41 22 13.76 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 13.76 26

OPTIONAL BELOW-THE-HOOK LIFTING DEVICES

August 2023

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

1.2 REFERENCES

1.3 SUBMITTALS

1.4 DESIGN CRITERIA

1.4.1 Design Factors for the Lifting Devices

1.4.2 Design Load Cases for Lifting Beam

1.4.3 Design Load Cases Generator Rotor Less Shaft Lifting Device

1.4.4 Design Load Cases Generator Shaft Only Lifting Device

1.4.5 Design Load Cases Intermediate Shaft and Guide Bearing Lifting

Device

1.4.6 Design Load Cases Lifting Links and Pins

1.4.7 Design Load Cases Single Leg (Sling hook/Grab hook)(SSG)

Lifting Device

1.4.8 Design Load Cases Lifting Device for Main Shaft & Inner Head

Cover Lifting Device

1.4.9 Bolts

1.4.10 Welds

1.4.11 Stress Concentration Factors

1.4.12 Use of Cast Iron

1.4.13 Shop and Field Connections

1.5 QUALITY CONTROL

1.5.1 Bill of Materials and Schedule of Equipment

1.5.2 Drawings

1.5.2.1 Dimensioned Design and Assembly Drawings

1.5.2.2 Detailed Shop Drawings

1.5.3 Product Data

1.5.4 Preliminary Design Calculations

1.5.5 Design Calculations

1.5.6 Lifting Beam Hooks NDE Report

1.6 FINAL APPROVED VERSIONS OF CONTRACTOR PREPARED DRAWINGS AND FINAL

CALCULATIONS

1.6.1 Final Approved Versions of Contractor-Prepared Drawings

1.6.2 Final Calculations

PART 2 PRODUCTS

2.1 NAMEPLATE AND WORKING LOAD LIMIT MARKINGS

2.1.1 Nameplate for Lifting Beam and or Lifting Devices

2.1.2 Safety Label for Lifting Beam and or Lifting Devices

2.1.3 Working Load Limit Markings

2.2 SLEEVE-TYPE BEARINGS

2.3 KEYS AND KEYSEATS

2.4 PINS

2.5 LIFTING BEAM

2.5.1 Lifting Beam Hooks

SECTION 41 22 13.76 26 Page 1 R0003

PART 3 EXECUTION

3.1 GENERAL

3.2 FIELD MEASUREMENTS AND LIFTING BEAM PRE-TEST

3.3 IN-SHOP LIFTING BEAM AND OR LIFTING DEVICES TESTING

3.3.1 In-Shop 125% Load Test

3.3.2 In-Shop Operational Test

3.3.3 Weighing of New Lifting Beam and or Lifting Devices

3.4 REMOVAL OF EXISTING LIFTING BEAM AND OR BELOW THE HOOK DEVICES

3.5 LIFTING BEAM AND OR LIFTING DEVICES O&M MANUAL

3.6 WARRANTY

-- End of Section Table of Contents --

SECTION 41 22 13.76 26 Page 2

SECTION 41 22 13.76 26

OPTIONAL BELOW-THE-HOOK LIFTING DEVICES

August 2023

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

This Section covers the mechanical work to design, fabricate, paint, install, and test a new optional lifting beam and or below the hook devices for Albeni Falls Powerhouse. The existing lifting beam and or below the hook devices are to be weighed, and after acceptance of the new lifting beam, is are to become the property of the Contractor.

Calculations and drawings are to be submitted as stated in paragraph SUBMITTALS below. Contractor-submitted design, assembly, and shop drawings are to show all details required to fabricate and install mechanical equipment. Design the new lifting beam and or below the hook devices to substantially duplicate the arrangement of the existing lifting beam and or below the hook devices. Retain the existing features for successful interaction with the new hooks. See FIO drawings for fits and arrangement; confirm all measurements and details of the existing lifting beam and below the hook devices onsite.

