Specs_Pt.6.pdf

TEMF 26041 Fort Hood, Texas

CORRECTED FINAL

3.1.2.2 Fertilizer Application Rates

Apply fertilizer at rates as determined by laboratory soil analysis of the soils at the job site.

3.2 SODDING

3.2.1 Finished Grade and Topsoil

Prior to the commencement of the sodding operation, the Contractor shall verify that finished grades are as indicated on drawings; the placing of topsoil, smooth grading, and compaction requirements have been completed in accordance with Section 31 00 00 EARTHWORK.

The prepared surface shall be a maximum 1 inch below the adjoining grade of any surfaced area. New surfaces shall be blended to existing areas. The prepared surface shall be completed with a light raking to remove from the surface debris and stones over a minimum 5/8 inch in any dimension.

3.2.2 Placing

Place sod a maximum of 36 hours after initial harvesting, in accordance with TPI GSS as modified herein.

3.2.3 Finishing

After completing sodding, blend edges of sodded area smoothly into surrounding area. Air pockets shall be eliminated and a true and even surface shall be provided. Frayed edges shall be trimmed and holes and missing corners shall be patched with sod.

3.2.4 Watering

Start watering areas sodded as required by daily temperature and wind conditions. Apply water at a rate sufficient to ensure thorough wetting of soil to minimum depth of6 inches. Run-off, puddling, and wilting shall be prevented. Unless otherwise directed, watering trucks shall not be driven over turf areas. Watering of other adjacent areas or plant material shall be prevented.

3.3 PROTECTION OF TURF AREAS

Immediately after turfing, protect area against traffic and other use.

3.4 RESTORATION

Restore to original condition existing turf areas which have been damaged during turf installation operations. Keep clean at all times at least one paved pedestrian access route and one paved vehicular access route to each building. Clean other paving when work in adjacent areas is complete.

-- End of Section --

SECTION 32 92 23 Page 6

SECTION 41 22 13.13

BRIDGE CRANES

04/08

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

ANSI/AGMA 2001 (2004D; R 2010) Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth

ANSI/AGMA 2015-1 (2001A; R 2014) Accuracy Classification System - Tangential Measurements for Cylindrical Gears

ANSI/AGMA 6013 (2006A; R 2011) Standard for Industrial Enclosed Gear Drives

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 (2017) Steel Construction Manual

AMERICAN WELDING SOCIETY (AWS)

AWS D14.1/D14.1M (2005; Amd 1 2017) Specification for Welding of Industrial and Mill Cranes and Other Material Handling Equipment

ASME INTERNATIONAL (ASME)

ASME B30.10 (2014) Hooks

ASME B30.16 (2017) Overhead Underhung and Stationary Hoists

ASME B30.17 (2015) Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung Hoists)

ASME B30.2 (2017) Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist)

ASME HST-1 (2012) Performance Standard for Electric Chain Hoists

ASME HST-4 (2016) Performance Standard for Overhead Electric Wire Rope Hoists

ASME NOG-1 (2015) Rules for Construction of Overhead

SECTION 41 22 13.13 Page 1 and Gantry Cranes (Top Running Bridge, Multiple Girder)

ASTM INTERNATIONAL (ASTM)

ASTM A1023/A1023M (2015) Standard Specification for Stranded Carbon Steel Wire Ropes for General Purposes

ASTM A159 (1983; R 2011) Standard Specification for Automotive Gray Iron Castings

ASTM A275/A275M (2015) Standard Test Method for Magnetic Particle Examination of Steel Forgings

ASTM A307 (2014; E 2017) Standard Specification for Carbon Steel Bolts, Studs, and Threaded Rod 60 000 PSI Tensile Strength

ASTM A325 (2014) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A490 (2014a) Standard Specification for Structural Bolts, Alloy Steel, Heat Treated, 150 ksi Minimum Tensile Strength

ASTM A563 (2015) Standard Specification for Carbon and Alloy Steel Nuts

ASTM A668/A668M (2017) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM A931 (2008; R 2013) Standard Test Method for Tension Testing of Wire Ropes and Strand

ASTM B438 (2017) Standard Specification for Bronze-Base Powder Metallurgy (PM) Bearings (Oil Impregnated)

ASTM B439 (2008) Standard Specification for Iron-Base Sintered Bearings (Oil-Impregnated)

ASTM E125 (1963; R 2013) Photographs for Magnetic Particle Indications on Ferrous Castings

ASTM F436 (2011) Hardened Steel Washers

ASTM F959/F959M (2017) Standard Specification for Compressible-Washer-Type Direct Tension Indicators for Use with Structural Fasteners, Inch and Metric Series

CRANE MANUFACTURERS ASSOCIATION OF AMERICA (CMAA)

CMAA 70 (2015) Specification for Multiple Girder Cranes

SECTION 41 22 13.13 Page 2

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2014) Enclosures for Electrical Equipment (1000 Volts Maximum)

NEMA ICS 2 (2000; R 2005; Errata 2008) Industrial Control and Systems Controllers, Contactors, and Overload Relays Rated 600 V

NEMA ICS 5 (2017) Industrial Control and Systems:

Control Circuit and Pilot Devices

NEMA ICS 6 (1993; R 2016) Industrial Control and Systems: Enclosures

NEMA ICS 8 (2011) Crane and Hoist Controllers

NEMA MG 1 (2016; SUPP 2016) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2017; ERTA 1-2 2017; TIA 17-1; TIA 17-2;

TIA 17-3; TIA 17-4; TIA 17-5; TIA 17-6;

