Work Specification 41 01 20.74 26.pdf

SECTION 41 01 20.74 26

NEW INTAKE GANTRY CRANE MECHANICAL AND STRUCTURAL WORK

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

a. This section covers the structural and mechanical work for a new Big Cliff Dam Intake Gantry Crane. The new crane will operate on existing crane rails that run the full length of the spillway dam and intake deck.

b. The existing intake gantry crane at the Big Cliff Dam is currently rated for 40/15 tons and must be removed from the site by the Contractor. Removal of the existing crane is addressed in SECTION 02 41 16.00 26.

c. Complete the following mechanical and structural work: Design, manufacture and erect complete new 40-ton intake gantry crane. The new intake gantry crane will be of a similar type steel construction. The new crane is to be constructed to preserve historical visual characteristics and appearance to the extent practical. The overall outside physical dimensions of the gantry crane and legs must not extend further downstream or upstream due to existing concrete intake parapet configuration and existing obstructions. The new intake gantry crane must have an overhang cantilevered sections designed to permit the crane to pick up loads outside of the main gantry legs on both the upstream and downstream sides of the crane.

d. Engineer and design all new systems and components of the new crane and must submit computations and drawings as stated in paragraph SUBMITTALS below. The design engineer for all calculations and drawings must be a registered Professional Engineer.

1.2 REFERENCES

The publications listed below form a part of this specification to the extent indicated by the reference. The publications are referred to in the text by basic definition only.

AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)

ABMA 8.2 (1999; S2010) Ball and Roller Bearing Mounting Accessories, Inch Design

ABMA 19.1 (2011) Tapered Roller Bearings - Radial Metric Design

ABMA 19.2 (1994; R 2008) Tapered Roller Bearings - Radial Inch Design

ABMA 20 (1996; R 2008) Radial Bearings of Ball, Cylindrical Roller and Spherical Roller Types Metric Design

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AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

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

AGMA 2015/915-1 (2002A) Accuracy Classification System - Tangential Measurement Tolerance Tables for Cylindrical Gears

AGMA 6013 (2016) Standard for Industrial Enclosed Gear Drives

AGMA 9005 (2002; R 2008) Industrial Gear Lubrication

ASME INTERNATIONAL (ASME)

ASME BPVC SEC VIII D1 (2010) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1

ASME BPVC SEC IX (2010) BPVC Section IX-Welding and Brazing Qualifications

ASME B4.1 (1967; R 2009) Preferred Limits and Fits for Cylindrical Parts

ASME B15.1 (2000; R 2008) Safety Standard for Mechanical Power Transmission Apparatus

ASME B16.3 (2011) Malleable Iron Threaded Fittings, Classes 150 and 300

ASME B16.39 (2014) Standard for Malleable Iron Threaded Pipe Unions; Classes 150, 250, and 300

ASME B17.1 (1967; R 2013) Keys and Keyseats

ASME B30.2 (2016) Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist)

ASME B30.10 (2014) Hooks

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

ASME B40.100 (2013) Pressure Gauges and Gauge Attachments

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

ASTM INTERNATIONAL (ASTM)

ASTM A108 (2013) Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished

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ASTM A123/A123M (2015) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A307 (2014) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength

ASTM A322 (2013) Standard Specification Steel Bars, Alloy, Standard Grades

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

ASTM A36/A36M (2014) Standard Specification for Carbon Structural Steel

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

ASTM A504/A504M (2014) Standard Specification for Wrought Carbon Steel Wheels

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

ASTM A572/A572M (2015) Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

ASTM A759 (2016) Standard Specification for Carbon Steel Crane Rails

ASTM A992/A992M (2011) Standard Specification for Structural Steel Shapes

ASTM B6 (2013) Standard Specification for Zinc

ASTM B22 (2009e1) Standard Specification for Bronze Castings for Bridges and Turntables

ASTM D445 (2015a) Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and the Calculation of Dynamic Viscosity)

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

ASTM E709 (2015) Standard Guide for Magnetic Particle Examination

ASTM D445 (2015a) Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and the Calculation of Dynamic

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Viscosity)

ASTM D664 (2011a; E 2016) Standard Test Method for Acid Number of Petroleum Products by Potentiometric Titration - British Standard 4457; IP Designation: 177/96

ASTM D2509 (2003; R 2008) Standard Test Method for Measurement of Load-Carrying Capacity of Lubricating Grease (Timken Method)

ASTM D4057 (2012) Standard Practice for Manual Sampling of Petroleum and Petroleum Products

ASTM D4950 (2008) Standard Classification and Specification for Automotive Service Greases

ASTM D5185 (2009) Determination of Additive Elements, Wear Metals, and Contaminants in Used Lubricating Oils and Determination of Selected Elements in Base Oils by Inductively Coupled Plasma Atomic Emission Spectrometry (ICP-AES)

ASTM D6304 (2016; E 2016) Standard Test Method for Determination of Water in Petroleum Products, Lubricating Oils, and Additives by Coulometric Karl Fischer Titration

ASTM F436 (2011) Hardened Steel Washers

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 316 (1989) ASD Manual of Steel Construction

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE)

ASCE 7 (2010; Errata 2011; Supp 1 2013) Minimum Design Loads for Buildings and Other Structures

AMERICAN SOCIETY OF SAFETY ENGINEERS (ASSE/SAFE)

ASSE/SAFE A1264.1 (2007) Safety Requirements for Workplace Walking/Working Surfaces and Their Access;

Workplace, Floor, Wall and Roof Openings;

