41 22 13.72 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 22 13.72 26

INTAKE GANTRY CRANE MECHANICAL AND STRUCTURAL WORK

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

1.2 REFERENCES

1.3 SUBMITTALS

1.4 NEW INTAKE GANTRY CRANE

1.4.1 General

1.4.2 Trolleys

1.4.3 Functions

1.4.4 Crane Electrification

1.4.5 Jib Hoist

1.4.6 Below the Hook (BTH) Lifting Devices

1.4.7 Testing

1.4.8 Sequence of Work

1.5 DESIGN CRITERIA

1.5.1 General

1.5.2 Definitions

1.5.3 Data, Capacities, Speeds, and Travel

1.5.4 Design Loads and Combination of Loads

1.5.4.1 General

1.5.4.2 Dead Loads

1.5.4.3 Live Loads

1.5.4.4 Combinations of Loads

1.5.5 Structural Design Criteria

1.5.5.1 Fatigue Design

1.5.5.2 Stability

1.5.6 General Stiffness Requirements

1.5.6.1 Gantry Frame Stiffness

1.5.6.2 Trolley Deflections

1.5.6.3 Bases

1.5.7 Crane Runway Structural Capacity Limits

1.5.8 Mechanical Design Criteria

1.5.8.1 General

1.5.8.2 Mechanical Equipment Allowable Stresses

1.5.8.3 Shafting

1.5.8.4 Gears and Speed Reducers

1.5.8.5 Stress Concentration Factors

1.5.8.6 Wire Rope Stresses

1.5.8.7 Drum Stresses

1.5.8.8 Machinery Efficiencies

1.5.9 Use of Cast Iron

1.5.10 Connections

1.5.10.1 Shop and Field Connections

1.5.10.2 Welded Connections

1.5.10.3 Bolted Connections

1.5.10.3.1 Structural Bolts

1.5.11 Clearances

1.5.12 Environmental Requirements

1.6 SUBMISSION OF CRANE DESIGN DATA

1.6.1 Crane Weight

SECTION 41 22 13.72 26 Page 1

Am-0003

1.7 FINAL APPROVED VERSIONS OF DRAWINGS AND CALCULATIONS

1.7.1 Final Approved Versions of Contractor Prepared Drawings

1.7.2 Final Calculations

1.8 FIELD MEASUREMENTS

1.9 MANUFACTURER'S REPRESENTATIVE

PART 2 PRODUCTS

2.1 NAMEPLATES AND CAPACITY PLATES

2.1.1 General

2.1.2 Contractor's Nameplate

2.1.3 Capacity Plates

2.1.4 Plate Details

2.1.5 Warning Labels

2.2 GANTRY FRAME

2.2.1 General

2.2.2 Gantry Frame Construction

2.2.3 Gantry Jacking Pads And Jacking Points

2.3 TROLLEYS

2.3.1 Trolley Frame Construction

2.3.2 Trolley Jacking Pads and Lifting Eyes

2.3.3 Trolley Bumpers

2.3.4 Trolley Maintenance Hoists

2.4 MAIN HOIST

2.4.1 General

2.4.2 Main Hoist Gear Reducer

2.4.3 Main Hoist Drum to Reducer Connection

2.5 AUXILIARY HOIST

2.5.1 General

2.5.2 Auxiliary Hoist Gear Reducer

2.5.3 Auxiliary Hoist Drum to Reducer Connection

2.6 JIB HOIST

2.6.1 General

2.6.2 Jib Hoist Gear Reducers

2.6.3 Jib Hoist Drum to Reducer Connection

2.6.4 Jib Hoist Slewing Drive

2.7 GANTRY DRIVE

2.7.1 General

2.7.2 Gantry Storm Brakes

2.7.3 Wheels

2.7.4 Axles

2.7.5 Gantry Trucks

2.8 MAIN TROLLEY DRIVE

2.8.1 General

2.8.2 Wheels

2.8.3 Axles

2.8.4 Trolley Trucks

2.9 AUXILIARY TROLLEY DRIVE

2.9.1 General

2.9.2 Wheels

2.9.3 Axles

2.9.4 Trolley Trucks

2.10 CRANE RAILS

2.10.1 Gantry Crane Rail Systems

2.10.2 Trolley Crane Rail Systems

2.10.2.1 Trolley Crane Rail

2.10.2.2 Crane Rail Clips

2.10.2.3 Track Bolts

2.11 GANTRY PARKING TIE-DOWNS

SECTION 41 22 13.72 26 Page 2

2.11.1 Parking Tie-Down Design Criteria

2.11.2 Parking Tie-Down Concrete Anchorage

2.12 GEARS AND SPEED REDUCERS

2.12.1 General

2.12.2 Gear Rating

2.12.3 Gear Manufacture and Assembly

2.12.4 Gear Dimension, Quality, and Hardness Verification

2.12.5 Speed Reducers

2.12.5.1 Commercial Speed Reducer Rating

2.12.5.2 Special Speed Reducer Rating

2.12.5.3 Speed Reducer Features

2.12.5.4 Speed Reducer Lubrication

2.12.5.5 Speed Reducer Nameplate

2.12.5.6 Speed Reducer Mounting

2.12.6 Additional Requirements for Standard Speed Reducers

2.13 GEAR CASES

2.13.1 General

2.13.2 Gear Reducer Seals

2.14 GEARMOTORS

2.15 BEARINGS

2.15.1 General

2.15.2 Sleeve-Type

2.15.3 Anti-Friction

2.16 SHAFTING

2.16.1 General

2.16.2 Support

2.17 KEYS AND KEYSEATS

2.18 SHAFT COUPLINGS

2.18.1 General

2.18.2 Configuration

2.18.3 Barrel Couplings

2.19 PINS

2.19.1 General

2.19.2 Gantry Truck Pivot (Equalizer) Pin Components

2.19.2.1 Pivot Pins

2.19.2.2 Pivot Bushings

2.20 DRUMS

2.20.1 General

2.20.2 Drum Measurements

2.21 HOIST SHEAVES AND LOAD BLOCKS

2.21.1 General

2.21.2 Rigging and Running Sheaves/Load Blocks

2.21.3 Hoist Equalizer Sheave Pins

2.22 WIRE ROPE

2.23 LUBRICATION

2.23.1 Speed Reducers

2.23.2 Speed Reducer Oil Testing

2.23.3 New Lubricating Oil Cleanliness

2.23.4 Grease

2.24 GUARDS, COVERS, AND DRIP PANS

2.24.1 Guards

2.24.1.1 Covers

2.24.1.2 Drip Pans

2.25 FIRE EXTINGUISHERS

PART 3 EXECUTION

3.1 GENERAL

3.2 SHOP ASSEMBLY AND TESTS

SECTION 41 22 13.72 26 Page 3

3.3 SHIPMENT

3.3.1 Preparation for Shipment

3.3.2 As-Delivered Inspection Report

3.4 ERECTION

3.5 SHAFT ALIGNMENT