The list of below the hook devices which the government may execute the option to replace 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 INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 (2017) Steel Construction Manual

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

SECTION 41 22 13.76 26 Page 3

ASME B30.20 (2021) Below-the-Hook Lifting Devices

ASME BTH-1 (2020) Design of Below-the-Hook Lifting Devices

ASTM INTERNATIONAL (ASTM)

ASTM A 514/A 514M (2022) Standard Specification for High-Yield-Strength, Quenched and Tempered Alloy Steel Plate, Suitable for Welding

ASTM A 668/A 668M (2020) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

AMERICAN WELDING SOCIETY (AWS)

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

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-01 Preconstruction Submittals

Field Measurements and Lifting Beam Pre-Test; G HDC To be submitted prior to commencing design or fabrication of lifting beam.

Working Load Limit Markings; G HDC

Shop Test Procedure; G HDC

SD-02 Shop Drawings

Nameplate for Lifting Beam and or Lifting Devices; G HDC

Safety Label for Lifting Beam and or Lifting Devices; G HDC

Detailed Shop Drawings; G HDC

Bill Of Materials and Schedule of Equipment; G HDC

Dimensioned Design and Assembly Drawings; G HDC

SD-03 Product Data

SECTION 41 22 13.76 26 Page 4

Product Data; G HDC

Hook Material Certification

Pin Material Certification

SD-05 Design Data

Preliminary Design Calculations; G, HDC

Preliminary Design Calculations must be submitted within 120 days of contract award.

Design Calculations; G HDC

Design Calculations must be submitted together with the detailed shop drawings, dimensioned outline drawings, and product data within 180 days of contract award, and shall be stamped by a registered Professional Engineer (PE), specifically a mechanical or structural PE.

SD-06 Test Reports

Existing Lifting Beam Weight Report

New Device Weight Report

Lifting Beam Hooks NDE Report

Shop Test Report; G HDC

SD-07 Certificates

Registered Professional Mechanical Engineer

SD-11 Closeout Submittals

Final Approved Versions of Contractor-Prepared Drawings; G HDC

Final Calculations; G HDC

LIFTING BEAM AND OR LIFTING DEVICES O&M MANUAL; G HDC

1.4 DESIGN CRITERIA

1.4.1 Design Factors for the Lifting Devices

Design the new below the hook lifting devices, (1) with a factor of safety of 5 based on the ultimate strength of the materials, provided that each part or component is proportioned to withstand the stresses produced by the maximum torque of the crane hoist motor with resultant stresses not exceeding 75 percent of the yield point of the materials involved, and (2) to meet or exceed all requirements of ASME BTH-1. The lifting devices are Design Category A, Service Class 0, per ASME BTH-1. For the purpose of design of the lifting devices, "maximum torque" is defined as the lesser of: loads resulting from the maximum possible hoist motor torque, typically locked-rotor torque, OR two-hundred-percent (200%) of the maximum rated torque, as regulated by the Variable Frequency Drive (VFD).

SECTION 41 22 13.76 26 Page 5

Generally, the (200%) of maximum rated motor torque, will be the lesser torque requirement. If there are conflicts between design criteria listed here and listed in referenced documents, the most conservative approaches govern. The load and unit stress definitions herein shall be used in the design of mechanical and structural parts of the lifting devices. Note that the working load limit stenciled on the beam will be lower than this rated load capacity, as specified in paragraph "NAMEPLATE AND WORKING LOAD

LIMIT MARKINGS".

1.4.2 Design Load Cases for Lifting Beam

Design the lifting beam for the following load cases.

Load Case 1 - lifting beam is carrying full rated capacity of 250 tons.

In this load case, the beam is functioning as a spreader beam, without carrying significant moment.

1.4.3 Design Load Cases Generator Rotor Less Shaft Lifting Device

Design the lifting Device for the following load cases.

Load Case 1 - Generator Rotor Less Shaft device carrying capacity of 180 tons.

1.4.4 Design Load Cases Generator Shaft Only Lifting Device

Design the lifting Device for the following load cases.