Stairs and Guardrails Systems

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015; Errata 1 2015; Errata 2 2016) Structural Welding Code - Steel

AWS D14.1/D14.1M (2005) Specification for Welding Industrial and Mill Cranes and Other

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Material Handling Equipment

CRANE MANUFACTURERS ASSOCIATION OF AMERICA (CMAA)

CMAA 70 (2015) Specification for Top Running Bridge and Gantry Type Multiple Girder Electric Overhead Traveling Cranes, No. 70

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2014) Safety and Health Requirements Manual

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS RR-W-410 (Rev H) Wire Rope and Strand

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 1940-1 (2003; R 2008) Mechanical Vibration - Balance Quality Requirements for Rotors in a Constant (Rigid) State - Part 1:

Specification and Verification of Balance Tolerances

ISO 4406 (2017) Hydraulic Fluid Power - Fluids - Method for Coding the Level of Contamination by Solid Particles

ISO 11171 (2016) Hydraulic Fluid Power - Calibration of Automatic Particle Counters for Liquids

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

29 CFR 1910.27 Fixed Ladders

UNDERWRITERS LABORATORIES (UL)

UL 484 (2014; Reprint Jul 2015) Standard for Room Air Conditioners

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 10 (2013) Standard for Portable Fire Extinguishers

WIRE ROPE TECHNICAL BOARD (WRTB)

WRTB (2005) Wire Rope Users Manual

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-80 (2013) Bronze Gate, Globe, Angle and Check Valves

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only or as otherwise designated. 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

Dimensioned Assembly Drawings; G HDC

Detailed Shop Drawings; G HDC

Nameplates; G

SD-03 Product Data

Bill of Materials and Schedule of Equipment; G HDC

Drum Dimensions; G HDC

Gear Dimension, Quality, and Hardness Verification Reports; G HDC

Contractor's Nameplate; G HDC

Spare Parts

Grease Product Data; G HDC

SD-05 Design Data

Design Package Submittals; G HDC

Crane Design Data; G HDC

Drum Groove Measuring Procedure; G HDC

Jib Hoist Design Calculations and Drawings; G HDC

SD-07 Certificates

Registered Professional Mechanical Engineer; G HDC

Registered Professional Structural Engineer; G HDC

Wire Rope Certificates

Manufacturer's Representative

SD-09 Manufacturer's Field Reports

Crane Weight; G HDC

Balance Quality Report; G HDC

Field Measurements; G HDC

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Gear Dimension, Quality, and Hardness Verification Procedure; G HDC

Shaft Alignment Report; G HDC

Dynamic Balancing Report; G HDC

Gantry Wheel Hardness Test Report; G HDC

Trolley Wheel Hardness Test Report; G HDC

Oil Test Results (new oil delivery); G HDC

SD-11 Closeout Submittals

Final Calculations; G HDC

1.4 DESIGN CRITERIA

1.4.1 General

a. Design and manufacture a complete, new outdoor intake gantry crane.

The existing spillway stoplog lifting beam is new and replacement is not required.

b. Equip the crane trolley with a main hoist and one trolley drive. The crane must be driven by a minimum of two gantry trucks with a minimum of half the wheels driven.

c. Design the gantry crane to be operable year-round. Gantry crane is in an outdoor environment on the North Santiam River.

d. Electrical equipment is covered in SECTION 41 01 20.73 26.

e. If there are conflicts between design criteria listed here and listed in referenced documents, the most conservative approaches will govern.

1.4.2 Functions

The gantry crane must provide for the functions and operations given below, within the dimensional constraints as shown:

a. Operate on existing crane rails that run the full length of the spillway dam and intake deck. Rails are 80# American Society of Civil Engineers (ASCE) installed on top of the intake/spillway deck are completely exposed, spaced 21 feet 9 inches center to center.

b. Connect to the existing: penstock stoplog lifting beam, and spillway stoplog lifting beam. New rigging, (i.e., slings, shackles, and pins) may be required for connection to existing lifting beams. This rigging will be paid for under Item 0003. Design block such that it can operate in all locations necessary to pick and place the stoplogs, including their storage and in-use slots.

c. Handle and move the penstock stoplogs and the spillway stoplogs between their deployed positions and storage locations using the main hoist of the gantry crane.

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d. Perform miscellaneous maintenance lifts with Owner-furnished rigging of spillway gate machinery equipment (note the southernmost spillway gate machinery is beyond the travel limits of the gantry), and the penstock gate hoist machinery equipment. The intent for this function is to allow the trolley to travel downstream into the overhanging cantilevered section to hoist spillway and penstock gate machinery, and tool loads for maintenance purposes.

e. Handle and transport hand rails, spillway, and hatch covers along the entire deck. Where picked load and location prevent the use of the main hoist, the tool hoist may be used to perform these functions.

f. The jib hoist must provide for the functions and operations given below, within the dimensional constraints as shown:

(1) Remove the trolley machinery housing and lower it to the deck.

(2) Remove the northernmost stoplog hatch covers and move them to a location of the deck that does not block the storage slot or roadway access.

(3) Hoist tools, lubrication containers, and equipment between the deck roadway, the upper crane walkway, and the machinery trolley within the capacities of the crane and walkway.

1.4.3 Data, Capacities, Speeds, and Travel

Data, capacities, travel distances, and rated speeds of the crane must be per SECTION 41 01 20.71 26 NEW INTAKE GANTRY CRANE DATA, TESTING AND

TRAINING.

