Specifications of Heavy Lift Transports.docx

EQUIPMENT SPECIFICATION

FOR

HEAVY LIFT TRANSPORT SYSTEM

Prepared By:

NORFOLK NAVAL SHIPYARD

LIST OF FIGURES

TABLE OF CONTENTS

vii

1.0 SCOPE - This specification is for the purchase of a specialized self - propelled elevating transport system. The system shall be complete and operational with all components, accessories, parts, and services specified herein. The system is to be used for handling naval ship components and subassemblies during removal and reinstallation.

2.0 APPLICABLE DOCUMENTS - The following documents form a part of this specification, to the extent specified herein. Unless otherwise indicated, the issue in effect on date of solicitation shall apply.

TITLE 29, CODE OF FEDERAL REGULATIONS, CHAPTER XVII, PART 1910 – OCCUPATIONAL SAFETY AND HEALTH STANDARDS

(Address application for copies to Superintendent of Documents, Government Printing Office, Washington, DC 20402)

AMERICAN NATIONAL STANDARDS INSTITUTE, INC. (ANSI)

(Address application for copies to the American National Standards Institute, Dept. 969, 1430 Broadway, New York, NY 10018)

AMERICAN WELDING SOCIETY (AWS)

(Address application for copies to the American Welding Society, 550 N.W. Lejeune Road, Miami, Florida 33126)

AMERICAN GEAR MANUFACTURER’S ASSOCIATION (AGMA)

(Address application for copies to the American Gear Manufacturer’s Association, 1901 Fort Myers Drive, Suite 1000, Arlington, VA 22209)

AMERICAN SOCIETY FOR MECHANICAL ENGINEERS (ASME)

SECTION VIII – BOILER AND PRESSURE VESSEL CODE

(Address application for copies to the American Society of Mechanical Engineers, 345 East 47th Street, 8th Floor, New York, NY 10017)

FEDERAL COMMUNICATIONS COMMISSION RULES AND REGULATIONS VOLUME II, PART 18 – INDUSTRIAL, SCIENTIFIC AND MEDICAL EQUIPMENT

(Address application for copies to Superintendent of Documents, Government Printing Office, Washington, DC 20402)

NATIONAL ELECTRICAL MANUFACTURER’S ASSOCIATION (NEMA)

(Address application for copies to National Electrical Manufacturer’s Association, 1300 N. 17th St., Suite 1847, Rosslyn, VA 22209)

ELECTRONIC INDUSTRIES ASSOCIATION (EIA) STANDARDS

(Address application for copies to the Electronic Industries Association, Engineering Dept., 2500 Wilson Blvd., Arlington, VA 22201-3834)

NATIONAL FIRE PROTECTION ASSOCIATION

(Address application for copies to the National Fire Protection Association, 1 Batterymarch Park, P.O. Box 9101, Quincy, MA 02269-9101)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

(Standard copies can be located on the internet at:

http://www.astm.org/cgibin/SoftCart.exe/NEWSITE_JAVASCRIPT/index.shtml?L+mystore+rreq8222+1197662301)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

(Address application for copies to SAE Automotive Headquarters, 755 W. Big Beaver, Suite 1600, Troy MI 48084 USA)

FEDERAL STANDARDS

(Address application for copies to Headquarters, Superintendent of Documents, Government Printing Office, Washington D.C. 20402)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

(Address application for copies to the American National Standards Institute, Dept. 969, 1430 Broadway, New York, NY 10018)

3.0 NOTES

3.1 DOMESTIC MAKE - Domestic make refers to equipment available from United States (U.S.) manufacturers.

3.2 SHORT TONS - Loads, where specified in tons, are in short tons (1 short ton = 2000 lbs.)

3.3 ENGLISH DOCUMENTATION - All documentation and equipment identification shall be provided in the English language.

4.0 PURPOSE - The purpose of this specification is to define the requirements for a transport system, intended to be used in a naval shipyard for removal and reinstallation of various large complex components and assemblies. This specification shall be used as a guideline in developing the final purchasing proposals.

4.1 PRIMARY USE OF TRANSPORTERS - The primary use for this transporter system will be to lift and carry various large complex components and assemblies. At the shipyard facility, the unloaded transporters will be lifted by crane and lowered onto the floor of a graving dock. Once located in the graving dock, the transport system will be used to lift, move, and precisely position the components during removal and reinstallation operations. During these operations, the major assemblies must be accurately positioned collinear to each other and to the ship’s axis.