Load Case 1 - Generator Shaft Only device carrying capacity of 93250 lbs.

1.4.5 Design Load Cases Intermediate Shaft and Guide Bearing Lifting Device

Design the lifting Device for the following load cases.

Load Case 1 - Intermediate Shaft and Guide Bearing device carrying capacity of 33260 lbs.

1.4.6 Design Load Cases Lifting Links and Pins

Design the Lifting Links and Pins for the following load cases.

Load Case 1 - 4 Lifting Links and 4 Pins device with a total carrying capacity of 250 tons.

1.4.7 Design Load Cases Single Leg (Sling hook/Grab hook)(SSG) Lifting Device

Design the lifting Device for the following load cases.

Load Case 1 - Single Leg (Sling hook/Grab hook)(SSG) device carrying capacity of 2013 lbs.

1.4.8 Design Load Cases Lifting Device for Main Shaft & Inner Head Cover Lifting Device

Design the lifting Device for the following load cases.

Load Case 1 - Lifting Device for Main Shaft & Inner Head Cover) device carrying capacity of 44 tons.

SECTION 41 22 13.76 26 Page 6

1.4.9 Bolts

Allowable stresses in bolts are limited to no more than 75 percent of AISC 325 allowable stresses.

1.4.10 Welds

Design of welded joints shall be in accordance with the applicable provisions of AWS D1.1/D1.1M , except that allowable stresses in welds are limited to 75 percent of AISC 325 allowable stresses.

1.4.11 Stress Concentration Factors

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

1.4.12 Use of Cast Iron

Do not use cast iron for any parts of the lifting beam except for counterweights as approved.

1.4.13 Shop and Field Connections

Shop connections may be designed for assembly by means of welding or by bolting. Riveting will not be acceptable. Field welding will not be acceptable, excluding seal welding and equipment mounting. Design field connections for assembly with bolts of the type specified for the application. Bolts used in connections shall not be considered as sharing the load in combination with welds. Welds, if used to acheive connection, shall be provided to carry the entire load in the connection. However, connections that are welded to one member and bolted to the other member are permitted.

1.5 QUALITY CONTROL

All drawings and calculations shall be prepared or fully reviewed and stamped by a Registered Professional Mechanical Engineer; submit qualifications for the engineer(s) who will be stamping these submittals.

1.5.1 Bill of Materials and Schedule of Equipment

Include bill of materials or parts lists on the drawings, consisting of total quantity, manufacturer, part number, material type, size, and weight of item or equipment; or bill of materials drawings that are part of the drawing set, having a title block, border, and sheet number compatible with the drawing set. For the bill of materials, provide a cross reference between manufacturer data and shop drawings.

1.5.2 Drawings

Drawings will not be approved without the relevant calculations. To obtain approval, submit drawings and calculations together, along with any relevant product data if applicable.

1.5.2.1 Dimensioned Design and Assembly Drawings

Submit design and assembly drawings for a complete lifting beam and or lifting devicesdesign. Provide drawings that are easily readable in

SECTION 41 22 13.76 26 Page 7 half-size format. Include weights of items on the drawings. Show assembly views and all details required for a complete lifting beam, including but not being limited to layout and installation of all moving parts. Include on drawings detailed locations of all welded brackets and all drilling required in structural members such as c-channels. Note on the drawing reference drawings used in the development of the Contractor-prepared drawings 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; every detail of the new lifting beam shall be included in the new drawings, such that the existing drawing may be entirely discarded, and a new lifting beam could be fabricated again from the new drawings.

Submit drawings in accordance with Section 01 33 00, SUBMITTAL PROCEDURES.

1.5.2.2 Detailed Shop Drawings

Submit detailed shop drawings for approval prior to fabrication of all lifting beam and or lifting devicescomponents. On drawings for individual components, reference an assembly drawing of the entire lifting beam which shows clearances where pertinent and shows the arrangement of the complete lifting beam assembly. Submit detailed drawings with arrangement and bill of materials/parts lists. Detail drawings for metalwork and machine work shall include catalog cuts, templates, fabrication and assembly details and type, grade and class of material, as appropriate.

