RFI_SPEC_for_TOWER_CRANE_5_2.1.docx

SPECIFICATION

FOR TOWER CRANE #5 ELECTRICAL CONTROL SYSTEM UPGRADES

1. Scope

The contractor shall upgrade the electrical systems and controls for Tower Crane #5, to include the following:

a) Replacing all the AC motors (main hoist, aux hoist, boom hoist, swing and gantry) with associated AC drive, encoders and wires/conduits.

b) Designing and furnishing new PLC panels with software and diagnostic systems, new cab with controls

c) Replacing emergency stop pushbutton stations.

The diesel power on Tower Crane #5 was recently converted to shore power electric. Upgrades have been completed from the ground electrical up to the slip ring, with the exception of the gantry (travel) motors. This specification is for the replacement all the AC motors (main hoist, aux hoist, boom hoist, swing and gantry) with associated AC drive, encoders, and wires/conduits. Design and furnish new PLC panels with software and diagnostic system, new cab with controls, and replace emergency stop pushbutton stations. The rip out and installation of equipment will be handled by USCG Yard personnel.

2. Reference Documents

2.1 NEMA MG-1, Motors and Generators, 2004

2.2 NEC 2014, Article 610 Cranes and Hoists

2.3 NEMA ICS1, Industrial Control & Systems, General Standards, 2000

2.4 29 CFR Occupational Safety and Health Administration, Dept of Labor

a. Subpart N, 1910.179 Overhead and Gantry Cranes

2.5 MIL-DTL-24784/4C, Commercial Off-the-shelf Equipment Manual Requirements

3. Enclosure

1. Tower Crane #5 One Line Diagram

2. Contract Drawing Definition

Contract Drawings depict designs, arrangements and features and functions, which shall be incorporated into the detail design. Specific components, machinery and equipment, which may be depicted on the Contract Drawings, are intended to represent location, arrangement and operational or technical function.

3. Requirements

4. General System Description This specification describes the general administrative, technical requirements and information defining the responsibilities required from the Contractor providing the upgrade to the Tower Crane #5 electrical control system. Power provided to the crane via shore power up to the slip rings is 480VAC, 3PH, 60Hz, 400A.

5. Scope of Work The contractor shall using below drawing Figure 1 showing a general arrangement of the new AC Drives and motors and general PLC communication. Figure 2 design and provide the following:

B. PLC Panel: Provide a Master PLC system in a cabinet to control the crane systems. The PLC to Interface with operator controls by providing Remote I/O in the operators CAB. Control and interfacing to drives via Fiber Optic Ethernet. The PLC software will be used to operate and control the equipment provided and interface to the operators cab HMI. The diagnostic system in PLC panel door is for troubleshooting and status indication. Provide 120VAC power distribution for remote I/O panels and equipment with protection.

C. Emergency Stops: Provide new/replacement emergency stop pushbutton station around crane.

D. Switchboard: 480VAC mains power Switchboard distribution and disconnects for power to drives.

E. Lighting and Auxiliary power: 480VAC panel-board and transformer for lighting and auxiliary circuits. Replace lighting panel-board for 208/120VAC circuits.

F. Load Weigh system: Add load weigh protection system to meet OSHA requirements for Main and Aux Hoist.

G. Encoder: Boom Angle Encoder for load weight protection and limits.

H. Operator View: HMI unit for the Operators cab that is interfaced with the PLC system. It is using Ethernet.

I. Operator Controls: Replacement Master Switches, indication panel and footswitches. New chair with minimum four joysticks maintained with dead-man button and emergency stop button for operator controls in CAB, all operator controls shall be interfaced via the PLC system and operate at 120VAC.

J. Technical Machine Survey: Full Technical machine survey with impedance testing for all motors.

K. Training: Training services for the supplied equipment.

Figure 1 One Line Diagram

Figure 2 Table of Reference Equipment

6. Alarms and Controls

Some alarms that shall be provided but not limited to: Overheat for main hoist, aux hoist, boom hoist, swing, and gantry motors; Limit switches for main hoist, aux hoist, and boom hoist; Motor overload that would threaten to open the main breaker 400-500A. A full list of faults is shown in Ref 1.8. The contractor needs to produce a specific list of alarms/shutdowns that will be provided.

7. Installation Notes

The installation of the system will be performed by the Coast Guard Yard. The contractor will support installation by providing the documentation as specified in Sections 10 & 11 below. Most of the arrangements and details to be provided are located in Sections 10 & 11. Ref 1.5 can be used as a guide, it used in Tower Crane #1 & 3’s installation and should match the Tower Crane #5 installation with some minor changes. These changes will be identified during the technical machine survey. Additionally they will provide an onsite support personnel as necessary specified by paragraph 14 below.

8. Performance Characteristics and Testing

At the completion of installation, the crane system shall be tested in accordance with Ref 1.4a, sections (b)(2),(3), and (5). Tower Crane #5 must be able to lift and lower its maximum rated load of 38 tons or 76,000 lbs for the main and auxiliary hoists. The speeds of the motors coupled with the AC drives shall be capable of up to rated speed and down to 2% of the rated speed based on the motor data.