5.0 PERFORMANCE REQUIREMENTS

5.1 GENERAL - Each transporter will work as a part of a system of transporters to assist with the assembly, installation, and removal of various large complex components and assemblies into and out of U.S. Navy vessels in a naval shipyard. Individual transporters shall have the capability to precisely and accurately lift, transport, and control a load within the parameters stipulated in Section 6. Each transporter will possess a high degree of maneuverability, whether being used independently or concurrently with other transporters. When operating concurrently, multiple transporters will be controlled by one operator, using one controller. Whether being operated independently or concurrently, each transporter will have the ability to independently and automatically control a load’s position by adjusting to variations in the surface over which it rolls, while imparting low contact pressures to those underlying surfaces. The unit performance will meet all other design parameters stipulated herein.

Transporters procured under this specification will utilize the original design, approved by Electric Boat under contract PPU246-064 (2009). All new additions to the vehicles based on upgrades or new requirements in this specification will be verified by design review, engineering analysis, or verification during testing. All original vehicle characteristics and requirements are assumed to be acceptable based on Electric Boat’s acceptance of the original design. Additionally, it is understood that the vehicles specified herein shall be compatible with the vehicles located at Portsmouth Naval Shipyard and Pearl Harbor Naval Shipyard, once all vehicles are upgraded to the same version of SynchroSteer software.

5.2 USAGE FOR HANDLING SUBASSEMBLIES - The transport system shall:

a) Interface with the lifting strongback areas (Figure 1 & 2) by fitting under the strongbacks and reacting at the current strongback load support areas.

b) Support the combined weight of the various components and the specialized lifting fixtures.

c) While loaded, the transport system shall be capable of aligning the axis of components both co-linear to each other and to the main axis of the ship.

d) Provide motive power to move components and subassemblies within the drydock at a slow controlled speed, while being able to fine-adjust a loaded transporter’s position parallel to the ship’s axis, vertically, and athwartship.

5.2.1 LOAD SUPPORT AREAS - The load support areas are under the four short, main, fore-aft beams of the strongbacks. There are four load support areas per strongback and two strongbacks per section (see Figures 1 & 2), resulting in eight load support areas per section. The main axis of the strongbacks shall be oriented in the same direction as the main axis of the transporter.

NOTE: Figures 1 & 2 are excerpted from EB DWG H902-1021 REV B. This drawing may be consulted for actual dimensions.

Figure 1 – 21’ Strongback

Figure 2 – 24’ Strongback

5.2.2 INTERCHANGEABILITY - All transporters shall have the capability to operate as a master or slave to any other transporter during concurrent operations. This shall include transporters currently owned and operated by Portsmouth Naval Shipyard (PNSY) and Pearl Harbor Naval Shipyard (PHNSY). Any incompatibilities with sister yard machines shall be identified by the Vendor and provided to the Government, in addition to suggested remedies for the identified incompatibilities. Adherence to machine interchangeability with sister yards shall not supersede the requirements of Paragraph 5.1. Verification of concurrent mode operation will be demonstrated during Factory Acceptance Testing using three vehicles.

5.2.3 CONCURRENT OPERATION - Multiple transporters will be ganged to operate together during component removal and installation. The transporter system furnished under this specification shall include all controls, indication, systems connections, etc., required so that two or more ganged transporters can be operated by a single operator using a single control unit. The vehicles shall communicate via a cabled connection. In addition to communication for motion control, E-Stop communication is required when transporters are being operated in a 2(or 3)+1 configuration (two or three transporters operated concurrently by one operator, and a separate transporter operated by a second operator, such that depressing the E-Stop on any transporter will shut down all transporters). Each transporter unit shall be provided with sufficient interconnecting cabling to accommodate up to fifty (50) foot spacing between the transporters.

5.2.3.1 RELATIVE POSITION - For concurrent operations, all transporters must have the capability to maintain their relative position to an accuracy of +/- 0.75” when traveling longitudinally in creep mode and +/- 0.38” when traveling transversely in creep mode without the addition of a structural link between the transporters. The vendor shall provide a permanently marked reflector or target with graduations to allow an operator to determine vehicle relative position while in concurrent operation.

5.2.3.2 OVERTORQUE LIMITATION - When the transport system is operating in a concurrent operation mode, the system shall have overtorque limiting features to prevent drive axle and gear reducer windup in either direction.

5.2.3.3 INTERCHANGEABILITY / CONCURRENT OPERATION - Each/all transporter(s) shall have the capability to operate as a master or slave to any other transporter during concurrent operations.

5.3 QUANTITIES - This specification is for four transporter units.

5.4 PHYSICAL CHARACTERISTICS - The following physical characteristics of the transport system may not be deviated from. Prior to any change in these areas the Contractor shall submit the proposed change to the Government, in writing, for Government’s written approval.

a) Transporter overall minimum/maximum envelope as shown in Figure 3.

b) Transporter, in the fully lowered position, unloaded, no higher than 27 inches. See Figure 3.

c) Transporter, in the fully raised position, unloaded, no less than 37 inches. See Figure 3.

