41 22 13.71 26 Am-0003.pdf

Intake Crane Replacement - Gavins Point Dam, South Dakota GP00104

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 01 20.71 26

INTAKE GANTRY CRANE DATA, TESTING AND TRAINING

PART 1 GENERAL

1.1 GENERAL INFORMATION

1.2 REFERENCES

1.3 SUBMITTALS

1.4 DATA, CAPACITIES, SPEEDS AND TRAVEL

1.4.1 Definitions

1.4.2 Data, Capacities, Speeds, and Travel

1.4.2.1 Intake Gantry Crane

1.4.2.2 Main Hoist

1.4.2.3 Auxiliary Hoist

1.4.2.4 Jib Hoist

1.4.2.5 Main Hoist Trolley

1.4.2.6 Auxiliary Hoist Trolley

1.5 QUALIFICATIONS

1.5.1 General

1.5.2 Qualified Crane Inspectors

1.5.3 Qualified Craftsmen

1.5.4 Qualified Crane Electricians

1.5.5 Crane Operators

1.6 OPERATING MANUAL FOR THE CAB

PART 2 PRODUCTS

2.1 SPARE PARTS AND SPECIAL TOOLS

2.1.1 Recommended by Manufacturer

2.1.2 Electrical Spare Parts

2.1.3 Mechanical Spare Parts

PART 3 EXECUTION

3.1 EQUIPMENT MONITORING

3.2 NEW GANTRY CRANE SHOP INSPECTION AND TESTING

3.2.1 Shop Inspection and Testing General

3.2.2 Shop Inspections and Testing to be Performed

3.2.3 Level of Crane Assembly for Shop Inspections and Testing

3.2.4 Shop Inspection and Testing Procedure

3.2.5 Shop Inspection and Testing Report

3.3 NEW CRANE SHOP FITMENT AND ALIGNMENT SURVEY

3.4 ONSITE INSPECTION AND TESTING GENERAL

3.4.1 Inspections and Test

3.4.2 On-Site Inspection and Testing Phases

3.4.3 Notifications

3.4.4 Onsite Inspections and Test

3.4.5 Touchup painting

3.4.6 Power Source

3.5 CRANE WEIGHT

3.6 INSPECTION AND TESTING TIMELINE

SECTION 41 22 13.71 26 Page 1

Am-0003

3.6.1 Timeline, General

3.6.2 Pre-Initial Phase

3.6.3 Initial Phase

3.6.4 Between Initial and Final Phases

3.6.5 Final Phase Activities

3.7 TEST WEIGHT

3.7.1 Test Weight Requirements

3.7.2 Below-The-Hook Lifting Devices

3.7.3 Water Bag Requirements

3.7.4 Solid Media Requirements

3.7.5 Test Weight Plan

3.8 INITIAL INSPECTION

3.8.1 General

3.8.2 Initial Inspection Report

3.9 INITIAL NO-LOAD PERFORMANCE TEST

3.9.1 General

3.9.2 Initial No-Load Performance Test Report

3.10 FINAL INSPECTION

3.10.1 General

3.10.2 Final Inspection Procedure

3.10.3 Final Inspection Report

3.10.4 Inspections to be Performed

3.11 ACCEPTANCE TESTING

3.11.1 General

3.11.2 Performance Requirements

3.11.3 Test Sequence

3.11.4 Acceptance Test Procedure

3.11.5 Acceptance Test Report

3.11.6 Data Measurement and Recording

3.11.7 No-Load Performance Test

3.11.8 100 Percent Rated Load Performance Test

3.11.9 125 Percent Rated Load Performance Test

3.12 FUNCTIONAL TESTING

3.12.1 General

3.12.2 Functional Test Procedure

3.12.3 Functional Test Report

3.12.4 Lifting Beam Testing Criteria

3.12.5 Main Hoist Lifting Beam

3.12.6 Trash Rack Lifting Beam

3.12.7 Jib Hoist

3.12.8 Hatch Pick

3.13 TOOL HOIST TESTING

3.13.1 General

3.13.2 Operational Test

3.13.3 Load Test

3.13.4 Testing Report

3.14 MANUFACTURER'S SERVICES

3.14.1 Installation Technicians

3.14.2 VFD Technician

3.15 AS-COMMISSIONED VFD PARAMETERS

3.16 SPEED REDUCER OIL TESTING

3.17 FIELD TRAINING

3.17.1 General Training

3.17.2 Training Materials

3.17.3 General Operation and Maintenance

3.17.4 Solid State Maintenance Training

3.17.5 Personnel Lowering Device

3.18 CRANE ACCEPTANCE

SECTION 41 22 13.71 26 Page 2

-- End of Section Table of Contents --

SECTION 41 22 13.71 26 Page 3

SECTION 41 01 20.71 26

INTAKE GANTRY CRANE DATA, TESTING AND TRAINING

PART 1 GENERAL

1.1 GENERAL INFORMATION

This SECTION covers capacities, inspections, acceptance testing, and personnel training for the new Gavins Point 80-ton Intake Gantry Crane.

Test the crane at the capacities shown in this SECTION.