1.4.4 Design

The contract drawings indicate the general arrangement and outline of the gantry, the clearances necessitated by the powerhouse structure, and other pertinent features. Furnish the detailed design in conformity with the design criteria and other requirements specified herein. Submit design calculations and detailed shop drawings per the requirements in paragraph SUBMISSION OF CRANE DESIGN DATA and in accordance with the requirements of

SECTION 01 33 00 SUBMITTAL PROCEDURES.

1.4.5 Loading

1.4.5.1 General

Base the design loads on the rated capacities specified in SECTION 41 01 20.71 26 NEW INTAKE GANTRY CRANE DATA, TESTING AND TRAINING. For the purpose of design of structural and mechanical parts, take loads resulting from the maximum torque of the motors as 200 percent of the rated full-load torque of the motor. Compute loads as follows, with the trolley in such positions as will give maximum loading or stress in any part of the crane and with due allowance for eccentricity of application. Place the loads for all tractive and collision forces at the centers mass or distribute according to mass for the inertial forces from dead loads and at the center of drums for the inertial forces due to live loads.

1.4.5.2 Dead Loads

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a. The dead load of the gantry crane must include the weight of the crane structure, trolley, and the weight of all machinery and equipment permanently attached to the crane frame except the weight of the movable blocks, lifting beam, and ropes included with the live load.

b. Dead load factor - This factor covers only the dead loads of the crane, trolley, and its associated equipment and must be taken according to CMAA.

1.4.5.3 Live Loads

a. Hoist Loads - The live load on the main hoist must include the rated capacity of 40 tons plus the weight of the load blocks and ropes.

b. Travel Loads - The travel load on the main hoist for trolley travel and gantry travel operations must be equal to the rated capacity (40 tons) on the hook plus the weight of the load blocks and ropes.

c. Vertical Impact - Impact must be taken as a minimum 10 percent of the hoist load. As specified in CMAA standard, the hoist load factor is related to hoist speed, which could result in a higher impact load. If this is the case, use the most conservative load.

d. Wind Load - Apply wind loads specified below to the horizontally projected area of the crane, lifting beam, and intake gate where applicable. No shielding effect of one element by another must be considered where the distance between them exceeds four times the smaller projected dimension of the windward element.

e. Tractive Horizontal Forces, Trolley - Limit the forces resulting from the acceleration or deceleration of the trolley to 10 percent of the sum of the travel load and trolley dead load. Impose the force on the crane in the direction of trolley travel. Also, as specified in CMAA standard, the travel drive inertia forces is related to acceleration and deceleration rate, and depends on the magnitude of torque applied to the drive wheels. Use the force that provides the most conservative value.

f. Tractive Horizontal Forces, Gantry - Limit the forces resulting from the acceleration or deceleration of the gantry crane to 10 percent of the sum of the travel load and dead load. Impose the force on the crane in the direction of gantry travel. Also, as specified in CMAA standard, the travel drive inertia forces is related to acceleration and deceleration rate, and depends on the magnitude of torque applied to the drive wheels. Use the force that provides the most conservative value.

g. Collision Horizontal Forces - Collision forces with rail stops must be taken as the forces produced by such collision with the trolley or gantry traveling at the lowest speed point with power on. Only the dead load will be considered as contributing to the collision forces.

h. Minimum design snow load: 60 LBS per square foot.

1.4.5.4 Combination of Loads

Design the structural parts of the crane for the following load

41 01 26.74 26-9 combinations and unit stresses:

a. Category I Load Cases. The unit stresses resulting from the following load combination(s) must not exceed the unit stresses specified in paragraph UNIT STRESSES:

(1) Dead, hoist, vertical impact, horizontal trolley tractive, and 10 psf operating wind load applied in the direction of trolley travel.

(2) Dead, hoist, vertical impact, horizontal gantry tractive, and 10 psf operating wind load applied in direction of gantry travel.

b. Category II Load Cases. The unit stresses resulting from the following load combination(s) must not exceed the unit stresses specified in paragraph UNIT STRESSES increased by 25%:

(1) Dead, hoist, vertical impact, 10 psf wind, and horizontal collision forces.

(2) Dead, 30 psf wind applied to crane only. (Stability Load Case.)

c. Category III Load Cases. The unit stresses resulting from the following load case(s) must not exceed 90 percent of the yield points of the materials involved save compressive stresses in column members must not exceed the unit stresses specified in paragraph UNIT STRESSES increased by 25%:

(1) Dead load, 10 psf wind to crane only, and the forces produced by the maximum torque of the hoist motor.

(2) Dead, hoist, 30 psf wind.

1.4.6 Unit Stresses

1.4.6.1 Structural Frame

a. The structural frame of the gantry crane must include beams, girders, columns, and other members carrying primary loads. Allowable stresses in structural parts (except bolts and welds) for the beams, girders, columns, and other members carrying primary loads inclusive gantry and trolley frames are defined as the lesser of 45% of the yield or 75% of AISC 316 allowable stresses for ASTM A36/A36M, ASTM A992/A992M or ASTM A572/A572M grade 50 steel. Design allowable stresses in structural parts not carrying primary loads to be no more than 100% of AISC 316 allowable stresses.

b. Design the structure to take into account the most severe combinations of loads as described above in 1.4.5.4, including the full travel range of the trolley/hoist located in the most adverse upstream and downstream position; do not exceed the allowable stresses as outlined in this section. Note: Theses loads are to be considered as a minimum; Contractor must complement these loads with the appropriate standards as outlined above in section 1.2 REFERENCES.

