41 22 13.74 26 Am-0001.pdf

Intake Crane Replacement - Gavins Point Dam, South Dakota GP00104

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 22 13.74 26

INTAKE GANTRY CRANE REPLACEMENT ELECTRICAL WORK

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

1.2 REFERENCES

1.3 SUBMITTALS

1.4 GENERAL REQUIREMENTS

1.5 QUALITY ASSURANCE

1.5.1 Electrical Drawing Index

1.5.2 Bill of Electrical Materials

1.5.3 Main One-Line Drawing

1.5.4 Schematic Drawings

1.5.5 Electrical Interconnecting Diagrams

1.5.6 Electrical Installation Drawings

1.5.7 Cable and Conduit Schedule

1.5.8 Cable Carrier Systems Drawings

1.5.9 Final Approved Versions Of Contractor Prepared Drawings

1.5.10 Submission of Product Data

1.5.11 Submission of Design Calculations

1.5.12 Submission of Test Results

PART 2 PRODUCTS

2.1 CRANE ELECTRIFICATION

2.1.1 General

2.1.2 Crane Runway Conductor and Collector System

2.1.2.1 General

2.1.2.2 Conductor

2.1.2.3 Collectors

2.1.3 Cable Carrier System

2.1.3.1 Cable Chain

2.1.3.2 Festoons

2.2 SYSTEM PROTECTION

2.2.1 General

2.2.2 Manual Disconnect Switch

2.2.3 Main Line Disconnect

2.2.4 Utility Disconnect

2.2.5 Main Line Contactor

2.2.6 Main Line Phase Monitor

2.2.7 Surge Protection

2.2.8 Lightning Protection

2.3 CONTROL SYSTEMS AND EQUIPMENT

2.3.1 General

2.3.2 Control Power

2.3.3 Hoist and Travel Operating Features

2.3.3.1 Hoisting and Lowering

2.3.3.2 Hoisting and Lowering Performances

2.3.3.3 Travel and Trolley Travel

2.3.3.4 Travel Performances

SECTION 41 22 13.74 26 Page 1

Am-0001

2.3.3.5 Positioning Accuracy

2.3.4 Variable Frequency Drives (VFDs)

2.3.4.1 General

2.3.4.2 VFD Operating Features

2.3.4.3 Line And Load Reactors

2.3.4.4 Dynamic Braking

2.3.4.5 Elapsed Time Meter

2.3.5 Limit Switches

2.4 OPERATOR CONTROL STATION

2.4.1 General

2.4.2 Location Of Controls And Control Equipment

2.4.3 Operator Chair

2.4.4 Operator Console

2.4.5 Operator Control Station Apparatus

2.4.5.1 Operator Control Station Apparatus Performances

2.4.5.2 Shop Inspection and Testing

2.4.6 REMOTE (RADIO) CONTROL SYSTEM

2.4.6.1 General

2.4.6.2 Crane Radio Control Transmitter

2.4.6.2.1 Radio Control Storage Enclosure

2.4.6.3 Transmitter Frequency Allocation

2.5 ACCESSORIES

2.5.1 Load Cells And Indication

2.5.1.1 High Load Warning Annunciation

2.5.1.2 Overload Annunciation

2.5.2 Wind Speed Monitor

2.5.3 Warning Signals

2.5.3.1 Travel Warning Bell

2.5.3.2 Horn

2.5.3.3 Crane Operation Warning Lights

2.5.4 Operator Cab Heater

2.5.5 Electric Heat Pump Units

2.5.6 Infrared Heaters

2.6 MOTORS

2.6.1 General

2.6.2 Motor Size, Speed, and Time Ratings

2.6.3 Motor Winding Heaters

2.6.4 Motor Encoders

2.7 HOLDING BRAKES

2.7.1 Brake Type

2.7.2 Brake Release

2.7.3 Brake Mechanical Construction

2.7.4 Brake Torque Rating, Duty, and Adjustment

2.8 GANTRY STORM BRAKES

2.9 HEATERS FOR SPEED REDUCERS

2.10 POWER, HEATING, LIGHTING AND CONVENIENCE OUTLET SYSTEMS

2.10.1 Utility Transformer

2.10.2 Power and Lighting Panelboards

2.10.3 Molded Case Circuit Breakers

2.10.4 Lighting

2.10.4.1 General

2.10.4.2 Working Area Floodlights

2.10.4.3 Catwalk and Machinery Housing Lights

2.10.4.4 Aircraft Warning Lights

2.10.4.5 Cab Lights

2.10.5 Convenience Outlets

2.10.6 480VAC Power Outlet

2.11 CONDUIT AND WIREWAYS

2.11.1 Conduit

SECTION 41 22 13.74 26 Page 2

2.11.2 Conduit Fittings

2.11.3 Outlet, Junction, and Pull Boxes and Cover Plates for Conduit

2.12 INSULATED WIRE AND CABLE

2.12.1 General

2.12.2 Material

2.12.3 Insulation

2.12.4 Jackets

2.12.5 Size

2.12.6 Stranding

2.12.7 Special Wire and Cable Requirements

2.12.7.1 Control Panel Wiring

2.12.7.2 Instrumentation Cable

2.12.7.3 Wire Near Resistors

2.12.7.4 Cable Carrier System Cable

2.12.8 Flame Tests

2.12.9 Wire Markers

2.13 TERMINAL BLOCKS

2.13.1 General

2.13.2 Control Signal Type

2.13.3 Power Terminal Blocks

2.13.4 Rail Terminal Blocks

2.14 CABINETS AND ENCLOSURES

2.14.1 General

2.14.2 Working Clearances

2.14.3 Control Cabinets

2.14.4 Control Cabinet Heaters

2.14.5 Control Cabinet Cooling

2.14.6 Brake Enclosing Case

2.14.6.1 Brake Enclosing Case Heaters

2.15 POSITION INDICATION

PART 3 EXECUTION

3.1 EQUIPMENT INSTALLATION

3.1.1 Crane Electrification

3.2 ARC FLASH ANALYSIS INFORMATION

3.3 ELECTRICAL TESTS

3.3.1 General

3.3.2 Motor Factory Testing

3.3.3 Holding Brakes Factory Testing

3.3.4 Control System and Equipment Factory Testing

3.3.5 Wiring Field Testing

3.4 FIELD TRAINING

3.5 OPERATION AND MAINTENANCE DATA

-- End of Section Table of Contents --

SECTION 41 22 13.74 26 Page 3

