41 22 13.72 26 R0003.pdf

AFD Powerhouse Bridge Crane Rehab 23011 Oldtown, ID W912DW24R0019

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 22 13.72 26

BRIDGE CRANE MECHANICAL AND STRUCTURAL REHABILITATION

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

1.2 REFERENCES

1.3 SUBMITTALS

1.4 DESIGN CRITERIA

1.4.1 General

1.4.2 Functions

1.4.3 Definitions

1.4.4 Data, Capacities, Speeds, and Travel

1.4.5 Design Loads and Combination of Loads

1.4.5.1 General

1.4.5.2 Dead Loads

1.4.5.3 Live Loads

1.4.5.4 Combinations of Loads

1.4.6 Structural Design Criteria

1.4.6.1 Fatigue Design

1.4.7 General Stiffness Requirements

1.4.7.1 Trolley Deflections

1.4.7.2 Bases

1.4.8 Maximum Trolley Wheel Loads

1.4.9 Mechanical Parts of the Crane

1.4.9.1 Mechanical Equipment Allowable

1.4.9.2 Shafting

1.4.9.3 Gears and Speed Reducers

1.4.9.4 Stress Concentration Factors

1.4.9.5 Wire Rope Stresses

1.4.9.6 Drum Stresses

1.4.9.7 Machinery Efficiencies

1.4.10 Use of Cast Iron

1.4.11 Connections

1.4.11.1 Shop and Field Connections

1.4.11.2 Welded Connections

1.4.11.3 Bolted Connections

1.4.11.3.1 Bolted Structural Connections

1.4.11.3.2 Mechanical Bolted Connections

1.5 SUBMISSION OF CRANE DESIGN DATA

1.5.1 General

1.5.2 Drawing Index

1.5.3 Bill of Materials/Schedule of Equipment

1.5.4 Drawings

1.5.4.1 Dimensioned Assembly Drawings

1.5.4.2 Detailed Shop Drawings

1.5.4.3 Clearance/Coverage Diagram

1.5.5 Product Data

1.5.5.1 General

1.5.5.2 Type of Equipment and Quality

1.5.6 Design Calculations

1.5.6.1 Finite Element Analysis (FEA)

1.5.6.2 Computer-Assisted Calculations

SECTION 41 22 13.72 26 Page 1 R0003

1.5.6.3 Structural Trolley Frame Design Calculations

1.6 FINAL APPROVED VERSIONS OF CONTRACTOR PREPARED DRAWINGS AND FINAL

CALCULATIONS

1.6.1 Final Approved Versions of Contractor Prepared Drawings

1.7 FIELD MEASUREMENTS

1.8 REHABILITATION PROCEDURE

1.9 MAINTENANCE

1.9.1 Accessories and Special Tools

1.9.2 Spare Parts

PART 2 PRODUCTS

2.1 TYPE OF EQUIPMENT AND QUALITY

2.2 NAMEPLATES AND CAPACITY PLATES

2.2.1 General

2.2.2 Contractor's Nameplate and Capacity Plates

2.2.3 Plate Details

2.2.4 Warning Labels

2.3 TROLLEYS

2.3.1 Trolley Frame

2.3.2 Trolley Jacking Pads and Lifting Eyes

2.3.3 Trolley Bumpers

2.4 WIRE ROPE

2.5 GREASE LINES AND GREASE FITTINGS

2.6 TUBE AND FITTINGS

2.6.1 Tubing

2.6.2 Tubing Joints

2.6.3 Tube Fittings

2.7 LUBRICATION

2.7.1 General

2.7.2 Speed Reducers

2.7.2.1 New Lubricating Oil

2.7.2.2 Speed Reducer Oil Testing

2.7.2.3 New Lubricating Oil Cleanliness

2.7.3 Grease

2.8 GUARDS, COVERS AND DRIP PANS

2.8.1 Guards and Covers

2.8.2 Drip Pans

2.8.3 Speed Reducer Secondary Containment

2.9 FIRE EXTINGUISHER

2.10 MAIN HOIST

2.10.1 General

2.10.2 Main Hoist Gear Reducer

2.10.3 Main Hoist Drum to Reducer Connection

2.11 AUXILIARY HOIST

2.11.1 General

2.11.2 Auxiliary Hoist Gear Reducer

2.11.3 Auxiliary Hoist Drum to Reducer Connection

2.12 HOIST DRUMS

2.12.1 General Drum Design

2.12.2 Drum Shell

2.12.3 Drum to Reducer Connection

2.12.4 Drum Materials

2.12.5 Drum Post-Weld Stress-Relief

2.12.6 Drum Weld Inspection

2.12.7 Drum Painting

2.12.8 Drum Final Machining Tolerances

2.12.9 Drum Measurements

2.12.9.1 General

SECTION 41 22 13.72 26 Page 2

2.12.9.2 Drum Shell Measurements

2.12.9.3 Drum Groove Measurements

2.13 TROLLEY DRIVE

2.13.1 General

2.13.2 Wheels

2.13.3 Axles

2.13.4 Trolley Trucks

2.14 HOIST LOAD BLOCKS, SHEAVES, AND HOOKS