9. Operator’s Manual and Technical Publications

The Contractor shall provide a full set of technical manuals, both in printed and electronic format (.pdf extension), and authored in Standard American English. The Contractor shall develop and provide technical manuals in accordance with Ref 1.6. Software for the programmable hardware can either be included in the technical manuals listed above or documented separately. The software manuals must also be in accordance with Ref 1.6.

10. Data for Provisioning (DFP)

10.1 The Contractor shall only be required to provide certain Data for Provisioning that includes drawings, commercial technical manuals, catalog data and product specification sheets, which form the minimum data to provision a system or piece of equipment. Examples of the DFP include, but are not limited to: certification data, name plate data, component characteristics data, commercial specification sheets, end item/component prices, manufacturer’s identification (or Commercial and Government Entity Code (CAGE)), part number, shelf life, and special material / operating requirements. This data will then be used for the Coast Guard’s identification, cataloging, selection and determination of initial requirements for support items to be procured through the provisioning process.

10.2 As a minimum, the Contractor’s DFP shall be detailed enough to include:

· A listing that identifies all the piece parts, which can be assembled, re-assembled, and/or replaced.

· General arrangement, diagrammatic drawing and/or detailed Technical Publication that describes the end item, end item’s equipment and/or piece parts; material, mechanical electrical, dimensional characteristics, location, and their function within the assembly.

· Drawing List and Arrangement drawing developed for showing the Control system and all attached components, in sufficient detail, to justify the basic configurations and space allocations reflected in the Contractor's design.

· Electrical interconnecting cabling and wiring diagrams and wiring lists (pin to pin or point to point).

· A list of special tools and test equipment required to maintain the end item.

· A listing of spare parts recommended by the Contractor to support the end item for a period of one (1) year. The listing must contain end item/component prices.

· DFP is required for each piece of equipment being procured by the Government through this specification.

· The Contractor shall notify the Coast Guard within five (5) working days of any changes effecting equipment/piece parts configurations during the performance of the contract.

a. Data For Provisioning (DFP) package shall be delivered to:

USCG Yard 2401 Hawkins Point Rd Baltimore, MD. 21226-5000

11. Engineering Documentation Package (EDP)

11.1 This section defines the minimum requirements for the Contractor to supply documents and data (EDP) necessary for Coast Guard engineers to integrate the Contractor’s equipment into the design for Tower Crane #5. Examples of EDP include, but are not limited to: hard copy paper drawings, electronic drawing files, commercial catalogue sheets, off-the-shelf tech pubs, photographs, etc.

11.2 The Contractor’s EDP shall be detailed enough to include:

· General arrangement drawings detailing overall dimensions; required maintenance area dimensions; locations, size and type of all electrical connections to the cranes systems

· Footprint drawings detailing the foundation/mounting areas and specifying any special interface requirements as may be necessary

· The overall weight shall be identified

· Electrical schematic of each circuit detailing the voltage and amperage requirements

· Manual, tech pub, and/or catalogue data detailing the installation requirements for each piece of equipment

· Detailed test plan and test procedure for upgraded crane system upon completion of installation

Drawings may be submitted as electronic media (preferred) or paper copies. Electronic media must be in AUTOCAD and at least Version 2000 or later. Where electronic media is submitted it shall be with the manufacturer’s permission to use the files in Coast Guard drawings.

EDP documents supplied as electronic media need only be one (1) copy. EDP documents supplied as paper must be at least six (6) copies. The Contractor shall be responsible for all EPD items, updates and “as built” documentation.

11.3 The Contractor shall provide a recommended list for a twelve-month supply of replacement spare parts for the system. The spare parts will meet the O.E.M. specifications. A spare parts inventory list shall be provided with each delivery. The inventory list shall give a full description of each part with O.E.M. part number and (NSN) National Stock Number if available. Each spare parts kit shall be packaged with each system. Parts shall be priced individually.

12 Warranty

The manufacturer’s standard warranty shall in no event be for a period of less than one (1) year from date of acceptance of the system and shall include repair parts, labor, reasonable travel expense necessary for repairs at the job site, and expendables (lubricating oil, brushes, and other service items made unusable by the defect) used during the course of repair. Submittals received without written warranties as specified will be rejected in their entirety. In one year warranty period, the contractor shall maintain qualified; factory trained service personnel that can respond to an emergency call within 12 hours of notification.

16. System Training Classes: The contractor will provide a technical training class for shipyard personnel based on the hardware being supplied. Training shall be provided by a qualified trainer and be conducted on-site at the customer facility. This training will be over a period of two days and will consist of a group of up to 8 students. Training is expected to be one day of classroom instruction and one day of hand-on training on the crane. No training units will be provided for the students, only product manuals and Power Point presentations.

16.1 Training will include the following:

· Basic drive layout and troubleshooting

· Basic drive programming

· Electrical drawing review

· System troubleshooting techniques

· Diagnostic operation and use image1.jpeg image2.jpeg