A.01.29_SPECS_UPDATED.pdf

SECTION 41 22 13.13

BRIDGE CRANES

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 (2011) Steel Construction Manual

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 Material Handling Equipment

ASME INTERNATIONAL (ASME)

ASME B30.10 (2014) Hooks

ASME B30.16 (2012) Overhead Hoists (Underhung)

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

ASME B30.2 (2011) Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist)

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

ASME NOG-1 (2015) Rules for Construction of Overhead and Gantry Cranes (Top Running Bridge, SECTION 41 22 13.13 Page 1

PN449862

Bridge Crane Rehabilitation Clearwater Dam Wayne County, Missouri Solicitation No. W9127S18R0015

AMENDMENT 0001 TO SOLICITATION W9127S18R0015 on 05/24/2018

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 A307 (2014) Standard Specification for Carbon Steel Bolts and Studs, 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 A931 (2008; R 2013) Standard Test Method for Tension Testing of Wire Ropes and Strand

ASTM B438 (2013) Standard Specification for Sintered Bronze Bearings (Oil Impregnated)

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

ASTM B633 (2015) Standard Specification for Electrodeposited Coatings of Zinc on Iron and Steel

ASTM F436 (2011) Hardened Steel Washers

ASTM F959 (2013) Compressible-Washer-Type Direct Tension Indicators for Use with Structural Fasteners

CRANE MANUFACTURERS ASSOCIATION OF AMERICA (CMAA)

CMAA 70 (2010) Specification for Top Running Bridge and Gantry Type Multiple Girder Electric Overhead Traveling Cranes, No. 70

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

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

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2014) Enclosures for Electrical Equipment

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Bridge Crane Rehabilitation Clearwater Dam

(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 (2000; R 2010) Control Circuit and Pilot Devices

NEMA ICS 6 (1993; R 2011) Industrial Control and Systems: Enclosures

NEMA ICS 8 (2011) Crane and Hoist Controllers

NEMA MG 1 (2016) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2017); 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 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 Jun 2016) UL Standard for Safety Rotating Electrical Machines - General Requirements

UL 1449 (2014; Reprint Mar 2016) 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

UL 50 (2015) UL Standard for Safety Enclosures for Electrical Equipment, Non-Environmental Considerations

UL 943 (2016) UL Standard for Safety Ground-Fault Circuit-Interrupters

1.2 DEFINITIONS

a. Crane Bridge: That part of an overhead crane system consisting of

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Bridge Crane Rehabilitation Clearwater Dam 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.

1.3.1 Load and Sizing Calculations

Submit complete list of equipment and materials, including manufacturer's

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Bridge Crane Rehabilitation Clearwater Dam descriptive data and technical literature, performance charts and curves, catalog cuts, and installation instructions. Submit calculations verifying the sizing of the components required in the rehabilitation.

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 one, located in building identified as gate tower, with the capacity expressed in 100 tons . 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 A, requirements for operation in indoor wet environment with multiple girder hoist systemelectric wire rope hoist conforming to ASME HST-4.

1.3.2.3 Rated Capacity and Speeds

Provide crane with rated capacity of 100 tons . Lower load block or assembly of hook, swivel bearing sheaves, pins and frame suspended by the hoisting ropes are not considered part of the rated capacity. Rated speeds (in fpm) for the hoist,, bridge and trolley at the rated load are as follows:

Rated Speeds feet per minute

Description Minimum Maximum Existing

Main Hoist 1.1 3 1.1

Trolley 10 20 Manual

Gantry 10 20 Manual

The speeds are approximate and adjustable. Trolley and bridge travel speeds are estimates due to existing being pull chain drives.

1.4 DESIGN SUBMISSION

Crane Component Design data for each major component, system, or equipment shall be submitted for approval prior to procurement or fabrication. All submissions for a component, system, or equipment shall be submitted in one package. Submissions, for Government approval, include but not limited to:

a. Bill of Materials/Schedule of Equipment; Consisting of total quantity, manufacturer, part number, material type, size, and weight of item or equipment; or bill of material.