2.14.1 General

2.14.2 Load Blocks

2.14.3 Sheaves

2.14.4 Sheave Pins

2.14.5 Hooks

2.14.5.1 Inspection of Hook Assembly

2.14.5.1.1 Hook Non-Destructive Test (NDT)

2.14.5.2 Hook Proof Test

2.15 GEARS AND SPEED REDUCERS

2.15.1 General

2.15.2 Gear Rating

2.15.3 Gear Manufacture and Assembly

2.15.4 Gear Dimension, Quality, and Hardness Verification

2.15.5 Speed Reducers

2.15.5.1 Commercial Speed Reducer Rating

2.15.5.2 Special Speed Reducer Rating

2.15.5.3 Speed Reducer Features

2.15.5.4 Speed Reducer Lubrication

2.15.5.5 Speed Reducer Nameplate

2.15.5.6 Speed Reducer Mounting

2.15.6 Additional Requirements for Speed Reducers

2.16 GEAR CASES

2.16.1 General

2.16.2 Gear Reducer Seals

2.17 GEARMOTORS

2.18 BEARINGS

2.18.1 General

2.18.2 Sleeve-Type

2.18.3 Anti-Friction

2.19 SHAFTING

2.19.1 General

2.19.1.1 Machine Dimensions and Surface Finish

2.19.2 Support

2.20 PINS

2.20.1 General

2.21 KEYS AND KEYSEATS

2.22 FITS

2.23 SHAFT COUPLINGS

2.23.1 General

2.23.2 Configuration

2.23.3 Barrel Couplings

2.24 BUMPER SAFETY CABLES/CHAINS

2.25 TROLLEY TANEDM MECHANICAL LINK

PART 3 EXECUTION

3.1 CLEANUP AND REMOVAL

3.1.1 Cleanup

3.1.1.1 Cleanup - Environmental Considerations

3.1.2 Removal

3.2 SHOP ASSEMBLY AND TESTS

SECTION 41 22 13.72 26 Page 3

3.3 PREPARATION FOR SHIPMENT

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 TIGHTENING OF FASTENERS

3.9 REDUCER OIL TESTING

3.10 BRIDGE TRAVEL OPERATIONAL TEST

3.10.1 Bridge Travel Operational Test Procedure

3.10.2 Video Recording

3.10.3 Bridge Travel Operational Test Reports

3.11 BRIDGE DRIVE MECHANICAL REHABILITATION

3.11.1 Bridge Drive Electric Motor

3.11.2 Bridge Drive Brake

3.11.3 Bridge Drive Speed Reducers

3.11.3.1 Bridge Drive Speed Reducer Oil Flushing

3.11.4 Couplings

3.11.5 Bridge Drive Truck Open Gears

3.11.5.1 Bridge Drive Truck Open Gear Inspection

3.11.5.2 Bridge Truck Open Gear Replacement (Optional)

3.11.5.3 Bridge Truck Shaft for Gears BD and BE (Optional)

3.11.6 Bridge Truck Grease Lines

3.12 SHAFT ALIGNMENT

3.13 DYNAMIC BALANCING OF MACHINERY

-- End of Section Table of Contents --

SECTION 41 22 13.72 26 Page 4

SECTION 41 22 13.72 26

BRIDGE CRANE MECHANICAL AND STRUCTURAL REHABILITATION

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

This SECTION covers the mechanical and structural work for the rehabilitation of the 250-ton powerhouse bridge crane at the Albeni Falls Powerhouse. Design all new and modified systems and components of the crane and submit computations and drawings as stated in paragraph SUBMITTALS and SUBMISSION OF CRANE DESIGN DATA. Furnish detailed shop drawings showing all details required to fabricate and install mechanical and structural equipment.

Design and manufacture:

a. Two complete new main hoist trolleys for the existing crane to work with the existing below the hook lifting devices and lifting beams.

Equip each trolley with a main hoist, an auxiliary hoist and trolley drive. The main hoist must have two holding brakes and the auxiliary hoist must have two holding brakes.

b. Replace lower hook sheave blocks and hooks.

c. Rehabilitate the bridge drive system to include new motor and brake. Oil flush the bridge drive speed reducers. Refill with new oil.

d. Inspect bridge drive open gears with optional items to replace gears, shafts, bearing and seals.

e. Replace operator cab with new.

f. Safe access to each trolley from bridge walkways and upper tolley walkways on each end of the bridge.