TIA 17-7; TIA 17-8; TIA 17-9; TIA 17-10;

TIA 17-11; TIA 17-12; TIA 17-13; TIA

17-14) National Electrical Code

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC SP 6/NACE No.3 (2007) Commercial Blast Cleaning

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910 Occupational Safety and Health Standards

29 CFR 1910.147 The Control of Hazardous Energy (Lock Out/Tag Out)

29 CFR 1910.179 Overhead and Gantry Cranes

29 CFR 1910.306 Specific Purpose Equipment and Installations

UNDERWRITERS LABORATORIES (UL)

UL 1004-1 (2012; Reprint Aug 2017) UL Standard for Safety Rotating Electrical Machines - General Requirements

UL 1449 (2014; Reprint Jul 2017) UL Standard for Safety Surge Protective Devices

UL 489 (2016) UL Standard for Safety Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosures

SECTION 41 22 13.13 Page 3

1.2 DEFINITIONS

a. Crane Bridge: That part of an overhead crane system consisting of girder(s), end trucks, end ties, walkway, and drive mechanism which carries the trolley(s) and travels along the runway rails parallel to the runway.

b. Crane Runway: The track system along which the crane operates horizontally, including track hangar rods, track connection devices, and runway structural supports.

c. Dead Loads: The loads on a structure which remain in a fixed position relative to the structure.

d. Girder: The principal horizontal beam of the crane bridge. It is supported by the crane end trucks. Normally the crane trolley mounted hoist is suspended from the girder below the crane.

e. Live Load: A load which moves relative to the structure under consideration.

f. Pendant: A control for a hoist and/or a crane. The pendant hangs from the hoist or the crane by a cable at a height that is easy for the operator to reach.

g. Rated Load: For the purpose of this specification the rated load is defined as the maximum working load suspended under the load hook.

Load block and wire ropes, conforming to ASTM A1023/A1023M and ASTM A931 are not included in the rated load.

h. Standard Commercial Cataloged Product: A product which is currently being sold, or previously has been sold, in substantial quantities to the general public, industry or Government in the course of normal business operations. Models, samples, prototypes or experimental units do not meet this definition. The term "cataloged" as specified in this section is defined as "appearing on the manufacturer's published product data sheets. These data sheets should have been published or copyrighted prior to the issue date of this solicitation bearing a document identification number or bulletin number.

i. Top Running Crane: An electric overhead traveling crane that runs on rails on top of support beams. The load is supported by the entire cross-section of the beam.

j. Trolley Mounted Hoist: A combined unit consisting of a wheeled trolley that provides horizontal motion along the bridge girder, and a hoist suspended from the trolley, that provides lifting and lowering of a freely suspended load.

k. Under running (Underhung) Crane: An electric overhead traveling crane that is supported by crane end trucks suspended below the crane runway. The load is supported by hanging from the lower flange of a beam.

1.3 SYSTEM DESCRIPTION

The requirements for the crane runway and rail supporting structures are specified in Section 05 12 00 STRUCTURAL STEEL.

SECTION 41 22 13.13 Page 4

1.3.1 Load and Sizing Calculations

Submit complete list of equipment and materials, including manufacturer's descriptive data and technical literature, performance charts and curves, catalog cuts, and installation instructions. Submit calculations verifying the sizing of the bridge girder, end trucks and travel drives.

1.3.2 OET Design Criteria

Cranes will operate in the given spaces and match the runway dimensions and rails indicated. Hook coverage, hook vertical travel, clear hook height, lifting capacity, and load test weight shall not be less than that indicated.

1.3.2.1 General

Include the following: Number of cranes 1, located in building identified as 17047, with the capacity expressed in 10 tons, for each OET. Also clearly locate and identify each multiple girder hoist and system components.

1.3.2.2 Classification

Provide crane designed and constructed to CMAA 70 Class C, moderate service requirements for operation in indoor environment with electric wire rope hoist conforming to ASME HST-4.

1.4 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Overhead Electric Traveling (OET) Crane(s); G

Crane runway system; G

Complete schematic wiring diagram; G

Description of operation.

SD-03 Product Data

OET Design Criteria; G

Overhead Electric Traveling (OET) Crane(s); G

Load and Sizing Calculations; G

Runway Electrification System; G

Variable Frequency Drives; G

Bumpers; G

SECTION 41 22 13.13 Page 5

End Stops; G, Spare Parts; G

Framed Instructions; G

Nameplates; G

Including all information called for in NFPA 70, Section 430.7.

Pendant Control Station; G

Overloads; G

Limit Switches; G

SD-06 Test Reports

Acceptance Testing; G

Hook Assembly; G

Including Hook Proof Test and Hook and Nut non-destructive Test Report.

SD-07 Certificates

Overload Test Certificate; G

No Hazardous Material; G

Loss of Power Test; G

Crane Runway System; G

Certificate of Compliance; G

Including listed Standards.

Wire Ropes; G

Including Manufacturer's Certificate of Breaking Strength.

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals; G

1.5 QUALITY ASSURANCE

1.5.1 Manufacturer Qualification

Overhead Electric Traveling (OET) Crane(s) shall be designed and manufactured by a company with a minimum of 10 years of specialized experience in designing and manufacturing the type of overhead crane required to meet requirements of the Contract Documents.

SECTION 41 22 13.13 Page 6

1.5.2 Pre-Delivery Inspections

Contractor is responsible for performance of quality control inspections, testing and documentation of steel castings, hook assembly and nuclear safety as follows. Submit all crane test data recorded on appropriate test record forms suitable for retention for the life of the crane. Visually inspect and test load-carrying steel castings ASTM A668/A668M using the magnetic-particle inspection method per ASTM A275/A275M. Reference allowable degree of discontinuities to ASTM E125, and relationship to service loads and stresses, critical configuration, location and type.

