014).

Code of Federal Regulations, Title 46 (Shipping), Subchapter F – Marine Engineering, (2013).

American Bureau of Shipping (ABS), Steel Vessel Rules, 2014.

American Petroleum Institute (API), API-2C, Offshore Pedestal Mounted Cranes, 8th edition, 8/2020.

American Petroleum Institute (API), API-9A, Specification for Wire Rope, 27th edition, 8/2020.

American Society of Mechanical Engineers (ASME), ASME B30.7 – Winches, 2016.

American Society of Mechanical Engineers (ASME), ASME B30.10 – Hooks, 2014.

American Society of Mechanical Engineers (ASME), ASME B30.26 – Rigging Hardware, 2015.

American Society of Testing and Materials (ASTM), ASTM F1166-07, Standard Practice for Human

Engineering Design for Marine Systems, Equipment, and Facilities, 2013.

American Society of Testing and Materials (ASTM), ASTM A312, Standard Specification for Seamless and Welded Austenitic Stainless Steel Pipes, 2021.

International Electrotechnical Commission (IEC), IEC 61131-3, System Hardware and Software Technical

Requirements, Edition 3.0, 2013.

International Organization for Standardization (ISO), ISO 4406, Hydraulic fluid power - Fluids - Method for coding the level of contamination by solid particles, 2021.

International Organization for Standardization (ISO), 6682, Earth-moving machinery – Zones of comfort and reach for controls, 1986.

National Electrical Manufacturers Association (NEMA), NEMA Standard ICS 1, Industrial Control and

Systems (series), 2003.

Society of Automotive Engineers (SAE), SAE J1942_200907, Hoses and Hose Assemblies for Marine

Applications.

Society of Automotive Engineers (SAE), SAE J1942/1_201012, Qualified Hoses for Marine Application.

Society of Automotive Engineers (SAE), SAE J2295_200605, Fastener Part Standard - Cap Screws, Hex

Bolts, and Hex Nuts (Inch Dimensioned).

Underwriters Laboratory (UL), UL 508, Industrial Control Panels, 2008.

1.4. USCG Drawings

SK-175MMA Interface 01, Rev (-), ISVS 175 WLM Replacement Ship-Crane Interface Sketch.

175-WLM-556-001 Hydraulic System Diagram Rev L

175 WLM-556-008 Deck Machinery Hydraulic Power Unit Piping Mods Rev –

2. Components, Parts, and Accessories

2.1. Components: The baseline solution for MMA is that each hull will require (1) each ATON Crane, Integrated Controls, & Central Hydraulic System.

2.1.1. The components sets are to be arranged as follows:

2.1.1.1. ATON Crane

2.1.1.2. Integrated Controls

2.1.1.3. Central Hydraulic System

2.1.2. A typical ship set will be the replacement of the existing ATON Crane, controls, & Central Hydraulic

System.

2.2. Parts and Accessories: Each component set (per Section 2.1.1.1, 2.1.1.2, or 2.1.1.3) shall consist of the required parts, plus such other accessories as are required to make a complete, self-contained functioning unit.

2.2.1. ATON Crane Sets: Each ATON Crane set shall consist of the following parts, plus such other accessories as are required to make the ATON Crane set a complete, self-contained unit that functions without dependence on any other ship auxiliary when connected to the ship’s electric and

Central Hydraulic Systems. Parts and accessories include, but are not limited to:

a) Turret

b) Boom

c) Operator Chair

d) Filters

e) Emergency Load Release System

f) Rotation Bearing

g) Slewing Drive

h) Rigging System

i) Luffing Cylinder

j) Hydraulic Valves

k) Tethered Chestpack Control

2.2.2. Integrated Controls Set: Each Integrated Controls Set shall consist of the parts and accessories required to modify the existing corresponding controls to be determined by design. The following parts, plus such other accessories as are required to make the Integrated Contols set a complete, self-contained unit that functions without dependence on any other ship auxiliary when connected to the ship’s electric system. Parts and accessories include, but are not limited to:

a) PLC

b) Primary Operator Control Interface

c) Remote Operator Control Interface

d) Operator Display Panel

e) Crane System Interfaces

f) Deck Machinery Interfaces

l) Central Hydraulic System Interfaces

2.2.3. Central Hydraulic System Set: Each Central Hydraulic System set shall consist of the following parts, plus such other accessories as are required to make the Central Hydraulic System set a complete, self-contained unit that functions without dependence on any other ship auxiliary when connected to the ship’s electric and water systems. Parts and accessories include, but are not limited to:

a) Motors

b) Pumps

c) Filter System

d) Hydraulic Tank

e) Frame Structure

m) Heat Exchanger

3. General Requirements

3.1. Operational Requirements: Unless otherwise specified within the Technical Specifications, all components, parts and accessories shall operate satisfactorily under the following conditions:

a) Atmospheric pressure: 14.5 psia or 100 kPa

b) Ambient temperature range: -40°F - 122°F

n) Sea water inlet temperature: 28°F - 95°F

3.2. Operating Conditions: Unless otherwise specified within the Technical Specifications, all components, parts and accessories shall operate satisfactorily and without damage to foundations or equipment (either stopped or operating) under the following conditions:

3.2.1. Survival: All equipment, components, parts, and accessories shall be designed to survive without damage up to Sea State 5 environmental conditions with a maximum vertical acceleration of 0.4 g and a maximum horizontal acceleration of 0.35 g with the crane parked on the cutter centerline, facing aft and unloaded.