Powerhouse access is limited to personnel doors and a heavy materials hatch in the intake deck. All large machinery, equipment and crane components must fit through the heavy materials hatch-clear dimensions 18'-0" by 23'-7"; equipment may be hoisted through the hatch with the intake gantry crane or a mobile crane.

NOTE: All furnished products are to be considered new, with associated design calculations, drawings, and product data provided by the Contractor; there are no "replace-in-kind" components. Contractor is responsible for any changes in material or quality which are necessary for products to conform with these specifications while maintaining clearances, fits, and alignment with existing equipment

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.

SECTION 41 22 13.72 26 Page 5

AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)

ABMA 8.2 (2023) Rolling Element Bearings - Shaft Mounted - Locknuts, Sleeves, and Locking Devices - Inch Design

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

ABMA 19.2 (2013) Tapered Roller Bearings - Radial Inch Design

ABMA 20 (2011) Radial Bearings of Ball, Cylindrical Roller and Spherical Roller Types Metric Design

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

ANSI/AGMA 2001-D04 (2004; R 2016) Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth

ANSI/AGMA 2003-D19 (2019) Rating the Pitting Resistance and Bending Strength of Generated Straight Bevel, ZEROL Bevel, and Spiral Bevel Gear Teeth

ANSI/AGMA 9002-C14 2014; R 2020) Bores and Keyways for Flexible Couplings (Inch Series)

ANSI/AGMA 6013-B16 (2016; R 2021) Standard for Industrial Enclosed Gear Drives

ANSI/AGMA 9005-F16 (2016; R2021) Industrial Gear Lubrication

ANSI/AGMA 2015-1 (2001A; R 2014) Accuracy Classification System - Tangential Measurements for Cylindrical Gears

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 (2017) Steel Construction Manual

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI B11/STD B11.19 (2019) Performance Requirements for Risk Reduction Measures: Safeguarding and other Means of Reducing Risk

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

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

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)

SECTION 41 22 13.72 26 Page 6

ASME B30.10 (2019) Hooks

ASTM INTERNATIONAL (ASTM)

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

ASTM A275/A275M (2018) Standard Practice for Magnetic Particle Examination of Steel Forgings

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

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

ASTM B22/B22M (2017) Standard Specification for Bronze Castings for Bridges and Turntables

ASTM A217/A217M (2022) Standard Specification for Steel Castings, Martensitic Stainless and Alloy, for Pressure-Containing Parts, Suitable for High-Temperature Service

ASTM D445 (2019a) Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and Calculation of Dynamic Viscosity)

ASTM D664 (2018; E 2018; E 2019) Standard Test Method for Acid Number of Petroleum Products by Potentiometric Titration

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

ASTM D4057 (2012; R 2018) Standard Practice for Manual Sampling of Petroleum and Petroleum Products

ASTM D4425 (2009) Standard Test Method for Oil Separation From Lubricating Grease by Centrifuging (Koppers Method)

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

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

ASTM E1571 (2011; R 2016; E 2016) Standard Practice

SECTION 41 22 13.72 26 Page 7 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

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

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

Specification and Verification of Balance Tolerances

ISO 4406 (1999) Hydraulic Fluid Power - Fluids - Method for Coding the Level of Contamination by Solid Particles - Fourth Edition

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

OCCUPATIONAL SAFETY & HEALTH ADMINISTRATION (OSHA)

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

RCSC A348 (2020) RCSC Specification for Structural Joints Using High-strength Bolts

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

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

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" or "F" 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

Submit the following submittals within the timeframe specified in the respective paragraphs that define the requirements of each submittal.

Field Measurements

Rehabilitation Procedure; G HDC

Speed Reducer Flushing Procedure; G HDC

SECTION 41 22 13.72 26 Page 8

Gear Inspection Procedure; G HDC

Bridge Truck Open Gear Rehabilitation Procedure; G HDC

Drum Shell Measuring Procedure; G HDC

SD-02 Shop Drawings

Submit shop drawings with Crane Design Data design package submittals under SD-05 Design Data.

SD-03 Product Data

Submit product data with Crane Design Data design package submittals under SD-05 Design Data (except items listed below must be submitted separately).

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

Nameplate; G HDC

Accessories and Special Tools; G HDC

SD-05 Design Data

Submit the following submittals within the timeframe specified in the respective paragraphs that define the requirements of each submittal.

