Amendment 0005 TechSpecs 20R0004.pdf

HLD Powerhouse Intake Gantry Crane Controls Upgrade W912EF20R0004 Amend- 0005

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 01 20.16 26

GANTRY CRANE DATA, SPARE PARTS, TESTING, AND TRAINING

PART 1 GENERAL

1.1 GENERAL INFORMATION

1.2 REFERENCES

1.3 SUBMITTALS

1.4 DATA, CAPACITIES, SPEEDS AND TRAVEL

1.4.1 Definitions

1.4.2 Data, Capacities, Speeds, and Travel

1.4.2.1 Intake Gantry Crane

1.4.2.2 Main Hoist

1.4.2.3 Actuating Hoist

1.4.2.4 Main Trolley

1.4.2.5 Upstream Auxiliary Hoist (#1)

1.4.2.6 Downstream Auxiliary Hoist (#2)

1.4.2.7 Monorail Hoist

1.4.2.8 Auxiliary Trolley

1.4.2.9 Tugger Hoists

1.5 QUALIFICATIONS

1.5.1 Qualified Crane Inspectors

1.5.2 Qualified Craftsmen

1.5.3 Qualified Crane Electricians

1.6 TEST WEIGHTS

1.6.1 Test Weight Requirements

1.6.2 Below-The-Hook Lifting Devices

1.6.3 Water Bag Requirements

1.6.4 Test Weight Plan

1.7 OPERATING MANUAL

PART 2 PRODUCTS

2.1 SPARE PARTS AND SPECIAL TOOLS

PART 3 EXECUTION

3.1 EQUIPMENT MONITORING DURING INSPECTIONS AND TESTING

3.2 CONTROL SYSTEMS SHOP INSPECTION AND TESTING

3.2.1 Shop Inspection and Testing General

3.2.2 Shop Inspections and Testing to be Performed

3.2.3 Control Systems Shop Inspection and Testing Procedure

3.2.4 Control Systems Shop Inspection and Testing Report

3.3 ON-SITE INSPECTION AND TESTING

3.3.1 General

3.3.2 On-Site Inspection and Testing Phases

3.4 INSPECTION AND TESTING TIMELINE

3.4.1 Timeline, General

3.4.2 Pre-Initial Phase

3.4.3 Initial Phase

3.4.4 Between Initial and Final Phases

3.4.5 Final Phase Activities

3.5 INITIAL INSPECTION

SECTION 41 01 20.16 26

g4ecctgh Line paragraph 1.6.2

3.5.1 General

3.5.2 Initial Inspection Report

3.6 INITIAL NO-LOAD PERFORMANCE TEST

3.6.1 General

3.6.2 Initial No-Load Performance Test Report

3.7 FINAL INSPECTION

3.7.1 General

3.7.2 Inspections to be Performed

3.7.3 Final Inspection Procedure

3.7.4 Final Inspection Report

3.8 ACCEPTANCE TESTING

3.8.1 General

3.8.2 Performance Requirements

3.8.3 Test Sequence

3.8.4 Acceptance Test Procedure

3.8.5 Data Measurement and Recording

3.8.6 No-Load Performance Test

3.8.7 100 Percent Rated Load Performance Test

3.8.8 125 Percent Rated Load Performance Test

3.8.9 Acceptance Test Report

3.9 MANUFACTURER'S SERVICES

3.9.1 General

3.9.2 VFD Technician

3.10 AS-COMMISSIONED VFD PARAMETERS AND SOFTWARE

3.11 FIELD TRAINING

3.11.1 General Training

3.11.2 Training Materials

3.11.3 General Operation and Maintenance Training

3.11.4 Solid State Maintenance Training

3.12 SUPPLEMENTARY REQUIREMENTS FOR OPERATIONS AND MAINTENANCE MANUAL

3.13 WARRANTY

-- End of Section Table of Contents --

SECTION 41 01 20.16 26

SECTION 41 01 20.16 26

GANTRY CRANE DATA, SPARE PARTS, TESTING, AND TRAINING

PART 1 GENERAL

1.1 GENERAL INFORMATION

This section covers capacities, inspections, control systems shop testing, acceptance testing, spare parts requirements, personnel training, and operation and maintenance documentation for the rehabilitated Ice Harbor 111-ton intake gantry crane. The crane must be tested at the capacities shown in this section.

1.2 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASME INTERNATIONAL (ASME)

ASME B30.2 (2017) Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist)

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

ASME BTH-1 (2017) Design of Below-the-Hook Lifting Devices

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 1 (2000; R 2015) Standard for Industrial Control and Systems: General Requirements

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 Safety and Health Requirements Manual

The Contractor shall be responsible for complying with the most current edition and all changes posted on the web as of the effective date of this solicitation.