3.2.2. Operational: All equipment, components, parts, and accessories shall be designed to operate without damage up to 3 ft significant waveheight, winds up to 30 knots within 30 degrees of the longitudinal centerline of the cutter, bow, or stern with a maximum vertical acceleration of 0.25 g and a maximum horizontal acceleration of 0.2 g conditions with the boom tip (6) feet outboard of the centerline of the buoy port and the crane luffed so that the crane hook is (30) feet above the water.

3.2.2.1. All equipment, components, parts, and accessories shall be designed to operate without damage up to 9 degree list athwart ship, 4 degree static list plus 5 degree dynamic list (roll), single significant amplitude (total 9 degree athwart ship) and 3.5 degree pitch.

3.3. Marine Use: The sets shall be designed and approved for marine use.

3.4. Vibration: All equipment, components, parts and accessories shall be capable of withstanding normal shipboard vibrations as defined in the requirements of MIL-STD-167-1A, Type I vibration up to and including 50 Hz. ANSI S2.26 is an acceptable alternative for MIL-STD-167-1A, Type I requirements and testing.

3.5. Cybersecurity: All components, parts and accessories shall have all wireless or Bluetooth connectivity capabilities physically disabled or removed prior to installation. After installation, connection of a

Contractor or Original Equipment Manufacturer (OEM) owned maintenance machine with external wireless capability will be prohibited. Potential cybersecurity concerns shall be identified by the

Contractor.

4. ATON Crane Set

4.1. General Requirements

4.1.1. Summarized Critical Parameters

Table 4.1-1

ATON Pedestal Boom Crane requirements:

Capacity

Mainfall – 20,000 lbs @ 42 ft outreach

Auxfall – 9,000 lbs @ 44 ft outreach

Performance Parameters

Mainfall – 40 ft/min block speed on first layer of rope

Auxfall – 60 ft/min block speed on first layer of rope

Luffing – 1.5 degree/sec average luff speed from 0 to 79 degree boom angle

Slewing – 1.0 rpm

Physical Dimensions

Existing Pedestal height – 238.0 inches

Hydraulic Power Requirements

Main hoist – 40 GPM @ 2,500 psi

Auxiliary hoist – 20 GPM @ 2,500 psi

Luffing – 47 GPM @ 2,500 psi

Slewing – 63 GPM @ 2,500 psi

Electric Power Requirements

115 VAC Single Phase @ 10 Amps

4.1.2. The Contractor shall provide all labor and material to manufacturer and provide a new pedestal mounted, fixed boom crane for installation on a USCG 175WLM Class Cutter. The new crane shall be complete and ready for installation on the existing crane pedestal flange on the cutter. The crane neutral and stowage position shall be facing aft. The crane shall have a single load rating over its entire operational area.

4.1.3. Provision shall be made for lifting the ATON Crane for installation. Lifting points shall be at the center of gravity or arranged symmetrically around them.

4.2. Crane Functions

4.2.1. Luff

4.2.1.1. The crane shall operate at boom luff elevations of 0 degrees to not more than 79 degrees (above horizontal), under rated load in operational sea states at 1.5 deg/sec.

4.2.2. Slew

4.2.2.1. The crane shall rotate + 90 degrees to pre-set limits from 0 degrees and return (180 degrees total), stop to stop, under rated load in operational sea states. “Zero” (0) orientation and normal stowage shall be centerline facing AFT.

4.2.2.2. A swing limit override function shall be provided to permit slewing into the defined restricted area. The system shall maintain an alert (visual & audible) that the crane is operating in restricted area.

4.2.2.3. The crane shall slew at a maximum rate of one 1.0 rpm. The crane neutral / stowage position shall be horizontal facing aft.

4.2.2.4. The crane shall decelerate and stop when approaching the slew limit positions to structural impacts or collision avoidance set points.

4.2.3. Lift

4.2.3.1. The crane shall have both a main and auxiliary (whip) lift.

4.2.3.2. The main lift shall be two part rigging.

4.2.3.3. The auxiliary lift shall have single part rigging.

4.2.3.4. The main winch shall have a first layer of rope hoist/lower speed of zero to 40 fpm, under full load and operational sea states.

4.2.3.5. The auxiliary winch shall have a first layer of rope hoist/lower speed of zero to 60 fpm, under full load and operational sea states.

4.2.3.6. Constant tension winch systems shall not be used.

4.2.4. Operations

4.2.4.1. The crane shall be able to launch and recover ATONs at sea in the operational sea state.

4.2.4.2. The crane shall support dock-side operations for load-out and on-load operations.

4.3. Structure

4.3.1. Lift Ratings

4.3.1.1. The crane shall have a “posted” API-2C “Off-board” lift rating under the operational sea state.

4.3.1.2. The crane shall have both a main lift with an “Off-board” rating of 20,000 lbs, and an auxiliary lift with an “off-board” rating of 9,000 lbs.

4.3.1.3. At all radii, the crane shall have a “posted” API-2C “On-Board” lift rating under the same operational sea states rating of 20,000 lbs (main) and 9,000 lbs (auxiliary).

4.3.2. Rotation Bearing

4.3.2.1. The existing crane is mounted on top of a Rotek A19-66E1 bearing with ring gear, bolted to a structural foundation flange. The replacement crane shall provide a new pedestal bearing and ring gear or equivalent, which shall bolt directly to the existing pedestal foundation flange.

4.3.3. Slewing Drive

4.3.3.1. The Slewing Drive system shall use hydraulic motors and brakes.

4.3.3.2. Installed parking brake systems shall be wet-type (oil filled).

4.3.3.3. Parking brake assemblies shall be fitted with a manual hydraulic release feature which will release all of the slewing brakes together.