Figure 3 - Transporter Envelope

5.5 OPERATING ENVIRONMENT

5.5.1 SHIPYARD CONDITIONS - The transport system shall be capable of functioning in a shipyard outdoor environment. Shipyard environments include dirt/grit, high humidity, exposure to weather, and exposure to salt spray. Materials, coatings, and design shall be suitable to protect bearings, hydraulic systems, electric systems, controls, gauges, mechanisms, and structures. All equipment susceptible to damage from particulate matter such as abrasive grit, weld spatter, metallic particles, and salt water spray shall be protected by appropriate enclosures. Such enclosures shall not interfere with the normal operation of the system.

5.5.2 WEATHER - The transport system shall be designed to operate as specified under the following weather conditions:

a) Ambient air temperature range 0°F (-29°C) to +110°F (49°C) (thermal radiation heating of transporter components is to be considered).

b) Salt air atmosphere (100% humidity).

c) Rain, snow, and icing.

d) Wind velocity 25 MPH from any direction.

5.5.3 ELECTROMAGNETIC INTERFERENCE (EMI) - A shipyards environment may contain strong fixed and intermittent electromagnetic signals. The transporter system shall be protected against electromagnetic interference. Protection from transporter equipment-generated voltage and current surges as well as from atmospherically generated electrical disturbances (including interference level EMI from high frequency arc welding, communication transceivers, etc.) will be part of the equipment.

5.5.4 GRADE - Whether operating independently or concurrently, the transport system shall be able to perform all functions at rated capacity up to a grade of 3%. The transport system shall be able to perform all functions specified at 90% of rated capacity up to a maximum grade of 4%. This aspect of performance may be verified by physical test at NNSY or by verification of calculations provided by the contactor, at the discretion of the Government. If a physical test is desired, prior to delivery, vendor and Shipyard will identify a test area within the shipyard to conduct this test during Site Acceptance Testing. Grade and/or payload may be adjusted to simulate the requisite drive motor torque to meet this requirement.

5.6 MATERIALS

5.6.1 MATERIAL SAFETY DATA SHEETS (MSDS) - All hazardous materials, fluids, coatings, sealants, thread lockers, lubricants, etc. and their latest Material Safety Data Sheets (MSDS), shall be identified and provided to Government for an Environment, Safety and Occupational Health (ESOH) compliance review.

5.6.2 OIL ABSORBSION - Use of any material with a tendency to absorb oil and become a fire hazard (e.g. open cell foams) shall be minimized when used in areas of the machine subject to high heat or the potential for electrical arcing.

5.7 COMMERCIAL OFF-THE-SHELF - Within the transport system, commercial off-the-shelf (COTS) parts shall be used whenever practical. COTS components shall be installed and used as directed by the part original equipment manufacturer (OEM). Where deviation from OEM installation and/or use instructions is necessary, written approval from the OEM or the Government shall be obtained. Written OEM approval for any COTS used against part OEM installation and/or use instructions shall be submitted to the Government prior to the commencement of work. The Vendor shall not assume ownership of any COTS components in which they do not own the rights.

5.8 DEVIATIONS - There shall be no deviations from issued drawings and submitted data without prior written approval of the Government.

5.9 CONFLICT - Where any conflict exists between the purchase order and this specification, the requirements of the purchase order shall govern.

5.10 EXCEPTIONS - If the Contractor takes exception to part or parts of this specification, he shall so designate in writing as part of his technical proposal.

5.11 RESPONSIBILITY FOR ERRORS - The Contractor shall be responsible for all errors in detailing and assembly of the equipment.

6.0 DESIGN

6.1 GENERAL - The equipment shall be new and unused, capable of performing its intended function in accordance with the operation and performance requirements specified herein. The equipment shall be complete, so that when connected to the utilities identified herein, it can be used for any function for which it is designed and constructed. The equipment shall be of the manufacturer's most current field proven design, representative of equipment whose design, capacity, and performance characteristics, having been proven through actual field application, are substantially the same as those required of the equipment specified herein.

6.1.1 APPLICABLE DESIGN CODES - The Contractor shall provide a listing of standards invoked for design and manufacture in their plant or in their suppliers’ plants. The applicable issue shall be the latest utilized by the Contractor in the regular production of transporters. Copies of other than United States Standards cited shall be provided as part of the Contractor’s technical proposal. English language versions are required. Standards shall be provided for the following:

a) Safety

b) Structural members

c) Welding

d) Electrical system

e) Electronic control system

f) Hydraulic system

g) Gearing

h) Threaded parts and fasteners

6.1.2 SAFETY AND HEALTH REQUIREMENTS - Covers, guards, or other safety devices shall be provided for all parts of equipment that present safety hazards. This shall include belting, flywheels, and fan blades, even where nominally covered by a general engine compartment cover. Safety devices shall not interfere with operation of the equipment. The devices shall prevent unintentional contact with the guarded part and shall be removable to facilitate inspection, maintenance, and repair of the parts. Machine parts, components, mechanisms, and assemblies furnished on the unit shall comply with all specific requirements of "OSHA Safety and Health Standards (29 CFR 1910), General Industry" that are applicable to the equipment itself. Additional safety and health requirements shall be as specified in other Sections of this specification. The design and manufacture shall be in accordance with all applicable ANSI safety standards.