1.4.6.2 Bolts

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Allowable stresses in bolts must be no more than 75% of AISC 316 allowable stresses. Design allowable stresses in structural bolts not connecting members carrying primary loads to be no more than 100% of AISC 316 allowable stresses.

1.4.6.3 Welds

Design of welded joints must be in accordance with the applicable provisions of AWS D1.1/D1.1M, except that allowable stresses in welds must be no more than 75% of AISC 316 allowable stresses, and provisions for repeated stress is not required except as noted elsewhere. Design allowable stresses in welds not connecting members carrying primary loads to be no more than 100% of AISC 316 allowable stresses.

1.4.6.4 Detailing Requirements

The detailing of structural components and connections must conform to the requirements of AISC 316.

1.4.6.5 Mechanical Parts of the Crane

Design mechanical parts of the crane as follows:

a. for rated load, with a factor of safety of 5 based on the ultimate strength of the materials, and

b. for maximum motor torque of the motor as limited by the VFD controls per SECTION 41 01 20.73 26, such that resultant stresses in each part or component do not exceed 75 percent of the yield strength of the materials involved, unless otherwise specified in component-specific paragraphs below.

1.4.6.6 Stress Concentration Factors

Use stress concentration factors where applicable. Reduction of allowable stresses to compensate for repeated cycles of loading is not required.

1.4.6.7 Wire Rope Stresses

In determining the size of hoisting ropes, use the maximum stress resulting from the rated load; take into consideration the overall efficiency of the hoist tackle in the blocks and other parts. The stresses must not be greater than 1/5 the nominal breaking strength of the rope. In addition, the rope tension resulting from the maximum torque of the motor selected must not exceed 0.7 of the nominal breaking strength of the rope.

1.4.6.8 Drum Stresses

The combined bending and crushing stress at rated load for the drums must comply with the requirements of the "Mechanical Parts of the Crane" paragraph. In addition, the stresses in the drums must not exceed 75 percent of the yield point of the material with loads resulting from the maximum torque of the motor as limited by the VFD controls per SECTION 41 01 20.73 26 NEW INTAKE GANTRY CRANE ELECTRICAL WORK. Design drum shafts in accordance with paragraph "SHAFTING". Allowable stresses of drum welds, other than drum shell longitudinal and circumferential splice welds, must not exceed 4,000 pounds per square inch. Perform drum buckling/crushing

41 01 26.74 26-11 calculations per Roark's equations, with a minimum bucking safety factor of 2.

1.4.7 Stability

a. The gantry crane must have a minimum factor of safety of 1.25 against overturning under each condition of loading stated in paragraph Combination of Loads, and must consider the full travel range of the trolley/hoist located in the most adverse upstream and downstream position. Provide counterweights if necessary to obtain the required stability.

b. Also, as specified in CMAA 70 (2015) clause 3.13.3, a gantry crane must have minimum Stability Factors against Overturning (SFO) when the specified loads are applied in the least favorable manner. The SFO is the ratio of the total moment tending to cause overturning:

(1) Normal Operating Loads, including Inertia Forces from Drives (IFD) and Operating Wind Loads (WLO); SFO>/=1.50.

(2) Normal Operating Loads, Operating Wind Loads (WLO) and collision Forces (CF) at 40% travel speed; SFO>/=1.33.

(3) Normal Operating Loads, Operating Wind Loads (WLO) and collision Forces (CF) at 100% travel speed; SFO>/=1.25.

(4) Load Hang-Up condition of the Hoist Load Block or Lifted Load with Operating Winds Loads (WLO); SFO>/=1.10.

(5) Out of Service Stored Wind Load (WLS); SFO>/=1.10.

c. Consider the loads listed above in paragraph 1.4.5.4, Combination of Loads, and CMAA-listed loads as a minimum; complement these loads with the appropriate safety due to stability as outlined above in this section and CMAA 70.

d. If there are conflicts between stability design criteria for the minimum factor of safety listed here and CMAA 70, the most conservative approaches will govern.

1.4.8 Stiffness

Deviations from the nominal span, center to center of the gantry rails, due to the overall deflection of the gantry must not exceed plus or minus 5/8 inches from the rated load to no load, respectively. Compute the deflection with the assumption that the base of the legs are pinned on one side and roller supported on the opposite side. Calculate deflection both parallel and transverse to the crane rails. Consider the stiffness of the gantry frame when determining the computed misalignment of mating gear teeth under the limitation of paragraph GEARS AND SPEED REDUCERS.

1.4.9 Use of Cast Iron

Do not use cast iron of a class less than 30 for any parts of the crane except for counterweights. Cast iron of class 30 or higher may be used for gear cases. Brake shoes and brake wheels must conform to materials specified in SECTION 41 01 20.73 26 NEW INTAKE GANTRY CRANE ELECTRICAL

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WORK.

1.4.10 Connections

1.4.10.1 Shop Connections

Design shop connections for assembly by means of welding or by bolting.

Welding must not be associated with bolting in the same joint. Design field connections for assembly with bolts of the type specified for the application. Riveting or field welding is unacceptable.

1.4.10.2 Welded Connections

Ensure design of welded connections is in accordance with the applicable provisions of AWS D1.1/D1.1M, except that allowable unit stresses in paragraph "Unit Stresses" applies and provisions for repeated stress is not required except as noted elsewhere.

1.4.10.3 Bolted Connections

Structural connection in the primary load path must conform to AISC "Specification for Structural Joints Using ASTM A325 or A490 Bolts", including tensile fatigue loading requirements as applicable.