SECTION 41 22 13.74 26

INTAKE GANTRY CRANE REPLACEMENT ELECTRICAL WORK

PART 1 GENERAL

In these Specifications, the word 'provide' means 'furnish and install' (applicable to materials, equipment, products, systems, etc. to be furnished and installed as part of the crane replacement).

1.1 DESCRIPTION OF WORK

The work specified under this Section includes the removal of the of all electrical equipment and wiring on the 80-ton gantry crane, and the design, fabrication, factory testing and field testing, furnishing, and installation of electrical and control equipment and associated systems.

The equipment and associated systems includes motors, brakes, storm brakes, limit switches, complete control systems including remote (radio) control system, collectors and conductors, conduit, wiring, load cells and indication, and auxiliary devices required to replace and enhance crane electrical power, lighting, and control systems. Additional requirements are given in Section 26 05 00.01 26 BASIC ELECTRICAL MATERIALS AND METHODS FOR CRANES and Section 41 22 13.71 26 INTAKE GANTRY CRANE DATA, TESTING

AND TRAINING.

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.

ASSOCIATION FOR IRON AND STEEL TECHNOLOGY (AIST)

AISE Technical Report No. 11 (1997) Brake Standards for Mill Motors

ASTM INTERNATIONAL (ASTM)

ASTM B3 (2013) Standard Specification for Soft or Annealed Copper Wire

ASTM B8 (2011; R 2017) Standard Specification for Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft

ASTM B33 (2010; R 2014) Standard Specification for Tinned Soft or Annealed Copper Wire for Electrical Purposes

ASTM B172 (2017) Standard Specification for Rope-Lay-Stranded Copper Conductors Having Bunch-Stranded Members, for Electrical Conductors

ASTM B173 (2017) Standard Specification for Rope-Lay-Stranded Copper Conductors Having Concentric-Stranded Members, for Electrical Conductors

SECTION 41 22 13.74 26 Page 4

ASTM B174 (2017) Standard Specification for Bunch-Stranded Copper Conductors for Electrical Conductors

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE Std 112 (2004) Standard Test Procedure for Polyphase Induction Motors and Generators

IEEE 383 (2015) Qualifying Class 1E Electric Cables and, Field Splices for Nuclear Power Generating Stations 2004

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

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA C80.1 (2015) Standard for Electrical Rigid Steel Conduit (ERSC)

NEMA FB 1 (2014) Standard for Fittings, Cast Metal Boxes, and Conduit Bodies for Conduit, Electrical Metallic Tubing, and Cable

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

NEMA ICS 2 (2000; R 2005) Industrial Control and Systems Controllers: Contactors and Overload Relays Rated 600 Volts

NEMA ICS 5 (2017) Industrial Control and Systems:

Control Circuit and Pilot Devices

NEMA ICS 6 (1993; R 2016) Industrial Control and Systems: Enclosures

NEMA ICS 8 (2011) Crane and Hoist Controllers

NEMA MG 1 (2016) Motors and Generators

NEMA OS 1 (2013) Sheet-Steel Outlet Boxes, Device Boxes, Covers, and Box Supports

NEMA ST 20 (2014) Standard for Dry-Type Transformers for General Applications

NEMA PB 1 (2011) Panelboards

NEMA WC 57 (2014) Standard for Control, Thermocouple Extension, and Instrumentation Cables

SECTION 41 22 13.74 26 Page 5

NEMA WC 58/ICEA S-75-381 (2008) Portable and Power Feeder Cables for Use in Mines and Similar Applications

NEMA WC 70 (2009) Power Cable Rated 2000 V or Less for the Distribution of Electrical Energy--S95-658

NEMA WD 6 (2016) Wiring Devices Dimensions Specifications

NEMA 250 (2018) Enclosures for Electrical Equipment (1000 Volts Maximum)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2023) National Electrical Code

UNDERWRITERS LABORATORIES (UL)

UL 1 (2005; Rev thru July 2007) Standard for Flexible Metal Conduit

UL 6 (2007; Reprint Nov 2014) Electrical Rigid Metal Conduit-Steel

UL 44 (2014; Reprint Feb 2015) Thermoset-Insulated Wires and Cables

UL 62 (2018) UL Standard for Safety Flexible Cords and Cables

UL 66 (2002) Fixture Wire

UL 1686 (2012; Reprint Jan 2014) Standard for Pin and Sleeve Configurations

UL 360 (2013; Reprint Jan 2015) Liquid-Tight Flexible Steel Conduit

UL 467 (2013; Reprint Jun 2017) Grounding and Bonding Equipment

UL 489 (2016; Rev 2019) UL Standard for Safety Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosures

UL 514A (2013) Metallic Outlet Boxes

UL 514B (2012; Reprint Nov 2014) Conduit, Tubing and Cable Fittings

UL 886 (1994; R 1999, Rev thru Nov 2005) Outlet Boxes and Fittings for Use in Hazardous (Classified) Locations