Design Package Submittals

Crane Design Data; G HDC

Clearance/Coverage Diagram; G HDC

Bolt Tension Chart; G HDC

Drum Groove Measuring Procedure; G HDC

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

Bridge Travel Operational Test Procedure; G HDC

Hoist Brake Alignment and Run-In Procedure

Hoist-Specific Submittals

Oil Test Results (New Oil Delivery); G HDC

Wire Rope Magnetic Flux Leakage Test Results (prior to installation); G HDC

Dynamic Balancing Report; G HDC

Trolley, Travel, and Truck-Specific Submittals

Trolley Wheel Hardness Test Report; G HDC

Other Report Submittals

SECTION 41 22 13.72 26 Page 9

Shaft Alignment Report; G HDC

Balance Quality Report; G HDC

Hook Proof Test Report; G HDC

Drum Shell Measurements Report; G HDC

Drum Groove Measurements Report; G HDC

SD-06 Test Reports

Pre-Rehab Bridge Travel Operational Test Report; G HDC

Post-Rehab Bridge Travel Operational Test Report; G HDC

Gear Inspection Report; G HDC

Hook Non-Destructive Test (NDT) Report; G HDC

Hoist Brake Torque Test Report; G HDC

Oil test results (12 month service)

SD-07 Certificates

Registered Professional Mechanical Engineer; G HDC

Registered Professional Structural Engineer; G HDC

Wire Rope Certificates; G HDC

SD-11 Closeout Submittals

Final Approved Versions of Contractor Prepared Drawings; G HDC

Final Calculations; G HDC

Spare Parts

1.4 DESIGN CRITERIA

1.4.1 General

The contract drawings indicate the general arrangement and outline of the bridge crane, 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 as per the requirements in paragraph SUBMISSION OF CRANE DESIGN DATA and in accordance with the requirements of SECTION 01 33 00 SUBMITTAL PROCEDURES.

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

1.4.2 Functions

For the bridge crane, provide for the functions and operations given

SECTION 41 22 13.72 26 Page 10 below, within the dimensional constraints as field-verified:

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

b. Connect to existing lifting beams.

c. Connect to existing below the hook devices.

d. Operate both trolleys simultaneously, including travel upstream or downstream. Tandem operation of both trolleys is specified in SECTION 41 22 13.74 26 BRIDGE CRANE REHABILITATION ELECTRICAL WORK. Trolley travel must be the full travel distance specified.

e. Operate trolleys independent of each other, including travel upstream or downstream. Trolley travel must be the full travel distance specified.

1.4.3 Definitions

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

b. 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 during each cycle; and the inertia forces acting during the movements of cranes, crane components, and hoist loads.

c. Structural Frame: The structural frame includes beams, girders, and other members carrying principal loads.

d. Crane Appurtenances: Those structures or mechanical features ancilliary 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.

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

f. Maximum Motor Torque: 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 motors.

1.4.4 Data, Capacities, Speeds, and Travel

Data, capacities, travel distances, and rated speeds of the crane are as per SECTION 41 22 13.71 26 BRIDGE CRANE DATA, TESTING AND TRAINING.

1.4.5 Design Loads and Combination of Loads

1.4.5.1 General

Base the design loads on the rated capacities specified in SECTION

41 22 13.71 26 BRIDGE CRANE DATA, TESTING AND TRAINING.

Compute loads as follows, with the trolley in such positions as will give

SECTION 41 22 13.72 26 Page 11 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.

1.4.5.2 Dead Loads

The dead load of the bridge crane includes 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, universal lifting beam, or wire ropes.

1.4.5.3 Live Loads

a. Hoist Loads - The live load on a hoist includes the rated capacity specified in SECTION 41 22 13.71 26 BRIDGE CRANE DATA, TESTING AND TRAINING, plus the weight of all wire rope, rigging, and movable load blocks.

b. Travel Loads - The travel load on the main hoist for trolley and bridge travel operations are equal to the maximum anticipated live load from rotor/turbine handling on the main hoist during travel.

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

d. Tractive Horizontal Forces, Trolley - The forces resulting from 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 applied at the top of the trolley rails with the trolley in such position as will give maximum loading or stress due to moment or shear in any part of the bridge crane. For the design of structural components, apply tractive forces equal to 10 percent of the sum of the travel load and trolley dead load.

e. Tractive Horizontal Forces, Bridge - The forces resulting from the acceleration or deceleration of the bridge crane are limited to a maximum of 10 percent of the sum of the travel load and dead load with the trolleys in such position as will give maximum loading or stress due to moment or shear in any part of the bridge crane. For the design of structural components, apply tractive forces equal to 10 percent of the sum of the travel load and dead load.

f. Collision Horizontal Forces - Collision forces with rail stops are taken as the forces produced by such collision with the trolley or bridge traveling at 40 percent rated speed with power on. Only the dead load will be considered as contributing to the collision forces.

1.4.5.4 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, and horizontal trolley tractive applied in the direction of trolley travel.

