Allatoona_Crane_Technical_Requirements_-_REVISED_17May2016.pdf

200‐TON POWERHOUSE CRANE INSPECTION AND REPAIR

ALLATOONA POWERHOUSE

CARTERSVILLE, GEORGIA

Technical Requirements

Table of Contents

Scope of Work & Specifications Site Photographs Appendix

Scope of Work &

Specifications

1 GENERAL

This section describes the requirements to inspect and repair the powerhouse bridge crane located at Allatoona Powerhouse, Cartersville, Georgia.

The paragraph entitled “Inspection and Basic Repairs” contains general project requirements. The paragraph entitled “Bid Options” describes additional aspects of work not covered in the “Basic Renovation” section. The paragraph entitled “Products” contains additional, detailed project requirements which applies to both the “Inspection and Basic Repairs” and all other bid options. Please see the bidding schedule for a detailed breakout of base bid and bid option items. All aspects of design, construction, testing, and inspection shall be in accordance with the criteria listed in the paragraph entitled “References” and the requirements of the paragraph entitled “Execution”.

1.1 Scope

The contractor shall furnish all labor, materials, and equipment to perform, in strict accordance with the requirements of these specifications, all the work necessary to completely inspect and repair the overhead powerhouse bridge crane. All work shall comply with the latest edition of the USACE Safety and Health Requirements Manual, EM385-1-1. All rehabilitation and design work shall be in accordance with the standards referenced in the section entitled “References”. Additional specifications for materials may be found in the section entitled “Products” and specific procedural requirements may be found in the section entitled “Execution”.

1.1.1 Reports

All inspections shall be performed within 30 days after the Notice to Proceed (NTP) is issued and all reports will be due to the Government within 45 days of NTP. Where a recommendation is made regarding a replacement or modification not covered by this or any other scope of work, the contractor shall provide itemized cost, complete, as well as the delivery time or time of repair with the report.

1.2 Base Bid & Bid Options

Please see the Bidding Schedule for all base bid and bid option items.

1.3 Site Photographs and Drawings

Site photographs and drawings have been included with this solicitation.

Please see the Site Photographs Appendix for all photographs and the Site Drawings Appendix for all drawings.

1.4 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)

AGMA 2000 (1988; Rev A) Gear Classification and

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

AGMA 2001

(1995; Rev C) Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth

AGMA 2009-B (1998; R 2001) Bevel Gear

Classification, Tolerances and Measuring Methods

AGMA 2011-A (1998) Cylindrical Worm gearing

Tolerance and Inspection Methods

AGMA 6009 (2000; Rev A) Standard for Gear motor

Shaft Mounted and Screw Conveyor Drives

AGMA 6010 (1997; Rev F) Standard for Spur, Helical, Herringbone, and Bevel Enclosed Drives

AGMA 6019-E (1989) Gear motors using Spur, Helical, Herringbone, Straight Bevel, or Spiral Bevel Gears

AGMA 6021-G (1989) Shaft Mounted and Screw Conveyer Drives Using Spur, Helical and Herringbone Gears

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 316 (1989) ASD Manual of Steel

Construction

AISC-S329 (1986) Allowable Stress Design

Specification for Structural Joints Using ASTM A325 or A490 Bolts

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI A14.3 (1992) Safety Requirements for Fixed

Ladders

ANSI A1264.1 (1995) Safety Requirements for

Workplace Floor and Wall Openings, Stairs, and Railing Systems

ANSI C80.1 (1990) Rigid Steel Conduit -Zinc

Coated

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2004) Structural Welding Code – Steel

AWS D14.1 (1997) Welding Industrial and Mill

Cranes and Other Material Handling Equipment

ASME INTERNATIONAL (ASME)

ASME B30.2 (2002) Overhead and Gantry Cranes (Top

Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist)

ASTM INTERNATIONAL (ASTM)

ASTM A 159 (1983; R 2001) Automotive Gray Iron

Castings

ASTM A 325 (2004b) Structural Bolts, Steel, Heat

Treated, 120/105 ksi Minimum Tensile Strength

ANTI-FRICTION BEARING MANUFACTURERS ASSOCIATION (AFBMA)

AFBMA 9 (1990) Load Ratings and Fatigue Life for Ball Bearings

AFBMA 11 (1990) Load Ratings and Fatigue Life for Roller Bearings

CRANE MANUFACTURERS ASSOCIATION OF AMERICA (CMAA)