1.5.3 Product Data

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 occurs as a result of approving (1) product data, (2) calculations, and (3) drawings that list these items on the drawing material lists.

Submit complete descriptive literature with drawings and specifications of each product or system of products provided for a complete lifting beam assembly. Product data literature shall 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 by crossing out non-applicable models, circling the correct options, etc. Include manufacturer's catalog numbers and designations, and clearly cross-reference with shop drawings as appropriate. For product data submitted for approval, clearly show conformance with these specifications, including, but not 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.

1.5.4 Preliminary Design Calculations

Preliminary design calculations must include but not be limited to a list of assumptions made, a list of all codes and standards referenced, equations, specified efficiencies, limits, factors of safety, component ratings, sources of values used, and free body diagrams or sketches of each load case. All equations, constants, and variables in the calculations shall be clearly defined with sources cited. Preliminary design calculations need not be in final format, need not be accompanied by a comprehensive set of drawings and product data, and need not be stamped by a PE. Approval of Preliminary Design Calculations in no way

SECTION 41 22 13.76 26 Page 8 indicates that any requirements for the actual Design Calculations have been satisfied.

1.5.5 Design Calculations

Submit explicit, step-by-step design calculations showing that the new lifting beam and or lifting devicesmeet all specified requirements, and determining the working load limit per paragraph Working Load Limit Markings. Submit design calculations for new components (or systems of components) concurrent with the drawings and product data specific to the designed component (or system of components). Calculations shall include but not be limited to a list of assumptions made, a list of all codes and standards referenced, equations, specified efficiencies, limits, stress calculations for all load carrying parts, 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. All equations, constants, and variables in the calculations shall be clearly defined with sources cited. When FEA data is submitted, it shall be submitted in addition to, not instead of, the above calculations. FEA shall be presented in report format. FEA report shall 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, 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 of the model, preprocessing and postprocessing files for any FEA performed.

1.5.6 Lifting Beam Hooks NDE Report

Hooks shall be 100% inspected in accordance with SECTION 05 05 33.20 26, NON-DISTRICTIVE TESTING by a magnetic-particle type inspection or X-rayed prior to delivery. Documentation of hook inspection shall be furnished to Contracting Officer at the field operational testing. As part of the acceptance standard, linear indications will not be allowed. Welding repairs of hook will not be permitted. A hook showing linear indications, damage or deformation will not be accepted, and shall be replaced.

1.6 FINAL APPROVED VERSIONS OF CONTRACTOR PREPARED DRAWINGS AND FINAL

CALCULATIONS

1.6.1 Final Approved Versions of Contractor-Prepared Drawings

Submit Final Approved Versions of Contractor-Prepared Drawings, meaning all drawings submitted per this specification section, for the lifting beam and or lifting devices assembly in accordance with Section 01 33 00, SUBMITTAL PROCEDURES. Update Contractor-prepared drawings if there are any outstanding comments. Immediately record changes to approved Contractor-prepared drawings made during fabrication and installation for inclusion into final versions of Contractor-prepared drawings. Insert a set of 11- by 17-inch final approved versions of Contractor-prepared drawings into the Operation and Maintenance Manuals.

1.6.2 Final Calculations

Submit for approval the Final Calculations for the lifting beamand or lifting devices prior to start of in-shop load testing. Assemble all

SECTION 41 22 13.76 26 Page 9 design calculations with a table of contents and submit 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.

Title them, "Final Lifting Beam Calculations." Submit one electronic copy, in the form of a bookmarked, page-numbered PDF on a marked DVD, and one hard copy of the final calculations to the Hydroelectric Design Center

(HDC).

PART 2 PRODUCTS

2.1 NAMEPLATE AND WORKING LOAD LIMIT MARKINGS

2.1.1 Nameplate for Lifting Beam and or Lifting Devices

Provide 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 of 250 tons.