UL 1449 (2014; Reprint Mar 2016) UL Standard for Safety Surge Protective Devices

UL 1581 (2001; Reprint Jun 2017) Electrical Wires, SECTION 41 22 13.74 26 Page 6

Cables, and Flexible Cords

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

30 CFR 7.407 (2003) Test for Flame Resistance of Electric Cables and Cable Splices

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 or designations following the "G" designation identifies the office that will review the submittal for the Government.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-01 Preconstruction Submittals

Control System Factory Test Plan; G, HDC

SD-02 Shop Drawings

Electrical Drawing Index; G HDC

Bill of Electrical Materials; G HDC

Main One-Line Drawing; G HDC

Schematic Drawings; G HDC

Electrical Interconnecting Diagrams; G HDC

Electrical Installation Drawings; G HDC

Cable and Conduit Schedule; G HDC

Cable Carrier Systems Drawings; G HDC

SD-03 Product Data

Cable Carrier System; G HDC

Main Line Disconnect; G HDC

Manual Disconnect Switch; G HDC

Control Systems and Equipment; G HDC

Conductor and Collector System; G HDC

Variable Frequency Drives (VFDs); G HDC

Elapsed Time Meter

Limit Switches; G HDC

Operator Chair; G HDC

Operator Console; G HDC

SECTION 41 22 13.74 26 Page 7

Pushbuttons and Selector Switches; G HDC

Indicating Lights

Master Switches; G HDC

Remote (Radio) Control System; G HDC

Load Cells and Indication; G HDC

Warning Signals

Motors; G HDC In addition to product data, provide performance characteristic curves for each motor to be furnished indicating current, torque, output, speed, efficiency, power factor, voltage, and input power, expressed in accordance with clause 12.31 of NEMA MG 1, per paragraph MOTOR FACTORY TESTING. Provide characteristics of the position encoders furnished with motors.

Holding Brakes; G HDC In addition to product data, provide dimension sheets for brakes and brake wheels, in accordance with Part 10 of NEMA ICS 8 .

Power, Heating, Lighting and Convenience Outlet Systems

Conduit and Wireways

Insulated Wire and Cable; G HDC

Terminal Blocks

Cabinets and Enclosures; G HDC

Position Indication; G HDC

Panelboards; G HDC

Molded Case Circuit Breakers; G, HDC

Line And Load Reactors; G, HDC

Utility Disconnect; G, HDC

Electric Heat Pump Units; G, HDC

Intercom; G, HDC

Wind Speed Monitor; G, HDC

Gantry Storm Brakes; G, HDC

Infrared Heaters; G, HDC

SD-05 Design Data

Electrical Calculations; G HDC

SECTION 41 22 13.74 26 Page 8

Arc Flash Analysis Information

Heating Capacity and Airflow Calculation

Dynamic Braking; G, HDC

SD-06 Test Reports In accordance with paragraph TEST RESULTS. Submit no later than 10 days after completion of tests:

Motor Test Reports

Brake Test Reports

Control System Factory Test Results

Field Wiring Test Reports

Operator Cab Wiring Testing

SD-07 Certificates

Brake Torque Rating

Factory Adjusted Torque Rating Of Holding Brakes; G, HDC

SD-10 Operation and Maintenance Data

Final Approved Versions Of Contractor Prepared Drawings; G HDC

1.4 GENERAL REQUIREMENTS

General requirements are given in Section 26 05 00.01 26 BASIC ELECTRICAL

MATERIALS AND METHODS FOR CRANES.

1.5 QUALITY ASSURANCE

1.5.1 Electrical Drawing Index

Submit a comprehensive index of shop drawings for each drawing set. The index must be part of the accompanying drawing set, having a title block, border, and sheet number that is compatible with the drawing set.

1.5.2 Bill of Electrical Materials

Submit a bill of electrical materials (schedule of equipment) for each shop drawing set. Provide a schedule that is part of the drawing set, having a title block, border, and sheet number compatible with the drawing set. The schedule must include the total quantity, manufacturer, part number, and location of each item of equipment supplied. Include a cross reference between manufacturer data and shop drawings (schematic drawings component identification within the schedule). Incorporate corresponding product data sheets with the submittal of bill of electrical materials.

1.5.3 Main One-Line Drawing

Submit an overview drawing, or one-line, of crane's power and lighting systems. The one-line must be confined to one (1) drawing sheet and have a title block and border compatible with the schematic drawings.

SECTION 41 22 13.74 26 Page 9

1.5.4 Schematic Drawings

Submit wiring schematics for power, lighting, and control circuits, enclosures, and equipment. Schematic drawings must indicate crane runway conductor system collectors and trolley supply conductors. Indicate terminal board connections, wire designations, and size and type of wire on schematic drawings.

1.5.5 Electrical Interconnecting Diagrams

Submit drawings showing interconnections between devices internal to equipment enclosures (control panels) and external equipment and assemblies. Indicate terminal board connections and wire designations on interconnecting diagrams.

1.5.6 Electrical Installation Drawings

Submit plan and elevation views of the crane, indicating locations and layout of all electrical equipment, including cabinets, motors, brakes, limit switches, lighting, controls, and cable carrier systems, with dimensions. Indicate adequate working clearances and conduit and cable routes. Show elevation view of control panels including internal devices, as seen by an observer standing in front of the open cabinet. Include detailed locations of all drilling required in structural members to mount new equipment. Include weights of major items (control panel, motors, brakes, etc.) on the drawings.

1.5.7 Cable and Conduit Schedule

Submit a comprehensive schedule of cable and conduit that cross references with the schematic drawings. The schedule must have a title block and border compatible with the schematic drawings.

1.5.8 Cable Carrier Systems Drawings

In addition to product data, submit dimensioned outline drawings detailing placement and operation of trolley cable carrier systems .