4.3.3.4. The active and braking loads shall be balanced across the drives.

4.3.3.5. The Contractor shall provide a means for alignment and adjustment of each hydraulic motor, gear reducer, pinion drive assembly to properly align and engage with the ring gear.

4.3.3.6. Change of oil shall not require removal of the gearbox or other components.

4.3.3.7. Contractor shall provide drain plugs.

- The drain plugs shall be piped as necessary to accessible locations.

- Gearboxes fitted with breather ports shall prevent intrusion of moisture / humidity and water.

4.3.3.8. The Contractor shall provide lubricant, lubrication schedule and lubricant condemnation recommendations in the Technical Publication and Integrated Logistics Support documentation.

Commercial marine grade lubricants shall be used.

4.3.3.9. Gearing shall comply with the requirements of the AGMA specifications, or equivalent.

4.3.4. Rigging System

4.3.4.1. Hoist Winches

- Hoist winches shall be self-contained, hydraulic, commercial marine grade winch assemblies complete with gearbox, dynamic brake, and spring set / hydraulic release parking brake. The winches shall meet API-2C and ASME B30.7 requirements. The winch brakes shall support the design wire loading requirements, and shall permit conduction of 150% of wire WLL Modified Static / Brake Tests.

- Winch parking brakes shall be fitted with a remote hydraulic release feature, which shall be extended so that personnel standing on the crane base can remotely release the parking brake with the crane in any alignment.

- Fleet angle shall not exceed +/-1.5 degrees.

- Winch drums shall be fitted with a LEBUS™ shell or grooving.

- With crane parked and hooks raised, the wire rope shall be contained on 4 full level wraps or less. Drum cheek plates shall permit at least one additional wrap of wire rope.

- Winches shall be furnished with lifting eyes.

4.3.4.2. Assemblies

- The main hoist shall utilize two-part rigging. The wire rope shall be high strength, compacted strand, 3/4 inch diameter, Dyform-18 ™ or Dypac-18™ or equivalent, 18 x 19 strand IWRC wire rope with rotation resistant properties. The wire rope shall not be galvanized.

- Wire rope shall have a WLL design factor of at least 5:1 on the rated breaking strength of the rope.

- Main Wire rope assembly of 220 ft (+ 3ft/-0 ft.) in length shall be provided.

- The auxiliary hoist shall utilize single part rigging. The wire rope shall be high strength, XIPS (EIPS) Grade, 5/8 inch diameter, Right Regular Lay, 6X36 class, IWRC, General Purpose wire rope. The wire shall not be galvanized. 6X25 Dypac-

6 or 6X26 6x26 Dyform-6 or equivalentl is also acceptable.

- Auxiliary Wire rope assembly of 140 ft (+ 3ft/-0 ft.) in length shall be provided.

- Wire ropes shall terminate with a poured open spelter socket assembly, Crosby

Group G-416 or equivalent with the second end seized. The wire rope and attached socket shall be pull tested to 200% of the WLL of the wire. A dated and signed pull test certificate shall be provided, and shall be attached to the coiled wire rope which is shipped. An example of an initial certificate and wire data shall be provided in the

Technical Publication.

- Wire rope shall be pressure lubricated after assembly with DynaGuard™, or

DynaGuard Blue™, or equivalent wire rope lubricant.

4.3.4.3. Sheaves

- Sheaves shall meet API-2C requirements, and shall be roll forged.

- Sheaves shall be furnished with roller type bearings with inner races. Bearings shall be configured for the application of grease through grease fittings and grease passages in the sheave pins.

- Grease seals shall be provided.

- Sheaves shall be furnished with a lifting hole in web.

- All sheaves shall be fitted with guards.

- Crane head sheaves shall pivot or flag up to + 45 degrees from vertical.

- Sheaves shall be fully painted as separate assemblies. The wearing surfaces of sheaves shall be double coated with modified inorganic zinc undercoating; no top color coat is required.

4.3.4.4. Hook Block / Overhauling Ball Assemblies

- Hook Block and Overhauling Ball assembles shall meet the requirements of ASME

B30.26.

- Hook block assemblies shall be furnished with stainless steel grab handles bolted to both sides of block.

- Hook block and overhauling ball assemblies shall be configured to make positive contact with anti-two-block switch actuator arm/weight.

- Grease fittings on sheave pins shall be located to prevent damage.

4.3.4.5. Load Hooks

- Hooks shall be of alloy steel and shall meet the requirements of ASME B30.1.

- Hook material shall be suitable for low temperature operations.

- Load hooks shall be supported in the hook block/overhaul ball by a thrust bearing allowing full rotation.

- Thrust bearing shall be greaseable by an accessible lube fitting.

- Load hooks shall be provided with permanent marks (such as punch marks) for checking hook throat spread. Initial as furnished dimension between marks shall be provided with the crane documentation.

- Hooks shall be furnished with a self-closing, safety latch mechanism. Hook safety latch hardware (pins, springs, etc) shall be constructed of corrosion resistant material for marine environment.

- Hook block assemblies shall be painted.

- Hooks shall be pull tested to 200% of rated capacity and furnished with a pull test certificate from the hook manufacturer.

4.3.4.6. Pins & Shafts

- All load bearing pins shall be installed with replaceable bushings on both sides of the pin and shall be lubricated prior to installation.

- Threaded pins shall be installed with anti-seize compound on the threads.

- Pins and shafts shall be 17-4 PH except for pins over 5 in diameter where Nichrome

302 may be used.