(2) Dead, hoist, vertical impact, and horizontal bridge tractive

SECTION 41 22 13.72 26 Page 12 applied in direction of bridge travel.

b. Category II Load Combinations.

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

c. Category III Load Combinations.

(1) Dead load and the forces produced by the maximum torque of the hoist motor.

1.4.6 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 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.

1.4.6.1 Fatigue Design

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

1.4.7 General Stiffness Requirements

1.4.7.1 Trolley Deflections

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

Primary frame members providing support between trolley rails must not

SECTION 41 22 13.72 26 Page 13 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.

1.4.7.2 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, including but not limited to loads resulting from maximum motor torque.

1.4.8 Maximum Trolley Wheel Loads

The bridge girders and bridge structure are designed for maximum trolley wheel reactions of 86,700 lbs vertical and 7,900 lbs laterally, each. New trolley wheel loads may not exceed these values unless approved by the Government.

1.4.9 Mechanical Parts of the Crane

1.4.9.1 Mechanical Equipment Allowable

Design mechanical parts 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 must be proportioned to withstand the stresses produced by the maximum torque of the motors with resultant stresses not exceeding 75 percent of the yield point of the materials involved.

For mechanical components which have different design criteria explicitly specified, such as wire rope, those criteria govern.

1.4.9.2 Shafting

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

1.4.9.3 Gears and Speed Reducers

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

1.4.9.4 Stress Concentration Factors

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

1.4.9.5 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.

SECTION 41 22 13.72 26 Page 14

1.4.9.6 Drum Stresses

Design drum shells, diaphragm plates, and hubs in accordance with CMAA 70 requirements. 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.

1.4.9.7 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.

1.4.10 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 BRIDGE CRANE REHABILITATION

ELECTRICAL WORK.

1.4.11 Connections

1.4.11.1 Shop and Field Connections

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

1.4.11.2 Welded Connections

Design welded connections in accordance with the applicable provisions of AISC 325 and AWS D1.1/D1.1M .

1.4.11.3 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 STRUCTURAL STEEL WELDING AND FABRICATION.

Consider prying effects, when applicable, when designing all bolted connections.

SECTION 41 22 13.72 26 Page 15

1.4.11.3.1 Bolted Structural Connections

a. Provide structural bolts for all bolted connections of crane structural frames and appurtenances.

b. Design and detail structural bolted connections in accordance with the applicable provisions of AISC 325 and RCSC A348 and as per requirements of paragraph STRUCTURAL DESIGN CRITERIA.

c. Clearly identify both in the calculations and on the detail drawings those bolted connections which are slip-critical and/or which require pre-tensioning. Identify all bolts subject to load reversal stresses greater than 7 ksi.

d. For bolted connections transmitting primary loads, utilize bolts as specified in SECTION 05 50 04.00 26 para "Structural Bolts".

1.4.11.3.2 Mechanical Bolted Connections

Design of bolted connections must be as follows:

a. Use fitted bolts for assembly connections on machine parts with alignment criteria.

b. Machine bolts (i.e. non-fitted bolts) may be used for mounting of machinery to bases when there are no alignment criteria.

c. All speed reducers, bearing bases, and pillow blocks must be held securely in place by one of the following methods:

(1) Fitted bolts installed with hardened, flat washers and double nuts.

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

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

d. All hoist machinery mounted to the trolley frame must have positive locking mechanisms on the bolt heads and the nuts unless otherwise approved.

e. For mechanical joints which are approved as not requiring clamp load, provide prevailing torque nylon locknuts or install with loctite unless otherwise approved.

f. Tighten connections that are made with machine bolts such that the clamp load in the joint is equal to 75 percent of the proof load of the bolt. Calibrate the tools to be used to the desired bolt tension with a Skidmore-Wilhelm unit. Submit a bolt tension chart prior to

SECTION 41 22 13.72 26 Page 16 crane assembly. In the bolt torque chart, indicate tightening torque values and resulting bolt tension for all the bolt configurations (type, material, size) that will be used in the assembly of the new crane. For each entry in the chart, include bolt diameter, bolt standard/material, tension in bolt, tightening torque, and any special characteristics of the joint such as galvanized or lubricated threads.