6.1.3 AUDIBLE NOISE LEVELS - Audible noise emitted by the equipment shall not exceed 84 dB at the operator's work position, nor at any other point at a distance of 3 feet from the equipment under all operating and service conditions. Noise shall be measured on the "A" weighted scale of a standard sound level meter. Measurements shall be taken at the operator's work position and at each side and end of the equipment. For each measurement, the microphone shall be located on a straight line perpendicular to the surface or corner being measured. The height shall correspond to the point of highest noise level emitted from the surface or corner at the location and distance from the equipment specified herein.

6.1.3.1 EXCESSIVE NOISE - In the event that audible noise levels cannot be maintained below the limits specified in 6.1.3, the machine(s) shall be placarded with requirements to wear hearing protection during operation. Signage shall be approved in writing by the Government prior to installation.

6.1.4 USE OF POLYCHLORINATED BIPHENYL (PCB) - The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited.

6.1.5 USE OF MERCURY - The equipment shall not contain mercury or mercury compounds, nor shall it be exposed to free mercury during manufacture.

6.1.6 USE OF ASBESTOS - The use of asbestos and materials containing asbestos on or in the furnished equipment is prohibited.

6.1.7 USE OF LEAD - The use of lead and materials containing lead on or in the furnished equipment is prohibited.

6.1.8 ENVIRONMENTAL PROTECTION - The equipment shall not emit materials hazardous to the ecological system, as prescribed by federal, state, and local statutes in effect at point of installation, under the operating, service, transportation, and storage conditions described herein.

6.2 GEARS - Gears used in the machine and its components shall be machined in either the standard or metric system. Gears shall meet the requirements of (obsolete) ANSI/AGMA 6013, 6034, or 6035. The conversion factors and methods specified in ASTM SI10-2002 shall be used for conversion of metric units (SI) to U.S. Customary System of Units (US) for comparison purposes.

6.3 CONSTRUCTION - The equipment shall be constructed of parts that are new, without defects, and free of repair. The equipment shall be complete. When connected to the specified utilities, it shall be capable of any operation for which it is being purchased. The equipment shall be devoid of any defects or characteristics that will preclude conformance with any of the requirements herein.

6.3.1 CASTING AND FORGINGS - Castings and forgings shall be free from defects, scale, and mismatching. Processes such as welding, peening, plugging, or filling with cold solders or metallic pastes shall not be used on castings or forgings for reclaiming any parts of the equipment.

6.3.2 WELDING, BRAZING, OR SOLDERING - Welding, brazing, or soldering shall be employed only where those operations are included in fabrication of the original design. These operations shall not be employed as repair measures for defective parts.

6.3.2.1 SOLDERING - Solder connections shall show evidence of good bonding in metal-to-metal contact. Cold solder joints, incomplete joining of solder and metal, excess or insufficient solder, or damaged insulation shall be considered reason for rejection of the equipment.

6.3.2.1.1 CLEANING - Any loose, spattered solder, flux, metal chips, insulation scrap, or other foreign material shall be removed from the equipment.

6.3.2.1.2 FLUX AND CLEANING AGENTS - Flux for soldering shall be rosin or rosin and alcohol. No acid, acid salts, or acid core solder shall be used in preparation for soldering of electrical connections.

6.3.3 FASTENERS AND LOCKING DEVICES - Screws, pins, bolts, nuts, washers, and similar internal and external parts shall be installed with means for preventing change of tightness. Parts subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently installed. Fastening devices shall be tightened to torque limits as established by the manufacturer's standard for tightening to preclude loosening by normal operation or vibration. Use of anaerobic compound is permissible. Where anaerobic compound is not used, anti-seize compound or other suitable material shall be applied to prevent corrosion/galling of fasteners.

6.3.3.1 CRITICAL FASTENERS - All fasteners for operational critical components (e.g. load bearing joints) shall use ASTM A325, ASTM A490, SAE J429 (Grade 5 or Grade 8) cap screws and shall be equipped with a locking (or self-locking) feature to prevent vibration induced loosening. Use of anaerobic compound is permissible. However, if a component manufacturer requires a fastener with a higher grade, then the higher grade will be required by this specification.