4.3.4.7. Fasteners

- All structural Fasteners materials shall be in accordance with API 2C, non structural fasteners shall be CRES 316L or Monel suitable for use in a marine environment.

Torque values for all fasteners shall be included in a table on sheet 1 of the drawings in which fasteners are used. Bolt length shall be sized such that the bolt shoulder provides the load path for shear. The use of Fluor-Kote #1® is acceptable.

- Fastener designation shall be in accordance with SAE J2295.

- A complete set of new turret mounting bolts shall be provided for the installation of the crane onboard.

4.3.4.8. Luffing Cylinders

- Hydraulic cylinders shall meet 46 CFR and ABS Steel Vessel Rules, and rated for marine service. Cylinder rod corrosion protection shall be provided with double chrome plated over corrosion resistant steel rods.

- Cylinders shall conform to dimensional standards of API 2c or its equivalent. Bore and area ratios shall comply with API2c.

- Cylinder rod wiper and seal systems shall be a cartridge type that is field replaceable.

- Cylinders shall be fitted with hydraulic cushions at both ends to reduce structural impact loading on the cylinder ends.

- Cylinders shall be equipped with dual direction counterbalance / load hold valves for safe operation, to maintain crane positions, and to lock the cylinder in case of hydraulic hose failure.

- Counterbalance valves shall be mounted at the highest possible location on cylinders to act as an air trap.

- Counterbalance valve manifolds shall be fitted with Schroeder 1215 series stainless steel test fittings (or equal) for bleeding air.

- Counterbalance valves shall be fitted with a hydraulic pressure over-ride capability to release the counterbalance valve, if required, to permit “recovery” of the crane to a position for repair or come-home transit.

- The system shall utilize the Emergency Brake Release portable hydraulic hand pump with sump, plugged into installed stainless steel quick disconnect fittings.

- Hydraulic tubing supporting emergency release of counterbalance valves shall not be pressurized and subject to fluid baking and to contaminant settling.

- Maintenance recommendations shall be provided in the Technical Publication for these tubing / hoses. Assembly instructions shall include scheduled

“demonstrations”, and flushing.

- Cylinders shall be arranged with rods retracted when stowed to minimize rod corrosion.

- Equipment arrangements shall stow with as minimal rod exposed.

- Hydraulic cylinder control shall be smooth and variable speed in both directions.

4.3.4.9. Portable Brake Release System

- The crane shall be furnished with an portable brake release system to permit manual

(or emergency) release of the winch holding/parking brakes and cylinder load/hold valves for the various motions to permit the manual maneuvering of the crane to allow lowering of the load in the case of a power failure. Note: Hydraulic tubing supporting emergency brake release is not pressurized and subject to fluid baking and to contaminant settling.

- All components of the emergency brake release systems shall be of stainless steel construction with Monel trim and shall be specifically designed for marine crane service.

- The emergency brake release systems shall be furnished with isolation valves to permit selective actuation of specific brakes and to isolate pressure during connection of the pump hose.

- The hand pump for the emergency brake release systems shall be self-contained with an oil sump adequately sized for this application. The pump shall be connected to the system via a hydraulic hose with stainless steel quick disconnect fittings to allow removal of the pump from the system for stowage below decks. Hose length shall be sufficient to permit the hand pump to be placed on adjacent walkway/deck for operation. The hand pump shall be provided with the crane system. Hydraulic cylinder control shall be smooth and variable speed in both directions.

4.4. Access

4.4.1. General

4.4.1.1. Maintenance access meeting ASTM F1166 ergonomic requirements for 5th percentile female through 95th percentile male personnel shall be provided to all areas of the crane.

4.4.1.2. Crane walkways shall be provided for maintenance access to all serviceable and replaceable components on the crane unless accessible from the deck. Walkways shall be of open grating construction with full handrail protection.

4.4.1.3. When necessary for maintenance access, sections of grating shall be hinged to provide access.

Raised grating shall have provisions to hold open grating in place.

4.4.1.4. At personnel access points, automatic safety closure devices shall be provided in railings.

- Personnel safety anchor points shall be provided for attachment of 29 CFR 1910 series OSHA personnel safety harnesses for working aloft on the crane platform, particularly at sea. The anchor points shall support multiple persons at 220 lbs each using D-ring type harness straps.

4.5. Plates

4.5.1. General

4.5.1.1. The crane body may be fitted on each side with a manufacturer’s decal and/or emblem not to exceed lettering of 2 ½ inch height, or a total of 100 square inches. Advertisement decals, emblems or ratings shall not be used.

4.5.1.2. A stainless steel builder’s plate, which shall include at least the manufacturer’s name, address, government contract number, manufacturer’s model number, date of fabrication (equipment delivery/acceptance) and a manufacturer’s serial number shall be provided on the back (spine) or one side of the crane.

- Lettering shall not exceed ¾ inch in height, and shall be back-filled with black enamel, and sealed with clear coat.

- The builder’s plate shall be drilled and installed with threaded fasteners or rivets.

4.5.1.3. A stainless steel rating plate with the contractor’s label applied shall be provided for field installation on the crane.

- The plate shall identify load ratings at sea of 20,000 and 9,000 lbs, and the test loads required for dynamic and modified static / brake tests.

- Text shall not exceed ¾ inch in height and shall be backfilled with black enamel and sealed with clear coat.

- The plate shall be drilled for installation with threaded fasteners or rivets.

- A printed copy of this plate shall also be in an appendix to the Technical Publication.