CMAA 70 (2004) Top Running Bridge and Gantry

Type Multiple Girder Electric Overhead Traveling Cranes

ELECTRONIC INDUSTRIES ASSOCIATION (EIA)

EIA 397-1 (1972; R 1979; Corr. 1980) Thyristors

FEDERAL SPECIFICATIONS (FS)

FS RR-W-410 (Rev D; Am 1) Wire Rope and Strand FS

WW-C-566(Rev C) Conduit, Metal, Flexible

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2005) National Electrical Code

UNDERWRITERS LABORATORIES (UL)

UL 50 (1995; Rev thru Sep 2003) Enclosures for Electrical Equipment

UL 489 (2002; Rev thru May 2003) Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit- Breaker Enclosures

UL 943 (1993; Rev thru Feb 2004) Ground-Fault Circuit-Interrupters

UL 1004 (1994; Rev thru Feb 2001) Electric Motors

UL 1449 (1996; Rev thru Jul 2002) Transient Voltage Surge Suppressors

1.5 Submittals

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

submittals not having a "G" designation are for information only. Government approval is required for submittals with a "GA" designation; submittals having an "FIO" designation are for information only. The following shall be submitted in accordance with contract requirements. The below indicates the required submittals, refer to the specification of this solicitation entitled “Submittals” for quantities and addressees.

SD-03 Product Data

Crane Design Criteria; G

A complete list of equipment and materials, including manufacturer’s descriptive data and technical literature, performance charts and curves, catalog cuts, and installation instructions.

SD-06 Test Reports

Acceptance Testing; FIO

Test reports in booklet form showing all field tests performed to adjust each component and all field tests performed to prove compliance with the specified performance criteria, upon completion and testing of the installed system. The report shall include the information as required by paragraph

ACCEPTANCE TESTING.

1.6 Government Inspection

The Government reserves the right to witness any contractor testing, repair, and inspection.

1.7 Delivery, Storage, and Handling

Equipment delivered shall be placed in a storage area as directed by the Authorized Representative of the Contracting Officer, protected from the weather, humidity and temperature variations, dirt and dust, or other contaminants.

1.8 Site Visit

Potential Contractors are urged to inspect the work site prior to bid to satisfy themselves as to all general and local conditions that may affect the cost of performance of the contract; to the extent such information is reasonably obtainable. In no event will failure to inspect the site constitute grounds for a claim after award of the contract.

2 Inspection and Basic Repairs

Provide all labor and materials to perform all work required for a fully operational crane. If basic repairs outlined in the requirements below do not render the crane fully operational, additional repairs will be addressed by contract modifications. A full written report as well as a verbal briefing with the COR shall follow the inspections detailing any recommendations or deficiencies.

2.1 Powerhouse Crane – General

The Allatoona powerhouse is serviced by a 200-ton maximum capacity bridge crane. The crane utilizes two trolley units, each with a 100-ton capacity main hoist and a 25-ton capacity auxiliary hoist. During full capacity lifts, the trolleys are coupled together and both 100-ton capacity hooks are used to pick up a 200-ton capacity lifting Beam. Due to a fire in the switchgear room in May 2014, the bridge crane was subjected to heavy smoke, but not high temperatures. The purpose of this contract is to thoroughly inspect, repair to full working condition, and perform a certified live load test on the bridge crane, including live load operational testing of all motions to ensure that the equipment is capable of lifting and moving the rated loads safely through all design motions at normal operating speeds. Load testing shall be performed using weights or water bags only.

2.2 Structural Inspection

Perform structural examination of foundation, columns, runway girders and runway rails.

2.3 Sheaves Inspection

Clean and inspect all sheaves for wear or damage. Re-lubricate if necessary.

2.4 Hooks Inspection

Thoroughly clean and perform NDE tests on all hooks. Visually inspect all hooks and throat openings.

2.5 Hoist Functions

Perform a complete mechanical and electrical inspection and testing of all bridge, trolley, and hoist functions.

2.6 Wire Rope Inspection

Perform a complete wire rope inspection on all hoists, including terminations and end fittings.

2.7 Gear Inspection

Perform a complete inspection of all exposed gear and pinion drives.

2.8 Electrical & Control Systems Inspection

Perform a complete inspection of all electrical components and assemblies;

emergency stop switch; master switches and drum controller; mainline disconnect; stationary, moveable, and auxiliary contacts; resistors; main controls in cab; load cells and digital readouts; remote control station and pushbuttons; control enclosures and junction boxes; proper festoon support;

and check that wiring meets current NEC standards.