1.5.9 Final Approved Versions Of Contractor Prepared Drawings

Submit final approved versions of Contractor prepared drawings in accordance with Section 01 33 00 SUBMITTAL PROCEDURES and and 01 78 39 .00 24 PROJECT RECORD DOCUMENTS. Update Contractor prepared drawings if there are any outstanding comments. Record and incorporate modifications made during fabrication and installation (as-built). Insert a set of 11 by 17 inch final approved versions of Contractor prepared drawings into the operation and maintenance manuals.

1.5.10 Submission of Product Data

Submit all product data in accordance with Section 01 33 00 SUBMITTAL PROCEDURES and Section 41 22 13.70 26 SUBMISSION OF CRANE DESIGN DATA.

Submit product data in conjunction with the Bill of Electrical Materials.

Include complete descriptive literature and specifications of each product or system of products listed in the submittal article with original, legible manufacturer's cut sheets and data sheets to clearly indicate physical construction, operation, electrical characteristics, ratings, and associated hardware. Show conformance with these specifications within the

SECTION 41 22 13.74 26 Page 10 product data, including, but not being limited to, product manufacturers' declarations of conformance to applicable technical standards. Product data will be used for supporting approval of components shown or listed on the drawings. Acceptance of product data alone does not give approval for procurement of associated materials and equipment. Approval of items for which product data is submitted will be by approving drawings that list these items on the corresponding bill of electrical materials.

1.5.11 Submission of Design Calculations

Submit electrical calculations for approval in conjunction with the submission of corresponding product data and shop drawings. Within the calculations, include: worst-case loading of the crane (cite assumptions, Codes, and Standards applied to calculation); minimum required horsepower for each drive motor; conductor sizing; overcurrent protection;

size/rating of each transformer; lighting calculations demonstrating specified illumination level; torque rating required for holding brakes;

and other computations as required to show conformance with these specifications and suitability of the existing feeder and existing breaker sizes.

1.5.12 Submission of Test Results

Document and submit results of tests performed in accordance with paragraph ELECTRICAL TESTS to the Government within ten (10) days after completion of the test .

PART 2 PRODUCTS

2.1 CRANE ELECTRIFICATION

2.1.1 General

Electrical power for the gantry crane is supplied to the existing rigid *Am-1 enclosed copper angle **Am-1 conductors from a nominal 480-volt, 3-phase, 60 Hz HRG grounded system. Existing power feed is from the station power center MCC 15, Breaker 4-3 using 4/0 AWG conductors.

2.1.2 Crane Runway Conductor and Collector System

For structural aspects of work related to the overhead conductor and collector system refer to Section 41 22 13.73 26 CRANE APPURTENANCES.

2.1.2.1 General

a. The crane runway conductor/collector system must *Am-1 be enclosed with have **Am-1 three (3) phase conductors and a separate ground conductor and complete with insulated mounting hardware. Voltage rating must be 600 volts, minimum. The crane runway conductor system must have a separate bonding conductor. The gantry structure must not be considered "electrically grounded" through the contact between the bridge wheels and the rail.

2.1.2.2 Conductor

The conductors must be copper with stainless steel contact surface with flexible insulating shrouds that prevent inadvertent contact of live parts. Conductor system must be 3-phase, and rated large enough to

SECTION 41 22 13.74 26 Page 11 service the worst-case loading, and limit the voltage drop to two (2) percent at the point of contact with the collectors. Minimum ampacity must be 225 amps. Provide conductor expansion sections for the system as recommended by the conductor system manufacturer.

2.1.2.3 Collectors

Collectors must be the sliding shoe type, spring-loaded, with a rating adequate to serve worst-case loading of the crane, but not less than the rating of the feeder breaker. Each phase must have an assembly with two

(2) shoes placed in tandem and spaced approximately 20 inches apart. Each collector shoe of the tandem assembly must be rated for full-capacity.

Collector shoes must be compatible with the crane runway conductor system and must be easily replaceable. Provide complete collectors with manufacturer-approved mounting assembly for installation on the gantry structure.

2.1.3 Cable Carrier System

Provide power and controls to the trollies by one of the following means:

2.1.3.1 Cable Chain

The cable carrier system must be a "Cable Chain" type. The cable carrier system must be heavy-duty, maintenance-free, corrosion-resistant, and designed for long-travel applications. The cable carrier system must have a bend radius of greater than the minimum bending radius of the largest cable to prevent cable stress. The cable carrier system must be designed to support the application on the crane with regard to cable fill, travel length, and environmental ratings. Follow the manufacturer's recommendations for installation. Provide junction boxes and additional manufacturer-approved hardware necessary for installation on the gantry structure. With the exception of encode and signal level cables, terminate all cables at both ends in dedicated cable carrier junction boxes. The cable carrier system must support jacketed and color coded multiple conductor power and control cables conforming to the requirements of paragraph INSULATED WIRE AND CABLE. Provide a dedicated grounding conductor for the trolleys.

2.1.3.2 Festoons

Festoon cables must be supported by four-wheel, heavy- or mill-duty carriers running on a common "I"-beam type rail. Festoon carrier wheels must be provided with lifetime-lubricated, anti-friction bearings.

Securely clamp festoon cables at each crest and each trough to prevent movement, twisting, and binding. Provide manufacturer-approved clamping saddles for crests and troughs. Festooned cable loops must not extend below the bottom of the girders. Provide junction boxes and additional manufacturer-approved hardware necessary for installation on the structure. With the exception of encoder and signal level cables, terminate all cables at both ends in dedicated junction boxes. The festoon system must support jacketed and color-coded multiple-conductor power and control cables conforming to the requirements of paragraph INSULATED WIRE AND CABLE. Provide a dedicated grounding conductor for the trolley.

SECTION 41 22 13.74 26 Page 12

2.2 SYSTEM PROTECTION

2.2.1 General

Mount protective equipment specified herein on steel panels and terminate wires to terminal blocks or studs, complete and ready for making external connections. Panels must be enclosed in cabinets as specified in Paragraph "CABINETS AND ENCLOSURES." Control panels and the main line disconnect must be located as shown. Mount the main line phase monitor and surge protection inside control panels.