Design bolted connections as follows:

a. Use machine bolts or fitted bolts for assembly connections on machine parts, frames, attaching machine parts, and similar items.

b. Use ASTM A325 or ASTM A490 type bolts on structural bolted connections carrying primary loads. Zinc (galvanizing) causes stress corrosion in A490 bolts and therefore galvanized A490 bolts are not to be used. Utilize corresponding lock washers with high strength bolted connections ASTM F436, nuts ASTM A563, etc., conforming to requirements of AISC.

c. Use ASTM A307, ASTM A325, or machine bolts for bolted connections on the cab, ladders, guard rails, and similar structural items.

d. Hold all speed reducers, bearing bases, and pillow blocks securely in place by one of the following methods:

(1) Fitted bolts installed with plain washers and double nuts.

(2) Machine bolts and dowels. The dowels must be of such size as to adequately locate the device and resist the total shearing forces. Install the bolts with nuts and lockwashers.

(3) Shear blocks installed at all four corners of the reducer, bearing base, or pillow block, with welds adequately sized to resist shearing forces. Shear blocks must be of sufficient width and welds adequately sized that they do not roll over if lateral forces are placed at the top edge of the blocks.

1.5 SUBMISSION OF CRANE DESIGN DATA

a. Submit Crane Design Data. Crane Design Data must be approved prior

41 01 26.74 26-13 to procurement of associated materials and equipment. Submit Crane Design Data for each major crane component or system of components;

include each of the following items, which are described in the following sub-paragraphs of same title:

(1) Drawing Index

(2) Bill of Materials and Schedule of Equipment

(3) Dimensioned Assembly Drawings

(4) Detailed Shop Drawings

(5) Product Data for Gantry Crane Components

(6) Design Calculations

b. Submit Crane Design Data for a complete crane design in a logical order with the major components submitted first and the lesser components submitted afterwards. The Crane Design Data submitted must include a detailed list of components and their weight together with a current estimate of the completed total crane weight which will be evaluated in terms of the requirements of paragraph 1.6.1.1 "Crane Weight." Examples of Crane Components or Systems include, but are not limited to:

(1) Gantry Frame

(2) Trolley Frame

(3) Gantry and Trolley Trucks (inclusive drive systems)

(4) Main Hoist System (inclusive drum and wire rope)

(5) Gen-Set

c. Uniquely name all submittals for Crane Design Data with the submittal and the system or component. For example: "Crane Design Data

- Gantry Frame."

d. All mechanical computations and drawings submitted as part of the Crane Design Data must be stamped and signed by a registered professional mechanical engineer who has done the design himself/herself or supervised and reviewed work if done by other engineers.

e. All structural computations and drawings submitted as part of the Crane Design Data must be stamped and signed by a registered professional structural engineer who has done the design himself/herself or supervised and reviewed work if done by other engineers.

f. Submit a list of proposed Design Package Submittals with submittal dates and at least one actual design package submittal no later than 90 calendar days after date of award. Submit crane design data for the remaining crane components or systems no later than 180 calendar days after date of award.

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1.5.1 Drawing Index

Contractor must submit an index for each drawing set submitted. The index must be part of the accompanying drawing set, having a title block, border, and sheet number compatible with the drawing set.

1.5.2 Bill of Materials and Schedule of Equipment

Include the bill of materials or parts lists on the drawings, consisting of total quantity, manufacturer, part number, material type, size, and weight of item or equipment; or bill of materials must be drawings that are part of the drawing set, having a title block, border, and sheet number compatible with the drawing set. Bill of materials must provide a cross reference between manufacturer data and shop drawings.

1.5.3 Drawings

Submit drawings for a complete crane design for each major system or component and for the crane as a whole. Drawings must be easily readable in half size format. Include weights of items on the drawings. Show assembly views and all details required for a complete crane design, including but not being limited to layout and installation of all hoist, trolley, and gantry machinery.

1.5.3.1 Dimensioned Assembly Drawings

Submit dimensioned assembly drawings for the overall gantry crane, for hoist machinery and gantry drive machinery, load blocks, and other components as specified. Show plan and elevation views of the crane, indicating locations and layout of all mechanical equipment, with dimensions, and working clearances. Drawings must include, but not be limited to, a clearance/coverage diagram showing that the cable reel system allows the crane to travel the full extent of the crane rails, as field-verified by the Contractor. Update and resubmit the assembly drawing with parts list with the detailed drawings.

1.5.3.2 Detailed Shop Drawings

Submit the detailed shop drawings for approval prior to fabrication of all components. Drawings for individual components must reference an assembly drawing of the entire crane which shows clearances where pertinent and the arrangement of the complete crane assembly. When detailed drawings are submitted, they must be submitted with arrangement drawings and bill of materials/parts lists. Detail drawings for metalwork and machine work must include catalog cuts, templates, fabrication and assembly details and type, grade and class of material as appropriate.

1.5.4 Product Data for Gantry Crane Components

Submit complete descriptive literature and specifications of each product or system of products for the crane with original, legible manufacturer's cut sheets and data sheets to clearly indicate physical construction, operation, mechanical and structural characteristics and associated hardware, as applicable. For sheets with extraneous data, clearly indicate which data applies by crossing out other models, circling the correct options, etc. Include manufacturer's catalog numbers and designations, and clearly cross-reference with shop drawings as appropriate. Product data

41 01 26.74 26-15 submitted for approval must clearly show conformance with these specifications, including but not limited to product manufacturers' declarations of conformance to applicable technical standards. Product data must be approved prior to procurement of associated materials and equipment.