6.3.3.2 LOCKING FASTENER INDEX - An index or table of fasteners that may be disassembled during transporter maintenance and that were initially assembled with anaerobic locking compound shall be provided to facilitate correct maintenance. This document shall also identify the type of locking compound used.

6.3.3.3 MISCELLANEOUS FASTENERS - All fasteners for covers, panels, brackets or other non-critical components shall be selected by the Contractor to meet the needs of the application.

6.3.3.4 GRADE IDENTIFICATION - All structural and mechanical bolts, screws and nuts shall have identification markings required by the relevant ASTM or SAE specifications.

6.3.3.5 INTERNALLY THREADED CONNECTIONS - All internally threaded fastener connections for operational critical components shall be sized to ensure adequate thread engagement is provided for the externally threaded fasteners develop their full tensile strength. All nuts shall have a minimum of one thread pitch of the bolt protruding above the nut top surface after the fastener is installed.

6.3.4 SURFACES - Surfaces of castings, forgings, molded parts, stampings and welded parts shall be cleaned and free from sand, dirt, fins, sprues, flux, or other harmful or extraneous materials. External surfaces shall be smooth. Edges shall be rounded or beveled unless sharpness is required to perform a function.

6.3.4.1 PAINTING - The equipment shall be properly painted. Paint specification shall be approved by the Government prior to application. Prior to painting, surfaces shall be properly prepared and primed. Painting shall provide a highly wear-resistant finish that guarantees continued protection to the surfaces covered against the specified environment in Section 5.5, under all service conditions. The colors red, yellow, and magenta shall not be used without written Government approval. No objection will be raised by the Government against OEM logos and similar small graphics/signage that are in color other than those specified herein.

6.3.4.1.1 COLOR SCHEME - The vehicles shall be painted/marked as follows:

· Overall vehicle body: Safety Orange, PPG95-805.

· Access Hatch Striping/No-Load Area Demarcation: Black stripes

· Lettering/graphics/signage, printed, painted, or otherwise: Black

· The contactor shall submit a proposed paint scheme for review and approval by NNSY.

6.3.4.2 ALUMINUM SURFACES - Aluminum parts for use outdoors shall be anodized or chemically treated followed by two coats of weather-resistant exterior paint.

6.3.4.3 FERROUS PARTS - Exposed ferrous parts such as screws, bolts, nuts, washers, etc., shall resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as cadmium or chrome plating, galvanizing or other electrical/chemical process, or stainless steel is acceptable.

6.3.4.4 DISSIMILAR METALS - Dissimilar metals shall not be used in direct contact with each other without suitable means for preventing electrolytic corrosion and without compromising joint tightness or fatigue life.

6.4 ELEVATING BED

6.4.1 AREA OF ELEVATING BED - The maximum dimensions of the elevating bed shall not exceed the maximum envelope for the transporter shown in Figure 3.

6.4.2 STRUCTURAL MEMBERS - The main frame members shall be adequately braced with sufficient members and cross-members to form a rigid platform with sufficient strength for the loads imposed. When the transport system is loaded with maximum rated loads, the maximum stress in each frame member(s) shall be not greater than 50 percent of the frame material minimum yield strength.

6.4.3 WELDING STANDARDS FOR STRUCTURAL MEMBERS - All welding, fabrication and inspection shall be in accordance with the requirements of American Welding Society (AWS) D14.4. If an equivalent alternate specification is recommended by the Contractor, it shall be identified in writing and submitted to the Government for approval.

6.4.4 CONNECTION TO LOAD - The bed shall have the capability to be mechanically attached to the underside of each strongback load support area or adjacent to it (see Figures 1 & 2). The attachment method shall be identical to that utilized by PNSY and PHNSY transporter vehicles. The maximum stresses in the attachment hardware shall be no greater than 50 percent of the material minimum yield strength. Welding of the elevating bed to the underside of the strongback is not permitted.

6.4.5 IDENTIFICATION OF LOAD SUPPORT AREAS - All load supporting areas on the deck shall be clearly and permanently identified. All non-load supporting areas of the deck shall be marked as such.

6.4.6 PROTECTION OF OPENINGS ON TOPSIDE OF TRANSPORTER - Openings larger than 6 inches in their greatest dimension on the topside of transporter shall be filled with lightweight decking such that one person can remove or open the section (for maintenance access). This decking shall be flush with the surrounding deck and as such shall be able to withstand a local load of 100 pounds per square foot without damage. The decking shall be restrained to prevent lifting by the wind.

6.5 LIFTING/HANDLING

6.5.1 LIFTING BY CRANE - In most cases the transporters will need to be lifted to and out of a graving dock work area by means of a crane. The transporters must be capable of being lifted and they must have lift points with appropriately sized permanent pad eyes or tapped holes for swivel hoist rings. At no time will a transporter be crane lifted in a loaded condition.