3.6 DYNAMIC BALANCING OF MACHINERY

3.7 HOIST BRAKE ALIGNMENT AND RUN-IN

3.7.1 General

3.7.2 Procedure

3.8 REDUCER OIL TESTING

3.9 NAMEPLATES AND CAPACITY PLATES

3.9.1 Crane Nameplates

3.9.2 Block Capacity Plates

3.9.3 Warning Labels

-- End of Section Table of Contents --

SECTION 41 22 13.72 26 Page 4

SECTION 41 22 13.72 26

INTAKE GANTRY CRANE MECHANICAL AND STRUCTURAL WORK

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

This section covers the structural and mechanical work for a new Gavins Point 80-ton Intake Crane. The new crane will operate on new crane rails that run the full length of the powerhouse intake deck. The new crane rails are to be installed as part of a separate contracting effort.

The existing intake gantry crane is currently rated for 80 tons and must be removed from the site by the Contractor. Removal of the existing crane is addressed in SECTION 02 41 16.00 10

The following mechanical and structural work must be completed: Design, manufacture and erect complete new 80-ton intake gantry crane for the Gavins Point Dam Powerhouse.

The Contractor must engineer and design all new systems and components of the crane and must submit computations and drawings as stated in paragraph SUBMITTALS below.

1.2 REFERENCES

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

AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)

ABMA 8.2 (1999; R 2008) Ball and Roller Bearing Mounting Accessories, Inch Design

ABMA 19.1 (1987; R 1999; R 2008) Tapered Roller Bearings - Radial Metric Design

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

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

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

AGMA 2000 (1988) Gear Classification and Inspection Handbook

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

AGMA 6013 (2006A; R2016) Standard for Industrial

SECTION 41 22 13.72 26 Page 5

Enclosed Gear Drives

AGMA 9005 (2002; R 2008) Industrial Gear Lubrication

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 (2023) Steel Construction Manual

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B4.1 (1967; R 1994; R 2004; R 2009; R 2020)

Preferred Limits and Fits for Cylindrical Parts

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

ASME B17.1 (1967; R 2017) Keys and Keyseats

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

ASTM INTERNATIONAL (ASTM)

ASTM A 108 (2007) Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished

ASTM A276/A276M (2024) Standard Specification for Stainless Steel Bars and Shapes

ASTM A 322 (2007) Standard Specification Steel Bars, Alloy, Standard Grades

ASTM A 325 (2010) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A 36/A 36M (2008) Standard Specification for Carbon Structural Steel

ASTM A 490 (2010) Standard Specification for Structural Bolts, Alloy Steel, Heat Treated, 150 ksi Minimum Tensile Strength

ASTM A 504/A 504M (2008) Standard Specification for Wrought Carbon Steel Wheels

ASTM A564/A564M (2019) Standard Specification for Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes

ASTM A 572/A 572M (2007) Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

ASTM A 759 (2010) Standard Specification for Carbon Steel Crane Rails

SECTION 41 22 13.72 26 Page 6

ASTM B 22 (2009e1) Standard Specification for Bronze Castings for Bridges and Turntables

ASTM D 445 (2006) Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and the Calculation of Dynamic Viscosity)

ASTM D 664 (2007) Standard Test Method for Acid Number of Petroleum Products by Potentiometric Titration

ASTM D 4057 (2006) Standard Practice for Manual Sampling of Petroleum and Petroleum Products

ASTM D 5185 Determination of Additive Elements, Wear Metals, and Contaminants in Used Lubricating Oils and Determination of Selected Elements in Base Oils by Inductively Coupled Plasma Atomic Emission Spectrometry (ICP-AES)

ASTM D 6304 (2007) Standard Test Method for Determination of Water in Petroleum Products, Lubricating Oils, and Additives by Coulometric Karl Fischer Titration

ASTM E1571 (2011; R 2016; E 2016) Standard Practice for Electromagnetic Examination of Ferromagnetic Steel Wire Rope

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2020; Errata 1 2021) Structural Welding Code - Steel

CRANE MANUFACTURERS ASSOCIATION OF AMERICA (CMAA)

CMAA 70 (2020) Specification for Top Running Bridge and Gantry Type Multiple Girder Electric Overhead Traveling Cranes

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-PRF-18458 (2007) Grease, Wire Rope - Exposed Gear

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS RR-W-410 (2022; Rev J) Wire Rope and Strand