Re-calibrate load cells.

2.9 Main Hoist Systems Inspection and Repairs

Perform a complete inspection of all main hoist systems including motors, slip-rings, and brushes; shafts, gearing, coupling, and guards; bearing assemblies; seals; sheave assemblies; lubrication; holding brakes; drums;

hook block assemblies; hooks; and brakes (mechanical and electrical).

Remove all rust from shafts. Replace motor grounding brushes. Replace pivoting hardware on the brakes and the brake shoes.

2.10 Auxiliary Hoist Systems Inspection and Repairs

Perform a complete inspection of all auxiliary hoist systems including motors, slip-rings, and brushes; shafts, gearing, coupling, and guards;

bearing assemblies; seals; sheave assemblies; lubrication; holding brakes;

drums; hook block assemblies; hooks; and brakes (mechanical and electrical).

Remove all rust from shafts. Replace motor grounding brushes. Replace pivoting hardware on the brakes and the brake shoes.

2.11 Bridge and Trolley Inspections and Repairs

Perform a complete inspection of all bridge and trolley systems including motors, slip rings, and brushes; shafts, gearing, couplings, and guards;

bearing assemblies; seals; bridge and trolley drives; all exposed gear and pinion drives; all wheel types (drive and idlers); rail sweeps, lugs, and bumpers; end stops; load rating markings; and lubrication.

Remove all rust from shafts. Replace motor grounding brushes.

2.12 Runway & Cab Inspections

Perform a complete inspection of rails, and rail alignment; rail anchors, bolts, and support beams; cab support; cab access; and cab doors.

2.13 Safety Inspections

Perform a complete inspection of all warning devices; safety and machine guards; access provisions; overload/travel limits; fire extinguisher; and hoist upper limits.

2.14 Operational Test

Perform a full functional no load operational test.

2.15 Lifting Beam

Perform a complete inspection on the lifting beam. Thoroughly clean all machined surfaces, mounting pins, and the holes the pins mount in.

2.16 Load Testing of Main Hoists

Load test all 100-ton main hoists per CMAA 70 and the latest edition of the USACE Safety and Health Requirements Manual, EM 385-1-1.

2.17 Load Testing of Auxiliary hoists

Load test all 25-Ton auxiliary hoists per CMAA 70 and the latest edition of the USACE Safety and Health Requirements Manual, EM 385-1-1.

2.18 Load Testing of Lifting Beam

Load Test the 200-ton lifting beam per CMAA 70 and the latest edition of the USACE Safety and Health Requirements Manual, EM 385-1-1.

3 Bid Options

Provide itemized costs for all labor and materials to perform all work for the following bid options.

3.1 Complete Crane Painting

Completely repaint the entire crane with a matching paint color. Prep solvent clean with a no rinse degreaser to remove oil, grease, dirt and dust. Scrape and sand smooth all loose paint. Spot prime where paint has been removed to bare metal. Primer shall be manufactured by the same manufacturer as the paint finish coat system and shall be 100% compatible with the paint finish coat system. The contractor shall bear all cost for the cleanup and disposal of all material generated in the preparation and painting of the crane. Since the frames may contain lead paint the contractor shall take all precautions to protect his employees from lead hazards and all lead shall be abated by the contractor per all applicable health and safety Federal laws.

3.2 Under Crane Lighting

Remove and replace the crane lighting system attached to the underside of the crane. Control panels shall be provided with a 120-volt lamp fixture with clear tempered glass lens and switch. Floodlights shall be provided to illuminate the work area under the crane and shall be controlled from crane control station. Floodlights shall be long life LED luminaries. Each floodlight shall be instant on/off, maintenance free, mercury free, produce no UV or IR, resistant to shock and vibration, and be reflector based optics for precise light control. Floodlights shall be spaced and attached to underside of crane to provide uniform lighting.

3.3 Operator’s Cab

Completely replace the Operator’s cab, utilizing the existing entry ladder and landing.

3.3.1 General

Operator's cab shall be in accordance with CMAA 70 and ASME B30.2. The front, right and left lower wall sections should be made of transparent, safety type glass. Provide operator chairs which rotate, recline, telescope, and allow for crane operation while operator is standing. The chairs shall have control cabinets that house the joystick controls. Location of cab access shall be easily accessed by crane operator. Cab shall have space near cab entrance for storage of a contractor provided carbon-dioxide, dry chemical or equivalent hand fire extinguisher. Cabs shall be provided with convenience outlets, penthouse safety railing, and door to entrance of cabs.