1.3 SUBMITTALS

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

submittals having an "I" designation are for information only. A designation following the "G" or "I" 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

Inspection Procedure ; G, HDC

Acceptance Test Procedure ; G, HDC

Test Weight Plan ; G, HDC

Final Inspection Procedure ; G, HDC

Control Systems Shop Inspection And Testing Procedure ; G, HDC

SD-06 Test Reports

Initial Inspection Report ; G, HDC

Initial No-Load Performance Test Report ; G, HDC

Final Inspection Report ; G, HDC

Acceptance Test Report ; G, HDC

Control Systems Shop Inspection And Testing Report ; G, HDC

SD-07 Certificates

Crane Inspectors ; G, HDC

Qualified Craftsmen ; G, HDC

VFD Technician ; G, HDC

Spare Parts And Special Tools ; G, HDC

Non-Contaminated Equipment Certifications ; G, ECC

SD-08 Manufacturer's Instructions

Training Agendas ; G, EOC

Training Manuals ; G, EOC

SD-10 Operation and Maintenance Data

Operating Manual ; G, HDC

SD-11 Closeout Submittals

As-Commissioned Software and VFD Parameters ; G, HDC

1.4 DATA, CAPACITIES, SPEEDS AND TRAVEL

1.4.1 Definitions

a. Crane Rated Capacity - The rated capacity of the main hoist.

b. Main Hoist Rated Capacity - The sum of the rated capacity of each of the two load blocks.

c. Actuating Hoist Rated Capacity - The sum of the rated capacity of each of the two load blocks.

d. Auxiliary Hoist Rated Capacity - The sum of the rated capacity of each of the two load blocks for each auxiliary hoist.

e. Tugger Hoist Rated Capacity - The maximum line pull that can be applied to each tugger hoist.

f. Rated Hoisting Speed - The linear velocity of the load when lifting the rated capacity for each hoist.

g. Gantry Rated Travel Speed - The linear velocity of the gantry when carrying a load equal to the rated capacity of the main hoist.

h. Main Trolley Rated Travel Speed - The linear velocity of the trolley when carrying a load equal to the rated capacity of the the main hoist.

i. Auxiliary Trolley Rated Travel Speed - The linear velocity of the trolley when carrying a load equal to the sum of the rated capacity of both auxiliary hoists.

j. Primary Upper and Lower Limit of Hoist Travel - The point which the rotary limit switch stops the hoist and is measured from the center of the pins for the main hoist, actuating hoists, and auxiliary hoists.

Additional lift is required to reach the secondary back up (weighted type) limit switches.

1.4.2 Data, Capacities, Speeds, and Travel

1.4.2.1 Intake Gantry Crane

Data, capacities, travel distances, and rated speeds of the crane must be as follows:

a. Rated Capacity, Tons (2,000 pounds)

b. Rated Gantry Travel Speed, Feet Per Minute

c. Gantry Span, Feet...................................... 38.0

d. Total Gantry Travel, Feet (Approx.)

1.4.2.2 Main Hoist

a. Rated Capacity (Both Load Blocks), Tons

b. Rated Capacity (Each Load Block), Tons ................. 55.5

c. Rated Hoisting Speed (Rated Load), Feet Per Minute..... 8.07

d. Load Block Pin Travel:

Upper limit of travel not lower than Elevation...... 515.0 Lower limit of travel not higher than Elevation..... 345.0

1.4.2.3 Actuating Hoist

a. Rated Capacity (Both Load Blocks), Tons

b. Rated Capacity (Each Load Block), Tons................. 7.5

c. Rated Hoisting Speed (Rated Load), Feet Per Minute

d. Load Block Pin Travel:

Upper limit of travel not lower than Elevation...... 515.0 Lower limit of travel not higher than Elevation..... 453.0

1.4.2.4 Main Trolley

a. Rated Trolley Travel Speed, Feet Per Minute

b. Total Trolley Travel, Feet (Approx.)

1.4.2.5 Upstream Auxiliary Hoist (#1)

a. Rated Capacity (Both Load Blocks), Tons

b. Rated Capacity (Each Load Block), Tons................. 7.5

c. Rated Hoisting Speed (Rated Load), Feet Per Minute

d. Load Block Pin Travel:

Upper limit of travel not lower than Elevation...... 483.0 Lower limit of travel not higher than Elevation..... 327.0

1.4.2.6 Downstream Auxiliary Hoist (#2)

a. Rated Capacity (Both Load Blocks), Tons

b. Rated Capacity (Each Load Block), Tons................. 7.5

c. Rated Hoisting Speed (Rated Load), Feet Per Minute

d. Load Block Pin Travel:

Upper limit of travel not lower than Elevation...... 483.0 Lower limit of travel not higher than Elevation..... 327.0

1.4.2.7 Monorail Hoist

a. Rated Capacity, Tons

b. Rated Hoisting Speed (Rated Load), Feet Per Minute

c. Load Block Pin Travel:

Upper limit of travel not lower than Elevation...... 488.0 Lower limit of travel not higher than Elevation..... 448.0

d. Rated Trolley Travel Speed, Feet Per Minute

e. Total Trolley Travel, Feet (Approx.)................... 20.3

1.4.2.8 Auxiliary Trolley

a. Rated Trolley Travel Speed, Feet Per Minute

b. Total Trolley Travel, Feet (Approx.)................... 55.1

1.4.2.9 Tugger Hoists

a. Number of Hoists

b. Rated Line Pull, Tons.................................. 0.5

c. Rated Hoisting Speed (at rated pull), Feet Per Minute.. 30-45

d. Load Block Pin Travel:

Upper limit of travel not lower than Elevation...... 517.0 Lower limit of travel not higher than Elevation..... 433.0

Note: Rated hoisting speed for the tugger hoists is defined as the linear speed of the hook at half drum. Acceptable range is 30 to 45 feet per minute at half drum.

1.5 QUALIFICATIONS

1.5.1 Qualified Crane Inspectors

Provide documentation showing that crane inspectors meet the following qualifications:

a. Experience and knowledge in performing inspection on cranes of similar size and capacity as the Ice Harbor intake gantry crane.

b. Certifications showing they have attended crane inspection training seminars provided by established training institution.

Certifications issued by the Contractor or any sub-contractors do not meet this requirement.

c. A history of employment as crane inspectors for at least the last two (2) years by a firm specializing in crane inspection work.

1.5.2 Qualified Craftsmen

Provide documentation showing that qualified craftsmen meet the following qualifications:

a. Have experience and knowledge in performing work on double girder bridge or gantry cranes of similar size and capacity as the Ice Harbor intake gantry crane.

b. Have continuously performed work on cranes or hoist machinery for at least three (3) years.

c. Are employed for at least the last two (2) years by a firm specializing in crane manufacture, repair, and/or rehabilitation work.

1.5.3 Qualified Crane Electricians

There must be a minimum of one (1) licensed electrician during field wiring and critical aspects of the crane field work.

1.6 TEST WEIGHTS

1.6.1 Test Weight Requirements

Test loads must weigh within plus 5 percent, minus 0 percent, of the nominal load specified. Loads for the main hoist, actuating hoist, and auxiliary hoist must be attached to the respective load blocks; use of the intake gate lifting beam, STS lifting beam, or other existing below-the-hook lifting devices as part of the test weight configuration is not allowed.

1.6.2 Below-The-Hook Lifting Devices

Any Contractor-provided below-the-hook (BTH) lifting devices must be clearly marked with the rated load of the device. The design, fabrication, marking, and load testing of the devices must conform to ASME B30.20 , ASME BTH-1, and EM 385-1-1 .

If Contractor-provided BTH lifting devices are fabricated specifically for this project, include design calculations in the Test Weight Plan. Design calculations must meet the requirements of the Paragraph: "Design Calculations" in Section 41 01 20.17 26 GANTRY CRANE MECHANICAL AND

STRUCTURAL REHABILITATION.

All Contractor-provided BTH lifting devices must be load tested prior to being used on-site for crane load testing. If a device has been previously load tested, include the documentation of the load test in the test weight plan. If a BTH load test is required, notify the Government a minimum of 14 days prior to the planned date of the load test so that the Government may witness the BTH load test.

None of the existing BTH devices currently in use on the intake crane at Ice Harbor may be used by the Contractor in order to load test, commission

SECTION 41 01 20.16 26

g4ecctgh Line g4ecctgh Line g4ecctgh or verify the capacity of the crane as outlined in this contract Government-owned BTH devices specifically for use by the intake crane may be used by the Contractor to load test or commission the crane if the devices have their respective submittals approved ('A' or 'B' code) under SECTION 41 01 20.75 26 including:

a. Working Load Limit Markings

b. Nameplates for Lifting Devices

c. Safety Labels for Lifting Devices

d. Analysis Calculations

e. Lifting Device Weight Report

f. Lifting Device Test Report

g. Lifting Device NDE Report

h. Lifting Device Inspection Report

Government-owned BTH devices not meeting the requirements above may not be used by the Contractor in order to load test or commission the crane .

1.6.3 Water Bag Requirements

If water bags are used, maintain clearance from electrical equipment.

Provide means of pumping water into the water bags from the forebay or gate/bulkhead slots, and after testing, a means of draining the bags into the forebay. Do not drain water bags into the intake structure drainage system. Size pumps, piping/headers and valves such that the total time to fill the main hoist water bags from 0-100% is no longer than four (4) hours. Use basket strainers that are approved by the pump manufacturer on the pump suction.

