STS_Crane_Product_Description.pdf

TWO SHIP-TO-SHORE CONTAINER CRANES

for

MILITARY OCEAN TERMINAL CONCORD

at

CONCORD, CALIFORNIA

APPENDICES

PART 1.0 GENERAL

Definitions

Specifications and Standards

General

US Domestic Codes and Standards and Specifications

International Codes and Standards

Substitution of Codes

Example of List of Codes Used in Industry Procurement Specifications

System Description and Scope of Supply

Scope of Supply

Minimum Criteria

Safety Design Criteria

Design Requirements

Performance Requirements

Unique Identifier Tags

Essential Repair Parts

Submittals

Quality Assurance

Quality Assurance

Government Inspections

Contractor Quality Control

Process Control Audit

Regulatory Requirements (FAA, OSHA)

Meetings

Post-Award Meeting

Design Review Conference

Functional Description and Presentation

Pre-Manufacturing Conference (Manufacturing Kick-Off Meeting)

Pre-Installation Conference

Delivery, Storage and Handling

Existing Conditions

Contractor Requested Engineering Changes

Warranty

Not Used

Design Life

Minimum Support Period

Duty Cycles and Load Spectra

Main Hoist and Trolley Design Duty Cycle

Gantry Drive Design Duty Cycle

Boom Hoist Design Duty Cycle

Rope Inspection Duty Cycles

Main Hoist Load Spectrum

Trolley Load Spectrum

Gantry Drive Load Spectrum

Boom Hoist Load Spectrum

Other Duty Cycles and Load Spectra

Duty Cycle Analysis Requirements

Load Spectra and Design Life Analysis Requirements

Crane Modes

Primary Operating Mode

Semi-Automated Operating Mode

Passing Mode

Stowed Mode

Cargo Beam Mode

Maintenance Mode

Limping Mode(s)

PART 2.0 PRODUCTS

Materials

Ductile Materials

Structural Steel

Structural Pipes and Tubes

High Strength Bolts, Nuts, and Washers

Aluminum Castings

Iron Castings

Steel Castings

Steel Forgings

Bronze Bushings and Thrust Washers

Steel Bars of Special Quality

Steel Bars of Standard Quality

Alloy Steel Bars

Welding Materials

Charpy V-Notch Impact Requirements

Plate Through-Thickness Requirements

Material Traceability

Mechanical Material

Structural Design

General Requirements

Fracture Critical Members

Access for Inspection

Members Subject to Buckling

Welding

Crane Structure

Trolley Girder

Boom

Connections

Trolley Structure

Trolley Rails, Clips, and Pads

Machinery House

Boom Control Station

Access Structures

Counter Weight (Ballast)

Equalizer Girders and Travel Trucks

Stowed Wind Condition Securing Devices

Hatchcover Support Structure

Boom Hoist Failure Prevention

Gantry Frame Deflections and Stiffness

Camber

Design Loads

Seismic Design

Design Loading Conditions

Fatigue Design

Allowable Design Stresses

Calculations

Stability

Wheel Loads

Structural Maintenance Program

Voyage Criteria

Mechanical Design

General Requirements

Safety Factors

Machinery Mounting, Installation, and Alignment

Drive Mechanisms

Shafts, Axles, and Pins

Gear Reducers

Bearings

Drums

Wire Ropes

Reeving

Fleet Angles

Catenary Rope Support System

List, Trim and Skew Adjustment

Headblock

Sheaves

Wheels and Guide Rollers

Couplings

Keys and Keyseats

Bumpers and End Stops

Snag Control

Slap Blocks and Deflector Rollers

Drip pans

Surface Finishes

Seals

Lubrication

Fits

Hydraulic Systems

Brakes

Boom Latch Mechanism

Bushings and Thrust Washers

Electrical Design

General Requirements

Main and Shore Power Supply

Medium Voltage Switchgear

Power Quality Meter (PQM)

Surge Protection Devices (SPD)

Medium Voltage Transformers

Low Voltage Transformers

Drive Control Systems

Converters

Inverters

Power Factor

Motors for the Major Motions

Enclosures

Conduits, Cable Trays, and Fittings

Cables

Terminations and Routing

Cable Reels

Trolley Cable Chain (Energy Chain)

Closed Circuit Television (CCTV)

Marking and Identification

Emergency Modes and Emergency Drives

Controls, Interlocks, and Indicating Devices

Programmable Logic Control (PLC)

PLC Program

Software Version Verification

Control Power Indicator

Anemometer

Emergency Stop Push Buttons

Crane Management System (CMS)

Control System and Network

Remote Crane Management System (RCMS)

Lighting

Convenience Outlets

Space Heaters

Lightning Protection

Intercom

Local Control Stations

Safety Equipment

Other Equipment Design

Operator's Cab

Spreader

Heavy Lift Cargo Beam

Machinery House and Electrical Room

In House Service Cranes

Outside the Machinery House Jib Structure or Monorail

Personnel Elevator

Safety Features

Wire Rope Re-Reeving

Load Weighing System

Wharf Level Cab

Crane Nameplates and Markings

Warning Signs

Test Weight System

Scale Models

Stairs, Ladders, Platforms, and Walkways

Fall Arrest Anchor Points

Automated Brake Tests

Stack Profiling System (SPS)