3.3.2 Cab

Construction Cab shall be enclosed type for indoor use, and designed to provide a clear view of the operating floor and hook for operator. Cab shall be provided with a heating and air conditioning unit.

3.3.3 Cab Heating and Air-Conditioning

Cab shall be thermally-insulated and shall be provided with air conditioner and electric heater. A filter unit shall pressurize the cab with filtered outside air. Air filter shall be a standard commercial type capable of removing airborne dust and shall be located where it can be readily cleaned or changed. Air conditioner with heater shall be controlled with an adjustable thermostat. The unit shall meet the Energy Efficient requirements of ASHRAE 90.1. The cab interior shall be maintained at 65 degrees F in winter with 25 degrees F ambient temperature and 78 degrees F in summer with 95 degrees F dry bulb and 79 degrees F wet-bulb ambient temperatures. All other hardware and components shall be of corrosion-resistant material or protected against corrosion. Motor compressor assembly shall be mounted on vibration isolators. Condensate from the cooling coil shall not be drained to the erection bay or generator floor below the bridge crane. Provide containment of all condensate.

3.3.4 Cab Safety Requirements

Install repel apparatus on cabs for emergency exit when bridges are not near exit stairways. Repel apparatus shall be sized for a person of no more than 350 pounds.

3.3.5 Controls

The new joystick controls shall tie into the existing hoist and travel motion control system.

3.4 Main and Auxiliary Hoist Brakes

If inspections reveal that new brakes are necessary in lieu of refurbishing the existing ones, remove and replace all hoist brakes on all main and auxiliary hoists.

4 PRODUCTS

4.1 Materials

4.1.1 General

Materials and equipment shall be standard products of manufacturers regularly engaged in the fabrication of complete and totally functional cranes including necessary ancillary equipment.

4.1.2 Paint Finish Coat System

The paint finish coat system on the crane shall be a high performance, multipurpose, surface tolerant, two-component chemically-cured epoxy semi-gloss coating for use on properly prepared steel surfaces including immersion (non-potable water) service. The paint finish coat system shall meet the performance alternate for Federal Specifications TT-C-550 and TT-C-545, MIL- P-24441-Type I & II, MIL-C-22750D-Type I, and MIL-P-23377E-Type I, MILl-P- 23236B-Type I & IV, Class 2, and MIL-P-24647B, and AWWA D102.

4.1.3 Use of Asbestos Products

Materials and products required for designing and manufacturing cranes shall not contain asbestos.

4.2 Structural Materials

4.2.1 Bolts, Nuts, and Washers

High-strength bolted connections shall utilize SAE Grade 5 bolts with corresponding lock washers, nuts, etc., conforming to requirements of AISC 316 bolts. Bolts, nuts and washers shall conform to ASTM A 325 bolts.

Galvanized bolts are not acceptable. ASTM A 490 bolts shall not be used.

4.2.2 Operator’s Cab

4.2.2.1 General

New cab shall be provided with all new controls and wiring. Control cab may not be relocated.

4.2.2.2 Cab Safety Requirements

Install repel apparatus on cabs for emergency exit when bridges are not near exit stairways. Repel apparatus shall be sized for a person of no more than 350 pounds.

4.3 Mechanical Equipment

4.3.1 Brakes

Brakes shall be of the shoe type with thermal capacity suitable for class C service. Shoe brakes shall be spring-set and electrically released. Brake lining material shall be asbestos free. Brake wheels shall be cast iron conforming to ASTM A 159 or shall be the manufacturer's standard high-strength ductile cast-iron, provided that the material exhibits wear characteristics in the form of powdered wear particles and is resistant to heat-checking. Brake torque shall be easily adjustable over a 2:1 torque range. Hydraulic “thruster” type brakes may be utilized.

4.4 Electrical Components

4.4.1 Control Panels

Control panels shall be fabricated of solid sheet steel designed and constructed to conform to requirements of NEMA ICS 6 Type 1.Thermostatically-controlled heaters to keep control enclosure temperatures at or above 0 degrees C shall be provided in each static crane control panel. Control panel heaters shall be energized when mainline contactor is de-energized, and shall be de-energized when mainline contactor is energized to prevent anti-condensation. Control panel doors shall be hinged, equipped with gaskets and fitted with keylock handle design, complete with a single key to open all locks.