Manufacturer’s Name

Crane Model # and Crane Serial #

Effective Date

CRANE RATINGS Main Auxiliary

Rated Load

- Crane Op Area at Pier

20,000 lbs 9,000 lbs

On-Load Rating

- Buoy Dk Service Area at SS 4

20,000 lbs 9,000 lbs

Off-Load Rating

- Buoy Port Service Area at SS 4

20,000 lbs 9,000 lbs

TEST LOADS

Rated Test Load (100% WLL) 20,000 lbs 9,000 lbs

Dynamic Test Load (125% WLL) 25,000 lbs 11,250 lbs

Mod Static / Brake Test Load (150% WLL) 30,000 lbs 13,500 lbs

4.5.1.4. A stainless steel Test Data Plate shall be provided by the manufacturer for field installation on the crane pedestal.

- The plate shall coordinate with the Rating Plate, and shall have blocks for field engraving of test dates and facility.

- Text shall not exceed ½ inch in height. Text shall be back-filled with enamel, and sealed with clear coat.

- The plate shall be drilled for installation with threaded fasteners or rivets. It is intended that this plate would be replaced every two years.

- A printed copy of this plate shall be in an appendix to the Technical Publication.

TEST DATA PLATE

Test Date, Main

Test Date, Auxiliary

Facility

Mod Static/ Brake Test

Dynamic Test

Rated Load Test nd

Yr Annual Test – Rated Load

4.5.1.5. A three-part Working Load Limit (WLL), stainless steel engraved graphic plate shall be provided for installation in the Buoy Deck Control Booth; printed copies shall be in the

Technical Publication.

- The plate (with 3 sections) shall show an arrangement of the crane over the buoy deck or working areas.

- The engravings shall be back-filled with enamel paint in multiple colors, and sealed with clear coat.

- The plates shall be drilled for attachment with threaded fasteners or rivets.

- One part shall highlight the Buoy Port Work Areas. Text shall identify the “Off-

Load” Working Load Limits (main and auxiliary) in operational sea states, and acceleration design factors.

- One part shall highlight the Buoy Deck Work Area. Text shall identify the “On-

Load” Working Load Limits (main and auxiliary) in operational sea states, and acceleration design factors.

- One part shall highlight the full reach of the crane. Text shall identify the Working

Load Limits (main and auxiliary), when tied to a pier. A footnote shall indicate that maximum load (main) at full outreach port and starboard may be “subject to cutter stability limitations”.

4.5.1.6. Testing Instructions graphic shall be provided in the Technical Publication. The Testing

Instructions shall specify the crane position, instructions and limitations for conducting the

125% Dynamic Load test and 150% Modified Static Load / Brake test with the crane head beginning over the Buoy Port Service Areas.

4.5.1.7. The control cabinet, the chair, the control console and other equipment provided (beyond the crane) shall each be fitted with a stainless steel or engraved plastic serial number plate, which shall include the manufacturers name and the system serial number.

- Lettering shall be black against white or metal, and nominal 1/4 to 3/8 inch in height.

- The plates shall be drilled and attached with threaded fasteners or rivets.

4.5.1.8. Identification / Functional Label Plates shall be provided and installed for each valve, major component (e.g. slewing drive #3), sensor, and piping connection.

- Label plates shall also be provided to identify normal fluid levels. The plates shall be stainless steel or engraved plastic plates, which shall be drilled and attached with threaded fasteners or rivets. If placing a label plate, via drilling or tapping, will adversely impact the warranty of a component, the label plate will be placed as close as possible the component.

- Lettering shall be black against white or metal, and nominal 1/4 to 3/8 inch in height.

- The plates shall be permanently affixed to their respective sub-assemblies in a position that is clearly visible after the crane is installed.

4.6. Coatings and Color

4.6.1. The crane assembly, ICC, and upgraded CHS shall be coated in accordance with SFLC Standard

Specification 6310. The coating system shall be an approved polysiloxane multi-coat system over an enriched inorganic zinc primer base.

4.6.2. All non-painted surfaces shall be 316L stainless steel unless otherwise noted.

4.6.3. The crane and all components exposed to the weather shall be colored SPAR (Fed Std 595 #10371).

4.6.4. Machinery or cabinets for inside installation, and equipment for installation in the Buoy Deck Control

R o o m shall be colored GRAY (Fed Std 595 #26307.

4.6.5. Crane hooks shall be colored YELLOW (Fed Std 595 #13538). Head block and headache ball assemblies shall be striped YELLOW (Fed Std 595 #13538) and BLACK (Fed Std 595 #17038) on a

45 degree angle; suggested stripe width 2 to 3 inches.

4.6.6. The wear tread of sheaves, the ring gear of the bearing, and other wear component areas, as appropriate, shall be double coated with enriched inorganic zinc based primer, without a top color coating. The ring gear of the bearing shall be coated with an open gear compound suitable for marine environments.

4.6.7. Emergency Stop devices shall be colored RED (Fed Std 595 #11105).

4.6.8. Grade 316L, or equal, corrosion resistant stainless steel cabinets, components and hardware suitable for a marine environment need not be painted.

4.6.9. Portable components intended for inside stowage may retain an appropriate OEM coating system, provided that the coating system is marine grade and either a multi-coat epoxy, polysiloxane coating system, or appropriate powder coating. If painting is required, they shall be colored GREY (Fed Std

595 #26307). Fully plumbed cylinders shall be fully painted as separate assemblies in accordance with SFLC Standard specification 6310.

4.7. Lubrication

4.7.1. The Contractor shall provide lubricant, lubrication schedule and lubricant condemnation recommendations in the Technical Publication and Integrated Logistics support documentation.