Air Compressor and Air Distribution System

Manufacture / Erection / Assembly

Corrosion Resistance

Surface Preparation

Paint Application

Faying Surfaces

Galvanizing

Workmanship

Structural Workmanship

Mechanical Workmanship

Electrical Workmanship

Coating

Software and Controls

PART 3.0 EXECUTION

Assembly and Erection

Erection Workmanship

Erection Program

Lubrication

Boom Alignment

Crane Weighing

Factory Inspection and Testing

Builder’s Test and Inspection

Government Drawing Verification

Factory Testing

Delivery

Installation and Inspection

Acceptance Test

Final Government Inspection

Acceptance

Training

Operator Training

Maintenance Training

Reliability and Maintenance Requirements

General

Minimum Reliability

Maintainability

Computerized Maintenance Management System

Special Tools

Spare Parts

Documentation

Operating Instructions

Maintenance Instructions and Manuals

Mechanical Maintenance Manuals

Electrical Maintenance Instructions - Drive System Supplier

Electrical Maintenance Manuals - Non-Drive Components

Structural Inspection Manual

As-Built Calculations

As-Built Drawings

Certificates

Test Documentation

APPENDICES

A –Reference Documents

A1 – Site plan

A2 – Crane and wharf clearance drawing

A3 – Control system inventory

A4 – Reference crane-wharf interface drawings

B – (Sample) Shop Testing Procedures

C – (Sample) Acceptance Testing Procedures

D – Safety

E – Essential Repair Part Stockage List

F – Structural Details for Cranes

PART 1.0 GENERAL

Definitions

Contractor – the Contractor supplying the Cranes and the Contractor’s representatives, subcontractors, and independent engineers retained by the Contractor.

Contractor’s Engineer of Record (Contractor’s EOR) – the Contractor’s professional engineers, for the design of the structure, ancillary structures, mechanical systems, and electrical systems, who shall be responsible for ensuring that the technical requirements of these Specifications are met. See Section 1.3.8 for other requirements, including for signing and sealing design drawings and calculations.

Crane, Cranes, or STS Cranes – the ship-to-shore, rail mounted, container handling gantry Cranes as described in these Specifications, including the structure, trolley, headblock, spreader, all attached and ancillary components, all control systems and components, all monitoring and maintenance systems and components, special tools, spare parts, and all other items defined in these Specifications.

Global Axis – Crane orientation and analysis axis system referenced in the Specification: X axis parallel to trolley travel, Y axis vertical, Z axis parallel to gantry travel.

MOTCO Facility – to be located at Military Ocean Terminal, Concord (MOTCO), Concord, California, USA. See Appendix A for site plan. See Section 0 for restrictions at the MOTCO Facility after delivery.

Point of Common Coupling (PCC) – The location where the Crane electrical system is connected to the wharf electrical system, defined as the end of the reeling cable where it terminates on the wharf furthest from the gantry cable reel on the Crane.

Specifications – This Specification, including appendices, and any clarifications, deviations, or other addenda agreed upon between the Government and the Contractor and incorporated into the Contract. The intent of these Specifications is to provide structural, mechanical, electrical, and functional criteria, dimensions, operating speeds and accelerations, and pertinent details for the design, construction, and installation of reliable and efficiently functioning Cranes with accessories. Unless specifically stated otherwise, the Specification requirements apply to all Cranes and all components, even if the requirement is stated in the singular. One gender means both genders.

Will and Shall – These Specifications are written to the Contractor. When a provision of this Specification requires action by the Contractor, the verb “shall” is used. If the Contractor is allowed to exercise an option when limited alternatives are available, the phrasing “either … or …” is used. However, where the words “or approved equivalent” are used, the Government reserves the option of rejecting the proposed equivalent. Statements provided in the Specification as information to the Contractor use the verbs “may” or “will.” Informational statements typically identify activities or options that “will be taken” or “may be taken” by the Government.

Specifications and Standards

General

The documents below form a part of this Specification to the extent specified herein. In case of difference between the following documents and this Specification, this Specification shall govern to the extent of such difference. In case of material specifications (ASTM), the design shall be based on the issue in effect at the time of bid, but material may be procured in accordance with the issue in effect at the date of manufacture.

Where reference is made to a standard specification, e.g., AWS D1.1, the latest edition in effect on the date of invitation for bids or request for proposal shall apply. If, however, the edition is stated, e.g., ISO 4628/3-1982(E), the stated edition shall apply.

US Domestic Codes and Standards and Specifications

FEDERAL

W-C-375 Circuit Breakers, Molded Case; Branch Circuit and Service

MILITARY

MIL-F-3541 Fittings, Lubrication

FED-STD-595C Color Used in Government Procurement

NAVY SEA SYSTEMS COMMAND (NAVSEA)

OP 3565 Vol. 1 Electromagnetic Radiation Hazards (U) (Hazards to Personnel, Fuel and Other Flammable Materials) (U)

OP 3565 Vol. 2 Electromagnetic Radiation Hazards (U) (Hazards to Ordnance) (U)

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

360 Specification for Structural Steel Buildings

ASSOCIATION FOR IRON AND STEEL TECHNOLOGY (AIST)

TR-06 Technical Report No. 6, Specification for Electric Overhead Traveling Cranes for Steel Mill Service

AMERICAN GEAR MANUFACTURERS' ASSOCIATION (ANSI/AGMA)

908 Geometry Factors for Determining the Pitting Resistance and Bending Strength of Spur, Helical and Herringbone Gear Teeth

2015 Gear Classification and Inspection Handbook – Tolerances and Measuring Methods for Unassembled Spur and Helical Gears (Including Metric Equivalents)

2001 Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth

2003 Rating the Pitting Resistance and Bending Strength of Generated Straight Bevel, Zerol Bevel and Spiral Bevel Gear Teeth.

2009 Bevel Gear Classification, Tolerances and Measuring Methods

6013 Spur, Helical, Herringbone, and Bevel Enclosed Drives

6109 For Shaft Mounted and Screw Conveyor Drives Using Spur, Helical and Herringbone Gears

AMERICAN IRON and STEEL INSTITUTE (AISI)

AISI 4320 Properties of alloy steel

AISI 4820 Properties of alloy steel

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ABMA 7 Shaft and Housing Fits for Metric Radial Ball and Roller Bearings (Except Tapered Roller Bearings)

A14.3 Ladders - Fixed - Safety

A17.1 Safety Code for Elevators and Escalators

A17.2 Inspectors Manual for Elevators and Escalators

A64.1 Walking and Working Surfaces, Personal Protective Equipment (Fall Protection Systems)