Water bags and other wetted equipment must be free of any invasive species or pollutants in order to dump water back into the river. Contractor must submit non-contaminated equipment certifications , which have been verified by a party independent of the Contractor, at least 10 days prior to start of testing. Information included as part of the test equipment cleanliness certification must include the storage locations, and all locations water bags, pumps, hoses, flow meters, valves and manifolds have been used since last certification, invasive species removal verification, and cleaning techniques after usage. Approved cleaning techniques are similar to the heat and freezing processes as described in the Bureau of Reclamation's Technical Memorandum No. 86-68220-07-05.

(1) Water bag cleaning by heat. Entire water bag surface must be held above a temperature of 140 degrees F for a minimum of 1 minute, as verified by infrared temperature reading. This can be achieved by live steam, autoclaving, boiling, or by a hot water wash, as long as hot water contact time is sufficient to effect required surface temperature

(2) Water bag cleaning by freezing. Entire water bag surface must be held below a temperature of 14 degrees F for a minimum of 4 hours, as verified by infrared temperature reading.

If the equipment is used at a different location between the time that the cleanliness certification is submitted to the Government, submit an updated cleanliness certificate. Do not use the equipment on-site until an updated certificate has been approved by the Government.

SECTION 41 01 20.16 26

HLD Powerhouse Intake Gantry Crane Controls Upgrade W912EF20R0004 Amend- 0005 g4ecctgh

1.6.4 Test Weight Plan

Prepare and submit a test weight plan that contains the following:

a. Type of test weight.

b. Test weight handling and setup procedure, including but not limited to sequence of operations and methods of keeping the load stable. Include a load plan for movement of heavy equipment and test weights for approval showing dimensioned and labeled anticipated loads and equipment to be used during the load test for government approval.

Additional constraints are detailed in Section 01 14 00.10 28 PROJECT SITE RESTRICTIONS and SECTION 01 55 10.00 28 CONTRACTOR WORK, ACCESS

AND STORAGE AREAS.

c. Detailed drawings showing test weight configuration (to scale) with the crane, intake structure, and other features shown on the drawings. Show details of lifting beams, shackles, slings, and related equipment. If water weights are used, show the configuration of the fill and drain system. Show deck protection measures. Lifting beams must be used in accordance with their design; for instance, if a lifting beam is designed to have the middle water bags filled first and the end water bags filled last due to the angle at which the bags hang from the lifting beam ears, that order of water bag filling must be observed.

d. Drawings showing the proposed transportation path and final placement spot on intake deck.

e. Detailed procedure for how the load applied to the crane will be measured and verified.

f. Documentation for any below the hook lifting devices as required.

g. Copies of up-to-date calibration certificates for any instrumentation that is going to be used.

1.7 OPERATING MANUAL

Submit an operating manual for the cab. Submit the operating manual in both .pdf and .docx file formats. Two hard copies of the operating manual must also be provided for the crane. It must be a separate manual from the operations and maintenance manual specified in Section 01 78 23.00 28 OPERATION AND MAINTENANCE DATA with supplemental requirements in this section. The operating manual must include, but not be limited to:

a. Crane rating, make, model, serial number, year of manufacture, and manufacturer's name, year of rehabilitation (this project), and name of rehabilitation company (Contractor).

b. Hoist capacity ratings, speeds, and all limit switch settings (expressed in terms of elevations in feet and inches).

c. Trolley and gantry function speeds and limits.

d. Special hazard warnings.

e. Operating instructions for upstream or downstream cab control.

f. Operating instructions for radio remote control.

g. Operating instructions for the tugger hoists.

h. Operating instructions specific for use with the three modes of auxiliary hoist control: Independent Control, Trash Raking Control, Tandem Control as detailed in Paragraph "Auxiliary Hoist Special Hoisting and Lowering Performances" in Section 41 01 20.18 26 GANTRY

CRANE ELECTRICAL REHABILITATION.

i. A list and description of all interlocks, warning/alarm annunciations, and operational limits separated by crane function as implemented as specified in Section 41 01 20.18 26 GANTRY CRANE

ELECTRICAL REHABILITATION.

j. Layouts of all HMI screens for description of each function visible parameter displayed or controllable from the HMI screens.

Include a description of all alarm banners that can be shown on the HMI screen.

k. Operating instructions for the closed-circuit television (CCTV) system.

PART 2 PRODUCTS

2.1 SPARE PARTS AND SPECIAL TOOLS

a. Furnish spare parts and special tools as specified below. Submit a list of spare parts and special tools for approval including part numbers, original manufacturer, and quantity. All spare parts will consist of the same material and workmanship, meet the same requirements, and be interchangeable with the corresponding original parts furnished for systems as outlined in Section 41 01 20.18 26 GANTRY CRANE ELECTRICAL REHABILITATION and Section 41 01 20.17 26 GANTRY CRANE MECHANICAL AND STRUCTURAL REHABILITATION. Carefully pack spare parts for long-term storage and protection and legibly label, identifying service and manufacturer's part number.

b. Provide the spare parts listed below after initial inspections and prior to the winter crane outage window as described in Section

01 11 01.00 28 SUPPLEMENTARY REQUIREMENTS:

(1) One complete set of seals and bearings for the existing main hoist gearbox.