1.2 REFERENCES

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

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

AGMA 9005 (2002; R 2008) Industrial Gear Lubrication

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B30.2 (2022) Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist)

ASME B30.16 (2022) Overhead Underhung and Stationary Hoists

ASME B30.17 (2020) Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung Hoists)

ASME B30.20 (2018) Below-the-Hook Lifting Devices

ASME BTH-1 (2017) Design of Below-the-Hook Lifting Devices

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 1 (2022) Standard for Industrial Control and Systems: General Requirements

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2024) Safety -- Safety and Health Requirements Manual

1.3 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:

SECTION 41 22 13.71 26 Page 4

SD-01 Preconstruction Submittals

Test Weight Plan; G HDC

Shop Inspection And Testing Procedure; G, HDC

Final Inspection and Acceptance Test Procedure; G, HDC

SD-03 Product Data

Spare Parts And Special Tools; G, HDC

Software, Licenses, And Cables; G, HDC

SD-06 Test Reports

Fitment and Alignment Survey; G, HDC

Crane Weight; G, HDC

Shop Inspection Report; G, HDC

Pre-Final Inspection and Preliminary No-Load Performance Test Report; G, HDC

Final Inspection and Acceptance Test Report; G, HDC

Oil Test Results (After Load Testing); G, HDC

SD-07 Certificates

Non-Contaminated Equipment Certifications; G, EC

Crane Inspectors and Craftsmen and Operators; G, HDC

SD-08 Manufacturer's Instructions

General Operation and Maintenance Training Agenda; G, OPS

Solid State Maintenance Training Agenda; G, OPS

SD-10 Operation and Maintenance Data

Operating Manual For the Cab; G, OPS

SD-11 Closeout Submittals

Training Manuals; G, OPS

As-Commissioned VFD Parameters; G, HDC

1.4 DATA, CAPACITIES, SPEEDS AND TRAVEL

FOR INFORMATION ONLY, THE WEIGHT OF THE EXISTING CRANE IS APPROXIMATELY 174

TONS.

1.4.1 Definitions

Use the following list of terms and definitions throughout this contract:

SECTION 41 22 13.71 26 Page 5

a. Rated capacity (rated load) of the main hoist is defined as the rated capacity of the main hoist lifting beam.

b. Rated capacity (rated load) of the auxiliary hoist is defined as the rated capacity at the load block pins.

c. Rated capacity (rated load) of the gantry crane is defined as the rated capacity of the main hoist.

d. Rated capacity of the jib hoist is defined as the rated capacity at the hook.

e. Rated hoisting speed is defined as the linear velocity of the load when raising at rated capacity.

f. Rated gantry travel speed is defined as the linear velocity travel speed when traveling at the rated capacity of the main hoist.

g. Rated trolley travel speed is defined as the linear velocity travel speed when operating at the largest rated capacity of the hoist on the trolley.

h. The upper limit and lower limit of main hoist travel is defined as the point which the rotary limit switch stops the hoist. For the main hoist, travel is measured from the main hoist lifting beam hook saddles. Additional lift is required to reach the back up limit switches.

i. The upper limit and lower limit of auxiliary hoist travel is defined as the point which the rotary limit switch stops the hoist.

For the auxiliary hoist, travel is measured from the center of the lower load blocks sheaves. Additional lift is required to reach the back up limit switches. Contractor to ensure that the stated upper limit of the auxiliary hoist as defined in these specifications and as shown on the Drawings will allow for the removal and placement of trash racks in a way congruent with the design of the new auxiliary hoist lower blocks, lifting beam, and central trash rack positioning walkway. Adequate clearances must be maintained such that the auxiliary hoist can properly remove and place trash racks.

j. The upper limit and lower limit of jib hoist travel is defined as the point which the rotary limit switch stops the hoist. For the jib hoist, travel is measured from the bottom of the log grapple style lifting attachment when it is attached to the jib hoist and in the closed position. Additional lift is required to reach the back up limit switches.

1.4.2 Data, Capacities, Speeds, and Travel

1.4.2.1 Intake Gantry Crane

Data, capacities, travel distances, and rated speeds of the crane are as follows:

a. Rated Capacity, Tons (2,000 pounds)

b. Rated Gantry Travel Speed, Feet Per Minute

c. Gantry Span, Feet...................................... 30.25

d. Total Gantry Travel is the length of the intake deck

SECTION 41 22 13.71 26 Page 6 runway, Feet............................................... 334.67

1.4.2.2 Main Hoist

a. Rated Capacity, Tons

b. Rated Hoisting Speed (Rated Load), Feet Per Minute

c. Lifting Beam Hook Saddle Travel, Feet:

Upper limit of travel not lower than Elevation Lower limit of travel not higher than Elevation

d. Clearance Between Intake Deck and Hook Saddle, Feet

1.4.2.3 Auxiliary Hoist

a. Rated Capacity, Tons

b. Rated Hoisting Speed (Rated Load), Feet Per Minute

c. Lower Load Block Sheave Travel:

Upper limit of travel not lower than Elevation...... 1259.125 Lower limit of travel not higher than Elevation..... 1149.5

d. Slope of the Face of the Dam, Rise to Run.............. 12:1.75

1.4.2.4 Jib Hoist

a. Rated Capacity, Tons

b. Rated Hoisting Speed (Rated Load), Feet Per Minute

c. Rated Slewing Speed (Rated Load), Degrees Per Minute... 60

d. Radial Reach, Feet

e. Hook Travel, Feet:

Upper limit of travel not lower than Elevation...... 1249.5 Lower limit of travel not higher than Elevation..... 1119.5

1.4.2.5 Main Hoist Trolley

a. Rated Trolley Travel Speed, Feet Per Minute

b. Total Trolley Travel, Feet, ........................... 22.33

1.4.2.6 Auxiliary Hoist Trolley

a. Rated Trolley Travel Speed, Feet Per Minute

b. Total Trolley Travel, Feet, ........................... 30.5

1.5 QUALIFICATIONS

1.5.1 General

Data showing that crane inspectors and craftsmen and operators meet the following qualifications must be submitted for approval:

1.5.2 Qualified Crane Inspectors

Crane inspectors must meet the following requirements:

a. Have experience and knowledge in performing inspection on cranes of similar size and capacity as the Gavins Point intake crane.

b. Have an active Crane Inspector Certification for Overhead Cranes from the National Commission For The Certification of Crane Operators (NCCCO) proving they meet the NCCCO qualifications and requirements.