Methods of repairing the discontinuities is subject to review by the Contracting Officer.

1.5.3 Certificates

Submit an Overload Test Certificate stating that the crane can be periodically load tested to 125 percent (plus 5 to minus 0) of rated load.

Also submit the following certificates:

a. stating that No Hazardous Material is contained within system or components.

b. stating that the system is safe to perform a Loss of Power Test

c. stating that the Crane Runway System conforms to the requirements as specified herein and as specified in Section 05 12 00 STRUCTURAL STEEL.

d. Certificate of Compliance with listed Standards.

1.5.4 Overhead Electric Traveling (OET) Crane(s)

a. Submit shop drawings showing the general arrangement of all components in plan, elevation, and end views; hook approaches on all four sides, clearances and principal dimensions, assemblies of hoist, trolley and bridge drives, and complete schematic wiring diagram with description of operation, and Runway Electrification System. Include weights of components and maximum bridge wheel loads and spacing.

b. Shop drawing quality shall be equivalent to the contract drawings accompanying this solicitation.

c. Provide integral schedule of crane components on each drawing. Provide maximum wheel loads (without impact) and spacing imparted to the crane runway system track beams. Indicate the crane speeds along the runway, the trolley speeds along the bridge girder, and the multiple girder hoist lifting speeds; all speeds indicated are speeds with hoist loaded with rated crane capacity load.

1.5.5 Safety Requirements

Comply with the mandatory and advisory safety requirements of ASME B30.2, ASME B30.10, ASME B30.16, ASME HST-1,ASME HST-4, NFPA 70, 29 CFR 1910, 29 CFR 1910.179, and 29 CFR 1910.306. Nuclear certification, testing, and rules of construction shall be in accordance with 29 CFR 1910.147, and ASME NOG-1 top running type cranes. Submit analysis and test reports to Contracting Officer for approval.

SECTION 41 22 13.13 Page 7

1.6 DELIVERY, STORAGE, AND HANDLING

Protect all delivered and stored equipment from the weather, humidity, temperature variations, dirt and dust, and other contaminants.

1.7 EXTRA MATERIALS

Submit spare parts data for each different item of material and equipment specified and/or as recommended by the manufacturer, after approval of the detail drawings and not later than two months prior to the date of beneficial occupancy. Include in data a complete list of parts and supplies, with current unit prices and source of supply. Furnish and deliver one set of manufacturer's recommended spare parts to the site.

Suitably package the spare parts for long-term protection and storage.

Legibly label the packaging to identify the spare parts. Also include a list of the furnished spare parts in the Maintenance manual.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 General

Provide materials and equipment which are standard products of manufacturers regularly engaged in the fabrication of complete and totally functional cranes including necessary ancillary equipment.

2.1.2 Nameplates

Secure nameplates to each major component of equipment with the manufacturer's name, address, type or style, model or catalog number, and serial number. Provide two bridge identification plates, one for each side of bridge. Provide noncorrosive metal identification plates with letters which are easily read from the floor, showing a separate number such as BC-1, BC-2, for each bridge crane.

2.1.3 Prohibited Use of Asbestos Products

Provide materials and products, required for designing and manufacturing cranes, which do not contain asbestos.

2.1.4 Capacity Plates

Two capacity plates indicating the crane capacity in tons are required, one secured to each side of bridge. Fabricate each capacity plate with a steel backing plate and exterior quality/fade-resistant stick-on labels with letters large enough to be easily read from the floor. Place capacity plates in a location visible to pendant operator's position after the crane has been installed.

2.1.5 Safety Warnings

Affix labels in a readable position to each lift block or control pendant in accordance with ASME B30.16, ASME B30.2 and ASME B30.17. Submit safety warnings, diagrams and other framed instructions suitably framed and protected for display as indicated by the Contracting Officer as follows:

a. Design and locate the word "WARNING" or other legend to bring the label to the attention of the operator. Provide durable type warning labels

SECTION 41 22 13.13 Page 8 and display the following information concerning safe-operating procedures: Cautionary language against lifting more than the rated load; operating the hoist when the hook is not centered under the hoist; operating hoist with twisted, kinked or damaged rope; operating damaged or malfunctioning hoist; operating a rope hoist with a rope that is not properly seated in its hoist drum groove; lifting people;

lifting loads over people; and removing or obscuring the warning label.

b. To avoid operation of crane in the wrong direction, affix the words "FORWARD" and "REVERSE" and accompanying directional arrows in a location on the trolley and bridge which are visible and readable to the operator from pendant station. The words "FORWARD" and "REVERSE" shall agree with the markings on control pendant. Do not indicate directional arrows on control pendant.

2.2 STRUCTURAL MATERIALS

2.2.1 Bolts, Nuts and Washers

High-strength bolted connections shall be SAE Grade 5 bolts with corresponding lockwashers, ASTM F436, nuts ASTM A563, etc., conforming to requirements of AISC 325 bolts. Bolts, nuts and washers ASTM F959/F959M shall conform to ASTM A325 bolts or ASTM A307. Galvanized bolts are not acceptable. Do not use ASTM A490 bolts.

2.2.2 Bridge Girder or Girders

Provide manufacturer's standard of size and shape to accomodate crane rating bridge girders.