(2) One complete set of seals and bearings for the existing actuating hoist gearbox.

(3) One complete set of seals and bearings for an existing auxiliary hoist gearbox.

(4) One complete sets of seals for each existing gantry drive gearbox (four total).

(5) One complete set of bearings for each existing gantry drive gearbox (four total).

(6) One complete set of seals and bearings for each type of existing open gear sets.

c. Provide the spare parts and special tools listed below within 30 days after completion of acceptance testing and Government approval of the Acceptance Test Report:

(1) One VFD of each type and size used.

(2) One PLC controller (processor module) of each type used.

(3) One I/O module of each type used for the PLC and any remote I/O used.

(4) One communications module of each type used for the PLC.

(5) One HMI of each type used.

(6) One PLC power supply for each type used.

(7) Six keys for each cabinet door lock on the crane.

(8) Six fuses of each type and rating used.

(9) Two replacement control relays of each type used.

(10) One limit switch of each type used for hoists and travel.

(11) One complete brake rectifier assembly of each type of brake rectifier used.

(12) Two complete control selector switch assemblies of each type used.

(13) Two complete pushbutton assemblies of each type used.

(14) One complete single axis master control switch assembly of each type used (spare two axis master switch for the monorail hoist is not required).

(15) Two indicating light assemblies of each type used.

(16) Six lamps of each type used in indicating lights.

(17) One set of special tools required to manually fix or lock each disc type brake provided.

(18) One friction disc for each type of disc brake used.

(19) One set of torque springs for each type of disc brake used.

d. Provide one diagnostic and commissioning tool to interface with all of the rehabilitated crane's software-equipped systems. Ship tool to the Government (HDC) a minimum of 45 days prior to scheduled start date of the Initial Inspection. HDC will perform cybersecurity hardening. The tool will then be available on site for the Final Inspection and Acceptance Testing, and finally transferred to the U.S.

Army Corps of Engineers Ice Harbor Lock and Dam. Additional requirements for the tool include:

(1) The diagnostic tool must be equipped with all ports, cable connections, and adaptors needed to allow all crane software to be checked and modified.

(2) The screen must be a minimum of 14 inches measured diagonally and be the anti-glare, non-touch type.

(3) The tool must be compliant to MIL-STD-810G.

(4) The tool must use Windows 10 Pro or Enterprise version 1809 or later operating system. Provide TPM 2.0 support (Trusted Platform Module) on the diagnostic tool to facilitate installation of encryption software and cyber security updates by the Government upon receipt. The programming software is to be licensed to the government: U.S. Army Corps of Engineers Ice Harbor Lock and Dam.

(5) Load diagnostic and commissioning tool with all necessary programming software licenses and remove any non-essential software (games, trial programs, etc.) prior to delivery to the Government.

(6) Additional requirements for the diagnostic and commissioning tool are provided in SECTION 41 01 20.18 26 GANTRY CRANE ELECTRICAL REHABILITATION Paragraph "Network Documentation".

PART 3 EXECUTION

3.1 EQUIPMENT MONITORING DURING INSPECTIONS AND TESTING

During all inspections and testing, monitor for improper operation or poor condition of safety devices, electrical components, mechanical equipment, and structural assemblies. Immediately report to the Contracting Officer (KO)any observed defects critical to continued inspection or testing.

Suspend inspection and testing activities until the deficiency has been corrected. Resume inspection and testing activities after the corrective action has been verified by the Government. Perform the following at each activity of inspection and testing:

a. Inspect for evidence of bending, warping, permanent deformation, cracking or malfunction of structural components.

b. Visually examine the motors, brakes, gearing, and other mechanical or electrical equipment to ensure no damage has occurred.

c. Inspect for evidence of slippage in wire rope sockets and fittings.

d. Check for overheating in brake operation; check for proper stopping. Inspect and test all safety devices, including emergency stop switches and power off pushbuttons, separately, to verify proper operation of the brakes.

e. Check for abnormal noise or vibration and overheating in machinery drive components.

f. Monitor gantry travel for binding and skewing.

g. Check wire rope sheaves and drum spooling for proper operation, freedom of movement, abnormal noise or vibration.

h. Inspect gears for abnormal wear patterns, damage or inadequate lubrication.

i. Check electrical drive components for proper operation, freedom from chatter, noise, or overheating.

j. Remove inspection covers from gear reducers for inspection of gearing after all testing.

3.2 CONTROL SYSTEMS SHOP INSPECTION AND TESTING

3.2.1 Shop Inspection and Testing General

Perform an inspection and operational test of the new control systems prior to shipping the individual assemblies (control panels, operator chair control consoles, HMI's, motors, brakes, etc.) from the shop. Prior to testing, electrical equipment must be completely manufactured, adjusted, lubricated, and otherwise made ready for operation.

