41 22 13.75 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 13.75 26

LIFTING DEVICE LOAD TESTING

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

1.2 REFERENCES

1.3 SUBMITTALS

PART 2 PRODUCTS

2.1 NAMEPLATE AND WORKING LOAD LIMIT MARKINGS

2.1.1 Nameplate for Lifting Device

2.1.2 Safety Label for Lifting Device

2.1.3 Working Load Limit Markings

PART 3 EXECUTION

3.1 LIFTING DEVICE FAMILIARIZATION

3.2 LIFTING DEVICE NDE INSPECTIONS

3.3 UNACCEPTABLE WELDS

3.4 LIFTING DEVICE LOAD TEST

3.4.1 Load Testing, General

3.4.2 Load Test Plan

3.4.3 Weighing of Lifting Devices

3.4.4 Repair Below the Hook Devices (Optional)

3.4.5 Load Test Report

3.5 CLOSEOUT SUBMITTALS

3.5.1 Lifting Devices O&M Manual

-- End of Section Table of Contents --

SECTION 41 22 13.75 26 Page 1 R0003

SECTION 41 22 13.75 26

LIFTING DEVICE LOAD TESTING

05/23

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

This Section covers the work to refurbish existing lifting devices for the powerhouse bridge crane at Albeni Falls Dam, ID. Load test plan and drawings are to be submitted as stated in paragraph SUBMITTALS below.

The list of below the hook devices to be tested are as follows:

a. Generator Rotor Less Shaft (General Electric Drawing 182C367).

b. Main Lifting Beam (Moffett Engineering Co. Drawings 466-10A, 466-10C).

c. Generator Shaft Only (General Electric Drawing 162D885)

d. Intermediate Shaft and Guide Bearing (Baldwin-Lima-Hamilton Drawing

38986)

e. Lifting Links and Pins for Runner Shaft Head Cover

Baldwin-Lima-Hamilton Drawing 39618)

f. Single Leg (Sling hook/Grab hook)(SSG)

g. Lifting Device for Main Shaft & Inner Head Cover (Baldwin-Lima-Hamilton

Drawing 39619)

1.2 REFERENCES

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

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

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

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2014) Safety and Health Requirements Manual

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following submittals within the timeframe specified in the respective paragraphs that define the requirements of each submittal. Submit the following in accordance with Section 01 33 00, SUBMITTAL PROCEDURES:

SD-SD-01 Preconstruction Submittals

Load Test Plan; G HDC

Lifting Device Weighing Procedure; G HDC

SECTION 41 22 13.75 26 Page 2

Prepossession Lifting Device Report

Lifting Device Shop Test Procedure; G HDC

SD-02 Shop Drawings

Nameplate for Lifting Device; G HDC

Safety Label for Lifting Device; G HDC

Working Load Limit Markings; G HDC

SD-06 Test Reports

Load Test Report; G HDC

Lifting Device Weight Report; G HDC

Weighing Equipment Calibration Certificates; G HDC

SD-11 Closeout Submittals

Lifting Devices O&M Manual; G HDC

PART 2 PRODUCTS

2.1 NAMEPLATE AND WORKING LOAD LIMIT MARKINGS

2.1.1 Nameplate for Lifting Device

For each lifting device, provide a new nameplate in conformance with ASME B30.20, including but not limited to:

(1) Manufacturer's name and address.

(2) Serial number, which is also included on the drawings.

(3) Year of fabrication.

(4) Rated capacity tons.

(5) Statement that lifting beam was load tested at 125%.

(6) Weight of the lifting beam.

(7) ASME BTH-1 Design Category A.

(8) ASME BTH-1 Service Class 0.

Make the new nameplate from stainless steel plate. Install new, corrosion-resistant metal plate to the lifting beam with corrosion-resisting steel fasteners. Submit drawings for each nameplate that show the proposed nameplate. Detail the size, wording, character size and location on the lifting device.

2.1.2 Safety Label for Lifting Device

Provide new safety label in conformance with ASME B30.20 paragraph 20-1.2.1 "Marking", subparagraph (d) "Product Safety Labels" including but not limited to the appropriate signal word, according to ANSI Z535.4 (4.14), to bring the label to the attention of the operator, and cautionary language to provide danger, warning, or caution notice to operators and others against:

(1) exceeding the working load limit.

(2) operating a damaged or malfunctioning beam or a beam with missing

SECTION 41 22 13.75 26 Page 3 parts.

(3) lifting suspended loads over people.

(4) leaving suspended loads unattended.

(5) removing or obscuring warning labels.

(6) operating without having read and understood the operating manual.

(7) not staying clear of the suspended load.

(8) lifting loads higher than necessary.