B4.1 Preferred Limits and Fits for Cylindrical Parts

B17.1 Keys and Keyseats

B30.10 Hooks

S1.13 Measurement of Sound Pressure Levels in Air

Z535 Product Safety Signs and Labels

Z26.1 Safety Code for Safety Glazing Materials for Glazing Motor Vehicles Operating on Land Highways

AMERICAN PETROLEUM INSTITUTE (API)

5LX Line Pipe

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE)

7-16 Minimum Design Loads and Associated Criteria for Buildings and Other Structures

49 Wind Tunnel Testing for Buildings and Other Structures

Paper # 3269 Wind Forces on Structures

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

B30.24 Container Cranes

B46.1 Surface Texture, Surface Roughness, Waviness, and Ly

HST-4 Performance Standard for Overhead Electric Wire Rope Hoist

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

TC-1A How to Qualify and Certify NDT Personnel

ASTM INTERNATIONAL (ASTM)

A6/6M General Requirements for Rolled Steel Plates, Shapes, Sheet Piling and Bars for Structural Use

A27 Mild to Medium Strength Carbon Steel Castings for General Application

A36 Structural Steel

A53 Welded and Seamless Steel Pipe

A106 Seamless Carbon Steel Pipe for High-Temperature Service

A108 Cold-Finished Carbon Steel Bars and Shafting

A123 Zinc Coating (Hot-Dip Galvanized) Coatings on Iron and Steel Products

A148 High-Strength Steel Castings for Structural Purposes

A153 Zinc Coating (Hot-Dip) on Iron and Steel Hardware

A159 Automotive Gray Iron Castings

A242 High-Strength, Low-Alloy Structural Steel

A275 Magnetic Particle Exam of Steel Forgings

A370 Mechanical Testing of Steel Products, Methods and Definitions

A434 Quenched and Tempered Alloy Steel Bars, Hot-Rolled or Cold-Finished

A500 Cold-Formed Welded and Seamless Carbon Steel Structural Tubing

A501 Hot-Formed Welded and Seamless Carbon Steel Structural Tubing

A504 Wrought Carbon Steel Wheels

A536 Ductile Iron Castings

A563 Carbon and Alloy Steel Nuts

A572 High-Strength Low-Alloy Columbium-Vanadium Steels of Structural Quality

A576 Special Quality Hot-Rolled Carbon Steel Bars

A588 High-Strength Low-Alloy Structural Steel

A618 Hot-Formed Welded and Seamless High-Strength Low- Alloy Structural Tubing

A666 Austenitic Stainless-steel, Sheet, Strip, Plate and Flat Bar for Structural Applications

A668 Alloy Steel Forgings for General Industrial Use

A673 Sampling Procedure for Impact Testing of Structural Steel

A709 Structural Steel for Bridges

A759 Carbon Steel Crane Rails

A1085 Cold-Formed Welded Carbon Steel Hollow Structural Sections (HSS)

B6 Zinc (Slab Zinc)

B148 Aluminum Bronze Sand Castings

B271 Copper-Base Alloy Centrifugal Castings

B505 Copper-Base Alloy Continuous Castings

B584 Copper Alloy Sand Casings for General Applications

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

C1036 Flat Glass

D4020-96 Ultra-High-Molecular-Weight Polyethylene Molding and Extrusion Materials

E23 Test Methods for Notched Bar Impact Testing of Metallic Materials

F436 Hardened Steel Washers

E543 Standard Specification for agencies performing Nondestructive Testing

F593 Stainless-steel Bolts, Hex Cap Screws, and Studs

F594 Stainless-steel Nuts

F3125 High Strength Structural Bolts, Steel and Alloy Steel, Heat Treated, 120 ksi (830 MPa) and 150 ksi (1040 MPa) Minimum Tensile Strength

AMERICAN WELDING SOCIETY (AWS)

A2.4 Welding Symbols

A4.3 Determination of the Diffusible Hydrogen Content of Martensitic, Bainitic, and Ferritic Steel Weld Metal Produced by Arc Welding

A5.1 Carbon Steel Electrodes for Shielded Metal Arc Welding

A5.5 Low-Alloy Steel Covered Arc-Welding Electrodes

A5.20 Mild Steel Electrodes for Flux-Cored Arc-Welding

C4.1 Oxygen-Cut Surfaces and Oxygen Cutting Surface Roughness Gauge

D1.1 Structural Welding Code

D1.3 Structural Welding Code-Sheet Steel

D1.5 Bridge Welding Code

ASSOCIATION OF IRON AND STEEL ENGINEERS (AISE)

No. 11 Brake Standards for Mill Motors

CRANE MANUFACTURERS' ASSOCIATION OF AMERICA, INC. (CMAA)

No. 70 Specifications for Electric Overhead Traveling Cranes

DEFENSE FEDERAL ACQUISITION REGULATIONS (DFAR)

DFARS 252.211-7003 Item Identification and Valuation

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

C37.20.1 IEEE Standard for Metal-Enclosed Low-Voltage Power Circuit Breaker Switchgear

C62.11 IEEE Standard for Metal-Oxide Surge Arresters for Alternating Current Power Circuits

JOINT INDUSTRIAL COUNCIL (JIC)

H-1-1973 Hydraulic Systems

NATIONAL ELECTRICAL MANUFACTURERS' ASSOCIATION (NEMA)

ICS 1 Industrial Control and Systems

ICS 1.1 Application, Installation and Maintenance of Solid State Control

ICS 2 Industrial Control Devices, Controllers and Assemblies

ICS 3 Industrial Systems

ICS 6 Enclosures for Industrial Control and Systems

ICS 9 Industrial Control and Systems Power Circuit Accessories

LI 1 Industrial Laminated Thermosetting Products

LS 1 Low Voltage Surge Protective Devices

MG1 Motors and Generators

250 Enclosures for Electrical Equipment (1000 Volts Maximum)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 National Electrical Code

NFPA 70E Standard for Electrical Safety in the Workplace

NFPA 780 Standard for the Installation of Lightning Protection Systems

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

Title 29 CFR, Part 1910

PACIFIC COAST MARINE SAFETY CODE (PCMSC)