2.2.2 Manual Disconnect Switch

The manual disconnect switch must be listed to UL 489 . Provide a manual disconnect switch to isolate the crane power source from the load. The switch for the main power source to the crane must be a single throw safety switch, non-fused, rated 600 volt, 175 amp (minimum), 3 pole, heavy duty, quick-make-quick-break, load make/brake, and the enclosure door must not be capable of opening when the switch is in the "ON" position. The switch handle must be capable of being locked in the open or "OFF" position. The switch must have a short circuit withstand rating of at least 10,000 amps (rms symmetrical) at 600 volts.

The new manual disconnect switch should fit within the existing recessed disconnect switch cavity located on the intake deck downstream wall. If a product cannot be identified that will fit within this existing space, a new manual disconnect switch will be surface mounted within an enclosure, on top of the existing recessed cavity, which will be utilized as a junction box for this new equipment.

2.2.3 Main Line Disconnect

Provide a main line circuit breaker disconnect listed to UL 489 to completely remove power from the crane. The breaker must be 600-volt, 3-pole, 25kAIC (minimum), manually-operated, molded case circuit breaker having suitable continuous rating. Mount the breaker in its own dedicated panel enclosure and provide means to permit operation of the breaker without opening the enclosure door. The breaker must be capable of being locked in the open position and have a minimum rating of 10,000 mechanical (manual) operations. Install the main line disconnect on the bridge walkway.

2.2.4 Utility Disconnect

Provide a utility disconnect circuit breaker listed to UL 489 to remove power from the crane's utility (auxiliary) circuits including motor heaters, convenience outlets, area lighting, and panel heaters. The intent of the utility disconnect is to remain ON (CLOSED) when the crane is not in use. The breaker must be 600-volt, 3-pole, 25kAIC (minimum), manually-operated, molded case circuit breaker having a suitable continuous rating. Mount the breaker in its own dedicated panel enclosure and provide means to permit operation of the breaker without opening the enclosure door. The breaker must be capable of being locked in the open position and have a minimum rating of 10,000 mechanical (manual) operations. Install the utility disconnect on the bridge walkway adjacent to the control panels.

SECTION 41 22 13.74 26 Page 13

2.2.5 Main Line Contactor

Provide a main line contactor that is 3-pole magnetic contactor to switch power to the crane's motion control circuits, with provisions to de-energize and drop-out the contactor during any condition of undervoltage, reverse-phase, or open-phase by the main line phase monitor. Include three installed spare auxiliary contacts, which can be easily changed from normally open to normally closed, in addition to those required by the control system design.

a. Contactor Rating, Performance, and Service Characteristics:

(1) The contactor must be the electrically-operated, magnetically-held type, insulated for 600 volts AC.

(2) Coils must be suitable for continuous operation at 120 volts AC, or as otherwise approved.

(3) The contactor's rating, performance, and service characteristics must conform to requirements of NEMA ICS 2 for contactors with continuous current ratings for the duty indicated.

(4) The contactor must be rated for full-voltage starting (Class A controllers) and be suitable for at least 200,000 complete operations under rated load without more than routine maintenance.

(5) Contacts must be easily replaceable.

(6) The contactor's current-carrying contact surfaces must be surfaced with silver or other approved material to prevent the formation of high-resistance oxides.

b. Contactor Operating Features:

Provide the contactor with its operating coil energized from the main line through a control power transformer. If the contactor is de-energized it must be necessary to return all cab master switches to the "OFF" position before the main line contactor can be re-closed. The contactor must de-energize when any of the "Emergency STOP" or power "STOP/OFF" pushbuttons is operated and as directed in these specifications. The contactor must operate without chatter or perceptible hum while energized.

2.2.6 Main Line Phase Monitor

Provide a main line phase monitor located on the line side of the main line contactor; the phase monitor must provide protection against phase unbalance, phase loss, phase reversal, undervoltage, and overvoltage.

Upon sensing fault, the protector must de-energize and drop-out the main-line contactor. The protector must use a combination of voltage and phase-angle sensing to detect phase loss even when regenerated voltages are present. The protector must have an adjustable line voltage trip level, adjustable trip delay, and both automatic and manual reset.

Protector operation must have repeatability of +1 percent of set point, maximum, and a dead band of 2 percent maximum. Protector must have LED indicators to show normal and tripped status.

SECTION 41 22 13.74 26 Page 14

2.2.7 Surge Protection

Provide Type 2 transient voltage and current surge protection to protect all of the crane electrical power and control systems. Surge protection equipment must be listed to UL 1449 . Surge protection must be rated for their service (i.e. rated for delta connection when installed on an ungrounded (delta or high resistance grounded) system).

2.2.8 Lightning Protection

The new intake crane is located in an area subject to high lightning activity. The design of the crane must consider and minimize the effect of lightning strikes. Provide grounding brushes for at least two gantry wheels and corresponding grounding conductors with an ampacity of 100A each (four total)that ensure a ground path between the crane structure and the crane wheels.