1.5 SUBMISSION OF CRANE DESIGN DATA

1.5.1 General

a. Submit Crane Design Data. Crane Design Data must be approved prior to procurement of associated materials and equipment. Crane Design Data must be submitted for each major crane component or system of components and must include the following items which are described in the following sub-paragraphs of same title:

(1) Drawing Index

(2) Bill of Materials/Schedule of Equipment

(3) Drawings

(4) Product Data

(5) Design Calculations

b. Crane Design Data for a complete crane rehabilitation must be submitted in a logical order with the major components/ systems submitted first and the lesserancillary components submitted afterwards. Include in the Crane Design Data submitted a detailed list of components and their weight together with a current estimate of the completed total crane weight. Examples of Crane Components or Systems include, but are not limited to those listed below:

(1) Main Hoist

(2) Auxiliary Hoist

(3) Bridge Drive

(4) Trolley Drive

(5) Trolley Frame

c. All submittals for Crane Design Data must be uniquely categorized into Design Package Submittals and must be named based off the Crane Components or Systems. For example: "Crane Design Data - Main Hoist".

d. All mechanical computations and drawings submitted as part of the Crane Design Data must be stamped and certified by a registered professional mechanical engineer who has done the design themselves or supervised and reviewed work if done by others.

e. All structural computations and drawings submitted as part of the Crane Design Data must be stamped and certified by a registered professional structural engineer who is either licensed in Washington state as a structural engineer or has passed the NCEES 16-hour Structural exam, and who has done the design themselves or supervised and reviewed work if done by others.

f. All registered professional mechanical and structural engineers taht that will be stamping and certifying crane design data submittals must have the following relevant experineceexperience:

(1) Have experience and knowledge in performing engineering design on cranes of similar size and capacity. At minimum, design experience

SECTION 41 22 13.72 26 Page 17 must be on bridge cranes with minimum capacity of 100-Tons. Experience on cranes other than bridge cranes may be submitted for consideration and the Contractor must explain the relevancy to this project; it will be the Government's discretion if it is considered relevant.

(2) The registered professional mechanical engineer must demonstrate a minimum of three years of relevant experience in designing new cranes and/or designing replacement components for existing cranes being rehabilitated. The three years experience must have occurred within the past 10 years to be considered.

(3) The registered professional structural engineer must demonstrate a minimum three years of relevant experience in designing cranes; and demonstrate experience in structural frame/column analysis and design, preparing calculations which comply with AISC standards, and with the use of structural modeling software such as Staad.Pro or RISA. The three years experience must have occurred within the past 10 years to be considered.

(4) Provide a resume for each registered professional engineer demonstrating the minimum years of experience; including name of firm(s) the engineer was employed by, name of project(s) they worked on, contract number, project location, date of design or construction completion, contract or project point of contact with contact information (address, phone number, e-mail), and describe relevant experience.

g. Submit a list of proposed Design Package Submittals with submittal dates and at least one actual design package submittal no later than 6045 calendar days after date of award. Submit crane design data for the remaining crane components or systems no later than 180 calendar days after date of award.

h. Submit Crane Design Data for all new/replaced/modified components (or system of components) no later than 240 calendar days after notice to proceed. The Crane Design Data submittal packages must be 100 percent technically complete, and all designs reviewed per the approved Contractor Quality Control (CQC) Plan, at time of initial submission. Crane Design Data must be separated into individual crane components or systems as defined in paragraph above, and submission must be staggered such that no more than four design packages are submitted within 10 business days of one another, unless otherwise approved by the COR.

i. Each Crane Design Data submittal must be coordinated across all engineering disciplines (e.g., mechanical, structural, electrical) at time of submission. The submittal must include evidence the design package has been coordinated, which shall be accomplished by a written narrative and signature from each of the approved registered professional engineers (e.g., mechanical, structural, and electrical) documenting their review and concurrence of coordination.

j. Identify all changes in Crane Design Data resubmittals (if resubmittals are required) to easily distinguish where changes were made to the calculations, drawing, and product data. Include a summary of revisions/additions at the beginning of the Crane Design Data submittal package.

SECTION 41 22 13.72 26 Page 18

1.5.2 Drawing Index

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

1.5.3 Bill of Materials/Schedule of Equipment

Bill of materials (BOM) or parts lists must be included on the drawings, consisting of descriptive name (e.g. "main hoist equalizer sheave"), total quantity, manufacturer, part number, material type, size, and weight of item or equipment; or bill of materials must be drawings that are part of the drawing set, having a title block, border, and sheet number compatible with the drawing set. Bill of materials must provide a cross reference between manufacturer data and shop drawings. Bill of materials (BOM) or parts lists must be included on the drawings. Organize the BOM or parts lists to include descriptive name, total quantity, manufacturer, part number, material type, finish, size, and weight of item or equipment. BOM or parts lists may be submitted as separate drawings that are part of the drawing set, having a title block, border, sheet number compatible with the drawing set, and cross reference between the assembly drawing and BOM/parts lists drawing. BOM must provide a cross reference between manufacturer data and shop drawings. List primary components of an assembly or arrangement drawing first in the BOM followed by secondary components, for example on a hoist assembly drawing the primary components include the motor, brakes, speed reducer, drum, wire rope, drum bearings, limit switches, etc. and secondary components include items such as fastener hardware, mounting brackets, unistrut, etc. The "descriptive name" data/information listed on the BOM must sufficiently describe the part characteristic and feature as used in the machine/equipment, and include common name terms, for example "drive axle" and "idler axle" are more descriptive than "axle" or "steel round".