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

RCSC Specification for Structural Joints Using High-Strength Bolts

STATE OF CALIFORNIA THE DIVISION OF OCCUPATIONAL SAFETY AND

HEALTH (DOSH)

Title 8 Regulations/Inspections for Cranes and Elevators

SOCIETY OF AUTOMOTIVE ENGINEERS, INC. (SAE)

J386 Operator Restraint System for Off-Road Work Machines

J429 Mechanical and Material Requirements for Externally Threaded Fasteners

J995 Steel Nuts

STEEL STRUCTURES PAINTING COUNCIL (SSPC)

SP Surface Preparation

SP 1 Solvent Cleaning

SP 2 Hand Tool Cleaning

SP 3 Power Tool Cleaning

SP 6 Commercial Blast Cleaning

SP 10 Near-White Metal Blast Cleaning

PA Paint Application

PA 2 Conformance to Coating Thickness Requirements

STRUCTURAL STABILITY RESEARCH COUNCIL (SSRC)

SSRC Guide to the Stability Design Criteria for Metal Structures

UNDERWRITERS LABORATORIES (UL)

595 Marine-Type Electric Fixtures

WIRE ROPE TECHNICAL BOARD

Wire Rope User’s Manual

International Codes and Standards

BRITISH STANDARDS (BS)

7608 Guide to fatigue design and assessment of steel products, 2014 edition

CONFORMITE EUORPEENE (CE)

2006/42/EC Machinery Directive

73/23/EC Low Voltage Directive

89/336/EC EMC Directive

DEUTSCHES INSTITUT fur NORMBURG (DIN)

DIN 15072 Crane, tread profile of crane rail wheels and table of rails for different wheel diameters

DIN 536 Crane Rails

DIN 16783 Ultra-high molecular weight polyethylene moulding materials

DIN 6914 High-strength hexagon head bolts with large widths across flats for structural steel bolting

DIN 17200 Carbon Steel Grades

DIN 18800 Structural Steelwork

DIN 15018 Crane, steel structures, verification and analysis

FEDERATION of EUROPEAN MATERIAL HANDLING (FEM)

FEM 1.001 Rules for the design of hoisting appliances

FEM 1.004 Recommendation for the calculation of wind loads on crane structures

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 7778 Steel plate with specified through-thickness characteristics

ISO 9001 Quality Systems-Model for Quality Assurance in Design, Development, Production, Installation, and Servicing

INTERNATIONAL SOCIETY of AUTOMATION (ISA)

ISA Hydraulic Systems

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

60204-32 Safety of Machinery – Electrical Equipment of Machines, Part 32

60034-14 Rotating Electrical Machines

Substitution of Codes

The Crane Contractor may select other DIN, FEM, JIS, ISO or BSI codes as applicable as the basis of Crane design in lieu of the referenced codes, provided the Contractor can show, by certification or industry publications, that these codes are equivalent to (meets or exceeds) the codes, with the exception of AISC, ASTM, AWS, NEMA, NFPA, and OSHA which shall govern in any case. If the Contractor selects one of these codes for design of the Cranes, the Contractor shall provide three current English language copies of the code, within 30 days after contract award. Once a code is selected for design, it shall be used for all portions of the Cranes.

Example of List of Codes Used in Industry Procurement Specifications

Unless otherwise noted, the applicable recommendations of the following organizations shall be used. Unless otherwise noted, ‘National’ means USA.

ABBREVIATION STANDARD

ABMA American Bearing Manufacturers Association

AGMA American Gear Manufacturers Association

AISC American Institute of Steel Construction - ASD

AISI American Iron and Steel Institute

AIST Association of Iron and Steel Technology (formerly AISE)

ANSI American National Standards Institute

ASA Acoustical Society of America

ASCE American Society of Civil Engineers

ASM American Society for Metals

ASME American Society of Mechanical Engineers

ASNT American Society for Nondestructive Testing

ASTM American Society for Testing and Materials

AWS American Welding Society - Bridges and Dynamically Loaded Structures

BSI British Standards Institute

CMAA Crane Manufacturer’s Association of America

DIN Deutsche Industrie Normen

DOSH Division of Occupational Safety and Health

EN European Standards

FEM Federation Europeene de la Manutention

IEC International Electrotechnical Commission

IEEE Institute of Electrical and Electronic Engineers

ISA Instrument Society of America

ISO International Standards Organization

NAAMM National Association of Architectural Metal Manufacturers

NEMA National Electrical Manufacturer’s Association

NFPA National Fire Protection Association

NFPA National Fluid Power Association

OSHA Occupational Safety and Health Administration of the United States Department of Labor

PCMSC Pacific Coast Marine Safety Code

SAE Society of Automotive Engineers

SSPC Steel Structures Painting Council

SSRC Structural Stability Research Council

UL Underwriters Laboratory

System Description and Scope of Supply

Scope of Supply

The intent of this Specification is to procure two (2) rail-mounted ship-to-shore container Cranes, to be located at Military Ocean Terminal, Concord (MOTCO), Concord, California.

Crane capacity shall be 40 long ton below the spreader, and the Cranes shall be able to service a Panamax vessel with 13 containers abeam. See Appendix A2, The Cranes shall be equipped with a spreader capable of lifting both single and twin 20-foot containers, single 40-foot containers, and single 45-foot containers. The Cranes shall be designed, fabricated, assembled, facility tested, delivered, installed, inspected, field tested and commissioned, and made ready for use in accordance with this Specification.

The scope of supply shall include the following, as described in this Specification:

Two (2) ship-to-shore Cranes, including rope-towed trolleys (RTT) with main hoist fleet-through reeving and headblocks

Three (3) telescoping 20 ft, 40 ft, 45 ft, separating twin-20 ft spreaders; this includes one (1) spare; refer to Section 2.5.2

One (1) heavy lift cargo beam (total for project); refer to Section 2.5.3

Test weights; refer to Section 2.5.14

Scale model and souvenir models; refer to Section 2.5.15

Initial spare parts; refer to Section 3.8.6

Significant technical features of the Crane include the following.