2.2.3 Bridge Rails or Bars

Trolley runway rails, crane girders and other sections shall be straight and true. When loaded with motor driven cranes the deflection of rails shall not exceed 1/800 of the span. Calculate the deflection with the worst case of two loaded bridge cranes located adjacent each other. Make all rail joints flush and true without misalignment of running tread and design to minimize vibration. The gap between adjacent rail ends and the vertical misalignment of running treads shall not exceed 0.0625 inch.

Level the bridge rail to a plus-or-minus 1/8 inch at all rail support joints. Fasten bridge rail to wide flange or centered on flange or offset near web plate for welded box sections, complete with welded clips. Bolt bridge rail joints using standard joint bars. Stagger rail joints.

Provide a positive stop at bridge rail ends to prevent creep.

2.2.4 End Ties and Bridge Girder End Connections

Use welded steel box sections for end ties. Provide full depth diaphragms at girder connections and jacking points. Provide horizontal gusset plates at the elevation of top and bottom end tie flanges for connection to girder ends. Make end connections with high-strength bolts. Use body-bound bolts fitted in drilled and reamed holes to maintain the crane square.

2.2.5 Bridge End Trucks

Provide rotating orfixed axle type end trucks fabricated of structural tubes or from structural steel to provide a rigid box section structure.

Provide jacking pads for removal of wheel assemblies.

SECTION 41 22 13.13 Page 9

2.2.6 End Stops and Bumpers

Fit crane runways and bridge girders with structural steel end stops. Fit bridge end trucks and trolley frames with shock-absorbing, hydraulic type bumpers capable of decelerating and stopping the bridge and/or trolley within the limits stated by OSHA and MHI CMAA. Provide trolley end stops of sufficient strength to withstand the impact of a fully loaded trolley moving at 50 percent of maximum rated travel speed. When two bridge cranes are on the same runway, one crane shall be fitted with shock-absorbing bumpers on each end of each end-truck, and the other crane shall have shock-absorbing bumpers as per above on one end only of each end-truck which is the opposite end of the adjacent crane. Fit the other end of the end-truck with a structural steel stop to engage the bumpers of the adjacent crane. Provide bridge bumper stops as specified in Section 05 12 00 STRUCTURAL STEEL. Locate stops to permit maximum bridge and trolley travel.

2.2.7 Runway Rails

Provide runway rail size as specified in Section 05 12 00 STRUCTURAL STEEL.

2.3 MECHANICAL EQUIPMENT

2.3.1 Variable Frequency Drives

2.3.1.1 Bridge Drives

Provide bridge drive arrangement as specified in CMAA 70, consisting of a single electric motor mechanically connected through gear reduction and drive shafts to the drive wheels or separate drive motors at each end of bridge. Acceleration and deceleration shall meet the requirements specified in this section. Gears shall conform to applicable AGMA standards. Gear reducers shall be oil tight and fully enclosed with pressure or splash type lubrication. Bridge-travel limit-switches are optional.

2.3.1.2 Trolley Drives

Provide complete trolley drive arrangement with a minimum of two wheels driven by an integral electric motor. Provide drive mechanism which runs in totally enclosed oil bath. Limit switches are optional for drive mechanism. Provide acceleration and deceleration controls meeting the requirements specified in this section.

2.3.2 Gearing

Provide enclosed gear reducers type gearing. Gears and pinions shall be spur, helical, or herringbone type only, and be forged, cast or rolled steel. Open-type gearing is not acceptable, except for final drives.

Provide gears and pinions with adequate strength and durability for the crane service class and manufactured to ANSI/AGMA 2001 Quality Class 6 or better precision per AGMA ISO 10064-6, AGMA ISO 17485, ANSI/AGMA 2011, and

ANSI/AGMA 2015-1.

2.3.2.1 Gear Reducers

Provide gear reducers which are integral components of standard hoists or hoist/trolley units of manufacturers regularly engaged in the design and manufacture of hoists or hoist/trolley units for Class A, B or C cranes.

SECTION 41 22 13.13 Page 10

Provide gear reducers designed, manufactured and rated in accordance with ANSI/AGMA 6013 (for trolley drives only), as applicable. Except for final reduction, provide the gear reduction units with fully enclosed in oil-tight housing. Design gearing to AGMA standards and to operate in an oil bath. Operation shall be smooth and quiet.

2.3.2.2 Open Gearing

Provide gears and pinions possessing adequate strength and durability for the crane service class and manufactured to ANSI/AGMA 2001 quality class 6 or better precision per AGMA ISO 10064-6, AGMA ISO 17485, ANSI/AGMA 2011, and ANSI/AGMA 2015-1. Enclose open gears with safety guard removable covers over openings for inspection and access for grease lubrication.

2.3.3 Brakes

a. In addition to the requirements of CMAA 70, provide shoe, disc, or conical type brakes with thermal capacity suitable for class and service specified in this section. Shoe, disc, and conical brakes shall be spring-set and electrically-released by a continuously rated direct acting magnet. Provide brakes which are self-aligning and easily adjusted for torque setting and lining wear. Brake lining material shall be asbestos free. Provide cast iron brake wheels conforming to ASTM A159 or the manufacturer's standard high-strength ductile cast-iron brake wheels, provided that the material exhibits wear characteristics in the form of powdered wear particles and is resistant to heat-checking. Disc brakes shall be totally enclosed and have multiple discs with stationary releasing magnets. Provide brake torque easily adjustable over a 2:1 torque range.

b. Provide braking system which automatically sets when controls are released or power is interrupted. Make provisions to facilitate easy brake adjustment. Provide brakes with a torque rating of at least 50 percent of bridge drive motor rated torque.