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

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

Specification and Verification of Balance Tolerances

SECTION 41 22 13.72 26 Page 7

ISO 4406 (2021) Hydraulic Fluid Power - Fluids - Method for Coding the Level of Contamination by Solid Particles

ISO 11171 (2022) Hydraulic Fluid Power - Calibration of Automatic Particle Counters for Liquids

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 10 (2022; ERTA 1 2021) Standard for Portable Fire Extinguishers

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only or as otherwise designated. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following must be submitted in accordance with SECTION

01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Grease Lubrication Shop Drawings; G, HDC

SD-03 Product Data

Drum Dimensions; G, HDC

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

Contractor's Nameplate; G, HDC

Spare Parts; G, HDC

SD-05 Design Data

Design Package Submittals; G, HDC

Crane Design Data; G, HDC

Bolt Tension Chart; G, HDC

Drum Groove Measuring Procedure; G, HDC

Gantry Parking Tie-Downs; G, HDC

Clearance/Coverage Diagram; G, HDC

Speed Reducer Oil Filter Micron Rating; G, HDC

SD-06 Test Reports

Hoist Brake Torque Test Report; G, HDC

Gantry Wheel Hardness Test Report; G, HDC

SECTION 41 22 13.72 26 Page 8

Trolley Wheel Hardness Test Report; G, HDC

Oil Test Results (new oil delivery); G, HDC

Oil Test Results (12 month service); G, HDC

*Am-3

Wire Rope Magnetic Flux Leakage Test Results (Prior To Installation); G, HDC

Wire Rope Magnetic Flux Leakage Tests (Pre-Load Test); G, HDC

Wire Rope Magnetic Flux Leakage Tests (Post-Load Test); G, HDC

**Am-3

SD-07 Certificates

Registered Professional Structural Engineer; G, HDC

Wire Rope Certificates; G, HDC

Manufacturer's Representative; G, HDC

Registered Professional Mechanical Engineer; G, HDC

SD-08 Manufacturer's Instructions

Hoist Brake Alignment And Run-In Procedure; G, HDC

SD-09 Manufacturer's Field Reports

Crane Weight; G, HDC

Balance Quality Report; G, HDC

Field Measurements; G, HDC

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

Shaft Alignment Report; G, HDC

Dynamic Balancing Report; G, HDC

As-Delivered Inspection Report; G, HDC

SD-11 Closeout Submittals

Final Calculations; G, HDC

Final Approved Versions Of Contractor Prepared Drawings; G, HDC

1.4 NEW INTAKE GANTRY CRANE

1.4.1 General

Design, manufacture, deliver, and make operable a complete new intake

SECTION 41 22 13.72 26 Page 9 gantry crane to work with the new and existing lifting beams for handling and transporting intake gates, intake gate hydraulic cylinders, bulkheads, and trash racks as described in paragraph FUNCTIONS. The crane must be of the outdoor type, electric motor operated, and be designed to present a smooth and pleasing appearance as shown on the contract drawings. The new crane arrangement and equipment locations are shown conceptually on the contract drawings.

1.4.2 Trolleys

Provide two trolleys with the new crane. Equip each trolley with the necessary hoist equipment, trolley drive, appurtenances, and machinery house. Provide safe access to each trolley from its respective walkway.

1.4.3 Functions

Provide a new crane with the functions and operations specified below, within the dimensional constraints as shown and field verified by the Contractor. Design the hoist and travel operating features, hoisting and lowering performances, and gantry/trolley travel performances to the requirements specified in SECTION 41 22 13.74 26 INTAKE GANTRY CRANE REPLACEMENT ELECTRICAL WORK and 41 22 13.71 26 INTAKE GANTRY CRANE DATA, TESTING AND TRAINING. New crane functions include but are not limited to:

a. Operate on crane rails that run the full length of the powerhouse intake deck.

b. Connect to new and existing below the hook lifting devices as required by the contract.

c. Handle and transport intake gates, intake gate hydraulic components, bulkheads, trash racks by trolleys and gantry travel within the limits shown on the drawings.

d. Handle and transport debris with the jib hoist within the limits shown on the drawings.

e. Place gates and bulkheads in the gate repair pit.

f. Handle and transport hand rails, jersey barriers, and deck hatch covers.

1.4.4 Crane Electrification

New crane must be powered from new four wire overhead conductor system.

See SECTION 41 22 13.73 26 CRANE APPURTENANCES for requirements on new conductor structural support system. See SECTION 41 22 13.74 26 INTAKE GANTRY CRANE REPLACEMENT ELECTRICAL WORK for requirements on four wire overhead conductor system.

1.4.5 Jib Hoist

Provide a jib hoist for handling jersey barriers, hydraulic cylinder covers, intake, bulkhead, and sluiceway hatches on the powerhouse intake deck. Locate the jib hoist as shown on the drawings. Provide the jib hoist with a new log-grapple style attachment as shown in the contract drawings and detailed in these specifications.

SECTION 41 22 13.72 26 Page 10

1.4.6 Below the Hook (BTH) Lifting Devices

Provide one new main hoist lifting beam and one new auxiliary hoist lifting beam to match the form and function of the existing lifting beams.

Provide one new log-grapple style attachment as shown and specified for use with the new jib hoist. Design, manufacture and test new BTH lifting devices in accordance with SECTION 41 22 13.75 26 LIFTING BEAM AND

BELOW-THE-HOOK LIFTING DEVICES.

1.4.7 Testing

Perform shop tests and field tests in accordance with this Section, SECTION 41 22 13.71 26 INTAKE GANTRY CRANE DATA, TESTING AND TRAINING and SECTION

41 22 13.74 26 GANTRY CRANE REPLACEMENT ELECTRICAL WORK.