1.5.4 Drawings

Submit design drawings for a complete crane rehabilitation for each major system and/or component for the crane as a whole. Drawings must be easily readable in half size (i.e. 11x17) format. Weights of items must be included on the drawings. Show assembly views and all details required for a complete crane rehabilitation, including but not limited to layout and installation of all machinery. Utilize revision markings ( e.g.

revision triangles) for all drawings that are revised between submittals (if resubmittals are required) to easily distinguish where changes were made to the drawings.

Each drawing which labels components with numbers from a Bill of Materials on a separate drawing must have a note referencing the drawing number of that Bill of Materials. Drawings must include detailed locations of all drilling required in structural members. Provide detailed drawings of any replaced components. Label components with descriptive names (e.g.

"Auxiliary Hoist Speed Reducer Mounting Base"). Reference drawings used in the development of the Contractor prepared drawings must be noted on the drawing by listing the FIO sheet number, file number, the manufacturer's drawing number, and reference drawing title. The use of reference drawings in lieu of providing new drawings will not be acceptable.

SECTION 41 22 13.72 26 Page 19

1.5.4.1 Dimensioned Assembly Drawings

Submit dimensioned assembly drawings for the overall bridge crane rehabilitation including hoist machinery, trolley and bridge drive machinery, and other components as specified. Show plan and elevation views of the overall crane and component systems, indicating locations and layout of all mechanical and electrical equipment, with dimensions and working clearances. Dimensioned assembly drawings must show installation of new equipment and how it is connected to existing equipment.

Provide new general assembly and layout drawings to replace the existing Moffett EngingeeringEngineering Company crane general drawings (see FIO drawings for listing of general drawings). The new general assembly drawings must reflect the details of the crane rehabilitation and include, at minimum, all dimensions, tabulated data such as hoist capacity and speeds, travel speeds, and wire rope spec/lengths that are shown on the reference drawings.

1.5.4.2 Detailed Shop Drawings

Detailed shop drawings must be submitted for approval prior to fabrication of all components. Drawings for individual components must reference an assembly drawing of the entire crane which shows clearances where pertinent and the arrangement of the complete crane assembly. Each component must be labeled with an appropriate descriptive name (e.g. "Main Hoist Gear-Side Drum Bearing Stand"). When detailed drawings are submitted, they must be submitted with arrangement drawings and bill of materials/parts lists. All welding symbols need to show the WPS and applicable NDE. Include details of all skewed t-joints in accordance with AWS D1.1/D1.1M. Detail drawings for metalwork and machine work must include catalog cuts, templates, fabrication and assembly details and type, grade and class of material as appropriate.

1.5.4.3 Clearance/Coverage Diagram

Provide a clearance/coverage diagram for the main and auxiliary hoist traveling the full extent of the crane rails as field-verified by the Contractor. Provide elevations and plan views of hook clearance and coverage. The main and auxiliary hoist hook coverage shall be the same as existing. If there are constraints in particular areas of the travel range, so indicate on the clearance/coverage diagram.

1.5.5 Product Data

1.5.5.1 General

Submit complete descriptive literature and specifications of each product or system of products provided for a complete crane rehabilitation, (including but not being limited to the items listed in the submittal article). Product data literature must include legible manufacturer's cut sheets and data sheets to clearly indicate physical construction, operation, mechanical and structural characteristics and associated hardware, as applicable. For sheets with extraneous data, clearly indicate which data applies, for example by crossing out non-applicable models and circling the correct options. Include manufacturer's catalog numbers and designations, and clearly cross-reference with shop drawings as appropriate. Product data submitted for approval must clearly show conformance with these specifications, including, but not being limited to product manufacturers' declarations of conformance to applicable technical

SECTION 41 22 13.72 26 Page 20 standards. Product data will be used for supporting approval of components shown or listed on the drawings. Approval of items for which product data is submitted will be by approving the design package submittal, including the relevant calculations together with relevant drawings and product data.

1.5.5.2 Type of Equipment and Quality

Materials and equipment must be of the type normally furnished for crane applications and service and must be the standard, unmodified, products of manufacturers specializing in the production of this type of equipment as evidenced by the existence of previously published catalog data.

Equipment and materials for the same, similar, or allied services must be of the same manufacturer and type, and when of the same rating, must be interchangeable. Materials and equipment must be new and unused.