4.4.2 Cab Control Station

4.4.2.1 General

Crane control shall be accomplished by a bridge-mounted cab control. Master switch operating handles shall be spring-returned to OFF, and shall have OFF position latching. Master switch enclosures shall be NEMA Type 1. POWER-OFF pushbutton shall have a red mushroom head. POWER-ON pushbutton shall be green or black. Cab master switches shall be as follows:

a. POWER-ON.

b. POWER-OFF.

c. Main Hoist - up/down AND selector switch for Upstream Main Hoist, Downstream Main Hoist, or both Main Hoists coupled together.

d. Auxiliary Hoist - up/down AND selector switch for Upstream Auxiliary Hoist, Downstream Auxiliary Hoist, or both Auxiliary Hoists coupled together.

e. Trolley - upstream/downstream AND selector switch for Upstream Trolley, Downstream Trolley, or both Trolleys coupled together.

f. Bridge – North/South.

4.4.2.2 Cab Indications

Amber pilot lights to indicate excessive hoist motor temperature shall be provided. A white pilot light to indicate that power is available on load side of crane disconnect switch shall be provided. A blue pilot light shall be provided to indicate that the main contact is energized.

4.4.2.3 Cab Controls

Cab shall be provided with a 2-position key-operated switch to allow transfer of control from cab to radio control station and a red pilot light mounted in cab shall be provided to indicate that the control has been transferred to other station. Selection of one operating station shall lock out the controls of other stations.

4.4.3 Wiring

Wiring shall comply with Article 610 of NFPA 70. Wires shall be numbered or tagged at connection points. Splices shall be made in boxes or panels on terminals boards or standoff insulators. Motor loop, branch circuit and brake conductor selection shall be based on NFPA 70 for 90 degree C conductor rating on indoor cranes, and for 75degree C conductor rating on outdoor cranes. Conductors in the vicinity of resistors and conductors connected to resistors shall be Type 5RML.

4.4.4 Electrification

All breakers/disconnects must have the capability of being locked in the open position.

4.4.5 Lighting

Control panels shall be provided with a 120-volt lamp fixture with clear tempered glass lens and switch. Floodlights shall be provided to illuminate the work area under the crane and shall be controlled from crane control station. Floodlights shall be long life LED luminaries. Each floodlight shall be instant on/off, maintenance free, mercury free, produce no UV or IR, resistant to shock and vibration, and be reflector based optics for precise light control. Floodlights shall be spaced and attached to underside of crane to provide uniform lighting.

5 EXECUTION

5.1 Erection of New Components

The erection of new components shall be in accordance with manufacturer’s instructions.

5.1.1 Shop Assembly

Major crane components shall be shop assembled as completely as possible.

Disassembled parts shall be match marked and electrical connections tagged after complete no-load shop testing. Parts and equipment at site shall be protected 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. Damaged painted surfaces shall be cleaned and repainted after crane is erected. All necessary grease and oil of approved quality and grade for the initial servicing and field test shall be provided by the Contractor.

5.1.2 Mechanical Alignment

Motors, couplings, brakes, gear boxes and drive components shall be aligned when reinstalled in accordance with manufacturer’s instructions. Provide reconfiguration of motors, shafts, and machinery bases in order to support new and replacement equipment.

5.1.3 Welding

Welders, welding operations and welding procedures shall be qualified or prequalified in accordance with AWS D14.1. Welding shall be performed indoors and the 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. Welding shall be performed 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. Allowable stress ranges shall be in accordance with CMAA 70. Welding of girders and beams shall conform with AWS D14.1.

5.1.4 Field Painting

Bridge crane including bridge, trolley, hoist and all attached items shall be painted. The complete crane shall be of one color. Bridge rail, supports and bracing shall be painted. 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 nameplates shall not be painted.

5.2 Acceptance Testing

5.2.1 General

Contractor shall provide all personnel necessary to conduct the required testing which shall include but not be limited to crane operators, riggers, rigging gear and test weights. Testing shall be performed in the presence of Contracting Officer or his designated representative. Contractor shall notify Contracting Officer 14 days prior to testing operations. Contractor shall 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. Three copies of all test reports shall be furnished to Authorized Representative of the Contracting Officer.