1.4.8 Sequence of Work

The dates of performance for each sequence of work must be as specified in Clause 52.211-10 Commencement, Prosecution, and Completion of Work. The sequence of work must be:

a. Design, manufacture, and deliver a new intake gantry crane and four wire overhead conductor system.

b. Remove existing gantry crane.

c. Erect and make operable a new intake gantry crane and four wire overhead conductor system.

1.5 DESIGN CRITERIA

1.5.1 General

The contract drawings indicate the general arrangement and outline of the gantry, the clearances necessitated by the powerhouse structure, and other pertinent features. Furnish the detailed design in conformity with the design criteria and other requirements specified herein. Submit design calculations and detailed shop drawings in accordance with the requirements in this SECTION and SECTION 01 33 00 SUBMITTAL PROCEDURES.

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

1.5.2 Definitions

a. Crane Appurtenances: Those structures or mechanical features ancillary to the crane which do not carry primary loads and are attached to the crane structural frames or are needed to allow the crane to function.

b. Full Load Torque: The torque produced by a motor operating at its rated horsepower and speed.

c. Primary Load Carrying Member: Those members that carry the principal loads during normal operations.

d. Principal Loads: All of the loads having an influence on engineering strength analysis are regarded as principal loads, namely the dead loads, which are always present; the hoist load, acting

SECTION 41 22 13.72 26 Page 11 during each cycle; and the inertia forces acting during the movements of cranes, crane components, and hoist loads.

e. Structural Frame: The structural frame includes beams, girders, columns, machinery decks, and other members carrying principal loads.

1.5.3 Data, Capacities, Speeds, and Travel

Data, capacities, travel distances, and rated speeds of the crane must be as per SECTION 41 22 13.71 26 INTAKE GANTRY CRANE DATA, TESTING AND

TRAINING.

1.5.4 Design Loads and Combination of Loads

1.5.4.1 General

Base the design loads on the rated capacities specified in SECTION 41 22 13.71 26 INTAKE GANTRY CRANE DATA, TESTING AND TRAINING. For the purpose of design of structural and mechanical parts, loads resulting from the maximum torque of the motors are defined as 200 percent of the rated full-load torque of the motor.

Compute loads as follows, with the trolley in such positions as will give maximum loading or stress in any part of the crane and with due allowance for eccentricity of application. Place the loads for all tractive and collision forces at the centers of mass or distributed according to mass for the inertial forces from dead loads and at the center of drums for the inertial forces due to live loads.

1.5.4.2 Dead Loads

The dead load of the gantry crane must include the weight of the crane structure, and the weight of all machinery and equipment permanently attached to the crane frame. Dead loads do not include the weight of the movable blocks, lifting beam, and wire ropes.

1.5.4.3 Live Loads

a. Hoist Loads - The live load on each hoist must include the rated capacity specified in SECTION 41 22 13.71 26 NEW INTAKE GANTRY CRANE DATA, TESTING AND TRAINING, plus the weight of all wire rope, rigging, load blocks, and lifting devices.

b. Travel Loads - The travel load on the main hoist for trolley travel and gantry travel operations are equal to the maximum anticipated live load from bulkhead/gate handlingon the main hoist during trolley or gantry travel.

c. Vertical Impact - Impact must be taken as 10 percent of the hoist load.

d. Wind Load - Apply wind loads specified below to the horizontally projected area of the crane, universal lifting beam and bulkhead where applicable. Wind loads from the bulkhead are applied to the crane frame during stability cases. No shielding effect of one element by another is to be considered where the distance between them exceeds four times the smaller projected dimension of the windward element.

e. Tractive Horizontal Forces, Trolley - The forces resulting from

SECTION 41 22 13.72 26 Page 12 the acceleration or deceleration of the trolley are limited to a maximum of 10 percent of the sum of the travel load and trolley dead load. For the design of structural components, apply tractive forces equal to 10 percent of the sum of the travel load and trolley dead load.

f. Tractive Horizontal Forces, Gantry - The forces resulting from the acceleration or deceleration of the gantry crane are limited to a maximum of 10 percent of the sum of the travel load and dead load.

For the design of structural components, apply tractive forces equal to 10 percent of the sum of the travel load and dead load.

g. Collision Horizontal Forces - Collision forces with rail stops are taken as the forces produced by such collision with the trolley or gantry traveling at 40 percent rated speed with power on. The weight of the intake gate/bulkhead must also be considered (added) to the dead load for the collision horizontal forces.

h. Asymmetric Hoist Loads - The load resulting from maximum torque of the motor applied to one of two lower blocks during motor stall event (caused by jammed lifting beam in gate/bulkhead slot during raising).

1.5.4.4 Combinations of Loads

Design the structural components of the crane for the following load combinations:

a. Category I Load Combinations.

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

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

b. Category II Load Combinations. (Stability Load Cases)

(1) Dead, main hoist, vertical impact, 10 psf wind applied in the direction of trolley travel, 10 psf wind applied to the full surface area of the intake gates or bulkhead in the direction of trolley travel, and horizontal collision forces.

(2) Dead, 40 psf wind applied to crane only.

(3) Dead, auxiliary hoist, jib hoist, vertical impact, 10 psf wind applied in the direction of trolley travel, and horizontal collision forces.

c. Category III Load Combinations.