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Bridge Crane Rehabilitation Clearwater Dam

b. Dimensioned Assembly Drawing; submit plan and elevational views for overall crane, hoist, trolley, lifting beam, and other components with dimensions and clearances.

c. Detailed Shop Drawings; Detailed drawings for individual components shall reference the overall drawing and be submitted with overall drawing and bill of materials/parts lists. Detail drawings of metalwork and machine work shall include catalog cuts, templates, fabrication and assembly details and type, grade, and class of material as appropriate.

d. Product Data; Submit complete descriptive literature and specifications of each product or system with original, legible manufacturer's cut sheet and data sheets. For sheets with extraneous data, clearly indicate which data applies by crossing out other models, arrow to correct options, or circle the correct options.

e. Design Calculations; Calculations shall include a list of assumptions made, a list of all codes and standards referenced, equations, specified values used, free body diagrams,or sketches of each load case. (AM001) Include load capacity calculations and adequacy checks on tower floor and roof slabs and supporting beams and girders.

1.5 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-01 Preconstruction Submittals

Rehabilitation Procedure; G

Test Weight Plan; G

(AM001) Load Capacity Calculations And Adequacy Checks On Tower Floor And Roof Slabs And Supporting Beams And Girders.; G

SD-02 Shop Drawings

Overhead Electric Traveling (OET) Crane(s); 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

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Bridge Crane Rehabilitation Clearwater Dam

Bumpers; G

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

Contractor Post-Erection Inspection And Operational Test; G

Post-Erection Inspection; G

Post-Erection Inspection And Acceptance Tests Procedures; G

SD-07 Certificates

Overload Test Certificate; G

No Hazardous Material; G

Loss of Power Test; G

Certificate of Compliance; G

Including listed Standards.

Wire Ropes; G

Including Manufacturer's Certificate of Breaking Strength.

Qualified Crane Inspector; G

Qualified Craftsmen; G

Qualified Crane Electricians; G

Level III Examiner

Wire Rope Certificates; G

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals; G

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Bridge Crane Rehabilitation Clearwater Dam

1.6 QUALIFICATIONS

1.6.1 General

Data showing that crane inspectors and craftsmen meet the following qualifications shall be submitted for approval.

1.6.2 Qualified Crane Inspector

Crane inspectors shall posses the following:

a. Have experience and knowledge in performing inspection on bridge cranes and lifting beams of similar size and capacity as the Clearwater Bridge crane.

b. Certifications showing they have attended crane inspection training seminar provided by established training institutions such as Morris Material Institute (866-821-4006) and CraneTech (800-290-0007). Certifications issue by the Contractor do not meet this requirement.

c. Are employed as crane inspectors for at least the last two (2) years by a firm specializing in crane inspection work.

1.6.3 Qualified Craftsmen

Craftsmen shall posses the following:

a. Have experience and knowledge in performing work on bridge cranes of similar size and capacity as the Clearwater Bridge Crane.

b. Have performed work on monorail cranes of similar size and capacity as the Clearwater Bridge Crane for at least five (5) years.

c. Are employed for at least two (2) years by a firm specializing in crane repair and rehabilitation work.

1.6.4 Qualified Crane Electricians

There shall be a minimum of one (1) license electrician during field wiring and critical aspects of the crane field work.

1.7 QUALITY ASSURANCE

1.7.1 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.

1.7.2 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

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Bridge Crane Rehabilitation Clearwater Dam components.

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

c. Certificate of Compliance with listed Standards.

1.7.3 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.