2.3 CONTROL SYSTEMS AND EQUIPMENT

2.3.1 General

Provide crane control systems and components that comply with the applicable provisions of NEMA ICS 8 . Design the control system such that operator interface, control commands, and load indication are not processed through a programmable logic controller (PLC). Controls must have static reversing of the direction of hoist or travel and provide smooth acceleration, deceleration, and stopping at all speeds and loads while operating within safe limits of overload currents. Design controls to be fail-safe, causing motor holding brakes to set automatically on control malfunction, protective device operation, or loss of power and so that, no matter how erratically the master switch handle may be operated, there must be no damage to controls or equipment, nor any danger of uncontrolled lowering of the load load. Control voltage must be 120 VAC or

24 VDC.

In addition:

a. Master Switches: All hoist and travel motions must be individually controlled with separate controllers and capable of simultaneous usage.

b. Variable Frequency Drives: All motions must have separate controllers, as directed by Paragraph VARIABLE FREQUENCY DRIVES (VFD).

c. Hoist Ultralift Control: Provide controls with field-selectable settings to allow driving each main hoist motor at greater than rated speeds (ULTRASPEED) when loads are light, up to 200 percent rated speed, inversely proportional to load. Provide Selector switches and control circuits to allow the operator to use this feature only when desired.

d. Hoist/Trolley/Gantry Microspeed Control: Provide hoist, trolley, and gantry controls with speed range selector switches to allow the operator to select full- or reduced-range speed control over full travel of the master switch. Provide reduced-range control that, when selected, the master switch continuously varies the speed setting from zero to a lower value within the full speed range. The reduced-range value must be field- programmable to between 10 and 30 percent of full speed, initially set to 25 percent.

SECTION 41 22 13.74 26 Page 15

NOTE: The microspeed selection switch and ultralift selection switch (detailed above) will be incorporated in a single three-position maintained selector switch (MICRO-NORMAL-ULTRA); when the speed selection switch is in the ULTRA (Ultralift) position the trolley and gantry travel functions must operate in the normal speed mode of operation.

e. "START & STOP" Pushbuttons: Provide controls with two pushbuttons, momentary-contact type, for activating and deactivating the main line contactor. Pushbuttons must be located on the operator control station, as shown and be colored "Green" for "START" and "Red" for "STOP". Provide main line contactor controls in the form of pushbuttons or a maintained selector switch on the radio remote.

f. Crane Energized Indicating Lights: Provide white lamps on the operator control station console and remote (radio) control to indicate that the crane's motion circuits (main line contactor) are energized.

g. "Emergency STOP" Pushbutton: Locate controls on the left and right console on the operator control station. "Emergency STOP" Pushbutton must remove all power for the crane motion circuits. The "Emergency STOP" Pushbutton must not be designed to be used for normal operation of the crane power-off. "Emergency STOP" Pushbutton must be red "Twist-to-Release" mushroom style with e-stop guard to prevent accidental activation. Label emergency stop pushbuttons as "EMERGENCY

STOP".

h. Provide an "Emergency STOP" Pushbutton for the remote (radio) control and on each of the outboard legs of the gantry structure at approximately 5 feet above the deck.

i. Brake Failure Indicating Lights: Provide a flashing red lamp to indicate holding brake failure for any hoist brake, located on the operator control station console. Provide annunciation of brake failure on the stack lights per Paragraph "Crane Operation Warning Lights".

j. Warning Signal Pushbuttons: Provide a pushbutton for manual activation of the travel bell and warning lights located at the operator control station. Operational requirements of the warning signals are given in Paragraph "WARNING SIGNALS."

k. Remote (Radio) Control: Provide a "Remote (Radio) Control Switch" on the console of the operator console to allow the operator to select either remote or local control. The selection of remote control must still permit only the use of the "STOP" pushbutton and the "Emergency STOP" pushbutton inside the operator cab. A blue pilot light must be provided on the operator control station console to indicate that cab control has been transferred to remote (radio) control.

l. Horn: Provide momentary pushbuttons to activate the horn

m. Floodlights: Provide 2-position switches to operate the floodlights

n. Alarm Silence: Provide momentary pushbuttons to allow the operator to temporarily (two minutes) silence all audible alarms (brake slip alarm and alarms associated with the high load and overload warnings).

SECTION 41 22 13.74 26 Page 16

o. IR Heaters: Provide 2-position switches to operate the IR heaters.

2.3.2 Control Power

Supply control power from a provided encapsulated control transformer meeting NEMA ST 20 . The transformer must be two-winding, 480/120-volt, single-phase, 60-Hz, dry-type, air-cooled, and continuous-rated. Secondary power circuits must be individually fused or protected by a circuit breaker. Provide individual circuit protection for the controls, Radio Remote Control System, Wind Speed Monitoring System, Load Cell System, and others as per the approved control systems design.

2.3.3 Hoist and Travel Operating Features

2.3.3.1 Hoisting and Lowering

a. Provide variable speed control from zero (0) to 100 percent for both hoisting and lowering. Additionally, provide fast speed operation above rated speed as described in this section. Include means to limit the maximum torque a hoist motor can develop and configure the controls such that hook loads greater than 150 percent rated capacity of each hoist cannot be lifted. The load-speed characteristics must be inherent in the controls at all speed positions. Positive control of the lowering movement of all hoist hooks must be maintained under all conditions of load.

b. Controls must be provided with adjustable compensation that allows initial electronic adjustment of the speed between hoists operating at the same selected speed and load to be within 0.1 percent of each other during synchronized operation.

2.3.3.2 Hoisting and Lowering Performances

The following hoisting and lowering performances are required, and must be suitable for administering all loads, from no load on the hook to rated load.

a. The speed control setting for hoisting and lowering must provide one-tenth of one (0.1) percent speed regulation, 1000 to one (1000:1) speed control range, and position control at zero speed. The starting speed control setting must start at the beginning of the master switch range (directional microswitch run command to the VFD). Hoist motion must meet the requirements of Paragraph Positioning Accuracy of this section.

b. Hoists. The highest (fastest) normal speed control setting for hoisting and lowering must provide a hoisting speed of 100 percent rated speed at rated load. This setting must be field-programmable for a range of 100 to 250 percent rated speed, operable above 100 percent rated speed only when there are light loads on the hook/block and when the ultra-lift is selected via the ultra-lift selector switch. The initial setting for ultra-lift must be 200 percent rated speed.

c. All intermediate speed control settings for hoisting and lowering must operate linearly between the starting speed control setting and the highest (fastest) speed control setting.

d. Sufficient starting torque such that when motion is initiated from

SECTION 41 22 13.74 26 Page 17 standstill with 100% of rated load on any hoist less than one-sixteenth (1/16) inch of roll back is measured at the load.