1.5.5 Design Calculations

Submit for approval all design calculations for mechanical and structural components provided per this contract. Submit design calculations for new components (or system of components) concurrent with the drawings and product data specific to the designed component (or system of components).

Calculations must include a list of assumptions made, a list of all codes and standards referenced, equations, specified efficiencies, limits, factors of safety, component ratings, sources of values used, free body diagrams or sketches of each load case. Calculations must show that the crane meets the capacities and speeds as listed in SECTION 41 01 20.71 26

NEW INTAKE GANTRY CRANE DATA, TESTING AND TRAINING.

1.5.5.1 Finite Element Analysis (FEA)

When FEA data is submitted it must be accompanied by sample written calculations that support the FEA analysis. Post-processing FEA data, such as graphics output, submitted alone are unacceptable.

1.5.5.2 Structural Frame Design Calculations

Computer models used for the analysis of the structural frame must provide output in terms of member forces such as shear, compression, tension, and bending. Member stresses must also relate to shear, compression, tension, and bending. Von Mises stresses in structural frame members are not acceptable as a substitute for the stresses and forces described above.

Analysis must include a sketch, drawing, or plot that shows the variation in moment throughout the height of the columns and the length of the beams. Submit computer models developed for the crane frame design submitted in "live" electronic form, along with a printout of the input file. Convert the frame model to STAAD.Pro prior to submission.

1.5.6 Crane Weight

Physically verify the weight of the entire crane and trolley once it is completely assembled. Submit the procedures and equipment used to obtain the crane weights, along with the weight information, which must be included in the operation and maintenance manual. Record the total weight of the crane and the weight of separate components such as the trolley and gantry structure on the FINAL APPROVED VERSIONS OF CONTRACTOR PREPARED DRAWINGS. Limit the final total crane weight such that the maximum leg reaction does not exceed 79,000 lbs with all dead loads plus a rated load of 80,000 lbs plus 10% and the trolley located in the most adverse upstream or downstream position. The intake deck over the powerhouse is the limiting factor for wheel loading.

1.6 FINAL APPROVED VERSIONS OF CONTRACTOR PREPARED DRAWINGS AND FINAL

CALCULATIONS

1.6.1 Final Approved Versions of Contractor Prepared Drawings

41 01 26.74 26-16

SECTION 01 33 00 CONTRACTOR SUBMITTALS has requirements for final approved versions of Contractor prepared drawings. Insert a set of 11 by 17 inch final approved versions of Contractor-prepared drawings in the operation and maintenance manuals.

1.6.2 Final Calculations

Assemble all design calculations with a table of contents and submit for review to verify that all calculations have been assembled and that they have incorporated all outstanding comments and changes to the design inclusive any changes needed to accommodate final field verified weight.

When final calculations are submitted, each section must include reference to submittals where that section was approved. They must be called "Final Calculations." On approval of the final calculations, insert them as a separate section in the Operation and Maintenance Manuals. Submit one electronic copy (CD) and one hard copy of the final calculations to Hydroelectric Design Center.

1.7 QUALITY ASSURANCE

1.7.1 Inspection of Steel Castings

Prior to any machining, visually inspect and test the load-carrying steel castings using the magnetic-particle inspection method. Reference allowable degree of discontinuities to ASTM E125, and relate to service loads and stresses, critical configuration, location and type. Methods of repairing the discontinuities are subject to review by the Contracting Officer.

1.8 FIELD MEASUREMENTS

Before performing any work, Contractor must become familiar with all details of the work, verify all dimensions in the field, and submit a letter describing the results of this verification including discrepancies to the Contracting Officer.

1.9 MANUFACTURER'S REPRESENTATIVE

Provide services of a manufacturer's representative who is experienced in the installation, adjustment, erection, and operation of the equipment specified. The representative must supervise the installation, adjustment, and testing of the equipment.

1.10 SPARE PARTS

a. Furnish and deliver spare parts to the site, suitably packaged for long-term protection and storage. Ensure packaging is legibly labeled to identify the spare parts. All spare parts must be of the same material and workmanship, must meet the same requirements, and must be interchangeable with the corresponding original parts furnished for systems as outlined in this SECTION. Include a list of the furnished spare parts in the Operation and Maintenance Manuals in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES. Spare parts must include at a minimum:

- 1 spare gear motor for each type used.

- 10 replacement filter elements of each type of air filter.

41 01 26.74 26-17

- 2 couplings for each type used.

- 20 silica-gel desiccant cartridges for desiccant air dryer.

b. In addition to the above, provide any spare parts not included in the above list but recommended by equipment manufacturers.

PART 2 PRODUCTS

2.1 NAMEPLATES AND CAPACITY PLATES

2.1.1 General

Provide identification plates, warning labels, and capacity rating markings in accordance with the requirements of ASME B30.2.

2.1.2 Contractor's Nameplate

The Contractor will be permitted to supply and attach to the crane structures a nameplate showing the Contractor's name and address and the trade name of their product. Submit a drawing or illustration showing the proposed nameplate, its size, and location on the crane.

2.1.3 Capacity Plates

Attach capacity plates showing the rated capacity of the crane to each end of the crane in an approved location so as to be legible when viewed from the intake deck. Provide capacity plates for both sides of all lower blocks.

2.1.4 Cantilever Load Ratings

Paint the load rating of each of the two cantilevers on the underside of the end cantilever beams in yellow with a black background.