(5) Statement that lifting beam was load tested at 125% of 250 tons.

(6) Weight of the lifting beam.

(7) ASME BTH-1 Design Category A.

(8) ASME BTH-1 Service Class 0.

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

2.1.2 Safety Label for Lifting Beam and or Lifting Devices

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 device or a device with missing parts.

(3) lifting people.

(4) lifting suspended loads over people.

(5) leaving suspended loads unattended.

(6) removing or obscuring warning labels.

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

(8) not staying clear of the suspended load.

(9) lifting loads higher than necessary.

(10) 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

SECTION 41 22 13.76 26 Page 10 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 beam and or lifting devices in accordance with the requirements of ASME B30.20 . Characters shall be easily legible from tailrace deck when lifting beam is at its highest elevation on the draft tube crane. Submit the working load limit markings for approval, including but not limited to documentation of the measured weight of the existing beam, the measured weight of the new beam, and the size and proposed locations of the stenciling. NOTE: See reference drawings. The crane is rated for 250 tons below the existing lifting beam. The working load limit markings will be { (250 tons) - (the weight of the new lifting beam) + (the weight of the existing lifting beam) }.

2.2 SLEEVE-TYPE BEARINGS

Provide sleeve-type bearings with removable bronze linings flanged at the ends where required for thrust or axial alignment. Provide sleeve-type bearings that conform to ASTM B22/B22M, Alloy C, or SAE Alloy Nos. 64 or

660. Unless otherwise specified herein, for bearings on revolving shafts provide the divided type, designed so that each shaft may be removed from the crane with its pinions and gears in position. Make provision for holding linings effectively against rotation or changing of position under load. Provide grooved linings, thrust washers, and bushings, if necessary, for satisfactory distribution of the lubricant. Provide grooves with round edges and end the grooves not less than 1/8 inch from the ends of the bearing. Limit the bearing pressure of bronze lining to a maximum value of 1,100 psi; in addition, provide the bearing with the proper contact area such that the product of the bearing pressure in psi and the square root of the rubbing velocity in feet per second does not exceed 900. Provide the thickness of bronze linings to not be less than given in the following tabulation:

SHAFT DIAMETER LINING THICKNESS

(inches) (inches)

Less than (2-1/2) 1/8

2-1/2 TO 4 1/4

4 TO 5-1/2 3/8

5-1/2 TO 7 1/2

7 TO 8 5/8

2.3 KEYS AND KEYSEATS

Keys and keyseats shall conform to ASME B17.1 .

2.4 PINS

Allowable bearing pressure for pins in steel frames must not exceed 9,000 psi of projected area for the fixed portions, and 5,000 psi for the movable portions. Do not exceed 9,000 psi of projected area for the allowable bearing pressure for non-revolving pins in steel frames. All pins, including but not limited to pins supporting the lifting beam hook arms must be constructed from ASTM A108, ASTM A322, unless otherwise

SECTION 41 22 13.76 26 Page 11 approved. Submit pin material certification.

2.5 LIFTING BEAM

2.5.1 Lifting Beam Hooks

Lifting beam hooks shall conform to the requirements of ASTM A 514/A 514M or ASTM A 668/A 668M Grade K, with a minimum of 100 ksi ultimate tensile strength. Submit hook material and heat treatment, design calculations, and shop drawings prior to fabrication. Submit hook material certification.

PART 3 EXECUTION

3.1 GENERAL

Design and fabricate lifting beam assembly including sheaves, in accordance with these specifications, and in accordance with the requirements in SECTION 05 50 04.00 26, METALS: MISCELLANEOUS, STANDARD ARTICLES, SHOP FABRICATED ITEMS. Paint lifting beam in accordance with SECTION 09 90 00.01 26 PAINTS AND COATINGS. The fit between a movable surface and a contacting shaft or pin shall be ASME B4.1 , Class LC-11, to reduce the tendency to bind. The fit between a nonmovable surface and the contacting shaft or pin shall be ASME B4.1 , Class LC-3.