Local Crane management system (CMS) 2.4.29

Closed circuit television system (CCTV), refer to Section 2.4.19

Hatchcover storage platform on the Crane, landside of the landside rail; refer to Section 2.2.18

Fire detection and suppression system; refer to Section 2.5.4.9

Vessel Profiling System, also known as “stack profiling system” (SPS) and Soft Landing System (part of SPS); refer to Section 2.5.19

Detailed operation and maintenance manuals in English

Electronic security requirements - such as restrictions for WiFi, Bluetooth, internet, etc.;

refer to Section 2.4.30

USA Professional Engineer as Engineer of Record; refer to Section 1.3.8

Crane structure consideration for operations on flexible wharf; refer to Section Error!

Reference source not found.

Minimum Criteria

The criteria specified herein shall be considered the minimum acceptable. If, in the Contractor’s opinion, any of the criteria specified herein or in the referenced standards is in any way inadequate or insufficient for the intended use, it shall be the Contractor’s responsibility to use more stringent criteria.

Except where otherwise specified, the Contractor shall furnish all materials, equipment, tools, labor, and incidentals necessary to fully and completely finish the project according to the true intent and meaning of this Specification and drawings, even though every item or activity is not particularly mentioned or shown in this Specification or drawings.

The Contractor shall remain responsible for adequacy and safety of the design, fabrication, supply, installation, transportation, commissioning, and testing of the equipment specified herein while adhering to the minimum criteria set forth in the Specifications.

Safety Design Criteria

A single electric (power or control) or hydraulic component failure or malfunction shall not damage the Crane or injure personnel.

Where possible, component failure or malfunction shall safely stop the Crane operation. Where this is not possible, a redundant system shall be supplied. The redundant system shall both safely stop the Crane and prevent operation until maintenance personnel make corrections.

A means shall be provided so maintenance personnel may routinely check each redundant or backup system. The checking procedure shall be included in the maintenance manual.

No Crane component shall change state as a result of a power failure. Powering or repowering the Crane or any system within the Crane shall not result in any unanticipated or potentially unsafe motion or condition.

Design Requirements

The Cranes shall, as a minimum, conform to the requirements of the Machinery Directive 2006/42/EC, the Low Voltage Directive 73/23/EC and the EMC Directive 89/336/EC.

Basic Crane design shall be a twin-box girder with a rope-towed trolley, catenary trolleys, and fleet-through main hoist. The hoist machinery shall be enclosed in a separate machinery house.

The machinery house shall include separate rooms for the hoist machinery and all electronic equipment. The electronic control room shall be separately climate controlled. Entrance and egress to the Cranes shall be via both a combination of ladders and stairways, and an elevator on the same landside leg as the cable reel, unless approved otherwise by the Government.

The Cranes shall be equipped with a spreader capable of lifting a single 20-foot container, twin- 20-foot containers, single 40-foot container, and a single 45-foot container. Crane shall have a means of stowing hatches on the landside of the Crane within the backreach of the trolley girder, so as not to infringe on the operating area between the Crane legs. Provisions also shall be made to lift other cargo using temporary slings.

The Crane shall be designed to operate in an outdoor, corrosive marine environment with an ambient temperature range of 20 °F to 110 °F.

Each Crane shall have a Crane number independent of the manufacturer’s serial number. The Crane numbers format shall be the year of manufacture-001 and -002, e.g. 2019-001 and 2019-002 if the Cranes are built in 2019.

The main characteristics of the Cranes are as follows. See the Appendix A2, Crane and Ship Clearance Drawing, for additional requirements.

Capacity

Capacity below the spreader

Twin-twenty 89,600 lb (40 LT, 44.8 t)

Single lift 67,200 lb (30 LT, 33.6 t)

Capacity below the heavy lift cargo beam 89,600 lb (40, 44.8 t)

Principal Dimensions

Gantry rail gauge 80 ft (21.384 m)

Outreach, minimum 127 ft (38.7 m)

Backreach, minimum 35 ft (10.7 m)

Lift height, clear under spreader above WS rail 100 ft (30.5 m)

Lift below waterside rail 35 ft (10.7 m)

Gantry out-to-out width (bumpers uncompressed) 88 ft 6 in (27.0 m)

Minimum clearance inside legs 60 ft (18.3 m)

Clearance under portal tie beam 50 ft (15.2 m)

Waterside rail setback from fender face 12.75 ft (3.9 m)

Boom stowage angle 45° (80° maintenance only)

Rail elevation, waterside vs. landside Same elevation

Allowable Crane Loads on Wharf

Maximum Allowable Service (ASD) Level Wheel Loads

Seaside Operating 30,000 lb/ft (44.7 t/m)

Landside Operating 31,000 lb/ft (46.1 t/m)

Seaside Non-Operating 30,000 lb/ft (44.7 t/m)

Landside Non-Operating 39,000 lb/ft (58.1 t/m)

Maximum Allowable Strength (LRFD) Level Wheel Loads

Seaside Operating 39,000 lb/ft (58.1 t/m)

Landside Operating 40,000 lb/ft (59.5 t/m)

Seaside Non-Operating 39,000 lb/ft (58.1 t/m)

Landside Non-Operating 52,000 lb/ft (77.4 t/m)

Refer to Appendix A4, drawing S-002 for additional maximum crane loads to the wharf, including crane rail lateral loads, crane stowage pin, and crane stop loads.

135 ft (41.2 m) total lift

Performance Requirements

Performance requirements for the Cranes shall be as follows:

Minimum Hoist High Speeds:

No Load under spreader 490 ft/min (150 m/min)

Rated Load under spreader 250 ft/min (76 m/min)

Hoist Acceleration/Deceleration

No Load 4 s

Rated Load 2 s

Minimum Trolley Speed:

With Rated Load 600 ft/min (180 m/min)

Trolley Acceleration/Deceleration

With Rated Load 5 s

Maximum Boom Hoisting Time 5 min

Minimum Gantry Travel High Speed 150 ft/min (45 m/min)

Minimum Gantry Acceleration 6 s

Unique Identifier Tags

The Contractor shall assign unique identifiers to the container Crane and the in-house service cranes in accordance with DFARS 252.211-7003. The Unique Identification Tags shall be attached to the outside of the main electrical disconnect panel of the respective Crane.