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

1.5.5 Structural Design Criteria

The structural components of the crane include beams, girders, columns, machinery decks, and other members carrying primary loads in addition to ancillary structural features such as but not limited to cabs, platforms, access ways, ladders, and stairs that are not carrying primary loads. The

SECTION 41 22 13.72 26 Page 13 detailing of structural components and connections must conform to the requirements of AISC 325 . At minimum, all structural components must be designed per the requirements of AISC 325 following the Allowable Strength Design methodology except as described below:

a. For Category I Load Combinations, the required strengths resulting from the Category I Load Combination(s) in all structural components carrying primary loads must not exceed 75% of AISC 325 allowable strengths.

b. For Category II Load Combinations, the required strengths resulting from the Category II Load Combination(s) in all structural components carrying primary loads must not exceed AISC 325 allowable strengths.

c. For Category III Load Combinations, the required strengths resulting from the Category III Load combinations(s) in all structural components carrying primary loads except columns must not exceed 90 percent of the nominal strength. Columns (members in compression or combined compression and bending) will not be permitted to exceed AISC 325 allowable strengths.

d. For structural welds and bolts carrying primary loads, the required strengths must not exceed 75% of AISC 325 allowable strengths. For all other structural welds and bolts, the required strengths will not be permitted to exceed AISC 325 allowable strengths.

e. Welded connections must also comply with the applicable provisions of AWS D1.1/D1.1M.

1.5.5.1 Fatigue Design

Fatigue design must be addressed for conditions resulting in high numbers of load cycles including excessive vibration. Design structural features and connections subject to fatigue loading conditions per the applicable provisions of AISC 325 Appendix 3 "Fatigue." For crane appurtenances, provide bracing and support such that excessive vibration does not occur during normal crane usage.

1.5.5.2 Stability

The gantry crane must have a minimum factor of safety of 1.25 against overturning under each condition of loading stated in paragraph Combination of Loads. Counterweights must be provided if necessary to obtain the required stability.

1.5.6 General Stiffness Requirements

The stiffness of the crane structure, structural components, and machinery must be considered when determining the computed misalignment of mating gear teeth under the limitation of paragraph GEARS AND SPEED REDUCERS.

1.5.6.1 Gantry Frame Stiffness

Deviations from the nominal span, center to center of the gantry rails, due to the overall deflection of the gantry frame must not exceed plus or minus 5/8 inches from the rated load to no load, respectively. The deflection must be computed with the assumption that the base of the legs are pinned on one side and roller supported on the opposite side.

SECTION 41 22 13.72 26 Page 14

Calculate deflection both parallel and transverse to the crane rails.

1.5.6.2 Trolley Deflections

Deflection of the trolley structure frame members are limited to L/360.

Primary frame members providing support between trolley rails must not exceed 1/4 inches vertical deflection measured as difference from dead load to rated load condition. Specify hoist drum shaft bearings with proper float to accommodate the change in center distance.

1.5.6.3 Bases

Mounting bases (i.e. machinery bases) must provide a suitable load path from the equipment being supported to the frame of the trolley or crane, as applicable. Bases must be of a suitable stiffness to provide support needed to attain all specified and manufacturer equipment alignment requirements. Bases must be of sufficient thickness that no loading scenario will result in buckling or excessive deflection, including but not limited to loads resulting from maximum motor torque.

1.5.7 Crane Runway Structural Capacity Limits

The intake deck downstream rail support has a limited capacity. Wheel loads applied by the crane for Category I Load Combinations (1) and (2) are not permitted to exceed 150,000 lbs. Contractor is required notify the Government in writing if the new crane wheel loads are anticipated to exceed the value(s) above.

1.5.8 Mechanical Design Criteria

1.5.8.1 General

Mechanical parts of the crane include but are not limited to components carrying hoisting loads not identified as part of the structural frames such as machinery bases with low aspect ratio such that buckling is not a failure mode, trucks unless wheels are mounted directly to a trolley frame member or gantry frame sill beam, hoist drums, load blocks, etc.. Examples of mechanical parts of the crane include but are not limited to:

a. Hoist drums, wire rope, load blocks, gears and speed reducers, wheels, axles, shafting, couplings, bearings, bumpers, and other members carrying hoisting loads and/or travel loads. Components carrying hoisting loads not identified as part of the structural frames such as machinery bases with low aspect ratio such that buckling is not a failure mode, trucks (unless wheels are mounted directly to a trolley frame member or gantry frame sill beam) are also considered mechanical components.

b. Mechanical parts of the crane also include ancillary mechanical features not carrying hoisting/travel loads (e.g. rotating machinery covers/guards, rail sweeps, wind speed direction mounting fixtures).

1.5.8.2 Mechanical Equipment Allowable Stresses

Unless specified otherwise, design mechanical components of the crane for rated load, with a factor of safety of 5 based on the ultimate strength of the materials, provided that each part or component, including speed reducers but excluding wire rope, must be proportioned to withstand the stresses produced by the maximum torque of the motors with resultant

SECTION 41 22 13.72 26 Page 15 stresses not exceeding 75 percent of the yield point of the materials involved.

1.5.8.3 Shafting

See paragraph SHAFTING for additional design requirements for shafting and axles.

1.5.8.4 Gears and Speed Reducers

See paragraph GEARS AND SPEED REDUCERS for additional design requirements for gears and speed reducers.

1.5.8.5 Stress Concentration Factors

Use stress concentration factors where applicable, including but not limited to changes in shaft sections and keyways.

1.5.8.6 Wire Rope Stresses

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

1.5.8.7 Drum Stresses

Design drum shells, diaphragm plates, and shafts/hubs in accordance with CMAA 70 requirements and this SECTION. Allowable stresses in drums are per paragraph "MECHANICAL EQUIPMENT ALLOWABLE STRESSES". Design drum shafts in accordance with paragraph "SHAFTING". Allowable stresses of drum welds, other than drum shell longitudinal and circumferential splice welds, must not exceed 4,000 pounds per square inch. Perform drum buckling/crushing calculations per Roark's Formulas for Stress and Strain, using a bucking safety factor of at least 2.

1.5.8.8 Machinery Efficiencies

The machinery efficiencies used for calculating the hoist and travel drive component sizing must not exceed the values provided in CMAA 70.