Certifications issued by the Contractor do not meet this requirement.

SECTION 41 22 13.71 26 Page 7

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

d. Demonstrate by providing a resume for each crane inspector submitted. Resume must show they have the minimum years experience;

include name of firm they were employed by, name of project(s) they worked on, contract number, project location, contract point of contact (POC) with contact information (address, phone number, e-mail), crane type and capacity, and describe relevant crane experience. Crane experience must be on gantry cranes with a minimum capacity of 30 tons.

1.5.3 Qualified Craftsmen

Craftsmen in both field and shop environments must meet the following requirements:

a. Have experience and knowledge in performing work on cranes of similar size and capacity as the new intake crane specified in this contract.

b. Have continuously performed work on gantry cranes as defined by ASME B30.2 of similar size and capacity as the new intake crane specified in this contract crane for at least five years.

c. Have been employed for at least the last two years by a firm specializing in crane work.

d. Have extensive and continuous experience and knowledge of erecting an overhead crane of similar size and capacity as the new gantry crane specified in this contract for at least three years.

1.5.4 Qualified Crane Electricians

There must be a minimum of one licensed electrician during field and shop wiring and critical aspects of the crane field work.

1.5.5 Crane Operators

Crane operators shall meet the requirements in USACE EM 385-1-1, Section 16 and Appendix G. In addition, for mobile cranes with Original Equipment Manufacturer (OEM) rated capacitates of 50,000 pounds or greater, crane operators shall be designated as qualified by a source that qualifies crane operators (i.e., union, a government agency, or and organization that tests and qualifies crane operators). Proof of current qualification shall be provided.

1.6 OPERATING MANUAL FOR THE CAB

Submit an electronic operating manual for the cab. Also provide a hardcopy of an operating manual for each operator cab separate from the operations and maintenance manual specified in SECTION 01 78 00 OPERATIONS AND MAINTENANCE MANUAL. The operating manual must include, but not be limited to:

a. Crane rating, make, model, serial number, year of manufacture, and manufacturer's name.

b. Hoist load ratings, speeds, and limits.

SECTION 41 22 13.71 26 Page 8

c. Trolley and gantry travel speeds and limits.

d. Crane general arrangement and overview drawings.

Note: Include the elevation and envelope coverage drawing for all hooks.

e. Hoist general arrangements and overview drawings.

f. Trolley general arrangements and overview drawings.

g. Operating instructions and warnings.

PART 2 PRODUCTS

2.1 SPARE PARTS AND SPECIAL TOOLS

2.1.1 Recommended by Manufacturer

a. Spare parts and special tools in accordance with manufacturers' recommendation for all systems supplied must be furnished.

Additionally, as a minimum but not limited to, provide spare parts and special tools as specified below. Submit a list of all Spare Parts and Special Tools for approval. All spare parts must consist of the same material and workmanship, meet the same requirements, and be interchangeable with the corresponding original parts furnished for systems as outlined in SECTION 41 22 13.73 26 INTAKE GANTRY CRANE ELECTRICAL COMPONENTS and SECTION 41 22 13.72 26 INTAKE GANTRY CRANE MECHANICAL AND STRUCTURAL WORK. Carefully pack spare parts for long-term storage and protection, legibly label, identifying service and manufacturer's part numbers. Include a list of the furnished spare parts in the Operation and Maintenance Manuals in accordance with SECTION 01 78 23 OPERATION AND MAINTENANCE DATA. For parts that are not proprietary to the Contactor, provide both Contractor's part number and the original equipment manufacturer's part number, and for parts that are interchangeable, also supply exchange part numbers from other manufacturers if applicable.

b. Provide spare parts and special tools as listed below.

c. Deliver spare parts with documentation to facilitate entry into existing government warehouse system. Include a spreadsheet (in a digital, editable Microsoft Office document as well as a hard copy format) containing each part provided. At minimum, list the part name, original manufacturer's part number (and, if different, also list the crane manufacturer's part number), list price, and the original manufacturer's name, phone, and address in columns. If the part is interchangeable with units from other manufacturers, include the appropriate exchange part numbers. Ensure parts sourcing is sufficient to allow the Government to procure the part from either the crane manufacturer, directly from the original parts manufacturer, or a third-party supplier. Furnish and deliver spare parts to the site, suitably packaged for long-term protection and storage. Ensure the packaging is legibly labeled to identify the spare parts and that they are for the Powerhouse Gantry Crane. For any parts having an expiration or use-by date, clearly mark this on the packaging.

SECTION 41 22 13.71 26 Page 9

2.1.2 Electrical Spare Parts

Electrical spare parts to include, at a minimum:

a. One complete variable frequency drive (VFD), including dynamic braking unit, of each type and size used.

b. Six keys for each cabinet door lock on the crane.

c. Six fuses of each type and rating used.

d. One control transformer of each type and rating used.

e. Two replacement control relays of each type used.

f. One limit switch of each type used for hoists and travel.

g. One complete brake rectifier assembly of each type used.

h. Four complete sets of contacts used by the main line contactor.

i. Two complete control selector switch assemblies of each type used.

j. Two complete pushbutton assemblies of each type used.

k. One complete master control switch assembly of each type used.

l. Four replacement rubber boots for the master control switch assemblies of each type used.

m. Two indicating light assemblies of each type used.

n. Six lamps of each type used in indicating lights.

o. One replacement encoder of each type used.

p. One thruster actuator for each type used.

q. One complete remote radio transmitter fully programmed and ready for use

r. Three sets of remote (radio) control batteries with expiration dates clearly marked.

s. Two replacement bulbs for each type of lighting used.