Essential Repair Parts

The Contractor shall provide the parts defined in Section 3.8.6.3 and those listed in the Appendix E, Essential Repair Part Stockage List.

After the completion of the design, the Contractor shall provide a list of any additional spare parts with prices for the Government’s consideration and potential purchase.

Submittals

The Contractor shall submit to the Contracting Officer all items of technical documentation listed hereinafter. The Contractor shall ensure that all submittals are entirely legible and suitable for reproduction. The content, number of copies, time of submission, and distribution shall be in accordance with Exhibit A of this Specification and as specified below. Compliance with the requirements of this Specification will be determined by a review of the design and construction submittals by the contracting officer and by field inspection and testing.

The Contractor’s EOR for each discipline shall be a professional engineer registered in the United States. The structural analysis of the Crane and drawings for the crane and trolley primary structures shall be approved by the Contractor's responsible Structural Engineer, who shall be a licensed Structural Engineer in the State of California.

Final design drawings and calculations shall be signed and sealed by the Contractor’s EOR. The intent is to include the structural, mechanical, and electrical systems.

However, this requirement is not intended to include shop drawings, third-party vendor drawings, or ancillary drawings that have no significant impact on the project or that require no engineering. The Contractor shall submit a list of components for which drawings and calculations will need seal and signature—the Contractor shall submit a detailed list of drawings and calculations that will and will not be signed for Government review and approval.

All Crane documentation and submittals shall be in English. Units shall be in U. S. Standard Units or SI Units.

All applicable submittals shall also be provided for the machinery house service crane and any associated lifting gear.

The submittal transmission documents shall clearly identify CDRL Item Number, Crane number and title as a minimum.

SD-01 Preconstruction Submittals

Prior to construction, the Contractor shall submit the following.

SD-01.S Schedule

The Contractor shall submit a schedule which identifies key milestone events in the design, fabrication, and installation of the Crane acquisition. At a minimum, the schedule shall include the following:

1. Post Award Meeting

2. Initial General Arrangement and Design Submittals

3. Government Review of First Design

4. Second General Arrangement and Design Submittals

5. Government Review of Second Design

6. Third General Arrangement and Design Submittals

7. Government Review of Third Design

8. Fabrication Initiation

9. Fabrication Completion

10. On-Site Pre-Installation Conference

11. Government Witnessed Shop Test

12. Contractor Site Mobilization

13. New Crane Installation

14. Government Crane Inspection

15. Field Acceptance Test

16. Crane Acceptance

17. Contract Completion Date

18. Receipt of Final O&M Manuals

19. Completion of Warranty

SD-01.Q Quality System

The Contractor shall submit, prior to fabrication, the written quality control plan for review. The plan shall be followed throughout the contract; any changes shall be submitted to the Contracting Officer. As a minimum, the plan shall include the following:

1. Incoming materials, consumables and machinery

2. Traceability of material

3. Lofting, cutting, fit-up, welding, forming and dimensions of structural materials

4. Welding and inspection procedures

5. Welding and inspection personnel qualification and certification

6. Welding and inspection equipment maintenance and calibration

7. Heat treating, stress relieving and other special treatments

8. Machining, finish surfaces, painting and bolting

9. Installation and alignment

10. Startup and Commissioning Tests

11. Functional Testing

SD-01.I Inspection Specification

Prior to completing the design and before commencing fabrication of the Cranes, the Contractor shall prepare, submit, and obtain the Contracting Officer's approval for inspection specifications. The Contractor shall write inspection specifications for mechanical and electrical components and structural assemblies. During fabrication the approved inspection specifications shall be utilized by the Contractor’s QA personnel to document various measurements and inspections, the partially completed inspection specifications shall be submitted to the Contracting Officer monthly for review. Submit completed inspection specifications upon completion of the contract.

SD-02 Drawings

The Contractor shall submit the drawings listed below for approval. Initial drawing submittals (preliminary, 90%, and final) shall bear a complete title block with a permanent drawing number and a registered professional engineer’s original seal with a dated signature. Subsequent submittals shall bear a new revision number and engineer’s seal with a dated signature for each sheet that has been modified.

The Contractor shall provide design submittals in three phases throughout the process of developing the Crane design.

The first submittal shall be a preliminary design. The preliminary design shall include the following: general arrangements, preliminary Crane stability, maximum wheel loads, selection of components for commonality, failsafe devices and features, ease of maintenance, and design factors utilized. The purpose of the initial submittal and review process is to identify and resolve problems early in the design phase.

The second design submittals shall be a 90% design submittal. The 90% design submittal shall include drawings required in SD-02, product data required in SD-03, and design calculations required in SD-04.

The third design submittal shall be the final 100% design submittal.

The final 100% design submittal shall be approved by the Government. The Government review and approval process does not relieve the Contractor from the responsibility for all aspects of the design of the Crane.

Fabrication of a specific assembly may commence after all submittal components for that assembly are “Approved” by the Government. This approval does not relieve the Contractor of his responsibility to comply with contract requirements.

Drawings within each category (such as structural, mechanical, etc.) shall be numbered consecutively. Each assembly and subassembly drawing shall include an integral Bill of Materials or shall be followed by a consecutively numbered drawing with the applicable Bill of Materials. There shall be no proprietary notes on any drawing. An index for all drawings shall be included.

Preliminary, 90%, and final design drawings shall be provided as a file viewable in Adobe Acrobat as a bookmarked portable document format (.pdf). PDF files shall be black/white with minimum resolution of 600 dpi. Filenames shall be in English.