Commercial marine grade lubricants shall be used.

4.7.2. The Contractor shall coordinate the use of a minimum number of lubricants.

4.7.3. Provision shall be made for the lubrication of all bearings, bushings, pins, etc. on the crane by personnel standing on structure or platforms, or within ergonomic reach. Fittings which are

“hidden” from view shall be avoided if possible. Grease fittings shall be stainless steel or monel, and be fitted with a spring loaded internal ball. Where multiple points requiring grease lubrication are in the same vicinity and access is limited, “ganged” grease fittings with stainless steel tubing extensions, or grease lubricant distribution systems shall be provided.

4.7.3.1. In the selection of grease for distribution through tubing, greases which harden under environmental “baking” conditions shall be avoided.

4.7.3.2. More manifolds with fewer but shorter lines are preferred over fewer larger manifolds with longer lines piped to them.

4.7.3.3. Manifolds shall be readily accessible from decks, crane walkways and inside the crane pedestal.

5. Central Hydraulic System (CHS) Set

5.1. General Requirements

5.1.1. The upgraded CHS shall include but not limited to: motors, pumps, filter system, hydraulic tank, frame structure, and heat exchanger.

5.1.2. The contractor shall provide an upgraded pressure compensated CHS which is capable of providing a minimum 160 gpm at 2500 psig with a design hydraulic fluid temperature of 140° F. 160 gpm is based on a crane requirement of 110 gpm, leaving 50 gpm for deck equipment. In cases where the crane’s requirement exceeds 110 gpm, the CHS’s capacity must be increased to maintain that 50 gpm margin.

5.1.3. The pumps for the new Central Hydraulic System (CHS) shall be pressure compensated with controls designed to prevent pressure hunt. Other types of pump control (i.e. load sensing) may not be used as the existing deck equipment is designed to be supplied with a constant 2500 psig.

5.1.4. To assist with cooling and hydraulic fluid cleanliness of the CHS pumps at idle, either a kidney loop or a bypass cooling loop shall be installed.

5.1.5. The kidney loop may use a separate pump and motor or pump(s) that are through-driven off of the main hydraulic pumps. The kidney loop shall contain filtration adequate to maintain the fluid cleanliness requirement of ISO 4406 Code 17/14/12, and adequate cooling for all pumps to run indefinitely on a design day at a compartment temperature of 110°F and seawater temperature of

95°F. Alternatively, a bypass loop may be connected between the pressure piping exiting the CHS skid and the return piping before it connects to the CHS skid. This bypass shall contain a solenoid valve and a flow control valve. The bypass shall contain adequate cooling for the pumps to run indefinitely on a design day at a compartment temperature of 110°F and seawater temperature of

95°F.

5.1.6. Cooling capacity shall exceed the heat output of all pumps running simultaneously in all scenarios of load in the aforementioned conditions so that idling the pumps can be used to cool the unit.

5.1.7. The cooler shall be a shell-and-tube design with double tubesheets to prevent seawater contamination in event of a tube failure. Wetted parts may be marine bronze, 90-10 or 70-30 copper nickel, or monel. Hardware shall be monel and the unit shall be protected by zinc anodes.

5.1.8. The CHS pump motors shall be designed to operate on 460 VAC/60Hz and be thermally protected.

Each motor’s horsepower rating must be greater than the combined load of the main pump at full stroke and any thru-driven accessory (ie cooling) pump. The motors shall have a Totally Enclosed

Fan Cooled (TEFC) enclosure in order to protect against grounding due to moisture. The motors shall have at least a Class F insulation rating.

5.1.9. The new CHS components shall be mounted on a rigid prefabricated welded structural frame which shall form a part of the CHS assembly. The frame will be secured by the installing activity to the

Cutter’s foundation through four anti-vibration isolation mounts.

5.1.10. The new CHS skid assembly shall fit within the existing footprint and height of the existing CHS assembly 77”W x 117”L x 79”H.

5.1.11. The contractor shall provide an interface diagram for the new CHS. The interface diagram shall designate each CHS component with a description and type/size of connection by the installing activity.

5.1.12. Hydraulic fluid used in the central hydraulic system shall be Mobil DTE-10M. All components of the new crane, new CHS, and existing buoy deck machinery shall be compatible with this fluid.

5.1.13. The upgraded hydraulic control system shall provide for full variable speed crane control (creep to rated speed, in both directions) of all individual lift, luff, and slew functions at rated load under operational sea states.

5.1.14. The upgraded hydraulic system shall not allow boom creep under any load.

5.1.15. The new filtering system shall be mounted in the crane pedestal and fitted with Schroeder model

KZ3 elements, or equivalent. Hydraulic return lines to the reservoir(s) are also filtered.

5.1.16. The upgraded CHS system shall operate with a target hydraulic particulate contamination level of

ISO 4406 Code 17/14/12 and a target water content level of 0.05% by weight. This contamination limit level shall be clearly identified on the hydraulic system diagram, and in the technical publication.

5.1.17. Hydraulic systems shall be cleaned during fabrication and assembly to ISO 4406 Code 16/14/11 or better. Provisions shall be made to maintain this cleanliness through delivery and installation.

5.1.18. The Contractor shall flush all piping, hoses and equipment per MIL STD 419D to achieve and maintain the required cleanliness level.

5.1.19. All points of hydraulic interface shall be capped or plugged immediately after flushing to prevent contamination and to prepare for shipping and storage of up to a year.