1.7.4 Welding Qualifications and Procedures

Perform welding in accordance with qualified procedures using AWS D14.1/D14.1M as modified. Written welding procedures shall specify the Contractor's standard dimensional tolerances for deviation from camber and sweep and not exceed those specified in AWS D14.1/D14.1M . Perform all welding indoors. Qualify welders and welding operators in accordance with AWS D1.1/D1.1M or AWS D14.1/D14.1M . Allowable stress values shall comply with CMAA 70.

1.7.5 Safety Requirements

Comply with the mandatory and advisory safety requirements of ASME B30.2 , ASME B30.10 , ASME B30.16 , 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.

1.8 REHABILITATION PROCEDURE

A complete rehabilitation procedure for all work done on this job shall be submitted and approved before any work will be allowed to start. The procedure shall include, but not be limited to the following:

(1) Step-by-step rehabilitation procedures.

(2) Schedule and sequence of work.

(3) Types of equipment used on-site including work platforms, cranes, scissor lifts, etc.

(4) Methods of removing and reinstalling components.

(5) Safety precautions.

(6) Work area restrictions.

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Bridge Crane Rehabilitation Clearwater Dam

1.9 TEST WEIGHT PLAN

A test weight plan shall be submitted for approval and shall contain the following:

a. Type of weight (water bags, concrete, steel, etc).

b. Test weight handling procedure.

c. Detailed drawings showing test weight configuration (to scale) showing configuration with the crane, powerhouse, draft tube deck, and other feature shown on the drawings shall be submitted. Drawings shall show details of lifting beams, shackles, slings, and related equipment. The lifting beam shall be used with the test weights but not included as part of the weight.

d. Load measuring devices such as water flow meters and load indicators shall have calibration certificates issued within the last two (2) years. Include copies of calibration certificates with the work plan.

If water bags are used, provide means of pumping water into the water bags from the draft tube deck and after testing a means of draining the bags into the water. Water bags shall be non-contained in order to dump water back into the river. Test load shall be plus 5 percent, minus 0 percent.

1.10 DELIVERY, STORAGE, AND HANDLING

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

1.11 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 2 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

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Bridge Crane Rehabilitation Clearwater Dam 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 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. See drawing E-602.

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 shall conform to ASTM A325 bolts or ASTM A307. Galvanized bolts are not acceptable. Do not use ASTM A490 bolts.

2.2.2 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, spring 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

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Bridge Crane Rehabilitation Clearwater Dam 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.

2.3 MECHANICAL EQUIPMENT

2.3.1 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 ANSI/AGMA 2015-1 .

2.3.1.1 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.

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.

2.3.1.2 Open Gearing

Provide gears and pinions possessing adequate strength and durability for the crane service class and manufactured to ANSI/AGMA 2001 quality class 8 or better precision per ANSI/AGMA 2015-1 . Enclose open gears with safety guard removable covers over openings for inspection and access for grease lubrication.

2.3.2 Brakes

a. In addition to the requirements of CMAA 70, provide shoe type brakes for hoist, and disc type brakes for bridge and trolley 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. Provide hoist brake that is capable of stopping and holding a 131.25 percent test load.

b. Provide bridge and trolley braking system with a spring-applied and electrically-released single shoe, disc, or conical brake for each

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Bridge Crane Rehabilitation Clearwater Dam bridge drive motor. 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 100 percent of bridge or trolley drive motor rated torque.

2.3.3 Wheels

Provide wheels manufactured of rolled or forged steel. Wheel treads and flanges shall be rim toughened to between 320 and 370 Brinell hardness number. 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.

2.3.4 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.