Machinery efficiency for grease lubricated gearing must be reduced by 0.02.

1.5.9 Use of Cast Iron

Cast iron of a class less than 30 must not be used for any parts of the crane except for counterweights. Cast iron of class 30 or higher may be used for gear cases. Brake shoes and brake wheels must conform to materials specified in SECTION 41 22 13.74 26 INTAKE GANTRY CRANE

REPLACEMENT ELECTRICAL WORK.

1.5.10 Connections

1.5.10.1 Shop and Field Connections

Accomplish all connections by either welding or bolting. Riveted connections are not permitted. For connections fabricated complete in the

SECTION 41 22 13.72 26 Page 16 shop, design welded connections at all locations practicable. For connections which must be completed in the field, provide bolted connections. Field welding will not be accepted without written approval from the COR. Avoid combining welds and bolts in the same connection.

When bolts are used in combination with welds, bolts should not be considered as sharing loads in combination with the welds and the welds should be designed to carry the entire load. Connections that are welded to one member and bolted to another are permitted.

1.5.10.2 Welded Connections

Design welded connections in accordance with the applicable provisions of AISC 325 and AWS D1.1/D1.1M and per requirements of paragraph STRUCTURAL DESIGN CRITERIA and as per SECTION 05 05 23.17 26 WELDING (STEEL), FABRICATION, AND MACHINE WORK.

1.5.10.3 Bolted Connections

For all bolted connections, provide installation (torque) requirements in the design documents and on the shop drawings.

For fastener definitions and types, see Section 05 50 04.00 26 METALS:

MISCELLANEOUS, STANDARD ARTICLES, SHOP FABRICATED ITEMS.

For fabrication and installation of bolted connections, see Section 05 05 23.17 26 WELDING (STEEL), FABRICATION, AND MACHINE WORK and Section

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

1.5.10.3.1 Structural Bolts

Provide structural bolts for all bolted connections provided for crane structural frames and appurtenances. For bolted connections transmitting primary loads, utilize Grade ASTM A 325 or ASTM A 490 structural bolts.

Structural bolts must comply with the requirements of paragraph STRUCTURAL DESIGN CRITERIA and Section 05 50 04.00 26 METALS: MISCELLANEOUS, STANDARD ARTICLES, SHOP FABRICATED ITEMS and structural bolted connections must be fabricated and installed as per Section 05 05 23.17 26 WELDING (STEEL), FABRICATION, AND MACHINE WORK.

1.5.11 Clearances

Clearances between the crane and fixed powerhouse structures must be maintained at normal operating conditions of the crane; as well as parallel running cranes if applicable. Design crane clearances per CMAA 70 and ASME B30.2 .

a. As a minimum, the clearance between the highest point of the crane and the lowest overhead obstruction shall not be less than 3 inches with the crane unloaded. Pipes, conduits, lights, etc., must not reduce this clearance.

b. As a minimum, the clearance between the end of the crane and the closest side obstruction shall not be less than 2 inches with crane centered on runway rails. Pipes, conduits, lights, etc., must not reduce this clearance. The same criteria applies for clearances between movable trolleys and fixed structures of the crane.

SECTION 41 22 13.72 26 Page 17

1.5.12 Environmental Requirements

Mechanical and structural equipment designs must be rated for continuous operation in ambient environmental conditions between -15 and +115 degrees F at 0 to 95 percent relative humidity, non-condensing. Unless specified otherwise in this section. All mechanical and structural equipment designs must be resistant to continuous vibration.

1.6 SUBMISSION OF CRANE DESIGN DATA

Submit Crane Design Data in PDF format and in accordance with specification herein and 41 22 13.70 26 SUBMISSION OF CRANE DESIGN DATA requirements.

1.6.1 Crane Weight

See specification 41 22 13.71 26 NEW GANTRY CRANE DATA, SPARE PARTS, TESTING AND TRAINING for weighing of crane and trolley requirements.

1.7 FINAL APPROVED VERSIONS OF DRAWINGS AND CALCULATIONS

In addition to all required crane components and systems indicated within this Section, include all contractor prepared drawings and calculations on structural crane appurtenances identified in SECTION 41 22 13.73 26 CRANE APPURTENANCES. Include all submittals from crane appurtenances so that there is a single volume of drawings and calcs.

1.7.1 Final Approved Versions of Contractor Prepared Drawings

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

1.7.2 Final Calculations

All design calculations must be assembled with a table of contents and submitted for review to verify that all calculations have been assembled and to verify that they have incorporated all outstanding comments and changes to the design inclusive any changes needed to accommodate final field verified weight. When final calculations are submitted, each section must include reference to submittals where that section was approved. They must be called "Final Calculations." Upon approval of the final calculations, they must be inserted as a separate section in the Operation and Maintenance Manuals. One electronic copy (CD) and one hard copy of the final calculations must be submitted to Hydroelectric Design Center.

1.8 FIELD MEASUREMENTS

Field verify all elevations, dimensions, deck clearances and coordinates of existing features indicated on the contract drawings that affect new construction. Before performing any work, Contractor must become familiar with all details of the work, verify all dimensions in the field, and submit a letter describing the results of this verification including discrepancies to the Contracting Officer. See contract drawings for identification of crane clearances, deck clearances, and dimensions to field measure (list of dimensions and clearances to field verify is not all inclusive).

SECTION 41 22 13.72 26 Page 18

In addition to what is described above, field measurements must include items not limited to the following;

a. Verification of main and auxiliary hoist upper limits, and measurements of the distances between the lower sheaves and the hoist hook saddles for each.

b. Verification of the jib hoist's upper limit.

c. Verification of clearances between the existing crane, crane rails, and surrounding equipment as necessary to inform the design of the new crane.

d. Verification of crane travel limit switches and position of the end stops relative to the crane bumpers in maximum North and South positions.

e. Verification of the crane's main hoist, auxiliary hoist, and jib hoist hook envelopes (also known as hoist coverage).