2.3.4 Wheels

Provide wheels manufactured of rolled or forged steel. Provide double-flanged Bridge and trolley wheels. Trolley and bridge wheels shall have straight treads. Equip wheels with self-aligning double-row spherical roller-bearings of capacity as recommended by bearing manufacturer for design load of trolley or bridge.

2.3.5 Bearings

All bearings, except those subject to a small rocker motion, shall be anti-friction type. Provide a means for lubrication for bearings not considered lifetime lubricated by the manufacturer. Equip equalizer sheaves with sintered oil-impregnated type bushings in accordance with ASTM B438 or ASTM B439.

2.3.6 Anti-Drip Provisions

Design cranes to preclude leakage of lubricants onto the lifted loads, floor, or external grounds. Fit all equipment and components which cannot be made leak-proof with suitable drip pans. Drip pans shall be manufactured of steel and designed to permit removal of collected lubricant.

SECTION 41 22 13.13 Page 11

2.4 ELECTRICAL COMPONENTS

2.4.1 Control Systems

Provide a separate controller for each motor; however, use a duplex controller two motor bridge drives. Provide overload protection in conformance with the requirements of NEMA ICS 2 and NEMA ICS 3.

Mechanically and electrically interlock contactors that are used for starting, stopping, and reversing.

2.4.1.1 Travel Motion Control System

Provide AC inverter duty, totally enclosed non-ventilated (TENV), squirrel cage induction type bridge and trolley drive motors. All motors shall have 60 minute duty rating minimum. Provide Class H insulation with Class B temperature rise.

2.4.1.2 Drive Control System

Provide static reversing, adjustable frequency controllers for the trolley and bridge infinitely variable electric drives. Provide dynamic braking.

Provide two step infinitely variable speed control for the bridge and trolley functions, controlled via pendant pushbuttons. The trolley, and bridge brakes shall set after associated controller decelerates motor to a controlled stop. Size the bridge and trolley controllers to provide sufficient starting torque to initiate motion of that crane drive mechanism from standstill with 0 to 131.25 percent of rated load on the hook and not produce any hook rollback. Drive motors shall run smoothly, without torque pulsations at the lowest speed, and be energized at a frequency not exceeding 60 HZ.

2.4.2 Power Sources

2.4.2.1 System Supply Voltage

Design cranes to be operated from a 208 volt, three-phase, 60 Hz, alternating current system power source. Design energy isolating devices for such machine or equipment to accept a lockout device in accordance with

NFPA 70.

2.4.2.2 Transformers

Provide dry type transformers and carry full load continuously at rated voltage and frequency without exceeding an average temperature rise of 115 degrees C above an ambient temperature of 40 degrees C. Provide transformer with totally enclosed case finished with manufacturer's standard coating system. Fully encapsulate transformers, except for those specifically designed for use as an isolation transformer for static power conversion units.

2.4.3 Motors

2.4.3.1 General Requirements for Motors

a. Provide motors designed specifically for crane and hoist duty. Provide drain holes at low points near each end. Provide inspection and service covers with gaskets. Hardware shall be corrosion-resistant.

Provide motors conforming to the requirements of NFPA 70, NEMA MG 1 and

UL 1004-1.

SECTION 41 22 13.13 Page 12

b. Provide one embedded thermal sensitive device in hoist motor windings.

Device and associated circuitry shall serve as an alarm activating an amber signal or pilot light visible to control stations when motor temperatures become excessive. Establish set point below the Class B insulation temperature limit. Thermal-sensitive device and associated circuits shall be self-restoring (automatic reset). Two-speed, two-winding motors with a solid-state control are not allowed for creep-speed use.

2.4.3.2 Bridge and Trolley Drive Motors

Provide ac type designed for ac adjustable frequency operation bridge and trolley drive motors.

2.4.3.3 Motor Enclosures

Provide motor enclosures that are drip-proof and conform to NEMA 250.

2.4.3.4 Motor Insulation and Time Rating

2.4.3.5 Bridge and Trolley Motor Insulation and Time Rating

Provide bridge and trolley drive motors with an insulation which has a Class F rating based on 220 degrees F motor temperature rise above 103 degrees F ambient with frame size selection based on continuous rating.

2.4.4 Electric Brakes

2.4.4.1 Hoist Brake Time Delay

Provide one of the hoist holding brakes with a time-delay setting (from 1 to 3 seconds). The time-delay shall be initiated upon releasing the control pushbutton or returning the master switch to OFF. Operation of mainline POWER-OFF pushbutton or power failure shall result in each hoist brake's setting without any time-delay.

2.4.4.2 Automatic Stop System

Provide fail-safe spring set electrically-controlled brakes when power is interrupted. Brakes shall be released with a mainline contactor POWER-OFF pushbutton or a master switch for the associated drive. Brakes shall automatically stop when there is a power failure. Design electric system to be mechanically released. Provide enclosures for electrical-controlled brake components conforming to NEMA ICS 6 Type 1, and NEMA ICS 8. Provide direct current shunt magnetic shoe brakes with an electrical forcing circuit for rapid release of brake. Each shunt coil brake shall be circuited for both conductors to open simultaneously when the brake is de-energized.

2.4.5 Control System

Provide a separate controller for each motor; a duplex type for 2-motor bridge drives and a quadraplex type for 4-motor bridge drives on ac central cranes. When 2-motor bridge drives are furnished and dc magnetic control is required, provide dc series-connected motors. When 4-motor bridge drives are furnished and dc magnetic control is required, provide dc series-parallel connected motors . Provide overload protection conforming to NEMA ICS 2 and NFPA 70. When contactors are used for starting, stopping

SECTION 41 22 13.13 Page 13 and reversing, contactors shall be mechanically and electrically interlocked.