2.3.3.3 Travel and Trolley Travel

Provide variable speed control from zero (0) to 100 percent for each direction of travel regardless of hook loads.

2.3.3.4 Travel Performances

Provide gantry and trolley travel performances as follows:

a. The speed control setting for travel must have a minimum operating travel speed of no more than one (1) percent of the 100 percent rated travel speed. The starting speed control setting must start at the beginning of the master switch range (directional microswitch run command to the VFD). Travel motions must meet the requirements of Paragraph "Positioning Accuracy" of this section.

b. The highest (fastest) speed control setting for travel must be 100 percent rated travel speed (for normal operating speed).

c. All intermediate speed control settings for travel must operate linearly between the starting speed control setting and the highest (fastest) speed control setting.

d. After a 5 second delay from any input for gantry travel, the mechanical gantry brakes must engage.

2.3.3.5 Positioning Accuracy

Design the control system so that is possible to limit the motion of any hoist or travel motion to not more than 0.125 inch by quick actuation of the respective master switch controller in the microspeed selection, with any load, up to and including, the rated load. The intent of this requirement is that the crane may position the load accurately with small movements of the crane functions. The Government will verify positioning accuracy during acceptance testing.

2.3.4 Variable Frequency Drives (VFDs)

2.3.4.1 General

Provide variable frequency drives (VFDs) of a type regularly supplied and specifically designed for use on cranes. VFD type and revision must be the current offering from the manufacturer and still in production at the time of the transmittal of the submittal. All VFDs must be from the same manufacturer. Drive controllers for hoists must be variable-frequency AC with closed-loop flux vector control with feedback from a motor-shaft-mounted encoder. Drives for trolley and gantry travel must be capable of both variable-frequency AC with open-loop vector or V/Hz control.

2.3.4.2 VFD Operating Features

a. Provide a separate VFD for each motion. VFDs for each motion must provide true four-quadrant control and be the solid state, pulse width modulated (PWM) type with adequate capacity to drive motors at all specified loads and speeds. VFDs must be rated for continuous

SECTION 41 22 13.74 26 Page 18 duty with an ambient temperature of 40 degrees C at the motor rated current. VFDs must have an overload capacity rating of 150 percent rated load for 1 minute. Speed regulation must be less than 1.0 percent from no-load to full-load, over the entire frequency range.

Acceleration and deceleration must be separately adjustable from 0.1 to 25 seconds. Include motor overload protection with the VFD. The control circuits must include an adjustable-operating current-limiting circuit capable of limiting maximum current to not more than the current necessary to obtain 200 percent motor torque.

b. VFDs must be capable of monitoring current and speed to verify that enough motor torque has developed before the holding brakes are released ("torque proving" for hoist functions) and monitoring current and speed to verify that holding brakes are maintaining load before removing power from the motor (for hoist functions).

c. VFDs used for hoists must monitor for failure of the hoist brakes.

When brake failure or slipping is detected based on encoder feedback the the drive must maintain the load in position and allow for lowering the load. Means of enabling, disabling, and adjusting the sensitivity of the brake failure alarm must be provided with adjustable VFD parameters. When a brake failure event is detected, the red lamp on the crane operation warning light stack must illuminate.

Provide a brake failure red indication lamp on the operator console that illuminates when a brake failure event is detected.

d. Each VFD must be equipped with a control pad to adjust drive parameters, display drive faults, display drive recorded status at the most recent fault (including, as a minimum: current, output frequency, output voltage, and digital input and output status), display elapsed time of operation, and display drive status including VFD output voltage, current, and frequency. Mount the control pad on the inside of the control panel. VFDs must be capable of storing, as a minimum, the five most recent fault conditions which must remain accessible after cycling power to the drive. Control pads must be no lower than four (4.0) feet and no higher than five and one half (5.5) feet from the walking surface in front of the panels.

2.3.4.3 Line And Load Reactors

Provide line and load reactors where recommended by the manufacturer of the variable frequency drives. Reactors must be of the type specifically designed for use with variable frequency drive systems and be applied in accordance with the VFD manufacturer's documented recommendations. All reactors must be rated for continuous duty operation based upon the motor nameplate amperes and be designed for 60 Hz operation.

2.3.4.4 Dynamic Braking

Provide a submittal for dynamic braking showing calculations and/or VFD manufacturer specifications demonstrating adequate selection of dynamic braking resistors. Provide dynamic braking for each hoist and travel function VFD. Mechanical or electrical load brakes must not be used.

Resistors for dynamic braking circuits must: be corrosion-resistant type and have resistance values and power ratings as required by the VFD manufacturer for the application used. Hoists must be provided with resistors rated for continuous use at 150 percent braking torque per Part 11 of NEMA ICS 8 . Gantry and trolley travel resistors must be rated for 60 seconds on and 60 seconds off at 150 percent braking torque per Part 11 of

SECTION 41 22 13.74 26 Page 19

NEMA ICS 8 . Each dynamic braking resistor must be shielded to allow for proper ventilation while providing adequate protection from objects falling or being dropped into the resistor enclosure from above. Provide adequate enclosures with outdoor ratings for dynamic braking resistors located outdoors.

2.3.4.5 Elapsed Time Meter

In addition to elapsed time of operation function required to be integral the VFDs, provide one elapsed time meter to measure overall operating time of the crane. The indicator must be non-resettable to accumulate total operating time of the main line contactor in increments of tenths of an hour and have a range of 99999.9 hours. Malfunction or failure of the meter must not adversely affect the crane's control systems.