6.5.2 LIFT POINTS - The equipment shall be provided with pad eyes or tapped holes for swivel hoist rings, oriented about the vertical center of gravity, to allow for safe handling and transport by overhead crane. When suspended by four equal (within manufacturing tolerance) length slings, the equipment shall hang perpendicular within five degrees of true vertical. This shall be demonstrated by calculation of Center of Gravity or during physical unloading of the vehicles at NNSY.

6.5.3 LOCATION OF LIFTING POINTS - The lifting/handling lift points shall be located on the four corners of the transporter.

6.5.4 PROTECTION OF LIFTING/FIXTURING POINTS - Removable/reusable non-metallic plugs shall be provided to protect any threaded lifting/fixturing holes.

6.5.5 FACTOR OF SAFETY - The lifting/handling lift points shall be sized such that each point is capable of supporting 50% of the total load while ensuring the combined material stresses have a factor of safety of ≥ 3.0 on material minimum yield strength and factor of safety ≥ 5.0 on material minimum ultimate strength. All lift points should be oriented such that the rigging will converge to one lift point (i.e. the crane’s hook). Each lift point shall be subject to a proof test of 200% of the maximum design load for that lift point.

6.5.6 LIFTING POINT IDENTIFICATION - All lifting points shall be clearly and indelibly marked. The marking shall specify the maximum rated capacity of each lifting point.

6.5.7 IDENTIFICATION OF TRANSPORTER WEIGHT - The weight of each transporter shall be permanently labeled. This labeled weight shall be accurate to +2%, -0% of the actual weight of transporter and shall be rounded up to the nearest 100 lbs.

6.5.8 LIFTING DIAGRAM - A lifting diagram illustrating the approved lifting locations and capacities shall be provided for Government approval. The Contractor shall supply any and all special rigging hardware as part of the transport system.

6.5.9 STACKABILITY - All transporters must be stackable on each other and be provided with a means to prevent relative motion when stacked.

6.6 PROPULSION - The transport system shall be self-propelled.

6.6.1 PROPANE INTERNAL COMBUSTION ENGINE - The primary source for motive force shall be provided by propane internal combustion engine driving a generator or alternator, feeding electric motors.

6.6.1.1 COOLING SYSTEM - The cooling system shall be of sufficient capacity to permit full load operation with air at a temperature of 120 degrees F entering the radiator. The transporter shall be delivered with glycol base antifreeze, providing protection to -20 degrees F.

6.6.1.2 AIR FILTERING - The engine air intake shall be provided with filtering system. The intake shall be located to minimize ingestion of ground level dust and debris.

6.6.1.3 FUEL SUPPLY - Each vehicle shall be equipped to run on four propane tanks. The tanks shall be easily removable for exchange and refill. The tanks shall be positively secured in the transporter to prevent shifting during operation. Friction clamps are not acceptable.

6.6.1.4 PROPANE TANKS - Commercial off-the-shelf propane tanks shall be used. They shall be provided with a fuel level indicator. The Contractor shall provide 4 spare tanks in addition to 4 tanks per vehicle. Tanks shall be of a size and model identical to the tanks used in the Heavy Lift Transporters at PNSY and PHNSY.

6.6.1.5 POWERPLANT START-UP - The transport system shall be capable of startup and operation under any and all combinations of environmental conditions specified in Section 5.5, with a maximum warm-up time of 20 minutes. Tank and engine heaters may be used to satisfy this requirement.

6.6.2 SECONDARY SOURCE OF MOTIVE POWER - The units shall be provided with a socket type feed for an umbilical electric cord as a secondary power supply (440/480 VAC, 60 cycles, three phase). A receptacle shall be located on the side or end of each unit, and located so as not to interfere with loaded and unloaded operations specified herein.

6.6.2.1 SHORE POWER CABLE/DISTRIBUTION BOX - Each transporter unit shall be provided with a 100 ft. long electrical umbilical cord, sheathed in abrasion resistant material to prevent damage as the transporter(s) move across unpolished concrete and asphalt surfaces. Rubber is not an acceptable sheathing material. In addition, a single distribution box shall be provided to supply power to up to three vehicles from one primary umbilical cable when the machines are being operated concurrently. A portable storage rack or cart shall be provided to allow handling, storage, and easy deployment of the cable.

6.6.3 EMERGENCY STOPS - Emergency stop controls shall be provided at the operator’s panel, wireless remote, and on each side of the transporter. A minimum of one emergency stop shall be located on each side of the transporter. These controls shall be capable of being linked together both via wireless communication and wired connection (in the event wireless cannot be used) such that activation of any one emergency stop control will stop all transporters operating simultaneously and will engage the parking brake feature. See 5.2.3 for configurations in which transporters will be used simultaneously.