As-built drawings shall be provided in the following formats:

1. As an editable file in the file format of the program it was originally generated in.

2. As a file in the file format of .dxf or .dwg editable in AutoCAD 2016.

3. A separate copy viewable in Adobe Acrobat as a bookmarked portable document format (.pdf).

NOTE: Applicable drawings listed below shall also be included for the elevator system, machinery house service crane, and all other buy-out assemblies or components as applicable.

SD-02.G General Arrangement Drawings

The Crane assembly and each major component shall be shown in plan, elevation, and end views. All major features of the Crane shall be shown including: clearances, dimensions, lifts, speeds, maximum wheel loads and power supply. The machinery house general layout shall include general locations of major components such as: brakes, motors, speed reducers, gear boxes, walkways, and control panels (including size). The type of structural bolted connection shall be specified on the drawing. In addition, calculated weights shall be shown for the completely assembled Crane and for each major component.

SD-02.B Control System Supplier’s Scope of Supply

The scope of supply, without pricing, from the Control System Supplier shall be provided. The scope of supply shall clearly describe all equipment and services the Control System Supplier is responsible for providing.

SD-02.S Structural Drawings

The structural design drawings shall show the fabrication details, weldments, fastener joint details, Bill of Materials and location and size of all structural members. The fabrication details shall clearly show the size, section, material grade and location (dimensions) of all members; all geometry necessary for layout; elevations; centers and offsets; camber requirements; and joining requirements between elements of built-up elements. Other critical information that shall be provided on the structural design drawings includes the welded-joint configuration. Fastener Joints - Structural joints designed as slip critical shall be labeled as slip critical on drawings. All other structural joints shall be labeled, and the required tensioning methods provided. All members required for fabrication shall be shown on drawings and shall be labeled to correspond with the Bill of Materials.

Structural drawings shall be provided for the following as a minimum:

1. Crane frame

2. Boom and trolley girder

3. Boom hinge

4. Boom latch

5. Trolley rail support at boom hinge

6. Forestay and backstay system

7. Gantry equalizers and trucks

8. Machinery house layout, foundation and support for all components

9. Counterweight or ballast

10. Walkway and ladder fabrication

11. Stowage pin

12. Lifting lugs

13. Trolley frame

14. Operator’s cab

15. Operator vision drawing

16. Quay layout including Crane interface systems layout

17. Crane stops

18. Crane transport and offload, including bracing

SD-02.E Electrical Drawings

The drawings shall at a minimum include:

1. Complete schematic diagram with narrative of any special description of operation. All components shown on schematics shall have labels that correspond to the nameplates that will be on the Cranes. Wiring type, size, and temperature ratings shall be included on schematic diagrams. All optional equipment not installed on the Crane shall be removed from the schematic diagrams. Locations of contacts and coils shall be cross-referenced to each other within the schematic diagrams. For components with adjustable settings, final settings shall be shown on the schematics.

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

3. Rating and types of over-current protective devices

4. Complete assembly (wiring) diagrams including a component material list showing all electrical components used on the Crane. These drawings shall show the layout of electrical equipment on the Crane, including control panel enclosures, motors, brakes, limit switches, conduits, and conductor systems.

5. Power demand, power factor and harmonics data

6. List of used symbols and designations

7. Grounding system, earthing system and lightning (SPD) protection including location of air terminals

8. Communication drawing of the Programmable Logic Control (PLC) system and the Crane Management System (CMS)

9. Electrical/PLC room layout diagrams.

10. Panel layout diagrams.

11. One-line diagram with circuit breaker sizing

12. Circuit diagram

13. Medium Voltage (MV) equipment arrangement with grounding switch

14. MV panel wiring diagram, MV & control

15. MV key interlock diagram

16. Drive and auxiliary transformer primary and secondary overcurrent protection

17. Drive and auxiliary transformer secondary short circuit and ground detection protection

18. Motor details including torque curves

19. Location and mounting of limit switches, encoders, and devices

20. Conduit & cable trays including routing, underfloor and external to machinery house

21. Layouts of all junction boxes

22. Floodlight illumination and arrangement, circuit segregation

23. Walkway lighting illumination and arrangement, emergency power light arrangement

24. Camera arrangement and layout of CCTV equipment

25. Anti-collision sensor arrangements and sensor details

26. FAA lights

27. Spare parts list, drives, motors, circuit breakers/fuses, controls, communications, PLC

SD-02.M Mechanical Drawings

1. Drive arrangements (including assembled components)

2. Reeving diagram for hoists and trolley, including catenaries

3. Travel trucks arrangements

4. Travel wheels dimensional and assembly including wheel material, wheel tread hardness, wheel to axle fit and assembly cross section details with the end truck frames.

5. Hydraulic systems diagram and schematic

6. Air compressor system

7. Lubrication drawing showing lubrication points

8. Jacking arrangement

9. Gear documentation

10. All drums

11. Sheave dimensional and assembly for top and equalizer sheaves including sheave material, sheave groove hardness and assembly cross section details with the structure that the assembly is mounted on.

12. Trolley assembly

13. Wheel axles

14. Shafts and pins

15. Base mounted component and coupling bolt torque values. Torque values shall be tabulated on drawing and shall consider any lubrication and/or washer types used. Torque values may be on a separate drawing that includes the mechanical arrangement and location of each bolt listed, or they may be listed on the drawing where the torqued bolts are shown.

16. Coupling and brake installation including: locations, applicable shaft engagement, and bore and key details.

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

SD-02.C Control System and Network Drawings

1. Network diagram must show equipment locations, names, models, and IP addresses on network communications schematic for all PLC, RTU, Supervisory Controller, and Other Network-Capable Devices

2. Software block, flow, and ladder diagrams

3. Layout diagrams for all operator’s stations and cabs showing component placement.

SD-02.D Detail Shop Drawings

Drawings shall show all the information necessary for the fabrication of all parts of the Cranes (except for standard commercial purchased assemblies). The drawings shall specify member size, dimensions with tolerances, surface finishes (roughness symbols), complete material designations, heat treatment, material hardness, ultimate tensile strength, welding symbols, nondestructive testing symbols, complete gear data, etc., as applicable. The drawings shall specify complete information as to the location, type, and extent of all welds. In welded joints where it is important to control shrinkage stresses and distortion, the sequence and technique of the welding process shall be shown. Post-weld heat treatment (such as stress relieving) of high strength steel parts, if employed, shall be recorded on the drawings. Provide ASTM or AISI equivalent designations for non-USA products along with hardening, annealing, or quenching requirements. If Contractor has documentation of standard NDT or weld separate from the drawing(s), the Contractor may submit this to the Government for approval in lieu of showing the requirements on the drawing(s).