Defective equipment or equipment damaged in the course of installation must be replaced or repaired as approved by the Contracting Officer.

1.5.6 Design Calculations

Submit design calculations for new, replaced, and modified mechanical and structural components provided as per this contract for approval. Submit design calculations for new/replaced/modified components (or system of components) concurrently with the drawings and product data specific to the designed component (or system of components). Calculations must show and define all constants, variables, and equations used, with sources cited. Calculations must show all work, including intermediate steps, such that a reviewer can reproduce the results without using any references other than the submitted calculation itself. Calculations must be reviewable without performing arithmetic independently. Actual hand-written calculations are acceptable but are not required.

Calculations must include an introductory narrative paragraph describing the methodology for the analysis including the failure theories used and/or the codes and standards referenced, a list of assumptions made, equations, specified efficiencies, limits, factors of safety, component ratings, sources of values used, free body diagrams, or sketches of each load case, and reference to the applicable Contractor shop drawings.

Calculations must show that the rehabilitated crane meets the capacities and speeds as listed in SECTION 41 22 13.71 26 BRIDGE CRANE DATA, TESTING AND TRAINING. Utilize revision markings for all calculations that are revised between submittals (if resubmittals are required) to easily distinguish where changes were made to the calculations, and include a summary of revisions/additions at the beginning of the calculations package. Provide a table of contents for all calculations included in each submittal.

1.5.6.1 Finite Element Analysis (FEA)

When FEA data is submitted, it must be submitted in addition to, not instead of, the design calculations defined in the previous paragraph.

Present FEA in report format. FEA report must include clear indication of all load scenarios, visual and narrative description of load location and application, boundary conditions / fixtures, global mesh attributes, detailed mesh attributes where mesh refinement is required, reasoning for mesh refinement along with a convergence study showing that further mesh refinement does not significantly change results of interest, verification that actual material is consistent with material used in the model, narrative explanation of any peak stresses noted, and narrative explanation of any peak deflections noted. Submit electronic files for

SECTION 41 22 13.72 26 Page 21 any FEA performed (in the FEA software file type). Accompany any FEA data submitted with sample written calculations that support the FEA analysis.

1.5.6.2 Computer-Assisted Calculations

When computer-assisted calculations or design tools (other than FEA) are used, they must either fulfill all requirements in paragraph "Design Calculations" above, or they must be submitted in addition to, not instead of, the design calculations defined in paragraph "Design Calculations".

Submit all reports and computed results with the computer-assisted calculations.

1.5.6.3 Structural Trolley Frame Design Calculations

FEA analysis using beam elements for structural moment frames is required. Computer models used for the analysis of the structural frame must provide output in terms of member forces such as shear, compression, tension, and bending. Prepare calculations in accordance with the methodologies of AISC 325 . Member stresses must also relate to shear, compression, tension, and bending. Von Mises stresses in structural frame members will not be accepted as a substitute for the stresses and forces described above. Analysis must include a sketch, drawing, or plot that shows the variation in moment throughout the height of the columns and the length of the beams. Computer models developed for the crane frame design must be submitted in "live" electronic form along with a print-out of the input file. The frame model must be converted to STAAD.Pro prior to submission. The final submission of the design data must include a text file of the STAAD input command file.

1.6 FINAL APPROVED VERSIONS OF CONTRACTOR PREPARED DRAWINGS AND FINAL

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.

including submittals from crane appertenances so that there is a single volume of drawings and calcs.

1.6.1 Final Approved Versions of Contractor Prepared Drawings

Final Approved Versions of Contractor Prepared Drawings for the Powerhouse Bridge Crane(s) must be submitted. Final approved versions of Contractor prepared drawings must be submitted in accordance with SECTION 01 78 00 CLOSEOUT SUBMITTALS for each complete crane. Contractor prepared drawings must be updated if there are any outstanding comments. Modifications to approved Contractor prepared drawings made during fabrication and installation must be immediately recorded for inclusion into final versions of Contractor prepared drawings.

1.6.2 Final Calculations

Final Calculations must be submitted and approved prior to start of acceptance testing. 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. When final calculations are submitted, each section must include reference to submittals where that section was approved with a "B" code or better. They must be called "Final Calculations." Upon approval of the final calculations, they must

SECTION 41 22 13.72 26 Page 22 be inserted as a separate section in the Operation and Maintenance Manuals, see SECTION 01 78 23 OPERATION AND MAINTENANCE DATA for requirements on the O&M manuals.

1.7 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 design 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). Any deviations must be updated as per SECTION 01 78 00, PROJECT RECORD DOCUMENTS, paragraph WORKING AS-BUILT DRAWINGS.

1.8 REHABILITATION PROCEDURE

Submit a complete rehabilitation procedure for all…