2.3.5 Wire Rope

a. Hoist wire rope shall be same size as existing diameter. All wire rope shall be the product of a domestic manufacturer.

b. Wire Rope Certificates shall be submitted in the Operation and Maintenance Manuals, including but not limited to: type and grade of wire rope, and wire rope tensile strength test-to-failure to verify the wire rope meets or exceeds FS RR-W-410 standards for nominal strength. The test shall meet or exceed the requirements of paragraph

4.4.1.1 of FS RR-W-410 , using suitable tension testing equipment and qualified personnel, both furnished by the Contractor.

c. Hoist wire rope shall conform to the requirements of FS RR-W-410 , Type I, Class 3, 6 x 37:

d. The wire ropes shall be lubricated, both the IWRC and the strands during manufacture. In addition, the wire ropes shall be coated on site with High Core wire rope lubricant distributed by Chemsearch or equal.

e. Wire rope shall be pre-stretched in accordance with the requirements of FS RR-W-410 .

f. Kinking of rope will be cause for rejection. A single broken wire in a "valley" between two strands will be cause for rejection.

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

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2.4.1.1 Travel Motion Control System

Provide AC totally enclosed non-ventilated (TENV) if totally enclosed fan-cooled (TEFC) cannot be used, squirrel cage induction type bridge and trolley drive motors. All motors shall have continuous duty rating minimum. Provide Class H insulation with Class B temperature rise.

2.4.1.2 Drive Control System

Provide static reversing, 2-speed controllers for the trolley and bridge drives. Provide dynamic braking. Provide two step 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 480 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 239 degrees F above an ambient temperature of 104 degrees F. 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 , and continuous duty.

b. Motor heaters, if required, shall energize when mainline contactor is de-energized, and operated by a separate power source. Provide motors 20 HP and larger with a suitable heater to prevent condensation during long periods of inactivity. Motor heater shall be an integral component of the hoist and motor manufacturer.

c. 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

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Bridge Crane Rehabilitation Clearwater Dam 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 crane type two-speed; two-winding NEMA design squirrel cage ac type rated 2-speed operation bridge and trolley drive motors.

2.4.3.3 Motor Enclosures

Provide motor enclosures that are totally enclosed, non-ventilated (TENV) or totally enclosed, fan cooled (TEFC) 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 or Class H 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 Brakes

a. Electric-hydraulic bridge and trolley brakes shall be dc shunt magnet type equipped with hydraulic actuators manually-operated for emergency operations, and electrically released with the operation of the mainline contactor POWER-OFF pushbutton or power failure.

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 12, 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 and reversing, contactors shall be mechanically and electrically interlocked.

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PN449862

Bridge Crane Rehabilitation Clearwater Dam

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 4 . Provide thermostatically-controlled heaters to keep control enclosure temperatures at or above 32 degrees F in each static crane control panel. 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 bridge and trolley main control systems with two speeds in each direction with an electrically-operated, full-magnetic, across-the-line reversing type starter. Use centrifugal switches in control circuit to prevent the plugging of trolley or bridge drive motors; arrange each switch to set the associated drive's brake while attempts are made to plug. Provide the bridge andtrolley main control system with reduced voltage starting for all speed points.

b. Provide ac magnetic control, five-speed, reversing, plugging type bridge and trolley main control systems.

c. Provide ac static stepless secondary saturable reactor bridge and trolley main control systems.Provide control with continuously-adjustable speed from minimum to full speed. Minimum speed with zero hook load shall not exceed 15 percent of full-rated speed.Provide control with speed regulation of 15 percent or less from no-load to full-load at all speed settings.

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 4/13 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 trolley and hang vertically with 5 extra feet of control cable including clip so bottom of pendant at 40 inches above floor. Do not support weight of pendant by control cable, provide cable support system including cable cord grips and cable strain relief to minimize cable tension.

2.4.6.2 Operating Controls

Provide heavy-duty, dust-and-oil-tight type operating pushbuttons or joysticks 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

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PN449862

Bridge Crane Rehabilitation Clearwater Dam 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:

"Emergency STOP"; Pushbutton shall read "Twist-to-Release" mushroom style.

POWER-OFF; red color.

POWER-ON; green color.

Hoist-up.

Hoist-down.

Bridge-forward.

Bridge-Reverse.

Trolley-left.

Trolley-right.