The inspections and testing must be performed in the presence of a designated Government witness. Notify the Government a minimum of 14 days in advance of the dates of the in-shop inspection and testing. If shop inspection and testing is planned for a facility outside the United States, notify the Government a minimum of 60 days in advance of the dates of the in-shop inspection and testing. Provide additional notification if there is any change in the dates.

3.2.2 Shop Inspections and Testing to be Performed

Inspect and perform operational testing of the control systems in accordance with NEMA ICS 1 . Shop inspections and testing must demonstrate that the control system is complete, fully functional, and meets the requirements of these specifications. Control systems must be fully assembled for testing including control enclosures, VFD's, dynamic braking resistors, operator consoles (upstream and downstream operator chair consoles), HMI's, motors, and brakes (as practicable), and tugger hoists (electric winches) for the test. Confirm functionality using both cab control console chairs and both radio transmitters provided. It is acceptable to use temporary wiring to connect the control and power systems to the associated drives.

3.2.3 Control Systems Shop Inspection and Testing Procedure

Prepare and submit a control systems shop inspection and testing procedure .

Submit the procedure a minimum of 14 calendar days before scheduled start date of the shop inspection. The procedure must contain the following elements, at a minimum:

a. A list of names and contact information for key Contractor personnel who will be involved with the inspections.

b. Location of test.

c. A checklist for verifying the fabricated and assembled equipment is accurate.

d. A checklist of each inspection and/or test to be performed.

3.2.4 Control Systems Shop Inspection and Testing Report

Prepare and submit a control systems shop inspection and testing report after completing the shop inspections and testing. At a minimum, include the following elements in the test report:

a. Date(s) that inspections and testing took place.

b. List of Contractor and Government personnel present during inspections and testing.

c. Completed checklists and data sheets verifying all inspections and tests were successfully performed. Completed checklists and data sheets must have signatures from the Contractor and designated Government witness present that verify that all inspections and tests were completed successfully.

d. Descriptions of any deficiencies that were discovered during the testing. If no deficiencies were found, state it in the report. If deficiencies were found, include a description of the means and measures taken to correct the deficiency, as well as verification that the deficiency has been corrected and tests were re-run.

Provide the Government witness that is present for the inspections and testing with a copy of the completed checklists and data sheets.

3.3 ON-SITE INSPECTION AND TESTING

3.3.1 General

After the crane has been completely rehabilitated, adjusted, lubricated, and otherwise made ready for operation, perform inspections and acceptance tests as specified herein.

3.3.2 On-Site Inspection and Testing Phases

Prepare and submit a Inspection Procedure . Perform on-site inspection and testing in two (2) phases: Initial and Final. The purpose of the initial phase is to have a trial run and to ensure all deficiencies are discovered and corrected before the final phase. It is not required that the Government witness the activities performed during the initial phase.

Do not perform any Final phase activities without the presence of the designated Government witness, unless previously waived in writing.

Initial phase activities consist of the following:

(1) Initial Inspection

(2) Initial No-Load Performance Testing

Final phase activities consist of the following:

(1) Final Inspection

(2) Acceptance Testing

3.4 INSPECTION AND TESTING TIMELINE

3.4.1 Timeline, General

Perform inspection and testing after the crane has been completely rehabilitated, adjusted, lubricated, and otherwise made ready for operation. The following sub-paragraphs list the required notification windows, submittal windows, and other time sensitive actions during the inspection and testing period.

3.4.2 Pre-Initial Phase

a. Submit all inspection and testing procedures a minimum of 45 days prior to the planned start of initial phase activities. The procedures that need to be submitted before inspection and testing can proceed are:

(1) Inspection Procedure

(2) Acceptance Test Procedure

(3) Test Weight Plan

b. Inspection and testing activities must not begin until the following has occurred:

(1) The Inspection Procedure has been approved by the Government.

(2) Shaft Alignment, per Section 41 01 20.17 26 GANTRY CRANE MECHANICAL AND STRUCTURAL REHABILITATION, Paragraph "Shaft Alignment" is complete and the alignment report has been approved by the Government.

(3) Dynamic Balancing of Machinery, per Section 41 01 20.17 26 GANTRY CRANE MECHANICAL AND STRUCTURAL REHABILITATION, Paragraph "Dynamic Balancing Of Machinery" is complete and the Dynamic Balancing Report has been approved by the Government.

(4) Wire Rope Magnetic Flux Leakage Test, per Section

41 01 20.17 26 GANTRY CRANE MECHANICAL AND STRUCTURAL

REHABILITATION, Paragraph "Wire Rope Flux Leakage Testing" has been approved by the Government.