2.3.5 Limit Switches

a. Provide limit switches in accordance with these specifications and as required per the manufacturer's approved design. All limit switches must: be UL Listed; be constructed in accordance with NEMA ICS 5 ; be provided with nonventilated NEMA Type 4X enclosures constructed in accordance with NEMA ICS 6 ; and be mounted where they are readily accessible for adjustment and inspection by site maintenance personnel. Contact ratings must be not less than the maximum currents of the devices they switch. All limit switches must be the control circuit type and not interrupt power to the motor directly.

(1) Hoist Block Activated Upper Limit (Secondary Upper Limit).

Provide a normally-closed, momentary contact, weighted-lever type limit switch actuated directly by the lower blocks. Upon actuation of the limit, upward hoist movement must stop. When this limit is reached, hoist movement must be blocked in either direction.

Provide a local bypass switch installed on the hoist control panel to lower out of the secondary upper limit switch range. The secondary upper limit is used as back up limit if the upper rotary (primary) limit were to fail. The weighted upper limit switch must be set no lower than the height of the primary upper limit switch setting plus the primary limit runout distance, but not less than the secondary runout distance below the lowest contact point of the hoist or trolley structure (two-block condition). The runout distances are defined as the load block maximum drift, after switch activation, in the hoisting direction at maximum speed (ultralift selection, up to 200% of base speed) with no load on the hoist. Block activated upper limits are required on all hoists. Provide an alarm and associated means of indication in the operator cab for block activated upper limit switch actuation.

(2) Hoist Upper Rotary Limit (Primary Upper Limit). Provide a normally-closed, momentary contact, traveling-nut or rotating-cam rotary type limit switch, driven through gearing by the hoist.

Provide the rotary upper limit switch to allow the operator, when hoisting, to activate a first initial upper rotary limit switch that slows the hoisting speed down to 25 percent speed. Lowering out of the upper slowdown limit must allow for full speed. The initial setting of the slowdown limit must be approximately two feet below the rotary upper stop limit. Upon actuation of a second rotary limit, upward hoist movement must stop but the operator must still be able to lower the blocks out of the primary upper limit. When this limit is reached, lowering the load blocks must

SECTION 41 22 13.74 26 Page 20 automatically reset the limit switch. The primary upper limit switch must be set at the maximum practical load block height but still allow for the distances required for the secondary (block activated) upper limit. Rotary upper limits are required on all hoists.

(3) Hoist Lower Rotary Limit. Provide a normally-closed, momentary contact, traveling-nut or rotating-cam rotary type limit switch, driven through gearing by the hoist. Provide the rotary lower limit switch to allow the operator, when lowering, to activate a first initial lower rotary limit switch that slows the hoisting speed down to 25 percent speed. Raising out of the lower slowdown limit must allow for full speed. The initial setting of the slowdown limit must be approximately ten feet above the rotary lower stop limit. Upon actuation of the limit, lowering hoist movement must stop but the operator must still be able to raise the load blocks out of the lower limit. When this limit is reached, raising the load blocks must automatically reset the limit switch. Set the lower limit switch at the minimum practical load block height. No less than two wraps of rope must remain on the drum when the hoist lower rotary limit is reached. Rotary lower limits are required on all hoists.

(4) Trolley Travel. Provide a normally-closed, maintained contact, adjustable lever type limit switch, capable of being reset by reversing the movement of the trolley. When the limit is reached, trolley movement must decelerate to a maximum of 25% of rated speed (field-programmable between 10% and 30% of full speed). Provide limits on each end of trolley runway to prevent the trolley from running into the trolley end stops at full speed.

The trolley must be able to reverse out of the limit at rated speed or slow speed, if selected. Travel limits are required on all trolleys. Provide an anti-collision limit switch to prevent collision between the aux hoist trolley and the main hoist wire rope or lifting beam.

(5) Gantry Travel Limits. Provide a normally-closed, maintained contact, adjustable lever type limit switch, capable of being reset by reversing the movement of the gantry. Provide the north and south ends of the gantry travel runway with apparatus used to actuate the limit switches on the crane. The apparatus used to actuate the switches at end of the travel runway must be robust enough to handle car and truck traffic with no deformation.

Arrange the limit switch to operate reliably even when covered by 1/2 inch of ice. Provide initial limits on each end of the crane runway such that when the limit is reached, gantry movement decelerates to a maximum of 25% of rated speed (field-programmable between 10% and 30% of full speed). Provide limits on each end of crane runway. The gantry function must be able to reverse out of the limit at rated speed or slow speed, if selected. Provide a second limit on each end of the runway to stop the crane prior to reaching the end of the runway. Arrange the limit switches to utilize the overtravel capabilities of the switch to operate reliably even when the dog is covered by 1/2 inch of ice. The gantry must be able to reverse out of the stop limits at rated speed or slow speed, if selected.

b. All limit switch trip mechanisms must be new and connected as necessary to accommodate new limit switches. Submit arrangement, SECTION 41 22 13.74 26 Page 21 placement, and construction of the limit switches and trip mechanisms for approval.

c. Provide a spring-returned two position keyed bypass switch for each hoist to bypass the rotary (primary) upper limit. Locate the keyed bypass switch on the respective hoist control panel door, accessible without opening the panel. The right position (actuated position) of the keyed switch must allow bypassing of the hoist upper rotary limit and upper slowdown limit to allow the hoist block activated upper limit (secondary upper limit) to be tested. The left position (un-actuated, spring return) position of the bypass switch must be the "normal" position with neither limit being bypassed.

2.4 OPERATOR CONTROL STATION

2.4.1 General

Operator control of crane motions must be accomplished by control switches located at the consoles of the operator chair in the cab, the secondary operator control console, and also at the radio transmitters.

Annunciation must be accomplished by indicating lights placed in the operator chair, indicating lights placed on the secondary operator control console, and the radio display.