5.2.1.1 Test Sequence

Crane shall be tested in accordance with applicable paragraphs of this procedure in the sequence provided.

5.2.1.2 Test Data

Operating and startup current measurements shall be recorded for hoist, trolley, and bridge motors using the appropriate instrumentation. Speed measurements shall be recorded as required by facility evaluation tests (normally at 100 percent load). Recorded values shall be compared with design specifications or manufacturer’s recommended values and the abnormal differences shall be justified in the remarks or appropriate adjustments performed. The high temperatures or abnormal operation of any equipment or machinery shall be noted, investigated and corrected. Hoist, trolley and bridge speeds shall be recorded during each test cycle.

5.2.1.3 Equipment Monitoring

Improper operation or poor condition of safety devices, electrical components, mechanical equipment and structural assemblies shall be monitored during the load test. Defects observed to be critical during the testing period shall be reported immediately to the Contracting Officer and the testing operations shall be suspended until the defects are corrected. During each load test and immediately following each load test, the following inspections shall be made:

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

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

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/tagout 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 cab and radio control operator's position.

5.2.1.4 Hooks

Hooks shall be measured for hook throat spread before and after load test. A throat dimension base measurement shall be established by installing two tram points and measuring the distance between the tram points to within 1/64 inch. This base dimension shall be recorded. Distance between tram points shall be measured before and after load test. An increase in throat opening by more than 1 percent from base measurement shall be cause for rejection.

5.2.2 No-Load Testing

5.2.2.1 Hoist Operating and Limit Switch

Test Load hook shall be raised and lowered through the full range of normal travel at rated speed and other crane speeds. Load hook shall be stopped below the geared limit-switch upper setting. In slow speed only, proper operation of upper and lower limit-switches for primary motions shall be verified. The test shall be repeated a sufficient number of times (minimum of

3) to demonstrate proper operation. Brake action shall be tested in each direction. Proper time-delay shall be verified between the actuation of dual brakes.

5.2.2.2 Trolley Travel

Trolley shall be operated the full distance of bridge rails exercising all primary drive speed controls in each direction. Brake operation shall be verified in each direction. In slow speed, trolley bumpers shall contact trolley stops located on the bridge girders. In slow speed the proper operation (interrupt power, automatic reset) of the trolley limit-switches at both limits of trolley motion shall be tested.

5.2.2.3 Bridge Travel

Bridge shall be operated in each direction the full distance of runway exercising all primary drive speed controls. Brake operation shall be verified in each direction. In slow speed the proper operation (interrupt power, automatic reset) of the bridge limit switches at both limits of bridge motion shall be tested. In slow speed the crane bridge bumpers shall contact the runway rail stops.

5.2.2.4 Hoist Loss of Power No-Load Test

Using the primary drive, hooks shall be raised to a height of approximately 12 feet or less. While slowly lowering the hook the main power source shall be disconnected, verifying that the hook will not lower and that both brakes will set.

5.2.2.5 Travel

Loss of Power No-Load Test With the hook raised to clear obstructions and trolley traveling in slow speed, the main power source shall be disconnected, verifying that the trolley will stop and the brake will set. Test shall be repeated for bridge slow speed primary drive controls.

5.2.3 Load Test

5.2.3.1 Hoist

Unless otherwise indicated, the following tests shall be performed using a test load of 125 percent (plus 5 percent, minus 0 percent) of rated load.

a. Hoist Static Load Test: Holding brakes and hoisting components shall be tested by raising the test load approximately 1 foot and manually releasing one of the holding brakes. Load shall be held for 10 minutes. First holding brake shall be reapplied and second holding brake released. Load shall be held for 10 minutes. Any lowering that may occur indicates a malfunction of brakes or lowering components.

b. Dynamic Load Test: Test load shall be raised and lowered through the full range operating in each speed. Machinery shall be completely stopped at least once in each direction to ensure proper brake operation.

c. Hoist Loss of Power Test: After raising test load to approximately 8 feet, slowly lowering the test load, the main power source and control pushbutton shall be released verifying that the test load will not lower and that both brakes will set.

d. Trolley Dynamic Load Test: Use test load of 100 percent. While operating the trolley the full distance of bridge rails in each direction with test load on the hook (one cycle), proper functioning of all drive speed control points and proper brake action shall be tested.

e. Bridge Dynamic Load Test: Use test load of 100 percent. With test load on hook, bridge shall be operated as far as possible in both directions without passing over Generator Units with trolley at each extreme end of bridge.