SD-02.F Field Notification of Revision (FNR)

During fabrication, erection and testing, the Contractor shall maintain two sets of prints that shall be marked to show modifications required on the drawings so that they accurately reflect the actual condition of the Crane at the time the Crane is offered for acceptance. Each modification shall be documented in an FNR report. The FNR shall list the drawing number, the department issuing the FNR, name and signature of the Contractor representative authorizing the FNR, date, Crane number, a sequential FNR number, reason for the FNR, and a description of the change. Attached to the FNR shall be the marked-up drawing or a copy of the affected area of the drawing with the changes noted. All FNR’s must be submitted to the Government.

SD-03 Product Data

Manufacturer’s catalog data shall be provided for all purchased components of the Cranes and the machinery house cranes. The catalog cuts shall be marked-up or supplemented with additional sheets to clearly identify the model or size, selected options, features, and/or modifications to demonstrate compliance with Specification requirements.

Catalog cuts which show modifications beyond the standard options and all supplemental pages shall bear original signatures and dates of the equipment manufacturer’s authorized representative. Each catalog cut sheet and each supplemental sheet shall clearly identify the item to which it applies. All catalog cuts shall be submitted in one file viewable in Adobe Acrobat and bookmarked as to the location of each catalog cut. The Contractor shall submit for approval the catalog cuts listed below:

NOTE: Applicable catalog cuts listed below shall also be included for the elevator system and machinery house service crane.

SD-03.M Mechanical Product Data

SD-03.M1 Speed reducers including reduction ratio, service factors, detailed drawings of components including gearing and shafts, and ratings for power, torque, and speed

SD-03.M2 Brakes (including electrical information, installation/service manuals and all information required to set or adjust)

SD-03.M3 Packaged hoist (machinery house service crane)

SD-03.M4 Bearings

SD-03.M5 Bumpers and end stops

SD-03.M6 Couplings

SD-03.M7 Load blocks

SD-03.M8 Hook

SD-03.M9 Wheels and sheaves

SD-03.M10 Spreader

SD-03.M11 Wire ropes

SD-03.E Electrical Product Data

SD-03.E1 Variable frequency drives and data recorders (including dynamic braking resistor and reactor selection)

SD-03.E2 Motors and encoders

SD-03.E3 Electrical enclosures

SD-03.E4 Runway electrification

SD-03.E5 Limit switches

SD-03.E6 Trolley electrification

SD-03.E7 Warning and pilot devices

SD-03.E8 Encoders

SD-03.E9 Disconnect switches

SD-03.E10 Fuses and circuit breakers

SD-03.E11 PLCs

SD-03.E12 Lighting

SD-03.E13 Contactors and relays

SD-03.E14 Operator controllers

SD-03.E15 Heating, ventilation, and air conditioning

SD-03.E16 Load indication system

SD-03.E17 Collision avoidance system

SD-03.E18 Cables including medium voltage, variable frequency, reeling, power, control, and data

SD-03.E19 Junction boxes, conduit, conduit fittings, cable trays

SD-03.E20 CCTV cameras and equipment

SD-03.S Structural Product Data

SD-03.S1 Travel trucks (including drive units)

SD-03.S2 Rails

SD-03.S3 Painting system

SD-03.S4 Lift points

SD-03.S5 Swing gates

SD-03.C PLC, RTU, Supervisory Controller, Control System Workstation, and Other Network-Capable Devices

Contractor shall ensure the following is provided in the product data for PLC, RTU, Supervisory Controller, or other network-capable (whether networked or not upon delivery) control devices:

(a) Draft hardware list (Hardware list must include the following for each device):

i. Manufacturer,

ii. Model,

iii. Location,

iv. Key technical ratings (e.g. memory),

v. Serial number

vi. MAC addresses,

vii. IP addresses.

(b) Software List (Software list must include the following for each device):

i. Manufacturer

ii. Version/subversion,

iii. Location/device,

iv. Used network ports/protocols/services.

(c) List and discussion of all security features of Vendor hardware and software.

SD-04 Design Data and Calculations

These calculations shall demonstrate compliance with all design requirements of this Specification. Calculations will not be approved if their evaluation/review is dependent on data or information not previously approved. All variables shall be listed and defined at the beginning of each calculation section and variables shall be in accordance with required references. Drawings shall include complete information so that they may be approved without reference to detail (shop) drawings.

SD-04.S Structural Calculations

SD-04.S1 Table of contents

SD-04.S2 General description of computer programs used with definitions of any special terminology

SD-04.S3 Summary of structural design criteria, including:

Listing of the governing specifications

Listing of all vertical loads; Crane weight shall be provided with centers of gravity, broken down by major component.

Calculations for determining the magnitude of each design load (if a dynamic analysis is used to determine impact loads, this analysis may be submitted separately).

Wind load operating (in service)

Wind load storm (out of service)

Load combinations for stress, stability, and wheel loads

Allowable stresses

Crane stiffness criteria, including for operating on flexible wharf

SD-04.S4 Computer output for the gantry frame and boom including the following information

Sketches showing computer input data including geometry, node numbers, member numbers, global axis, local axis, member properties and boundary restraints

Member forces for each of the specified individual loads—for moving loads, results need not be given for all members for each moving load position; however, maximum and minimum forces and the corresponding moving load positions shall be provided for all members

Displacements at appropriate joints for each of the specified individual loads

Sum of forces at each node; computer results will not be accepted if this summary shows significant round-off error

Stress calculations for members; stress calculations…