2.4.5.1 Control Panels

Fabricate control panels of solid sheet steel designed and constructed to conform to requirements of NEMA ICS 6 Type 1. Hinge and equip control panel doors with gaskets and fitted with key-lock handle design, complete with a single key to open all locks.

2.4.5.2 Bridge and Trolley Control

a. Provide ac adjustable-frequency, speed-regulated, control of ac squirrel cage motors for bridge and trolley main central systems.

Provide control with continuous-speed adjustment from minimum speed (2.5 percent at no-hook load) to full-speed. Provide control with automatic regenerative or dynamic braking for speed reduction and slow down before brake setting. Provide a minimum 40-to-1 speed range with constant torque acceleration, for base and sub-base speeds.

2.4.5.3 Drift Point

Provide a trolley and bridge main control systems with a drift point between OFF and first speed control point in each direction or have a separate pushbutton.

2.4.6 Pendant Control Station

2.4.6.1 General

Provide NEMA Type 1 pendant control station. Hold physical size of pendant to a minimum. Provide a separate cable of corrosion-resistant 1/8 inch wire. Attach pendant station to underside of crane bridge footwalk and hang vertically with bottom of pendant at 40 inches above floor. Do not support weight of pendant by control cable.

2.4.6.2 Operating Pushbuttons

Provide heavy-duty, dust-and-oil-tight type operating pushbuttons with distinctly-felt operating positions which meet requirements of NEMA ICS 2.

Pendant control buttons shall be momentary pushbuttons. Provide recessed type pushbuttons (except the POWER-OFF button) to avoid accidental operation. Make diameter of buttons a size which will make operation possible with a thumb while holding the pendant with same hand. Provide nameplates adjacent to each pushbutton. Provide barriers on pendant between various pushbutton functions, except on elements mounted in junction box. In a multi-speed application, dual-position pushbuttons shall have a definite click-detent position for each speed. Design and manufacture pushbuttons not to hang up in control case. Pendant shall include a separate set of pushbuttons for each motion and for POWER-ON POWER-OFF. Provide the following pushbuttons:

POWER-OFF.

POWER-ON.

Hoist-up.

Hoist-down.

Trolley-East.

Trolley-West.

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2.4.6.3 Light Indicators

Provide pilot lights meeting heavy-duty requirements of NEMA ICS 5.

Provide one red or amber pilot light to indicate excessive hoist motor temperature on pendant station. Provide a blue pilot light to indicate that the main contactor is energized, and a white pilot light to indicate that power is available on the load side of crane disconnect switch.

Provide a bright red mushroom head for the POWER-OFF pushbutton. Provide a 2-position selector switch to select between normal and VFAC drive.

Provide a single green pilot light to indicate all VFAC drive functions are engaged.

2.4.7 Protection

2.4.7.1 Main Line Disconnect

Provide a main line disconnect consisting of a combination circuit breaker (50,000 AIC) and non-reversing starter, starter without overloads (mainline contactor) in NEMA Type enclosure. Control circuit of mainline disconnect shall cause all crane motions to stop upon mainline undervoltage, overload, control circuit fuse failure, or operation of POWER OFF pushbutton. Equip mainline disconnect with energy isolating devices designed to accept lockout devices.

2.4.7.2 Isolation Transformer

Provide an SCR drive type isolation transformer specifically designed for cranes, with a continuous rating which will exceed that required of the sum of rated full-load full-speed KVA of hoist plus 50 percent of rated full-load full-speed KVA of trolley and bridge motors plus the rated KVA of controls. Multiply the total KVA by 1.05 (efficiency factor). Connect the isolation transformer to the load side of mainline disconnect of the transformer. Supply crane dc static control electric power distributed on the crane through this isolation transformer.

2.4.7.3 Surge Protection

Provide surge suppressors meeting the requirements of UL 1449. Provide three metal oxide varistors on the line side of each SCR drive isolation transformer to provide transient over-voltage protection.

2.4.7.4 Circuit Breakers

Provide circuit breakers meeting the requirements of UL 489.

2.4.7.5 Overloads

Alternating current circuit overload relays shall be of the ambient compensated, automatic reset, inverse time type located in all phases individual motor circuits. Arrange overload relays to de-energize the associated motor on an overload condition.

2.4.8 Limit-Switches

Provide heavy-duty quick-break double-pole double-throw type gear limit switches conforming to NEMA ICS 2. The geared limit-switch interruption of a motion in one direction shall not prevent the opposite motion. Geared limit-switches shall reset automatically. Provide NEMA Type 1 limit switch housings. Limit-switches shall interrupt power to the primary control

SECTION 41 22 13.13 Page 15 systems.

2.4.8.1 Bridge and Trolley Travel Limit-Switches

Provide runway (track-type) limit-switches for crane bridge and trolley motions to stop the bridge and trolley motions, respectively. Install limit-switch actuators on building and trolley frame to actuate the limit-switches and stop the crane bridge or trolley prior to contacting the trolley frame bumpers. Locate trip mechanism for trolley motion on crane runway to trip the switch before the bumper contacts the stop. Locate trip mechanism for bridge motion on crane runway to trip switch before bumper contacts the stop. When the switch is tripped, permit the switch opposite travel in the direction of stop and then automatically reset.