2.1.3 Mechanical Spare Parts

Mechanical spare parts must include at a minimum:

a. One set of brake shoes for each different brake.

b. One spare gear motor for each type used.

c. Ten replacement filter elements of each type used.

d. Two couplings for each type used.

e. Twenty silica-gel desiccant breathers for each type used.

SECTION 41 22 13.71 26 Page 10

f. One set of bearings and seals for each size and type of motor.

g. One set of replacement oil seals for each type gearbox and gearmotor used

h. One brake coil of each type used.

i. One brake release hydraulic actuator (thruster) of each type used.

In addition to the above, any spare parts not included in the above list and recommended by equipment manufacturers must be provided.

PART 3 EXECUTION

3.1 EQUIPMENT MONITORING

During all inspections and testing, improper operation or poor condition of safety devices, electrical components, mechanical equipment, and structural assemblies must be monitored and recorded or otherwise documented. Immediately report to the Contracting Officer any observed defects critical to continued inspection or testing. Suspend inspection and testing activities until the deficiency has been corrected. After corrective action has been taken, the tests must be continued or rerun as directed until the contract requirements are met. The following inspections must be made:

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

b. Visually examine the motors, brakes, gearing, and other mechanical or electrical equipment to ensure no damage has occurred.

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

d. Check for overheating in brake operation; check for proper stopping. Inspect and test all safety devices, including emergency stop switches and power off pushbuttons, separately, to verify proper operation of the brakes.

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

f. Monitor gantry and trolley travel for binding and skewing.

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

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

i. Check electrical drive components for proper operation, freedom from chatter, noise, or overheating.

j. Remove inspection covers from gear reducers for inspection of gearing after all testing.

k. All functions of the crane must be demonstrated for proper

SECTION 41 22 13.71 26 Page 11 operation. This includes but not limited to all alarms and all limit switches for proper operation.

3.2 NEW GANTRY CRANE SHOP INSPECTION AND TESTING

3.2.1 Shop Inspection and Testing General

Perform a Shop Inspection, also known as Factory Acceptance Testing (FAT).

Perform the inspection and operational test of the new gantry crane prior to shipping the individual assemblies from the shop. Prior to testing, mechanical and electrical equipment must be completely manufactured, adjusted, lubricated, and otherwise made ready for operation. Deficiencies that were discovered during the FAT must be corrected and retested. All deficiencies must be corrected before the crane is shipped to the powerhouse.

The inspection and testing must be performed in the presence of a designated Government witness, unless waived in writing. Prepare and submit a Shop Inspection and Testing Procedure a minimum of 45 days prior to performing in-shop inspections. If shop inspection and testing is planned for a facility outside the United States, notify the Government a minimum of 60 days in advance of the dates of the in-shop inspection and testing. Notify the Contracting Officer, a minimum of three business days in advance, of any revisions of the dates for the Shop Inspection.

Include in the Shop Inspection procedure applicable portions of the Final Inspection and the No-Load Performance Test. Inspection and no-load performance test must be performed by qualified crane inspectors and findings recorded.

3.2.2 Shop Inspections and Testing to be Performed

Perform inspections in accordance with the requirements of the Final Inspection, as specified in the PARAGRAPH: FINAL INSPECTION, of this SECTION. Inspect the control system in accordance with NEMA ICS 1 . All inspections must be made by personnel approved as crane inspectors, per PARAGRAPH: Qualified Crane Inspectors.

Perform operational testing in accordance with the requirements of the No-Load performance test as specified in the PARAGRAPH: ACCEPTANCE TESTING, of this SECTION. Perform operational testing of the control systems in accordance with NEMA ICS 1 . Perform operational testing and confirm functionality using the cab and the radio controls including all radio transmitters provided.

During all inspections and testing, monitor equipment as specified in PARAGRAPH: Equipment Monitoring During Inspections and Testing, of this

SECTION.

3.2.3 Level of Crane Assembly for Shop Inspections and Testing

At a minimum the crane must be assembled in the shop as follows:

a. Trolleys completely assembled with complete main and auxiliary hoist and trolley drive(s). Do not install the wire rope on the drums until after shop testing is completed. At a minimum, support the trolley in a manner that allows the trolley drive to freely operate.

b. Gantry trucks and drive(s) completely assembled. The gantry trucks

SECTION 41 22 13.71 26 Page 12 do not need to be attached to the gantry legs and the gantry girders do not need to be bolted together. At a minimum, support the gantry trucks in a manner that allows the gantry drives to freely operate.

c. Control systems, this includes the operator cab and chair, must be complete and fully assembled. Applicable equipment includes, but is not limited to: control and protective panels, variable frequency drives (VFD) and dynamic braking resistors, and radio control system including all transmitters. It is acceptable to use temporary wiring to connect the control and power systems to the associated drives.

d. Jib hoist completely assembled with complete slew drive. At a minimum, support the jib hoist in a manner that allows the slew drive to freely operate.

3.2.4 Shop Inspection and Testing Procedure

Prepare and submit a Shop Inspection and Testing Procedure that contains the following elements, at a minimum:

a. A list of names and contact information for key Contractor personnel who will be involved with the inspections; including the qualified crane inspectors.

b. Location of test.

c. A checklist for verifying the fabricated and assembled equipment is accurate.

d. A checklist of each inspection and/or test to be performed. For each inspection or test to be performed, include the criteria that must be met for the test to be considered successful.

e. A step-by-step, repeatable procedure for each inspection and test to be performed.

f. A list of equipment that will be used during the inspections and testing.

g. Sample data sheet(s) or form(s) that inspection data will be recorded on.