6.6.4 EMERGENCY PARKING BRAKE RELEASE - Means shall be provided for releasing the braking feature in the event of vehicle breakdown.

6.7 LIFT SYSTEM

6.7.1 LOAD CAPACITY - The rated load capacity shall be 150 tons for each transporter. Transporters must be able to withstand loading at the points illustrated in Figures 1 & 2.

6.7.2 METHOD OF LIFT - Motive force for raising and lowering the bed shall be by means of hydraulic cylinders.

6.7.3 HYDRAULIC LIFT SYSTEMS - The lift system shall be provided with a feature to prevent an uncontrolled lowering or loss of bed height in the event of a hydraulic system hose or piping failure (e.g. cylinder mounted check valves).

6.7.4 SUSPENSION TRAVEL - The transporter shall be capable of traveling at a maximum bed height of no less than 34 inches and a minimum bed height of no more than 30 inches, and anywhere between these limits at maximum rated load, under any and all combinations of environmental and grade conditions specified in Section 5.5.

6.7.4.1 PRECISION MODE SUSPENSION TRAVEL - The transporter shall be capable of traveling at a maximum bed height of no less than 37 inches and a minimum bed height of no more than 27 inches, and anywhere between these limits at maximum rated load, on a smooth and level surface such as a drydock floor during fitup evolutions.

6.7.5 RATE OF LIFT - The transporter lift system raise and lower positioning speed shall be capable of 0.25 inch per minute minimum in the loaded condition. For concurrent operations, all transporters must have the same lifting positioning speed within ±2%.

6.7.6 NORMAL MODE OF LIFTING - The normal mode of lifting and lowering shall be by concurrent operation of all four corners for each section. Additionally, the transport systems controls shall provide a mode that facilitates pitch and roll maneuvers, when directed by the operator, whether operating in single or concurrent modes.

6.7.7 LOAD INDICATION - Load indication shall be built into the transporters, allowing for the resolution of loads at the reaction points (i.e. the four transporter-strongback load support areas). Loads shall be displayed at the control station and on the hand held controller(s). The display readout shall be in pounds. The accuracy of the displayed load shall be such that the indicated load is +/- 3% of actual load over the range of 15 to 100% of rated load full scale.

6.7.8 EMERGENCY LOWERING - Means shall be provided for manually lowering the transporter in the event of a breakdown.

6.8 MAINTAINING LOAD POSITION

6.8.1 HOLDING BRAKES - Each transporter shall include holding/parking brakes that automatically engage whenever there is no drive or rotate inputs from the operator. The brakes shall automatically disengage whenever the operator provides input to either drive or rotate the transporter(s). The braking system shall be designed such that improper action by the operator cannot result in loss of function of the holding brakes. The holding brakes shall be capable of maintaining the transporter(s) in position, while carrying maximum rated load, in all steering modes, under conditions specified in Section 5.5. The holding brake(s) shall automatically engage in the event of a loss of power. The vehicle shall be provided with the ability to electronically test for and indicate satisfactory brake holding torque for each individual drive motor.

6.8.2 ELECTRONIC BRAKING - Each transporter shall rely on its electronic drive to slow and stop its motion. The electronic drive will apply the appropriate input to the electric motors to maintain position until the holding brakes engage. Brake resistors shall not be used without written approval of the Government.

6.8.3 MECHANICAL LOAD SUPPORT - Built in mechanical means shall be provided to transfer the load from the hydraulics to the ground to prevent loss of vertical position due to hydraulic sag. This may be accomplished by use of jack screws, etc. The mechanical means shall have the ability to be actuated from the control station and/or the handheld controller and must have the ability to be manually deployed. The resulting floor loading must not exceed 1000 psi. In addition, even if positive mechanical stops have not yet been set, the vertical positioning method shall prevent uncontrolled lowering of the load if hydraulic pressure is lost (e.g. cylinder mounted check valves).

6.9 HYDRAULIC SYSTEM

6.9.1 HYDRAULIC SYSTEM CAPACITY - The hydraulic system shall have sufficient capacity to continuously drive, maneuver, and elevate the bed at maximum rated load. Lift and lower speeds shall be per Section 6.7.

6.9.2 HYDRAULIC SYSTEM COOLING - Sufficient cooling shall be provided to limit the temperature of the hydraulic system to a value suitable to the application per the design requirements of the hydraulic system.