Provide warning lights meeting heavy-duty requirements of NEMA ICS 5 as indicated in this specification. Provide arrow indicators on push buttons pointing to direction of movement.

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 3R 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 control motor overload-protection shall be electronic.

2.4.8 Limit-Switches

Provide heavy-duty quick-break double-pole double-throw type gear limit

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PN449862

Bridge Crane Rehabilitation Clearwater Dam 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 4 limit switch housings. Limit-switches shall interrupt power to the primary control systems. Hoist shall also have a normally-closed, momentary contact, weighted-lever type, actuated directly by the blocks of the lifting beam. The hoist upper limit switch shall be used as a backup upper limit switch if the upper rotary stop limit switch were to fail.

Capable of being reset by reversing the movement of the hoist.

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 blocks. 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 festooned type crane runway conductor system consisting of a support rail, cables, junction boxes, cable cars and accessories.

Hardware shall be corrosion-resistant or protected against corrosion.

Festoon storage area shall not restrict the crane travel at the ends of runway. Do not allow cable loops to drop below the hook high position.

2.4.10.3 Bridge Span Conductors

Provide festooned type consisting of a support rail, electrical cables, junction boxes, cable cars and accessories or rigid conductor/collector type located within enclosure bridge span conductor system. Cable loops shall not drop below the hook high position. Provide corrosion resistant outdoor crane bridge festoon system hardware. Do not allow cable loops to drop below the hook high position.

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PN449862

Bridge Crane Rehabilitation Clearwater Dam

2.4.11 Special Requirements

2.4.11.1 Accessory Power

Use three-phase 480Y/277 volt ac power supplied via a circuit breaker and isolation transformer from the line side of the main line disconnect for lighting, heaters, and accessory circuits on the crane. Provide the circuit breaker with a NEMA Type 3R 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. New Disconnect switches, isolation transformers, panelboard shall be sized and provided by manufacturer instructions based on loads. The panelboards shall supply branch circuits for utilization of various accessories such as receptacles, panel internal lighting, motor heaters and control enclosure which meets NEMA requirements. Provide transformer and panelboard with the same NEMA classification as the circuit breaker.

2.4.11.2 Receptacles

Provide single-phase, 120-volt 20-amp, grounded, duplex type receptacles complete with metal weather-proof enclosure with self-closing weatherproof receptacle cover. Provide a receptacle on the trolley at each end of the front bridge walkway in the vicinity of bridge travel drive motors and in the cab. Provide several receptacles in the vicinity of the control equipment equally spaced every 10 feet. Breakers used to protect circuits supplying the receptacles for outside cranes shall incorporate ground fault current interruption feature and meet the requirements of UL 943 .

2.4.11.3 Lighting

Provide control panels with a 120-volt lamp fixture with an unbreakable lens and switch.

2.4.12 Fungus Resistance

Coat electrical connections such as terminal connections, circuit connections, components and circuit elements with fungus-resistant varnish. Do not treat components and elements which are inherently inert to fungi or hermetically sealed. Do not treat elements whose operation will be adversely affected with the application of varnish.

2.5 ELECTROMAGNETIC INTERFERENCE SUPPRESSION

2.5.1 Shielded Cable

Provide shielded type pendant and festooned cables of braided tinned-copper. Ground each cable shielding with a single connection to equipment grounding conductor.

2.5.2 EMI/RFI Shielded Boxes

2.5.2.1 General

Boxes designed to house electronic and electrical control equipment, instruments, metering equipment, etc., in installations where electromagnetic compatibility and/or system security is required shall protect interior components from stray radio frequency (RF) fields and contain RF signals produced by interior components.