2.1.5 Plate Details

Nameplates and capacity plates lettering must not be constructed of plastic or vinyl plates or lettering. Attach plates or lettering to the structure using corrosion-resisting steel fasteners. Powder-coated aluminum plate is an acceptable product.

2.1.6 Warning Labels

Affix warning labels to appropriate locations on the gantry crane per requirements of ASME B30.2.

2.2 GANTRY STRUCTURE

2.2.1 Gantry Frame

a. Construct the gantry crane of built-up members fabricated by welding, structural steel shapes, and plates as may be required by the design. Box-type members must either be designed so that all of the interior can be readily inspected, cleaned, and painted, or all joints and openings where water can enter the member must be seal welded.

Provide drain holes at low points or pockets to prevent accumulation of water from condensation or rain. Make longitudinal joints of built-up

41 01 26.74 26-18 members with continuous welds. Machine-finish bearing surfaces of joints designed to transmit stress by bearing to provide full contact.

Erect frame in such a manner as to be straight and plumb, including individual pieces between splices, unless a member is specifically designed, as shown in calculations and drawings, to be other than straight or plumb. Define plumb as having a centerline that deviates from the vertical by no more than 1/500. Define straight as having a centerline that deviates from its own endpoints by no more than 1/500.

The maximum allowable deviation from a straight line between brace points is L/1000, or 1/500, whichever is more stringent. Demonstrate compliance with this requirement per SECTION 41 01 20.71 26, NEW INTAKE

GANTRY CRANE DATA, TESTING AND TRAINING.

b. Assemble the gantry frame in the shop; check for dimensional correctness and proper squareness prior to shipping components to the site.

2.2.2 Gantry Jacking Pads and Jacking Points

Provide jacking pads and jacking points to allow for wheel truck removal and wheel maintenance and removal, and also for weighing the crane. Design gantry structure for lifting the entire weight of the crane, including the hook blocks and lifting beam, by these jacking points. Design jacking pads to carry primary loads with allowable stresses as defined in paragraph

1.4.6.1 Structural Frame.

2.2.3 Gantry Crane End Stops

Analyze existing crane end stops and confirm that they meet current code requirements. If they do not, replace existing crane stops to meet the requirements ofDesign the new crane leg bumper system to utilize the existing crane rail end stops and meet the requirements of CMAA 70, ASME B30.2, and OSHA.

2.3 TROLLEY STRUCTURE

2.3.1 Trolley Frame

a. Construct the trolley frames of built-up members fabricated by welding, structural steel shapes, and plates as may be required by the design. Design box-type members so that all of the interior can be readily inspected, cleaned, and painted, or all joints and openings where water can enter the member must be seal welded. Provide drain holes at low points or pockets to prevent accumulation of water from condensation or rain. Make longitudinal joints of built-up members with continuous welds. Machine finish bearing surfaces of joints designed to transmit stress by bearing to provide full contact.

b. Design the machinery floor for a uniform load of 100 psf or a concentrated load of 750 pounds, using the load that produces the greater stress, in addition to the weight of any equipment attached to or supported thereon. Construct the floor of reinforced checkered floor plate, not less than 1/4 inch thick and weld to the framework.

2.3.2 Trolley Jacking Pads and Lifting Eyes

Provide jacking pads underneath the trolley near the wheels to allow for

41 01 26.74 26-19 wheel maintenance and removal, and also for weighing the trolley. Provide lifting eyes or rigging points at each corner of the trolley; design the trolley structure for lifting of the dead weight of the trolley and all permanently attached equipment, including hoist, ropes, and blocks required to facilitate installation, removal, and maintenance of the trolley.

2.4 TROLLEY BUMPERS

Provide four fixed polyurethane bumpers for the trolley; ensure they meet the requirements of CMAA 70. Provide cast steel or structural steel bumper stops to meet the trolley bumpers squarely; the centerline of contact must not be lower than the centerline of the wheel axles. Install means on the crane trolley bumpers to retain the bumpers in case of broken or loosened mounting connections per requirements in ASME B30.2.

2.5 TROLLEY

Provide the gantry crane with one trolley consisting of one main 40-ton hoist.

2.6 MAIN HOIST

2.6.1 General

The main hoist must consist of a single double-reeved drum with a single motor connected through a speed reducer and shafting. To minimize future field lubrication requirements, design the crane with enclosed gear boxes only, if feasible. If open gears are required due to physical constraints, submit design approach for COR approval prior to manufacture. Design the main hoist so as to limit the maximum rope fleet angles to not more than

3.5 degrees, unless otherwise approved. The reeving must be such as to allow all lifting beams to travel vertically. The new load blocks must be similar in size as the existing load blocks and designed to be pinned to the existing lifting beams as described in paragraph "Functions". Provide the main hoist with motor, brakes, load indicator, and limit switches conforming to the requirements of SECTION 41 01 20.73 26 NEW INTAKE GANTRY

CRANE ELECTRICAL WORK.

2.6.2 Main Hoist Gear Reducer

The main hoist gear reducer must provide the hoisting speed listed in

SECTION 41 01 20.71 26 NEW INTAKE GANTRY CRANE DATA, TESTING AND TRAINING,

using the motor horsepower required in SECTION 41 01 20.73 26 NEW INTAKE GANTRY CRANE ELECTRICAL WORK. The gear reducer input shaft, on the motor side, must be long enough to mount a brake wheel and also a flex/flex coupling half on it. Brake wheel couplings are not allowed.