2.4.9 Wiring

Provide wiring complying with Article 610 of NFPA 70. Number or tag wires at connection points. Make all splices in boxes or panels on terminals boards or standoff insulators. Base motor loop, branch circuit and brake conductor selection on NFPA 70 for 184 degrees F conductor rating on indoor cranes, and for 154 degrees F conductor rating on outdoor cranes.

Conductors in the vicinity of resistors and conductors connected to resistors shall be Type 5RML.

2.4.10 Electrification

2.4.10.1 Main Power Electrification

Main power electrification system shall provide power to crane starter/disconnect circuit breaker.

2.4.10.2 Crane Runway Conductors

Provide covered conductor bar type crane runway conductor system designed and manufactured to meet UL requirements. Provide rigid or flexible self-closing type protective cover designed to cover all live conductors and shaped to prevent accidental contact with conductors. Provide heavy-duty sliding shoe type collectors compatible with the electrification system. Provide two tandem designed collector heads for each conductor rail to provide redundancy.

2.4.10.3 Bridge Span Conductors

Provide festooned type consisting of a support rail, electrical cables, junction boxes, cable cars and accessories bridge span conductor system.

Cable loops shall not drop below the hook high position. Provide corrosion resistant outdoor crane bridge festoon system hardware.

2.4.11 Special Requirements

2.4.11.1 Warning Horn

Provide a solid-state electronic warning horn on the crane. Accompany any bridge or trolley motion by a continuous series of alternating tones. The warning horn shall not sound when the crane is in the VFAC drive mode.

2.4.11.2 Accessory Power

Use three-phase 208Y/120 volt ac power supplied via a circuit breaker and

SECTION 41 22 13.13 Page 16 isolation transformer from the line side of the main line disconnect for lighting, and accessory circuits on the crane. Provide the circuit breaker with a NEMA Type 1 enclosure. The enclosure shall have provisions to lock the breaker in the OFF position. Provide each circuit breaker pole with individual thermal and magnetic trip elements and the enclosure cover with a button for mechanically tripping the circuit breaker. Supply three-phase 480 volt delta primary and 208Y/120 volt wye secondary general lighting transformer from the accessory circuit breaker and feed a 208Y/120 volt UL listed circuit breaker panelboard and a heater circuit breaker/combination starter. The panelboard shall supply branch circuits for utilization of various accessories such as lighting . Provide transformer and panelboard with the same NEMA classification as the circuit breaker.

2.4.11.3 Lighting

Provide control panels with a 120-volt lamp fixture with an unbreakable lens and switch. Provide floodlights to illuminate the work area under the crane and drum area on crane, controlled from crane control station.

Provide metal halide industrial floodlight luminaries. Totally enclose each floodlight, vapor-tight design, gasketed and provided with a heat-resistant and impact-resistant glass lens. Space and attach floodlights to underside of crane to provide uniform lighting.

2.4.12 Load-Limit System

Provide a load-limit visual/audible system for the main hoist to inform the operator that the preset load has been exceeded. The load-limit system shall consist of a load-cell, load-sensing electronics, overload indicator lights, overload alarm bell and alarm cut-out switch. Mount load cell to receive the load from equalizing sheave pin or upper block sheave pin.

Provide adjustable alarm setpoint.

2.4.12.1 Load-Sensing Electronics

Provide NEMA Type 1 enclosures for load sensing electronics. Provide adjustable alarm setpoint.

2.4.12.2 Alarm and Indicator Light

Provide an overload alarm light to indicate a load greater than the preset maximum. Overload alarm shall be indicated with a red light and clearly labeled "OVERLOAD". Also provide a bell to indicate when an overload condition exists. Make provisions to turn off the bell from pendant station.

PART 3 EXECUTION

3.1 EXAMINATION

After becoming familiar with all details of the work, and before performing any work, verify all dimensions in the field, and submit a letter describing the results of this verification, including discrepancies, to the Contracting Officer and crane manufacturer. The Contractor is responsible for the coordination and proper relation of the contracted work to the building structure and to the work of all trades. Verify all dimensions of the building that relate to fabrication of the crane and notify the Contracting Officer of any discrepancy before finalizing the crane order.

SECTION 41 22 13.13 Page 17

3.2 ERECTION

Perform the entire crane erection in accordance with manufacturer's instructions under the full-time supervision of the manufacturer's representative. Provide a written certificate from crane manufacturer indicating the crane is erected in accordance with manufacturer's recommendations before testing the completed installation.

3.2.1 Shop Assembly

Shop assemble major crane components as completely as possible. Match mark disassembled parts and tag electrical connections after complete no-load shop testing. Protect all parts and equipment at site from weather, damage, abuse and loss of identification. Erection procedures shall ensure that the crane is erected without initial stresses, forced or improvised fits, misalignments, nicks of high-strength structural steel components, stress-raising welds and rough burrs. Clean and repaint damaged surfaces after crane is erected. Provide all necessary grease and oil of approved quality and grade for the initial servicing and field test.

3.2.2 Mechanical Alignment

Align motors, couplings, brakes, gear boxes and drive components when reinstalled in accordance with manufacturer's instructions.

3.2.3 Electrical Alignment

Align control system in accordance with manufacturer's instructions. Store a copy of the final alignment data in control panel door, including but not limited to, timer settings, resistor tap settings, potentiometer settings, test-point voltages, supply voltages, motor voltages, motor currents and test conditions such as ambient temperature, motor load, date performed and person performing the alignment.

3.2.4 Welding

Welders, welding operations and welding procedures shall be qualified or pre-qualified in accordance with AWS D14.1/D14.1M. Perform welding indoors. Surface of parts to be welded shall be free from rust, scale, paint, grease or other foreign matter. Minimum preheat and interpass temperatures shall conform to the requirements of AWS D14.1/D14.1M.