6.9.3 HYDRAULIC SYSTEM PRESSURE - Proof pressure of hydraulic system piping and components shall be a minimum of 1.25 times normal operating pressure (not to exceed 2400 psig) and shall be greater than the maximum pressure that may occur due to abnormal operating conditions such as transient system impact loading or pressure intensification due to differential areas of system components. External leakage at proof pressure shall be zero. Means shall be provided to perform a 1.25 X operating pressure hydrostatic test that does not require modification of the hydraulic system configuration prior to test performance (removal of pressure relief valves, manually changing system pressure, etc.). Manual manipulation of permanently installed valves is acceptable.

6.9.4 HYDRAULIC FLUID - The operating medium of the hydraulic system is to be a common grade of domestically produced commercial hydraulic fluid, and shall be specified by the Contractor. For minimization of inventory, the fluid used shall be compatible with Shell Tellus MX32, which is the fluid used in the transporter vehicles currently operated by the Shipyard.

6.9.5 HYDRAULIC SYSTEM COMPONENTS - The Contractor shall provide the U.S. manufacturer’s identification number for all hydraulic system pipe fittings, seals, and hoses.

6.9.5.1 PRESSURE GAUGES - Pressure gauges and a low pressure alarm shall be provided for the hydraulic system. Gauges shall be provided as back-up in any hydraulic circuit that is normally monitored by a pressure transducer. Gauges may be mounted in the machinery spaces, and are not required at the control station.

6.9.5.2 SOFT GOODS INDEX - A list of all serviceable/replaceable hydraulic system soft goods (seals, O-Rings, back-up rings, gaskets, etc.) shall be provided. This list shall identify all components by manufacturer, manufacturer part number, and, wherever appropriate, by standard identification number (MIL-S, AS568, etc.). In addition, seal material and hardness shall be specified where appropriate.

6.9.5.3 CHECK VALVES - Check valves shall be installed at all hydraulic cylinders to prevent lowering of the vehicle in the event of a hose failure.

6.9.5.4 HYDRAULIC CYLINDERS - Hydraulic cylinders shall be of a rebuild-able type.

6.9.5.5 RESERVOIR

6.9.5.5.1 RESERVOIR FLUID LEVEL INDICATION - The reservoir shall be equipped with a fluid level indicator marked with high and low levels and system filling instructions.

6.9.5.5.2 RESERVOIR VENT - The reservoir vent shall be protected by an air cleaner capable of maintaining system cleanliness under the conditions of Section 5.5. A desiccant breather or similar air filter shall be provided to reduce moisture levels in the reservoir.

6.9.5.5.3 RESERVOIR ACCESS - The reservoir shall be provided with suitable connections for filling and draining and access plates for cleaning.

6.9.5.6 LOCATION OF PRESSURE TEST POINTS - Built in pressure check points shall be provided throughout the hydraulic system. Specifically, test pressure points shall be provided for all charge pumps, actuator ports, and on either side of control valves.

6.9.5.7 IDENTIFICATION OF HYDRAULIC SYSTEM COMPONENTS - Major components shall be identified and marked per the requirements specified in Section 6.10.3.

6.9.6 FILTRATION

6.9.6.1 FILTRATION STANDARD - Sufficient filtration shall be provided to maintain the hydraulic system cleanliness in accordance with ISO 4406 cleanliness level 18/16/13. Water contamination shall not exceed 0.03% by volume. If different cleanliness levels are recommended by the Contractor, they shall identify these levels in writing in their proposal and shall provide adequate filtration to meet these requirements.

6.9.6.2 FLUID SAMPLING - Means of obtaining a representative fluid sample without disturbing piping shall be provided to permit periodic measurement of the fluid cleanliness level.

6.9.6.3 FILTER LOCATION - Filters shall be provided at the hydraulic pump discharge and at the return line to the reservoir.

6.9.6.4 FILTER ACCESSIBILITY - All filters and housings shall be accessible for servicing.

6.9.6.5 FILTER COUNTRY OF ORIGIN - All hydraulic system filters shall be made by a U.S. manufacturer.

6.9.7 HYDRAULIC ENERGY LOCKOUT - Means shall be provided to depressurize and discharge the system to allow for maintenance.

NOTE: Hydraulic pressure will remain in the transporter hydraulic cylinders due to check valves specified in 6.9.5.3.

6.10 HYDRAULIC SYSTEM IDENTIFICATION AND MARKINGS

6.10.1 PIPING IDENTIFICATION - Each pipe shall be identified at each termination and junction by means of plastic or metal tags. Markers shall be installed within 3 inches of each point of termination or junction. Markings shall be readily visible in the as-installed configuration (e.g. not behind piping, etc.).

6.10.2 NUMBERING - All numbering and identifying of piping shall be identical with that shown on the issued diagrams and drawings.

6.10.3 HYDRAULIC VALVES AND COMPONENTS

6.10.3.1 LABELS AND TAGS - All hydraulic pipes, valves, solenoids, and components shall be…