(9) making alterations to the lifting beam.

Do not provide vinyl logos and lettering for label. Install new, corrosion-resistant metal plate to the lifting beam with corrosion-resisting steel fasteners. Submit for approval a safety label drawing including but not limited to the proposed label, its size, wording, character sizes, and location on the lifting beam; location shall be somewhere on the upstream side of the lifting beam. Label lettering must be easily legible from a distance of five feet.

2.1.3 Working Load Limit Markings

Provide stenciled lifting beam working load limit markings, to the nearest tenth of a ton, on both sides of the lifting device. Make characters large enough so that they are legible from the powerhouse floor when the lifting beam is at its highest elevation. The working load limit for each device is as follows:

Main Lifting Beam (Moffett Engineering Co. Drawings 466-10A, 466-10C): 250 Tons

Generator Rotor Less Shaft (General Electric Drawing 182C367): 170 Tons

Generator Shaft Only (General Electric Drawing 162D885): 45.5 Tons

Intermediate Shaft and Guide Bearing (Baldwin-Lima-Hamilton Drawing 38986): 23260 lbs.

Lifting Links and Pins for Runner Shaft Head Cover Baldwin-Lima-Hamilton Drawing 39618):

Single Leg (Sling hook/Grab hook)(SSG) : 2000 lbs

Lifting Device for Main Shaft & Inner Head Cover(Baldwin-Lima-Hamilton Drawing 39619): 44 tons

Submit drawings that detail the character size and proposed location for each lifting device.

PART 3 EXECUTION

3.1 LIFTING DEVICE FAMILIARIZATION

The Contractor must coordinate with the Contracting Officer to establish an agreed upon date to become familiar with all bridge crane BTH lifting devices at Albeni Falls Dam prior to the Contractor taking possession of the lifting devices. Before performing any BTH lifting device work, become familiar with all details, functions, and abilities of all BTH lifting devices and their components. The Contractor must verify all BTH lifting devices appear to function properly within reason without attaching the lifting devices to their intended components. Immediately raise any

SECTION 41 22 13.75 26 Page 4 concerns about the lifting devices' condition and operability to the Contracting Officer Representative and submit a Prepossession Lifting Device Report to the Government in writing for review and comments prior to any lifting device leaving the powerhouse. The Prepossession Lifting Device Report must include the current condition of all devices, note malfunctions if applicable, and if the devices appear to function and operate as intended.

3.2 LIFTING DEVICE NDE INSPECTIONS

All BTH lifting devices and their components must undergo NDE weld inspections in accordance with section 05 05 33.20 26, NON-DESTRUCTIVE

TESTING.

3.3 UNACCEPTABLE WELDS

Visually inspect and NDE welds to the acceptance criteria of AWS D1.1.

Unacceptable welds must be repaired in accordance with section

05 05 23.17 26 STRUCTURAL STEEL WELDING AND FABRICATION.

The Weld Repair Plans for all BTH lifting devices that require weld repair must be approved by the Government in writing prior to commencing with weld repairs. The weld repairs must have an NDE after completion and before the 125% load testing of the BTH lifting device.

3.4 LIFTING DEVICE LOAD TEST

3.4.1 Load Testing, General

Perform a load test on each lifting device using a test load that is equal to 125 percent of the rated load of the load device. Perform the load testing off-site. Do not perform the load testing on-site at the Albeni Falls Powerhouse. The Government will witness the test. Do not perform the test without the Government witness present, unless previously waived in writing.

Notify the Contracting Officer (CO), a minimum of 14 calendar days in advance, the dates of each load test. Notify the CO, a minimum of three business days in advance, any revisions of the dates of each load test.

3.4.2 Load Test Plan

Prepare and Submit a Lifting Device Shop Test Procedure which includes but is not limited to a test weight plan, procedures to meet the testing requirements of ASME B30.20 and EM 385-1-1 , weld paint removal, pre-load-test magnetic-particle NDT, and pre-load-test visual inspections, post-load-test magnetic-particle NDT, and post-load-test visual inspections for deformation, cracks, or other defects for each lifting device assembly, painting of each lifting device. Arrange the procedure so that the information is organized in an orderly fashion with separated and labeled sections for each lifting device and appropriately titled.