1.9 MANUFACTURER'S REPRESENTATIVE

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

PART 2 PRODUCTS

2.1 NAMEPLATES AND CAPACITY PLATES

2.1.1 General

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

2.1.2 Contractor's Nameplate

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

2.1.3 Capacity Plates

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

2.1.4 Plate Details

Nameplates and capacity plates lettering must not be constructed of plastic or vinyl plates or lettering. Plates or lettering must be attached to the structure using corrosion-resisting steel fasteners.

Powder-coated aluminum plate is an acceptable product.

2.1.5 Warning Labels

Warning labels must be affixed to appropriate locations on the crane per requirements of ASME B30.2 .

SECTION 41 22 13.72 26 Page 19

2.2 GANTRY FRAME

2.2.1 General

PE-stamped drawings and calculations for all gantry crane structural components must be submitted for approval as per paragraph 1.5 "SUBMISSION

OF CRANE DESIGN DATA".

2.2.2 Gantry Frame Construction

The gantry crane must be constructed of built-up members fabricated by welding, structural steel shapes, and plates as may be required by the design. Box-type members must either be designed so that all the interior can be readily inspected, cleaned, and painted, or all joints and openings where water can enter the member must be seal welded. Drain holes must be provided at low points or pockets to prevent accumulation of water from condensation or rain. Longitudinal joints of built-up members must be made with continuous welds. Bearing surfaces of joints designed to transmit stress by bearing must be machine finished to provide full contact.

Fabricate and erect frame in accordance with the approved drawings and as per the requirements of SECTION 05 05 23.17 26 WELDING (STEEL), FABRICATION, AND MACHINE WORK. Perform frame fitment and alignment testing per SECTION 41 22 13.71 26 CRANE DATA, TESTING AND TRAINING.

2.2.3 Gantry Jacking Pads And Jacking Points

Jacking pads and jacking points must be provided to allow for wheel truck removal and wheel maintenance and removal, and also for weighing the crane. Gantry structure must be designed for lifting the entire weight of the crane, including the universal lifting beam, by these jacking points.

Jacking pads must be designed to carry primary loads.

2.3 TROLLEYS

The gantry crane must be provided with two trolleys, one for the main hoist and one for the auxiliary hoist. Provide each trolley with drives and appurtenances as detailed in these specifications.

2.3.1 Trolley Frame Construction

The trolley frame(s) must be constructed of built-up members fabricated by welding, structural steel shapes, and plates as may be required by the design to support machinery bases and primary loads. Box-type members must either be designed so that all the interior can be readily inspected, cleaned, and painted, or all joints and openings where water can enter the member must be seal welded. Drain holes must be provided at low points or pockets to prevent accumulation of water from condensation or rain.

Longitudinal joints of built-up members must be made with continuous welds. Bearing surfaces of joints designed to transmit stress by bearing must be machine finished to provide full contact.

The machinery floor (not carrying primary loads) must be designed for an uniform load of 300 psf or a concentrated load of 750 pounds, using the load that produces the greater effect, in addition to the weight of any equipment attached to or supported thereon. Do not superimpose live loads used to design machinery floor with primary load combinations for crane design. The floor must be constructed of reinforced checkered floor plate, not less than 1/4 inch thick and must be welded to the framework.

SECTION 41 22 13.72 26 Page 20

2.3.2 Trolley Jacking Pads and Lifting Eyes

Jacking pads must be provided underneath the trolley near the wheels to allow for wheel maintenance and removal, and also for weighing the trolley. Lifting eyes or rigging points must be provided at each corner of the trolley, and the trolley structure must be designed for lifting of the dead weight of the trolley and all permanently attached equipment including ropes and blocks required to facilitate installation, removal, and maintenance of the trolley.

2.3.3 Trolley Bumpers

Four fixed polyurethane bumpers must be provided for the trolley and must meet the requirements of CMAA 70. Cast steel or structural steel bumper stops must be provided to meet the trolley bumpers squarely and the centerline of contact must not be lower than the centerline of the wheel axles. Means must be installed on the crane trolley bumpers to retain the bumpers in case of broken or loosened mounting connections per requirements in ASME B30.2.

2.3.4 Trolley Maintenance Hoists

Provide two one-ton bridge crane style maintenance hoists, one in each trolley, that each meet the requirements of SECTION 41 22 13.73 26 CRANE APPURTENANCES. Provide an access hatch for each trolley for the purpose of transferring components between the intake deck and machinery house floor using the maintenance hoists. These access hatches must be adequately sized for removal of equipment as specified in 41 22 13.73 26 CRANE APPURTENANCES and as shown on the contract drawings. Hatches must be capable of laying flat on the trolley floor when in the open position.

2.4 MAIN HOIST

2.4.1 General

The main hoist must consist of one double-reeved drum with a single motor connected through a speed reducer and shafting. Drum gears and pinions (external gearing) are not allowed. The main hoist must be so designed as to limit the maximum rope fleet angle off the grooved drum to not more than 2.0 degrees, and not more than 2.5 degrees fleet angle for sheaves.

Rope entering or leaving sheaves must not contact other crane components or structure. Rope entering or leaving a grooved drum must not rub against adjacent rope. The reeving must be such as to allow all lifting beams to travel vertically. The new main hoist lifting beam must be dimensionally interchangeable with the existing lifting beam and must be designed to properly interface with the existing intake gate hydraulic cylinder lifting beam and gates/bulkheads as described in paragraph "Functions". The main hoist must be provided with motor, brakes, load indicator, and limit switches conforming to the requirements of SECTION

41 22 13.18 26 INTAKE GANTRY CRANE ELECTRICAL WORK.