Proper functioning of all drive and speed control points and brake action shall be verified. Binding of the bridge end trucks shall indicate malfunction.

5.2.3.2 Trolley and Bridge

Loss of Power Test: A test load of 100 to 105 percent of rated load shall be raised clear of any obstructions on operating floor. Starting at a safe distance from walls or other obstructions, a slow speed shall be selected using the trolley and bridge drive. While maintaining a safe distance to obstructions, the main power source shall be disconnected and brakes shall be verified to have set and that the equipment stops within the distance recommended by manufacturer.

5.2.4 Overload Tests

After the operational tests, bridge crane system and all functions of bridge crane shall be tested at 125 percent of rated load.

5.2.5 Acceleration and Deceleration Tests

The acceleration and deceleration of bridge and trolley shall be tested with approximately 10 percent of rated load at lowest possible location of hook.

Bridge and trolley shall be operated to run up to high speed and then stopped without jarring or swinging the load.

5.2.6 Grounding Test

Hoist shall be tested to determine that the hoist, including hook and pendant, are grounded to building during all phases of hoist operation. The grounding of bridge and trolley shall be tested with approximately 10 percent of rated load on hook. Grounding shall be tested between hoist hook and the structure's grounding system.

5.2.7 Adjustments and Repairs

Adjustments shall be performed by Contractor under the direction of the Contracting Officer at no additional cost to the Government, until satisfactory conditions are maintained, and contract compliance is affected.

After adjustments are made to assure correct functioning of the components, pertinent testing shall be repeated. If any repairs are needed they will be addressed by contract modification.

5.3 Acceptance

Final acceptance of crane system will not be given until Contractor has successfully completed all testing operations, corrected all material and equipment defects, made all proper operation adjustments, and removed paint or overspray on wire rope, hook and electrical collector bars.

**********END OF SECTION**********

Site Photographs Appendix

Site Drawings Appendix

Mechanical Drawings

OPERATIONS AND MAINTENANCE MANUAL

US ARMY CORPS OF ENGINEERS - MOBILE DISTRICT

POWERHOUSE CRANE REHABILITATION

ALLATOONA DAM

CONTRACT NO. W91278-06-C-0005

AAT JOB NO. 50.5427B

REVISION NO. <00>: JANUARY 22, 2008

Advanced Automation Technologies, Inc. Page 14-1

14. AS-BUILT DRAWINGS

DRAWING LIST

DRAWING NUMBER DRAWING TITLE

5427-2000 POWER HOUSE CRANE

5427-2001 CRANE ARRANGEMENT

5427-2002 REFURBISHED TROLLEY ARRANGEMENT

5427-2003 REFURBISHED TROLLEY SECTIONS

5427-2004 REFURBISHED BRIDGE DRIVE ARRANGEMENT

5427-2005 ELECTRICAL PANEL LOCATIONS

5427-2006 POWERTRACK ARRANGEMENT

5427-2007 LOAD BRAKE GEARBOX MODIFICATIONS

5427-2008 TROLLEY SAFETY GATE ARRANGEMENT

5427-2009 DELETED

5427-2010 ACCESS PLATFORM ARRANGEMENT

5427-2011 RUNWAY CONDUCTOR ARRANGEMENT

5427-2012 MAIN HOIST LIMIT SWITCH

5427-2100 MOTOR BASE ADAPTER DETAILS

5427-2101 POWERTRACK BRACKET DETAIL

5427-2102 MOTOR MOUNTED BRAKE SCOOP DETAILS

5427-2103 MAIN HOIST HOOK LATCH

5427-2104 ELECTRICAL PANEL SUPPORTS

5427-2105 GEAR CLUTCH ASS’Y MODIFICATIONS

5427-2106 SHIMS AND CHOCKS

5427-2107 DELETED

5427-2108 LIMIT SWITCH DETAILS

5427-2200 ACCESS PLATFORM DETAIL – DN RIVER END

5427-2201 ACCESS PLATFORM DETAIL – UP RIVER END

5427-2202 CRANE CROSSOVER ACCESS DETAILS

ATLANTA GEAR WORKS

270812-P HS BRIDGE GEARBOX HIGH SPEED PINION

270812-G HS BRIDGE GEARBOX LOW SPEED GEAR

200-TON POWERHOUSE CRANE INSPECTION AND REPAIR

Electrical Drawings