Perform welding in accordance with written procedures which specify the Contractor's standard dimensional tolerances for deviation from camber and sweep. Such tolerances shall not exceed those specified in accordance with AWS D14.1/D14.1M. Allowable stress ranges shall be in accordance with CMAA 70. Perform welding of girders and beams conforming to

AWS D14.1/D14.1M.

3.2.5 Field Painting

Painting required for surfaces not otherwise specified, and finish painting of items only primed at the facility, shall conform to SSPC SP 6/NACE No.3 and as specified in Section 09 90 00 PAINTS AND COATINGS. Paint bridge crane including bridge, trolley, hoist and all attached items in accordance with the manufacturer's standard practice. The complete crane shall be of one color. Paint bridge rail, supports and bracing in accordance with Section 09 90 00 PAINTS AND COATINGS. Do not paint items such as surfaces in contact with the rail wheels, wheel tread, hooks, wire rope, surfaces on the electrical collector bars in contact with the collector shoes and

SECTION 41 22 13.13 Page 18 nameplates.

3.3 ACCEPTANCE TESTING

3.3.1 General

Provide all personnel necessary to conduct the required testing, including but not limited to, crane operators, riggers, rigging gear and test weights. Perform testing in the presence of Contracting Officer. Notify the Contracting Officer 4 days prior to testing operations. Operate all equipment and make all necessary corrections and adjustments prior to the testing operations witnessed by Contracting Officer. A representative of the Contractor responsible for procuring and installing hoist equipment shall be present to direct the field testing. Test loads shall be compact and permit a minimum of 50 percent of vertical lift. Use test loads which are 100 percent and 125 percent of the rated load, and verified prior to testing. Do not perform operational testing until after building interior has been painted. Furnish three copies of all test reports to Contracting Officer.

3.3.1.1 Test Sequence

Test crane in accordance with applicable paragraphs of this procedure in the sequence provided.

3.3.1.2 Test Data

Record operating and startup current measurements for coils, hoist, trolley, and bridge motors using the appropriate instrumentation. Record speed measurements as required by facility evaluation tests (normally at 100 percent load). Compare recorded values with design specifications or manufacturer's recommended values. Justify abnormal differences in the remarks and perform appropriate adjustments. Note any high temperatures or abnormal operation of any equipment or machinery, investigate and correct.

Record hoist, trolley and bridge speeds during each test cycle.

3.3.1.3 Equipment Monitoring

Monitor improper operation or poor condition of safety devices, electrical components, mechanical equipment and structural assemblies during the load test. Report defects observed to be critical during the testing period immediately to the Contracting Officer and suspend the testing operations until the defects are corrected. During each load test and immediately following each load test, make the following inspections:

a. Inspect for evidence of bending, warping, permanent deformation, cracking or malfunction of structural components.

b. Inspect for evidence of slippage in wire rope sockets and fittings.

c. Check for overheating in brake operation; check for proper stopping.

Test all safety devices including emergency stop switches and POWER-OFF pushbuttons and inspect separately to verify proper operation of the brakes. When provided, inspect all safety accessories including warning horn, lighting, gauges, warning lights and accuracy of wind indicating device and alarm.

d. Check for abnormal noise or vibration and overheating in machinery drive components.

SECTION 41 22 13.13 Page 19

e. Check wire rope sheaves and drum spooling for proper reeving and operation, freedom of movement, abnormal noise or vibration.

f. Check electrical drive components for proper operation, freedom from chatter, noise, overheating, and lockout/tag-out devices for energy isolation.

g. Inspect gears for abnormal wear patterns, damage, or inadequate lubrication.

h. Verify that locations of crane capacity plates are visible from pendant operator's position.

3.3.2 Trolley Travel

Operate trolley the full distance of bridge rails exercising all primary drive and VFAC drive speed controls in each direction. Verify brake operation in each direction. In slow speed trolley bumpers shall contact trolley stops located on the bridge girders. In slow speed, test the proper operation (interrupt power, automatic reset) of the trolley limit-switches at both limits of trolley motion.

3.3.3 Bridge Travel

Operate bridge in each direction the full distance of runway exercising all primary drive and VFAC drive speed controls. Verify brake operation in each direction. In slow speed the proper operation (interrupt power, automatic reset) of the bridge, test limit-switches at both limits of bridge motion. In slow speed or VFAC drive the crane bridge bumpers shall contact the runway rail stops.

3.3.4 Bridge Crane Tests

3.3.4.1 Dynamic Load Tests

a. Trolley Dynamic Load Test: While operating the trolley the full distance of bridge rails in each direction with test load on the hook (one cycle), test proper functioning of all primary drive and VFAC drive speed control points and proper brake action.

b. Bridge Dynamic Load Test: With test load on hook, operate bridge for the full length of runway in both directions with trolley at each extreme end of bridge. Verify proper functioning of all primary drive and VFAC drive speed control points and brake action. Binding of the bridge end trucks indicates a malfunction requiring adjustment.

3.3.4.2 Trolley and Bridge Loss of Power Test

Raise a test load of 100 to 105 percent of rated load clear of any obstructions on operating floor. Starting at a safe distance from walls or other obstructions, select a slow speed using the trolley and bridge primary drive. While maintaining a safe distance to obstructions, disconnect the main power source and verify brakes have set and that the equipment stops within the distance recommended by manufacturer.

3.3.5 Overload Tests

After the operational tests, test bridge crane system and all functions of

SECTION 41 22 13.13 Page 20