5.2. Piping

5.2.1. All piping materials, design and fabrication shall comply with CFR Title 46 (Shipping).

5.2.2. Hydraulic piping, tubing, and fittings shall be seamless stainless steel with a design factor of at least

4.0. Stainless steel shall be in accordance with ASTM A312.

5.2.3. The use of materials containing cadmium is prohibited.

5.2.4. Piping design and installation shall provide sufficient flexibility to absorb stresses on the piping imposed by the crane’s structural flexing and thermal gradients from minimum ambient temperatures to maximum ambient temperatures and full operating temperature conditions and to absorb the full range of motion permitted by the crane.

5.2.5. Piping shall not be pre-stressed during installation.

5.2.6. Piping shall be supported with isolation type hangers.

5.2.7. Equipment interfaces and take-down joints for maintenance purposes shall be fitted with flange type connections with O-ring seal or SAE straight thread type connections with O-ring seal. National Pipe

Connections or British Standard Pipe (BSPP) tapered threaded connections shall not be used.

5.2.8. The hydraulic oil return line in the crane turret shall be designed to prevent the formation of air pockets.

5.2.9. Interface of piping to drive unit hydraulic motors shall be accomplished with hydraulic tubing and flexible hydraulic hoses.

5.2.10. Tubing bends shall be used to the maximum extent possible in lieu of elbow fittings. For fittings 2 inch and smaller, standard radius tees and elbows shall be used. For fittings larger than 2 inch, standard tees and long radius elbows shall be used.

5.3. Hoses

5.3.1. All hoses shall be in accordance with SAE J1942 and SAE J1942/1.

5.3.2. All hose assemblies (with fittings attached) shall be proof load tested to 150% of their pressure rating.

5.3.3. All hoses shall be equipped with corrosion resistant metal fittings.

5.3.4. Skived hoses shall be sealed on ends to prevent water entry into the hose layers and reinforcing material.

5.3.5. Hose fittings shall be SAE J518/1 flanged connections (code 61 or code 62, split flange) or SAE

Straight Thread O-Ring Boss type fittings.

5.3.6. Except where absolutely required, hoses shall not exceed 36 inches in length except as necessary to support the movement or articulation of equipment.

5.3.7. Hoses shall have a service life of at least 8 years.

5.3.8. Hoses exposed to the weather shall have a weatherproof cover intended for marine service in direct sunlight that is resistant to ultraviolet light degradation.

5.3.9. Hose covers shall be easily removable for inspection purposes, shall not fit tightly.

5.3.10. Hose covers shall not contain insulation or similar material that may entrain water.

5.3.11. The use of fire shield covers on hoses is not permitted to achieve the fire resistance requirements of

ABS 4-6-2/5.7.

5.3.12. Access to installed hose fittings shall be provided, so that a ruptured hose may be replaced in the field without total disassembly of the crane. Access may include the use of bolted access plates.

5.3.13. Hoses shall be assembled to standardized lengths, to the extent practical.

5.3.14. The Contractor shall fully identify all hoses in the Technical Publication (hose log), to permit fabrication and assembly of replacement hoses. Hose replacement information shall be shown on the hydraulic system diagram.

5.3.15. Each installed hose shall have affixed a weather resistant tag engraved or embossed in ¼” high letters with the part number, “S/N CR-HYD-XXX” (where XXX is a sequential number). The hose tag numbers shall relate to a deliverable hose log spread sheet which shall identify system design pressure, hose test pressure, test date and other information.

5.4. Hydraulic Valves

5.4.1. Hydraulic directional control valves shall be housed in a totally water-tight enclosure with a removable, gasketed cover and a heater.

- The cover shall be made of corrosion resistant material.

- The cover and gasket configuration shall keep the interior of the enclosure totally dry from direct splash, rain and wind-blown spray. It shall also not permit ice to form, expand and lift the gasket from its sealing surface.

- The gasket shall be located in the cover and not on the enclosure to prevent damage to the gasket when servicing the hydraulic control valve.

- The weight and configuration of the cover shall permit easy removal by one man/woman without the use of lifting equipment.

- Removal of the cover shall permit full access to the control valve.

5.4.2. All valves shall be fully accessible for manual operation, maintenance, repair, and replacement.

Manifold and sub plate type valves are preferred for maintenance purposes.

5.4.3. Manual valve handles shall be provided and attached for all control valves whose operation is necessary for emergency recovery of the crane to a transit position to “come home”, in the event of failure of the PLC control system. Functional operation of the crane is not required.

5.4.4. In-line welded valves shall be modular in construction, to permit disassembly and maintenance.

5.4.5. Locking devices shall be provided for locking adjustable valves at service adjustment and valves that are required to be locked in the open or closed position for normal operation, the use of wire ties or similar devices as locking devices are prohibited.

5.4.6. Manually adjustable valves shall have a calibration marking system to permit repeat setting.

5.4.7. Test, vent and sampling poppet type valves (Schroeder S1215 series) shall be installed on both sides of all control valves, regulating valves, counterbalance valves, and all major components such as pumps, motors and cylinders to provide for diagnostic testing and analysis of hydraulic systems and for bleeding air out of the system. The valves shall be stainless steel commercial marine grade poppet valves which are interchangeable with MIL-DTL-24695C valves with reverse buttress threads;

Hydrotechnik / Schroeder Industries Series 1215 valves shall be provided. These valves shall be used for validation of set pressures and working pressures during system operation, for sampling the system for particulate contamination, for bleeding air from the system.

5.5. Gages

5.5.1. The hydraulic system shall be fitted with shock-resistant type gages sufficient for normal operation of the system.