(5) All Crane Design Data package submittals, per Section

41 01 20.17 26 GANTRY CRANE MECHANICAL AND STRUCTURAL

REHABILITATION have been submitted to and approved by the Government with no resubmittal required ("A" or "B" Code).

(6) Trash raking performance calibration and testing, per Section 41 01 20.18 26 GANTRY CRANE ELECTRICAL REHABILITATION is complete and the associated test report has been submitted to and approved by the Government with no resubmittal required ("A" or "B" Code).

(7) Draft copies of the Operations and Maintenance Manuals have been submitted to and approved by the Government ("A", "B", or "C" Code).

(8) The Operating Manual has been submitted, per this section, and been approved with no resubmittal required ("A" or "B" Code).

3.4.3 Initial Phase

a. Notify the Government, a minimum of 7 calendar days in advance, the planned start of any inspection or test.

b. Submit the Initial Inspection Report within 1 business day of completing the inspections.

c. Submit the Initial No-Load Performance Test Report within 1 business day of completing the testing.

3.4.4 Between Initial and Final Phases

Allow the Government a minimum of two (2) full business days to review the Initial No-Load Performance Test Report prior to start of final phase activities. "Two (2) full business days" constitutes the Government receiving the reports electronically, not later than 0800 hours of the first date of review, to allow all Government reviewers adequate time to review the reports.

3.4.5 Final Phase Activities

a. Notify the KO, a minimum of 14 calendar days in advance, the planned start of any inspection or test.

b. Notify the KO, a minimum of five (5) business days in advance, any revisions to the dates of the final inspections and acceptance tests.

c. The designated Government witnesses will be on site for the final inspection and acceptance tests no earlier than one (1) business day after approval of the Initial Inspection Report and Initial No-Load Performance Test Report.

d. Final inspection and acceptance testing must be conducted within the following hour and day restrictions. Written permission from the KO is required to deviate from the following:

(1) The final inspection and acceptance testing must occur on separate days.

(2) The final inspection and acceptance testing must not occur during the week of a Federal Holiday.

(3) Accomplish final inspection and acceptance testing activities on a Monday through Thursday schedule.

(4) Government personnel will be available for the final inspection and acceptance testing for a maximum of 12 continuous hours in a 24 hour time period.

e. Government witness representatives will not arrive onsite until all test materials and Contractor personnel are on-site and ready for testing.

f. Provide the Final Inspection Report and copies of all collected data to the Government representatives. On-site approval of the inspection report is required before the acceptance tests can begin.

3.5 INITIAL INSPECTION

3.5.1 General

The initial inspection is the same inspection as the final inspection.

Perform the initial inspection in accordance with the approved Final Inspection Procedure.

Only approved, qualified crane inspectors will be allowed to perform crane inspections.

Correct any deficiencies or anomalies prior to preparing and submitting the inspection report.

3.5.2 Initial Inspection Report

Prepare and submit a Initial Inspection Report after all initial phase inspections are complete. The report shall include the following elements, at a minimum:

a. Completed inspection checklist.

b. Discussion of any deficiencies that were discovered during the inspections. If no deficiencies were found, state it in the report.

c. If deficiencies were found, include a description of the means and measures taken to correct the deficiency as well as verification that the deficiency has been corrected and re-inspected.

3.6 INITIAL NO-LOAD PERFORMANCE TEST

3.6.1 General

The Initial No-Load Performance Test requirements and procedure are identical to the No-Load Performance Test that is performed during acceptance testing. Perform the Initial No-Load Performance Test in accordance with the procedures of the approved Acceptance Test Procedure.

Correct any deficiencies or anomalies prior to preparing and submitting the test report.

3.6.2 Initial No-Load Performance Test Report

Prepare and submit a Initial No-Load Performance Test Report , after all Initial Phase No-Load Performance tests are complete. Include the following elements in the report, at a minimum:

a. A narrative summary that describes the testing that took place.

Include notation that all planned tests were completed with successful outcomes.

b. Completed inspection checklist and verification each required inspection was successfully completed.

c. Descriptions of any deficiencies that were discovered during the testing. If no deficiencies were found, state it in the report.

d. If deficiencies were found, include a description of the means and measures taken to correct the deficiency, as well as verification that the deficiency has been corrected and tests were re-run.

3.7 FINAL INSPECTION

3.7.1 General

Perform a Final Inspection. Correct any deficiencies that are discovered during inspections, and repeat portions of inspections to verify corrections prior to preparing and submitting the inspection report.

Only approved, qualified crane inspectors will be allowed to perform crane inspections.

The Final Inspection is the inspection that is witnessed by the Government. Do not perform the Final Inspection until the following has occurred:

a. The Initial Inspection Report has been submitted and approved by the Government.

b. The Initial No-Load Performance Test Report has been submitted and approved by the Government.