2.4.2 Main Hoist Gear Reducer

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

SECTION 41 22 13.71 26 NEW INTAKE GANTRY CRANE DATA, TESTING AND TRAINING,

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

SECTION 41 22 13.72 26 Page 21

2.4.3 Main Hoist Drum to Reducer Connection

Design the connection between the wire rope drum and the speed reducer using one of the following methods:

a. Barrel coupling. Design one end of the drum for mounting of the barrel coupling as specified in paragraph "BARREL COUPLINGS" and "DRUMS". Extend the speed reducer output shaft completely through the coupling hub. Key and interference fit the shaft to the hub bore in accordance with paragraphs "KEYS AND KEYSEATS" and "FITS". Consult barrel coupling manufacturer for interference fit and key/keyseat design, and provide letter from coupling manufacturer approving the design.

b. Means to allow the drum and the reducer to operate without binding such as using a torque arm for the reducer. Simply support the drum with bearings on each end. Support the speed reducer with a torque arm. The drum solid output shaft must be long enough to extend through the hollow output shaft of the speed reducer.

c. Other means to allow for misalignment between the drum and the reducer and operate without binding.

2.5 AUXILIARY HOIST

2.5.1 General

The auxiliary hoist must consist of one double-reeved drum with a single motor connected through a speed reducer and shafting. Drum gears and pinions (external gearing) are not allowed. The auxiliary hoist must be so designed as to limit the maximum rope fleet angle off the grooved drum to not more than 2.0 degrees, and not more than 2.5 degrees fleet angle for sheaves. Rope entering or leaving sheaves must not contact other crane components or structure. Rope entering or leaving a grooved drum must not rub against adjacent rope. The reeving must be such as to allow all lifting beams to travel vertically. The new load blocks must be similar in size as the existing load blocks and must be designed to be pinned to the existing lifting beams as described in paragraph "Functions". The auxiliary hoist must be provided with motor, brakes, load indicator, and limit switches conforming to the requirements of SECTION 41 22 13.18 26

INTAKE GANTRY CRANE ELECTRICAL WORK.

2.5.2 Auxiliary Hoist Gear Reducer

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

SECTION 41 22 13.71 26 NEW INTAKE GANTRY CRANE DATA, TESTING AND TRAINING,

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

2.5.3 Auxiliary Hoist Drum to Reducer Connection

Design the connection between the wire rope drum and the speed reducer using one of the following methods:

a. Barrel coupling. Design one end of the drum for mounting of the barrel coupling as specified in paragraph "BARREL COUPLINGS" and

SECTION 41 22 13.72 26 Page 22

"DRUMS". Extend the speed reducer output shaft completely through the coupling hub. Key and interference fit the shaft to the hub bore in accordance with paragraphs "KEYS AND KEYSEATS" and "FITS". Consult barrel coupling manufacturer for interference fit and key/keyseat design, and provide letter from coupling manufacturer approving the design.

b. Means to allow the drum and the reducer to operate without binding such as using a torque arm for the reducer. Simply support the drum with bearings on each end. Support the speed reducer with a torque arm. The drum solid output shaft must be long enough to extend through the hollow output shaft of the speed reducer.

c. Other means to allow for misalignment between the drum and the reducer and operate without binding.

2.6 JIB HOIST

2.6.1 General

The jib hoist must consist of a swinging boom, a slewing drive, and two hoisting units, of which one operates the holding line and the other the closing line of the existing clamshell bucket and a new log-grapple style lifting attachment for debris removal in the forebay. The jib must be capable of operating BOTH the existing clamshell bucket and the new log grapple style attachment. The jib is to be mounted on the north side upstream corner of the gantry frame as shown in the contract drawings.

Mount the jib operating machinery to the uppermost crane walkway as shown in the contract drawings. The boom must swing through a 270 degree arc allowing for debris removal from the river to the intake deck and access to the intake deck for equipment placement. The jib must be rated for a 5-ton lift. The holding line hoist unit must also be capable of being rigged for operation with a hook on a single-part line or with a hook which swivels on anti-friction bearings are provided. Ensure that all jib components that will come into contact with water during operation are designed to be submerged.

The jib must be provided with motors, brakes, load indicators, and limit switches conforming to the requirements of SECTION 41 22 20.73 26 NEW INTAKE GANTRY CRANE ELECTRICAL WORK. Enclose the hoist and slew drives against weather and animal intrusion with a single level machinery housing as shown conceptually in the contract drawings. Design all drive and hoist equipment in a location that does not require fall protection for regular inspection and maintenance. Install remote grease points where possible to allow for greasing of critical jib components from an easy to access location.

The two hoists must consist of two sets of reeved drums, each with a single motor connected through a speed reducer and shafting as shown on the reference drawings of the existing crane except as modified herein.

One drum and motor assembly must be for a jib operating line (to open and close the new log-grapple style attachment), and one drum and motor assembly must be for a jib holding line (to raise and lower the jib hoist). External gearing is not allowed. The hoists must be so designed as to limit the maximum rope fleet angle off the grooved drums to not more than 2.0 degrees, and not more than 2.5 degrees fleet angle for sheaves, unless otherwise approved. Rope entering or leaving sheaves must not contact other crane components or structure. Rope entering or leaving a grooved drum must not rub against adjacent rope. The reeving must be such

SECTION 41 22 13.72 26 Page 23 as to allow all lifting attachments to travel vertically. The new load lifting attachments at the end of each wire rope must be similar in size as the existing attachments and must be designed to be…