3.2.5 Shop Inspection and Testing Report

Prepare and submit a Shop Inspection and Testing Report after completing the shop inspections and testing. At a minimum, include the following elements in the test report:

a. Date(s) that inspections and testing took place.

b. List of Contractor and Government personnel present during inspections and testing.

c. Completed checklists and data sheets verifying all inspections and tests were successfully performed. Completed checklists and data sheets must have signatures from the Contractor and designated Government witness present that verify that all inspections and tests were completed successfully.

SECTION 41 22 13.71 26 Page 13

d. Descriptions of any deficiencies that were discovered during the testing. If no deficiencies were found, state it in the report. If deficiencies were found, include a description of the means and measures taken to correct the deficiency, as well as verification that the deficiency has been corrected and tests were re-run.

e. Photographs taken during the inspection and testing, including but not limited to the test set up, the equipment arrangement, and any deficiencies found and the result after correction.

Provide the Government witness that is present for the inspections and testing with a copy of the completed checklists and data sheets.

3.3 NEW CRANE SHOP FITMENT AND ALIGNMENT SURVEY

Assemble finished crane structures in the shop and check for conformity to dimensional tolerance and alignment requirements prior to shipping to the work site for final assembly. Complete an optical or laser survey to verify the crane meets required erection tolerances as required per SECTION 05 05 23.17 26. Submit a fitment and alignment survey report for approval.

3.4 ONSITE INSPECTION AND TESTING GENERAL

3.4.1 Inspections and Test

After the crane has been completely assembled onsite, adjusted, lubricated, and otherwise made ready for operation, perform inspections and acceptance tests as specified herein.

For all inspections and tests, provide all personnel and equipment necessary to conduct the tests including but not limited to crane operators, riggers, data recorders (personnel), rigging gear, test weights, and measuring instruments.

3.4.2 On-Site Inspection and Testing Phases

Perform on-site inspection and testing in two phases: Initial and final.

The purpose of the initial phase is to have a trial run and to ensure all deficiencies are discovered and corrected before the final phase. It is not required that the Government witness the activities performed during the initial phase.

Do not perform any final phase activities without the presence of the designated Government witness, unless previously waived in writing.

Initial phase activities consist of the following:

(1) Initial Inspection

(2) Initial No-Load Performance Testing

Final phase activities consist of the following:

(1) Final Inspection

(2) Acceptance Testing

(3) Functional Testing

SECTION 41 22 13.71 26 Page 14

3.4.3 Notifications

Notify the Contracting Officer in accordance with the following:

a. a minimum of 14 calendar days in advance, the date of the Pre-Final inspection and Preliminary No-Load Performance Test.

b. a minimum of three (3) business days in advance, any revisions of the date of the Pre-Final inspection and Preliminary No-Load Performance Test.

3.4.4 Onsite Inspections and Test

The Contracting Officer and HDC representatives will be onsite for the Final Inspection and Acceptance Test Procedure.

3.4.5 Touchup painting

Touchup painting may be performed after completion of acceptance testing.

3.4.6 Power Source

Test the crane using the primary power source which is via bus.

3.5 CRANE WEIGHT

The weight of the entire crane and the trolleys must be physically verified once it is completely assembled. The procedures and equipment used to obtain the crane weights must be submitted along with the weight information which must be included in the operation and maintenance manual. The total weight of the crane and the weight separate components such as the trolley and gantry structure must be recorded on the FINAL

APPROVED VERSIONS OF CONTRACTOR PREPARED DRAWINGS.

3.6 INSPECTION AND TESTING TIMELINE

3.6.1 Timeline, General

Perform inspection and testing after the crane has been completely assembled on-site, adjusted, lubricated, and otherwise made ready for operation. The following sub-paragraphs list the required notification windows, submittal windows, and other time sensitive actions during the inspection and testing period.

3.6.2 Pre-Initial Phase

a. Submit all inspection and testing procedures a minimum of 45 days prior to the planned start of initial phase activities. The procedures that need to be submitted and approved before inspection and testing can proceed are:

(1) Inspection Procedure

(2) Acceptance Test Procedure

(3) Test Weight Plan

b. Inspection and testing activities must not begin until the

SECTION 41 22 13.71 26 Page 15 following has occurred:

(1) Shaft Alignment, per SECTION 41 22 13.72 26 INTAKE GANTRY CRANE MECHANICAL AND STRUCTURAL WORK, Paragraph SHAFT ALIGNMENT is complete and the alignment report has been approved by the Government.

(2) Dynamic Balancing of Machinery, per SECTION 41 22 13.72 26 INTAKE GANTRY CRANE MECHANICAL AND STRUCTURAL WORK, Paragraph DYNAMIC BALANCING OF MACHINERY is complete and the Dynamic Balancing Report has been approved by the Government.

(3) Gantry Frame Alignment Survey, per SECTION 41 22 13.72 26 INTAKE GANTRY CRANE MECHANICAL AND STRUCTURAL WORK, Paragraph GANTRY FRAME ALIGNMENT SURVEY is completed and the Alignment Survey Report has been approved by the Government.

(4) Wheel Alignment Survey, per SECTION 41 22 13.72 26 INTAKE GANTRY CRANE MECHANICAL AND STRUCTURAL WORK, Paragraph WHEEL ALIGNMENT SURVEY is completed and the Wheel Alignment Survey Report has been approved by the Government.

(5) Wire Rope Magnetic Flux Leakage Test, per SECTION

41 22 13.72 26 INTAKE GANTRY CRANE MECHANICAL AND STRUCTURAL WORK

*Am-3 , Paragraph: Wire Rope Flux Leakage Testing **Am-3 .

(6) All Crane Design Data package submittals, per SECTION

41 22 13.72 26 INTAKE GANTRY CRANE MECHANICAL AND STRUCTURAL WORK

and 41 22 13.74 26 INTAKE GANTRY CRANE ELECTRICAL WORK have been submitted to and approved by the Government with no resubmittal required ("A" or "B" Code).