5.5.2. Gages shall be stainless steel.

5.5.3. Gages shall be installed with isolation valves and damping devices, and sampling valves in parallel.

5.5.4. Thermometers or thermocouples shall be installed with isolation thermo-wells.

6. Control System Set

6.1. General

6.1.1. The integrated crane control system (ICCS) shall have PLC based control outputs and hardware capable of controlling the crane functions (through control of hydraulic valves), existing deck machinery, and upgraded CHS as listed herein. The Contractor shall supply all hardware necessary to interface the PLC outputs with the hydraulic valves and other devices. This includes modifications to deck machinery and upgraded CHS to make compatible with crane/ICCS controls.

6.1.2. The PLC shall interface with existing cutter systems. Specifically, the PLC shall be capable of interfacing with buoy deck machinery. This section shall describe the input and output signals required to interface with each external system. The Contractor shall be responsible for validating system interfaces after contract award.

6.1.3. Controllers shall retain logic programming without electrical power for a minimum period of 4 months.

6.1.4. The operation of any safety, interlock or abnormal sequence shall be alarmed. Continued use of equipment shall be restricted to safe movements.

6.1.5. The Contractor shall provide a PLC capable of sending and receiving at least the following types of industrial control signals:

Industrial Control Signals

• 4-20 mA

• ± 5 VDC

• ± 10 VDC

• 0 – 10 VDC

• 0 – 5 VDC

• 24 VDC

• 24 VAC

• 115 VAC

• Discrete I/O – Relay contact closure

• Deterministic fieldbus (PROFIBUS, CONTROLNET, MODBUS, etc)

• Encoder outputs with or without quadrature

6.1.6. The integrated crane control system (ICCS) shall consist of a PLC, an operator control interface

(primary and remote), an operator display panel, internal (crane) system interfaces and external system interfaces (including deck machinery).

6.1.7. Crane controls shall fail safe upon loss of power. FMECA shall describe fail safe conditions.

6.1.8. The crane control system shall be a deterministic, real time operating system. The maximum jitter, cycle time, error handling times, task execution times, hardware response times and communication time shall be known and specified by the Contractor. Operators shall use control system applications without consideration of variability in response time or execution time.

6.1.9. The ICCS shall possess supervisory circuits and self-diagnostics for isolating systems faults.

6.1.10. Digital fieldbus shall be utilized where possible for communication/remote display of data to reduce calibration.

6.1.11. The ICCS shall employ a fieldbus protocol common to all devices connected to the system, including internal and external communications, where applicable. This shall only apply to devices on the fieldbus network. Standalone analog I/O devices shall be permitted and shall not require fieldbus communication.

6.1.12. Fieldbus communications shall be open, industry standard, industrial protocols.

6.1.13. Radio communications or other means of telemetry are prohibited for any sensors, controls or signals.

6.1.14. The installing activity shall provide field wiring of signals between the PLC and the external systems. The Contractor shall include any necessary hardware for interfacing external signals with the

PLC.

6.1.15. For existing equipment control inputs/outputs refer to SK-175MMA INTERFACE 01.

6.2. Instrumentation

6.2.1. Rigging shall be fitted with load cell systems to digitally display the suspended load on the Buoy

Deck Control Room (BDCR) Console (lbs and tons). The BDCR Console controls shall provide a means for maintenance personnel to perform adjustment of instrumentation display parameters.

6.2.2. Rigging shall be fitted with suspended anti-2-block systems to prevent the hooks or hook blocks from being drawn in to the head sheaves. The systems shall utilize proximity type switches for sensing.

6.2.3. Crane instrumentation systems and sensors shall be hard-wired.

6.2.4. Main and auxiliary lift functions shall be instrumented for load and speed, for display on the BDCR

Operator Display.

6.3. Crane Controls

6.3.1. Individual Hook Operation Limits and Indication

6.3.1.1. The individual hook operation limits and alerts shall prevent the system from operating both hooks when WL greater than 10% of the working load limit (WLL) exists on either hook.

6.3.1.2. Disable operation and activate normal operation alert with either the main or auxiliary hook at a

WL greater than or equal to 10% of the WLL.

6.3.1.3. Individual hook limits and alerts shall be maintained until the WL on the hook in operation is reduced to less than 10% of the WLL for that hook.

6.3.1.4. When a hook has a less than a substantial load, activate the idle operation alert.

6.3.1.5. Operation of hook beyond the WLL shall be design to operate in test mode only.

6.3.2. Local/Remote Crane Control Lockout and Indication

6.3.2.1. The crane shall be controlled from either the BDCR or from a tethered, remote control. The

BDCR shall be the primary or “local” control. The tethered control shall be the auxiliary or

“remote” control.

6.3.2.2. If selector switch MC-SS6 is in position 1 (BDCR Local):

- The crane shall be in “Local” control mode.

- All inputs/outputs to/from the remote source shall be disabled.

- The BDCR local control indicator MC-IL9 shall be activated.

6.3.2.3. If MC-SS6 is in position 2 (BDCR remote) and the tethered controller is connected to the plug the operator must then press TC-PB2 to take remote control of the crane. If these events happen in this order, the following operation takes place:

- The crane shall be in “remote” control mode.

- All BDCR operator crane control inputs shall be disabled. Crane limits, data displays, alarms, indications and deck equipment controls shall remain operational.

BDCR control indicator MC-IL9 shall go off.

- The tethered remote control indicator TC-IL9 shall be activated.

- If either of these conditions are not met, both the “local” and “remote” inputs shall be locked out and the “no control” indicator shall be activated. Attempting to control the crane from the local control location while in “remote” mode shall activate the inhibit alert.

6.3.3.