The load test procedures must fully describe the testing methods and equipment used, test setup detailing how the lifting devices are subjected to the applied testing loads, including diagrams pictorially showing where and how the test loads are attached to the lifting devices and how the lifting devices are supported during testing, and type of test loads applied with a full description (i.e. dimensions if solid material such as concrete or steel weights, or complete description if using hydraulics or other means). The load test procedures must include enough detail that

SECTION 41 22 13.75 26 Page 5 allows replicating the tests if necessary. Ensure that the loads are applied to the lifting devices in the same load paths as for normal operations, for example, the lifting beam must be subjected to shear, tension, and bending in the same areas as during normal use. The load test procedures must also include certificates of calibration for the instruments, tools, and equipment that will be used to verify the applied test loads, and must be under the direction of a qualified person.Testing shall be done under the direction of a qualified person, and shall include but not be limited to hoisting 125% of the rated capacity. Include the following elements in the plan, at a minimum:

a. Location of testing and contact information for the Contractor point of contact (POC) that is responsible for the testing.

b. Step-by-Step repeatable procedure for the load test. Include specific steps that are unique to each device. Ensure that the procedures to meet the testing requirements of ASME B30.20 and

EM 385-1-1 .

c. Diagrams showing the test setup of each lifting device.

d. List of equipment and measurement instruments that will be used during load testing. Include up-to-date calibration certificates for each measurement instruments.

3.4.3 Weighing of Lifting Devices

The weighing of all the lifting devices must be completed before performing calculations. Submit to the Government for review and approval a Lifting Device Weighing Procedure for all lifting devices along with Weighing Equipment Calibration Certificates. Separately weigh all the lifting devices with their respective accessories (i.e. pins, shafts, links, hooks, eye bars, and hardware) according to approved plan with properly calibrated equipment and submit a consolidated Lifting Device Weight Report. The report must include, but is not limited to, the approved lifting device weighing procedure, approved calibration certificate(s), type of equipment used and their serial number(s), photos of tared values and of the BTH devices and their measured weight, and recorded weights of all BTH lifting devices. Arrange the report so that each lifting device reported weight and pictures are organized in an orderly fashion with labeled sections for each lifting device. Submit the Lifting Device Weight Report to the Government for review and approval.

3.4.4 Repair Below the Hook Devices (Optional)

Perform weld repairs on the below the hook devices if directed by the Contracting Officer. This work is an optional bid item. Perform weld repairs in accordance with Section 05 05 23.17 26 STUCTURAL STEEL WELDING AND FABRICATION. All weld repairs and NDE of repaired welds must be performed within the scheduled outage.

3.4.5 Load Test Report

Prepare and submit a load test report for each lifting device that is tested. Include the following elements in the report, at a minimum:

a. Identify which lifting device the report covers.

b. Document the results of the test. Clearly indicate if the test was

SECTION 41 22 13.75 26 Page 6 successful and include the final load that the device was tested to.

c. Document if any issues occurred during testing.

d. Approved procedure.

3.5 CLOSEOUT SUBMITTALS

The Contractor must submit to the Government, but is not limited to, the Final Approved Versions of Contractor Prepared Shop Drawings, and the Final Approved Reports as part of the Lifting Devices O&M Manual. The Contractor must verify that all final approved documents have no open comments and are complete according to this specification.

3.5.1 Lifting Devices O&M Manual

Submit a Lifting Device O&M Manual that consolidates and includes, but not be limited to:

(1) Contractor's contact information.

(2) General description of lifting devices and their operation.

(3) Lubrication points, recommended frequency of lubrication, and type of lubrication provided.

(4) All BTH lifting device Government provided calculations.

(5) All final approved Contractor-prepared shop drawings or As-Built drawings (11x17) depending on what is prepared for each device.

(6) All complete lifting device weight reports.

(7) All complete load test reports.

(8) All complete NDE reports arranged in order as performed.

(9) Any weld repair reports.

(10) Painting system data and instructions.

(11) Final inspection report.

All combined O&M Manual documents must be complete and finalized with no outstanding comments. Update any document if there are outstanding comments. Two copi es of the Lifting Device O&M Manual must be submitted to the Government in a bound three ring binder and as an electronic PDF copy that contains a table of contents with functional working bookmarks. Label the binder on the cover and spine with the Contract's name, Contract number, date, name and location of the Project, and title it "Albeni Falls Lifting Devices O&M Manual" with a subtitle of "Below-The-Hook Lifting Device Certifications". Binder dimensions must not exceed 3 inches in width or 11.75 inches in height, and must not have any protruding clasps, hooks, or other hardware. Loose-leaf ring binders and spiral bound manuals are not acceptable and will be rejected by the Government. The electronic PDF version must be submitted on a disc with a label marked with the Contract's name, Contract number, date, name and location of project, and title it "Albeni Falls Lifting Devices O&M Manual" with a subtitle of "Below-The-Hook Lifting Device Certifications". Alternately, the electronic PDF version may be submitted by utilizing a secured data transfer website that is approved by the Government in lieu of a disc; a hard copy is still required.

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SECTION 41 22 13.75 26 Page 7