(7) Draft copies of the Operations and Maintenance Manuals have been submitted to and approved by the Government ("A", "B", or "C" Code).

(8) The Operating Manual has been submitted, per this SECTION, and been approved with no resubmittal required ("A" or "B" Code).

(9) Draft copies of the As-Built Drawings have been submitted to and approved by the Government ("A", "B", or "C" Code).

3.6.3 Initial Phase

a. Notify the Government, a minimum of 7 calendar days in advance, the planned start of any inspection or test.

b. Submit the Initial Inspection Report within 1 business day of completing the inspections.

c. Submit the Initial No-Load Performance Test Report within 1 business day of completing the testing.

3.6.4 Between Initial and Final Phases

Allow the Government a minimum of two full business days to review the Initial Inspection and No-Load Performance Test Reports prior to start of final phase activities. "Two full business days" constitutes the Government receiving the reports electronically, not later than 0800 hours

SECTION 41 22 13.71 26 Page 16 of the first date of review, to allow all Government reviewers adequate time to review the reports.

3.6.5 Final Phase Activities

a. Notify the Contracting Officer, a minimum of 14 calendar days in advance, the planned start of any inspection or test.

b. Notify the Contracting Officer, a minimum of five business days in advance, any revisions to the dates of the final inspections and acceptance tests.

c. The designated Government witnesses will be on site for the final inspection and acceptance tests no earlier than one (1) business day after approval of the Initial Inspection Report and Initial No-Load Performance Test Report.

d. Final inspection and acceptance testing must be conducted within the following hour and day restrictions. Written permission from the Contracting Officer is required to deviate from the following:

(1) The final inspection and acceptance testing must occur on separate days.

(2) The final inspection and acceptance testing must not occur during the week of a Federal Holiday, the final two weeks of the calendar year, or on weekends.

(3) Accomplish final inspection and acceptance testing activities on a Monday through Thursday schedule.

(4) Government personnel will be available for the final inspection and acceptance testing for a maximum of 12 continuous hours in a 24 hour time period.

e. Government witness representatives will not arrive onsite until all test materials and Contractor personnel are on-site and ready for testing.

f. Provide the Final Inspection Report and copies of all collected data to the Government representatives. On-site approval of the inspection report is required before the acceptance tests can begin.

h. All collected data must be provided to the Government and discussed at an onsite review meeting after the Final Inspection before performing the No-Load Performance testing, and after the No-Load Performance Testing before performing Load Testing (100% and 125%). If there are unexpected results or inconsistencies in the data, that portion of the test must be rerun to verify the data. Any repairs and adjustments must be made prior to completion of the test and appropriate portions of the test must be rerun. The testing maybe re-run as many times as necessary in order to successfully complete that portion of the testing.

3.7 TEST WEIGHT

3.7.1 Test Weight Requirements

Test loads must weigh within plus 5 percent, minus 0 percent, of the

SECTION 41 22 13.71 26 Page 17 nominal load. Test weights may be solid media or water bags.

3.7.2 Below-The-Hook Lifting Devices

Any Contractor-provided below-the-hook (BTH) lifting devices must be clearly marked with the rated load of the device. The design, fabrication, marking, and load testing of the devices must conform to ASME B30.20 , ASME BTH-1, and EM 385-1-1 .

If BTH lifting devices are custom fabricated or not pre-engineered, include design calculations in the Test Weight Plan. Design calculations must meet the requirements of 41 22 13.75 26 LIFTING BEAM AND BELOW-THE-HOOK LIFTING DEVICES. Perform all fabrication or modification of custom fabricated below-the-hook lifting devices in accordance with

SECTIONS: 05 05 23.17 26 WELDING (STEEL), FABRICATION, AND MACHINE WORK

and 05 50 04.00 26 METALS: MATERIALS, PRODUCTS, AND MISCELLANEOUS ITEMS.

All BTH lifting devices must be load tested prior to being used on-site for load testing. If a device has been previously load tested, include the documentation of the load test in the test weight plan. If a load test is required, notify the Government a minimum of 14 days prior to the planned date of the load test so that the Government may witness the load test.

3.7.3 Water Bag Requirements

If water bags are used as the test weight media, observe the following requirements:

a. Maintain clearance from electrical equipment.

b. Provide means of pumping water into the water bags from the forebay, and after testing, a means of draining the bags into the forebay. Do not drain water bags into the powerhouse drainage system. Size pumps, piping/headers and valves such that the total time to fill the main hoist water bags from 0-100% is no longer than four (4) hours. Use basket strainers that are approved by the pump manufacturer on the pump suction.

c. Check water bags, hoses, valves, and other associated equipment for leaks prior to using them on-site. Replace leaking equipment so that the volume of spilled water is minimized.

d. The river water at Gavins Point Dam contains invasive species. It is the contractor's responsibility to clean all water bag and test equipment after the completion of testing to prevent the spread of invasive aquatic species to other water bodies.

3.7.4 Solid Media Requirements

If solid media is used as the test weight, observe the following requirements:

a. Solid media must be able to be stacked in under four hours (i.e.

for each iteration of load testing, assembly of the solid media for testing must not require more than 4 hours).

b. The test weights must be designed to be stacked on the intake deck without being suspended by a crane.

SECTION 41 22 13.71 26 Page 18

c. Stacking of the solid media test weights must not damage the intake deck or exceed intake deck load limits in any configuration.