2.6.3 Main Hoist Drum to Reducer Connection

a. The connection of the drum to the reducer must be of one of the following methods:

(1) Barrel coupling.

(2) Other means to allow for misalignment between the drum and the reducer.

41 01 26.74 26-20

(3) Means to allow the drum and the reducer to operate without binding such as using a torque arm for the reducer.

b. Support the output shaft or hollow shaft of the reducer by two bearings, one bearing on each side of the gear on the shaft. Support both shaft bearings by the reducer housing.

2.7 GANTRY DRIVE

2.7.1 General

The gantry must be driven by two gear motors, one mounted on each of the gantry drive trucks. Shaft-mount the gear motors on the drive wheel axles and ensure they have torque arms. Any additional gears must be in an enclosed case and lubricated by reducer oil. Government prefers that all gears be enclosed, with no open gearing. The driving mechanism must be so designed and must have such capacity that the movement of the structure will be steady, with a minimum of vibration or racking while moving at rated speed with maximum travel load against a wind pressure of 5 psf of exposed surface of the crane and the travel load. The capacity of the gantry travel motors must be sufficient to provide the specified performance without exceeding the full-load torque. The tractive effort provided to overcome the rolling friction of the gantry wheels and mechanical losses of the drive must be a minimum of 15 pounds per ton.

Provide gantry motors, couplings, and brakes in accordance with SECTION

41 01 20.73 26 NEW INTAKE GANTRY CRANE ELECTRICAL WORK.

2.7.2 Gantry Storm (Parking) Brakes

The idler wheels, wheel guards and rail sweeps must incorporate storm brakes. Storm brakes must conform to the requirements of SECTION 41 01 20.73 26 NEW INTAKE GANTRY CRANE ELECTRICAL WORK, paragraph GANTRY

STORM BRAKES.

2.7.3 Wheels

a. The design load on any gantry wheel must be taken as the load resulting from the rated live load of the hoist and the applicable dead load. Loads resulting from the maximum torque of the hoist motors need not be considered in determining wheel size. The design load on any wheel must not exceed the maximum permissible wheel loading values listed in Table 4.13.3-4 of CMAA 70. The trolley and bridge wheel load coefficient as defined in CMAA 70 must be 1.0. The existing intake gantry crane rail is ASCE 80 pounds per yard.

b. Determine the load with the crane in the operating position that results in maximum value; include any other eccentricity of application. Wheels must be double-flanged and must be made from solid wrought wheel blanks conforming to the applicable requirements of ASTM A504/A504M, Class C. All wheels must have flat/straight tread.

Turn or ground the wheels to true and uniform diameter, matched within

0.001 inch. High capacity wheels with wheel hardness of 58 Rockwell C may be used to meet wheel rating design limits. Note required wheel hardness on the shop drawings and test wheel hardness after wheels and axles are assembled. The wheel hardness must exceed the hardness of the rails. Submit a gantry wheel hardness test report.

2.7.4 Axles

41 01 26.74 26-21

Wheel axles must be accurately turned all over and ground to fit the bearings. Fix axles to the gantry wheels with an interference fit that provides the capacity to transfer the torque from the axle to the wheels to drive the gantry structure. Key the driving wheels to the axles in addition to forced fit. Equip axles with anti-friction roller bearings in accordance with Paragraph BEARINGS. Design the bearings and all affected mechanical and structural parts for axial loads to not less than 15 percent of the radial wheel load, applied to the wheel at the railhead in either direction. Design axles in accordance with the paragraph SHAFTING.

Bearings for the same service must be interchangeable. Provide pressure grease lubrication for all axle bearings.

2.7.5 Gantry Trucks

The crane must be carried on eight wheels; two wheels per equalizing truck. The trucks must be made of cast or structural steel.

Machine-finish bolted parts of the truck at the bolting surfaces. Arrange trucks to minimize the danger of injury to the crane or surroundings in case of failure of any part of the truck. Provide lugs on the truck frames to limit the drop to not more than one inch, in case of broken axle.

Provide safety lugs on each trolley truck, which extend below the top of the rail on both sides to prevent the wheels from leaving the rails.

Provide jacking lugs. Provide trucks with substantial track clearers at each end of the trucks, which must be effective in both directions of travel. Because the crane will occasionally operate with snow and ice on the rails, design trucks to rake the snow and ice away from the crane to the outside of the upstream and downstream rails.

2.8 TROLLEY DRIVE

2.8.1 General

The trolley must be driven by one gear motor driving two of the four wheels on a common shaft in the A-1 arrangement. Design the driving mechanism to have such capacity that the movement of the structure will be steady, with a minimum of vibration or racking while moving at rated speed with maximum travel load against a wind pressure of 5 psf of exposed surface of the trolley and the travel load. The capacity of the trolley drive motors must be sufficient to provide the specified performance without exceeding the full-load torque. The tractive effort provided to overcome the rolling friction of the trolley wheels and mechanical losses of the drive must be a minimum of 15 pounds per ton. Provide trolley drive motors and brakes in accordance with SECTION 41 01 20.73 26 NEW INTAKE GANTRY CRANE ELECTRICAL

WORK.

2.8.2 Wheels

a. The design load on any trolley wheel must be taken as the load resulting from the rated live load of the main hoist and the applicable dead load. Loads resulting from the maximum torque of the hoist motors need not be considered in determining wheel size. The design load on any wheel must not exceed the maximum permissible wheel loading values listed in Table 4.13.3-4 of CMAA 70.

b. Determine the load with the crane in the operating position that results in maximum value and must include any…