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PN449862

Bridge Crane Rehabilitation Clearwater Dam

2.5.2.2 Construction

Design Electromagnetic Interference/Radio Frequency Interference (EMI/RFI) shielded boxes to meet UL 50 Type 12 and Type 13. Construct the shielded boxes of 14 gauge steel with seams continuously welded and ground smooth, without holes and knockouts. Cover gasket shall be a combination of woven plated steel mesh and oil-resistant gasket which will provide an EMI/RFI seal as well as an oil-tight, dust-tight and water-tight seal between cover and body. Attach gasket to cover with oil-resistant adhesive.

Provide stainless steel cover clamps and screws which are quick and easy to operate on three sides of hinged cover for positive clamping.

2.5.2.3 Attenuation

Design EMI/RFI shielded boxes to provide maximum shielding of electric and magnetic components of radiated RF energy. Provide RF filters to suppress conducted radio frequency in cables and conductors. Provide shielded boxes with attenuation greater than 60 db at 14.5 KHz to greater than 100 db at 1 MHz for magnetic fields and greater than 100 db from 14.5 KHz to 430 MHz for electric fields.

2.5.2.4 Finish

Provide zinc-plated EMI/RFI shielded boxes in accordance with ASTM B633 SC3/Type II to provide corrosion-resistant conductive surfaces for gasket contact area and conduit entries. The finish coat shall match the crane finish.

2.6 LOAD BLOCK AND LIFTING BEAM

Load block shall be disassembled, inspected, and a Load Block Condition Report shall be provided. The lifting beam shall be inspected with disassembly and a Lifting Beam Condition Report shall be provided.

Reports shall give the condition of each component but also offer recommendations of repairs. Any repairs will be paid for using the miscellaneous CLIN's.

2.6.1 Non-Destructive Testing

The following requirements apply:

a. All NDT Procedures shall be submitted for approval.

b. The Load Block and Lifting Beam NDT Report supplier shall submit for approval a letter certifying that the requirements of each type of test are met.

c. The NDT supplier shall develop, and submit for approval, NDT Test Procedures, including technique sheets specific to the types, shapes, and sizes of the parts being examined (e.g., hooks, pins, nuts). For the magnetic particle method, the procedures shall adequately describe the orientation of the hook or nut, or pin with the magnetizing equipment.

d. These procedures shall be reviewed by a Level III examiner who is independent of the NDT supplier and is certified in the applicable NDT method. Each Level III examiner shall submit his certificate for review and Government approval.

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PN449862

Bridge Crane Rehabilitation Clearwater Dam

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. The Contractor is responsible for the coordination and proper relation of the contracted work to the building structure, existing crane structure, and to the work of all trades. Verify all dimensions of the building that relate to fabrication of the crane parts and notify the Contracting Officer of any discrepancy before finalizing the crane order.

3.2 ERECTION

Perform the entire crane erection in accordance with manufacturer's instructions.

3.2.1 Mechanical Alignment

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

3.2.2 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.

3.2.3 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 .

3.2.4 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 97 02 PAINTING, HYDRAULIC STRUCTURES. Paint bridge crane including bridge, trolley, hoist and all attached items in accordance with the manufacturer's standard practice only where work is being performed. 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 nameplates.

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PN449862

Bridge Crane Rehabilitation Clearwater Dam

3.3 FIELD QUALITY CONTROL

A Contractor Post-Erection Inspection and Acceptance Tests Procedures shall be submitted at least ninety (90) days prior to performing any inspections and tests. All inspections and tests shall be in accordance with ASME B30.16 and meet the standards of CMAA 70.

The Government will not attend and the Contractor Post-Erection inspection and acceptance tests shall not be performed until the following have been completed:

a. Submittal and approval of Post-Erection Inspection and Acceptance Tests Procedures including all documents for each test.

b. Submittal and approval of weight test plan.

c. Submittal and approval of the Contractor Post-Erection Inspection and Acceptance Test Report.

3.3.1 Notifications

The Contractor shall notify the Contracting Officer in accordance with the following:

a. a minimum of 14 calendar days in advance of all inspections and tests.

b. a minimum of three (3) business days in advance, any revisions of all inspections or…