3.7.5 Test Weight Plan

Prepare and submit a Test Weight Plan that contains the following:

a. Type of test weight.

b. Test weight handling and setup procedure, including but not limited to sequence of operations and methods of keeping the load stable. In general, the intake deck is designed for a live load of 1000 psf, and most hatch covers are designed for AASHTO HS20 truck loads. A load plan must be submitted for heavy equipment and for test weights for approval showing dimensioned and labeled anticipated loads and equipment to be used during the load test for government approval.

c. Detailed drawings showing test weight configuration with the crane, intake deck, and other features shown on the drawings. Show details of lifting beams, shackles, slings, and related equipment. If water weights are used, show the configuration of the fill and drain system, and deck protection measures. Lifting devices must be used in accordance with their design; for instance, if a lifting beam is designed to have the middle waterbags filled first and the end waterbags filled last due to the angle at which the bags hang from the lifting beam ears, that order of water bag filling must be observed.

d. Detailed procedure for how the load applied to the crane will be measured and verified.

e. Documentation for any below the hook lifting devices as required.

f. Copies of up-to-date calibration certificates for any instrumentation that is going to be used.

3.8 INITIAL INSPECTION

3.8.1 General

The Initial Inspection requirements and procedure are identical to the Final Inspection. Perform the initial inspection in accordance with the approved Final Inspection Procedure.

Only approved, qualified crane inspectors will be allowed to perform crane inspections.

Correct any deficiencies or anomalies prior to preparing and submitting the inspection report.

3.8.2 Initial Inspection Report

Prepare and submit an Initial Inspection Report after all initial phase inspections are complete. The report must include the following elements, at a minimum:

a. Completed inspection checklist.

b. Discussion of any deficiencies that were discovered during the

SECTION 41 22 13.71 26 Page 19 inspections. If no deficiencies were found, state it in the report.

c. If deficiencies were found, include a description of the means and measures taken to correct the deficiency as well as verification that the deficiency has been corrected and re-inspected.

3.9 INITIAL NO-LOAD PERFORMANCE TEST

3.9.1 General

The Initial No-Load Performance Test requirements and procedure are identical to the No-Load Performance Test that is performed during Acceptance Testing. Perform the Initial No-Load Performance Test in accordance with the procedures of the approved Acceptance Test Procedure.

Correct any deficiencies or anomalies prior to preparing and submitting the test report.

3.9.2 Initial No-Load Performance Test Report

Prepare and submit an Initial No-Load Performance Test Report, after all Initial Phase No-Load Performance tests are complete. Include the following elements in the report, at a minimum:

a. A narrative summary that describes the testing that took place.

Include notation that all planned tests were completed with successful outcomes.

b. Completed inspection checklist and verification each required inspection was successfully completed.

c. Descriptions of any deficiencies that were discovered during the testing. If no deficiencies were found, state it in the report.

d. If deficiencies were found, include a description of the means and measures taken to correct the deficiency, as well as verification that the deficiency has been corrected and tests were re-run.

3.10 FINAL INSPECTION

3.10.1 General

Perform a Final Inspection. Correct any deficiencies that are discovered during inspections, and repeat portions of inspections to verify corrections prior to preparing and submitting the inspection report.

Only approved, qualified crane inspectors will be allowed to perform crane inspections.

The Final Inspection is the inspection that is witnessed by the Government. Do not perform the Final Inspection until the following has occurred:

a. The Initial Inspection Report has been submitted and approved by the Government.

b. The Initial No-Load Performance Test Report has been submitted and approved by the Government.

SECTION 41 22 13.71 26 Page 20

3.10.2 Final Inspection Procedure

Prepare and submit a Final Inspection Procedure. Include the following elements in the procedure, at a minimum:

a. A list of names and contact information for key Contractor personnel who will be involved with the inspections; including the qualified crane inspectors.

b. A checklist of all inspections to be performed.

c. A step-by-step, repeatable procedure for each inspection to be performed.

d. A list of equipment that will be used during the inspections.

e. Sample data sheet(s) or form(s) that inspection data will be recorded on.

3.10.3 Final Inspection Report

Prepare and submit a Final Inspection Report immediately after all final inspections are complete. Include the following elements in the report, at a minimum:

a. A brief narrative summary that describes the inspections that took place.

b. Completed inspection checklist and verification each required inspection was successfully completed.

c. Descriptions of any deficiencies that were discovered during the inspections. If no deficiencies were found, state it in the report.

d. If deficiencies were found, include a description of the means and measures taken to correct the deficiency as well as verification that the deficiency has been corrected and re-inspected.

3.10.4 Inspections to be Performed

Perform all inspections as required by ASME B30.2 , Periodic Inspection.

Perform the following additional inspections:

a. Verify that the work to be performed under this contract was completed, including all cleaning activities.

b. Test all auxiliary equipment for proper operation and calibration, including, but not limited to - load cells, cable carrier, reels or festoons, storm brakes, locking and indicating devices. Verify all indication lamps and warning devices operate correctly. Verify convenience receptacles operate correctly.

c. Brakes - For each brake, verify the following:

(1) Brake Wheels - Verify that brake wheels have been burnished in accordance with the manufacturer's instructions.

(2) Pad Clearance - Verify that brake pad clearance is correctly adjusted to be within the manufacturer's recommended range.

SECTION 41 22 13.71 26 Page 21

(3) Torque Settings - Physically verify and test that brake torque settings are correct.

(4) Emergency Stop - For each hoist, trolley and gantry, while slowly operating the machinery (less than 25% rated speed), disconnect the main power source by pressing one of the emergency stop push buttons. Verify the brake(s) set(s) and that there are no more than 1/4 of a brake wheel revolution after the brake(s) set(s). Re-perform the test at fast speed.

(5) Hoist Brake Setting Delay Test - For hoists with two brakes, verify that second brake sets approximately 1 second after the first brake.

d. Hoists - For each hoist, verify the following:

(1) Range of Speed - Verify the hoist operates correctly across the entire speed range in each direction, at normal speed, slow speed and fast speed selections. Verify correct brake operation.