3.2 FIELD MEASUREMENTS AND LIFTING BEAM PRE-TEST

Field measurements must be performed prior to commencing any lifting beam design work. Before performing any work, become familiar with all details of the work, verify all dimensions in the field, weigh the existing lifting beam, and take note of which direction of counterweight movement actuates the lifting beam linkages to latch on to the bulkhead.

Coordinate with the CO to schedule a lifting beam pre-test. Lifting beam pre-test will be performed by the Government operating the crane, and will include lowering the existing lifting beam into each of the four bulkhead slots. Witness this test and immediately raise any concerns about the lifting beam not moving smoothly in a slot. Submit the results for approval. At the Contractor's discretion, the Existing Lifting Beam Weight Report may be part of the Field Measurements submittal.

3.3 IN-SHOP LIFTING BEAM AND OR LIFTING DEVICES TESTING

3.3.1 In-Shop 125% Load Test

a. Submit a 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 , and post-load-test visual inspections for deformation, cracks, or other defects. 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, a sufficient distance to ensure the load is supported by the lifting beam hooks.

b. After the lifting device has been assembled, service the equipment.

Provide all necessary grease of approved quality and grade for the initial servicing for shop tests.

c. Notify the CO, a minimum of 14 calendar days in advance, the dates of the In-Shop Load Test. Notify the CO, a minimum of three business days in advance, any revisions of the dates of the In-Shop Load Test.

SECTION 41 22 13.76 26 Page 12

d. Submit for approval a Shop Test Report, including but not limited to the approved procedure, photos of the lifting device holding the 125% load and close-up photos of load path elements after the test.

3.3.2 In-Shop Operational Test

Demonstrate that new lifting beam successfully latches and unlatches to each of the new or existing below the hook devices.

3.3.3 Weighing of New Lifting Beam and or Lifting Devices

Weigh the new lifting device with properly calibrated equipment and submit a New Device Weight Report, including but not limited to the calibration certificate(s) and serial number(s) of equipment used, and the weight of the beam.

3.4 REMOVAL OF EXISTING LIFTING BEAM AND OR BELOW THE HOOK DEVICES

After the successful conclusion of onsite operational testing and authorization from the CO, remove and properly dispose of the existing lifting beam and or below the hook devices.

3.5 LIFTING BEAM AND OR LIFTING DEVICES O&M MANUAL

Submit three (3) copies for approval, both in bookmarked and page-numbered PDF form on marked DVDs, and in hardbound format (3-ring binder is acceptable) a lifting beam and or lifting devices O&M Manual including but not limited to:

(1) General description of lifting beam and or Lifting Devices and operation.

(2) Approved Final Calculations.

(3) Explanation of Working Load Limit calculation.

(4) Final Approved Versions of Contractor-Prepared Drawings, 11x17.

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

(6) Manufacturer's contact information and product data for any components not fabricated by the Contractor.

(7) Lifting beam material certifications.

(8) Completed Report for Lifting Beam Weld Inspection.

(9) Lifting Beam or Lifting Devices Shop Test Report.

(10) Lifting Beam or lifting Devices Onsite Test Report.

(11) Load Test Results

3.6 WARRANTY

The complete lifting beam and or lifting devices assembly shall be warranted for a period of one year, or the contracted period of any extended warranty agreed upon by the Contractor and the Government, after successful completion of all testing. Any component failing to perform its function as specified and documented shall be repaired or replaced by the Contractor at no additional cost to the Government. Items repaired or replaced shall be warranted for an additional period of at least one year from the date that the system becomes functional again. The warranty period shall start after official turnover of the lifting beam to the Government for beneficial use. This turnover shall not occur until after successful onsite testing, approved final calculations and drawings, O&M manual etc.

SECTION 41 22 13.76 26 Page 13

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SECTION 41 22 13.76 26 Page 14