(2) Fast Speed - Verify proper operation of the VFD fast speed control feature as described in SECTION 41 01 20.73 26, NEW GANTRY CRANE ELECTRICAL WORK. Verify that the fast speed is only enabled when selected and only with light loads.

(3) Brake Failure Detection - Verify proper operation of the VFD brake failure detection feature as described in SECTION 41 01 20.73 26 NEW INTAKE GANTRY CRANE ELECTRICAL WORK. Simulate a brake failure by manually releasing the brakes and manually turning the motor shaft as needed; verify VFD detects and responds to the simulated brake failure as described in SECTION

41 01 20.73 26 NEW INTAKE GANTRY CRANE ELECTRICAL WORK.

(4) Lower Blocks - Verify that the hoist load blocks hang with no visible twist.

(5) Wire Rope - Verify that wire rope fleet angles are acceptable by physically measuring distances to show that they match the submitted calculations and drawings.

(6) Bolt Torque - Verify that all mechanical fasteners are torqued to the value specified in the Bolt Tension Chart, per SECTION

41 22 13.72 26, NEW INTAKE GANTRY CRANE MECHANICAL AND STRUCTURAL

WORK.

e. Hoist Limits - Verify the operation of all upper and lower limit switches on each hoist. Set hoist limits before the FINAL INSPECTION in accordance with maximum and minimum hook elevations per paragraph DATA, CAPACITIES, SPEEDS, AND TRAVEL and as specified in SECTION

41 22 13.72 26, NEW INTAKE GANTRY CRANE ELECTRICAL WORK.

(1) Hoist Upper Rotary Limit (Primary Upper Limit) - Raise the hoist until the primary upper rotary limit switch is reached.

Verify that the hoist stops after the limit switch is reached and that a minimum of one empty groove is left in the wire rope drum.

Verify that the rotary upper stop limit stops the load blocks before they reach the upper weighted block limit switch. Verify elevation of the load blocks at the upper rotary limit using

SECTION 41 22 13.71 26 Page 22 physical or optical measurement tools. Verify that the hoist cannot be raised and is only capable of lowering.

(2) Hoist Weighted Upper Limit (Secondary Upper Limit) - Use the bypass keyswitch to bypass the upper rotary limit. Raise the hoist until the weighted limit switch is tripped. Verify the hoist motion stops and the hoist is inoperable in both the lowering and raise directions. Verify that the limit stops the load prior to two-blocking without the benefit of a programmed ramp rate. Use the bypass keyswitch to bypass the weighted upper limit. Verify that the hoist is not operable in the raise direction and is only operable in the lowering direction.

(3) Lower Limit Switches - Lower the hoist until the primary lower limit switch is reached. Verify that the hoist stops after the limit switch is reached. Verify elevation of the load blocks at the lower rotary limit using physical or optical measurement tools. Verify that the hoist cannot be lowered, but is possible to operate in the raise direction. Manually activate the lower limit switch if the blocks cannot be lowered to the lowest elevation;

verify that when the lower limit switch is actuated, there will be at least 3 wire rope wraps remaining on the drum. Physically verify that the blocks are capable of reaching the lowest elevation.

(4) Slowdown Limits - While raising and lowering the hoist, verify that the rotary limit switches activate the slowdown limits prior to activating the primary limits.

f. Verify the main and auxiliary hoist load blocks are level with each other within 3/16-inch at any location of the lift under both unloaded and loaded conditions. Measurements must be made at five (5) approximately equally spaced load block elevations for each test.

g. Verify the functionality of the main and auxiliary hoists.

(1) Verify that the main and auxiliary hoists are capable of attaching to all new bulkheads, gates, trash racks, lifting devices or other equipment that they are designed to handle. Verify that each hoist is capable of properly interfacing with new equipment (i.e. new lifting devices) and equipment to be reused (existing lifting devices to be reused, gates, bulkheads, trash racks, etc.).

h. Verify the function of the jib hoist.

(1) Verify that the new log grapple style lifting attachment and the existing clamshell bucket lifting attachment can both be attached and operated by the jib hoist holding and operating lines.

(2) Verify that the jib hoist is capable of rotating through its entire range of operation and that its holding and operating lines are functional.

i. Gantry and Trolley Travel Operation - For the gantry and each trolley, verify correct operation across the entire speed range, in each direction, at normal speed and slow speed directions. Over the complete length of travel of the gantry and each trolley verify that:

(1) Travel operation is smooth;

SECTION 41 22 13.71 26 Page 23

(2) No binding on the rails occurs;

(3) The wheel flanges do not continuously contact the rail head while traversing the runway at any speed;

(4) When wheel flanges contact the rail head, they must immediately begin to realign with the center of the rails and that the wheels do not continue to contact the side of the rail head;

(5) There is no screeching or other abnormal noises caused by contact between the rail head and wheels.

j. Gantry and Trolley Travel Limits - For the gantry and trolley verify the correct activation and setting of all travel limits to slow or stop the gantry or trolley. When the slow speed limit is activated, the travel speed must be limited to 25% rated speed. If the gantry or trolley is traveling faster than 25% rated speed when the limit switch is tripped, the travel speed must slow to 25% rated speed. When the stop limit is activated, the gantry or trolley must decelerate to a stop. The gantry or trolley must be able to reverse out of either the slow speed limit or stop limit at rated speed or slow speed (if selected).

k. Emergency Stop Pushbuttons - Verify correct operation of every emergency stop pushbutton (operator chair, all remote controls, and gantry legs). To verify correct operation, activate each pushbutton and verify that all power is removed from the crane's motion circuits (the main line contactor opens).

l. Remote Control - Verify all functions of the remote control operation.