3.7.2 Inspections to be Performed

Perform all inspections as required by ASME B30.2 , Periodic Inspection.

Perform the following additional inspections:

a. Verify that the work to be performed under this contract was completed, including all cleaning activities.

b. Test all auxiliary equipment for proper operation and calibration, including, but not limited to - load cells, cable carriers and festoons, wind speed indicator, locking and indicating devices.

Verify all indication lamps and warning devices operate correctly.

Verify convenience receptacles, heating and cooling apparatus, and lighting operate correctly.

c. Brakes - For each hoist shoe brake, verify the following:

(1) Pad Clearance - Verify that brake pad clearance is correctly adjusted to be within the manufacturer's recommended range.

(2) Torque Settings - Physically verify and test that brake torque settings are correct.

(3) Emergency Stop - For each hoist, trolley and the gantry function, while slowly operating the crane function (less than 25% rated speed), disconnect the main power source by pressing one of the emergency stop push buttons. Verify the brake(s) set(s) and that the function comes to a complete stop.

(4) Hoist Brake Setting Delay Test - For hoists with two brakes, verify that second brake sets approximately 1 second after the first brake.

d. Hoists - For each hoist, verify the following, as applicable:

(1) Range of Speed - Verify the hoist operates correctly across the entire speed range in each direction, at normal speed, slow speed (micro speed) and fast speed (ultralift) selections. Verify correct brake operation.

(2) Fast Speed (Ultralift) - Verify proper operation of the VFD fast speed control feature as described in Section 41 01 20.18 26 GANTRY CRANE ELECTRICAL REHABILITATION. Verify that the fast speed is only enabled when selected and only with light loads.

(3) Brake Failure Detection - Verify proper operation of the VFD brake failure detection feature as described in Section 41 01 20.18 26 GANTRY CRANE ELECTRICAL REHABILITATION. Simulate a brake failure by manually releasing the brakes and turning the motor shaft as needed; verify VFD detects and responds to the simulated brake failure as described in Section 41 01 20.18 26

GANTRY CRANE ELECTRICAL REHABILITATION.

(4) Lower Blocks - Verify that the hoist load blocks hang with no visible twist.

(5) Bolt Torque - Verify that all mechanical fasteners are torqued to the value specified in the Bolt Tension Chart, per Section 41 01 20.17 26 GANTRY CRANE MECHANICAL AND STRUCTURAL

REHABILITATION.

e. Hoist Limits - Verify the operation of all upper and lower limit switches on each hoist as applicable. Set hoist limits before the FINAL INSPECTION in accordance with maximum and minimum load block elevations per Paragraph "DATA, CAPACITIES, SPEEDS, AND TRAVEL" and as specified in Section 41 01 20.18 26 GANTRY CRANE ELECTRICAL

REHABILITATION.

(1) Hoist Upper Rotary Limit (Primary Upper Limit) - Raise the hoist until the upper rotary limit switch is reached. Verify that the hoist automatically slows down when approaching the upper limit. Verify that the hoist stops after the limit switch is reached. Verify elevation of the load blocks at the upper rotary limit using physical or optical measurement tools. Verify that the hoist cannot be raised and is only capable of lowering.

(2) Hoist Weighted Upper Limit (Secondary Upper Limit) - Use the bypass keyswitch to bypass the upper rotary limit. Raise the hoist until the weighted limit switch is tripped. Verify the hoist motion stops. Verify that the hoist is not operable in the raise direction and is only operable in the lowering direction. Return the bypass to the normal (un-bypassed selection).

(3) Lower Limit Switch - Lower the hoist until the lower limit switch is reached. Verify that the hoist automatically slows down when approaching the lower limit. Verify that the hoist stops after the limit switch is reached. Verify elevation of the load blocks. Verify that the hoist cannot be lowered, but is possible to operate in the raise direction. Verify that when the lower limit switch is reached, there are at least two wire rope wraps remaining on the drum. Physically verify that the blocks are capable of reaching the lowest elevation.

f. Gantry and Trolley Travel Operation - For the gantry and trolleys, verify correct operation across the entire speed range, in each direction, at normal speed and slow speed selections. Over the complete length of travel of the gantry and trolleys verify that:

(1) Travel operation is smooth.

(2) No binding on the rails occurs.

(3) The wheel flanges do not continuously contact the rail head while traversing the runway at any speed.

(4) When wheel flanges contact the rail head, they must immediately begin to realign with the center of the rails and that the wheels do not continue to contact the side of the rail head.

(5) There is no screeching or other abnormal noises caused by contact between the rail head and wheels.

g. Gantry and Trolley Travel Limits - For the gantry and trolleys verify the correct activation and setting of all travel limits to slow or stop the gantry or trolleys. When the slow speed limit is activated, the travel speed must be limited to 25% rated speed. If the gantry or trolley is traveling faster than 25% rated speed when the limit switch is tripped, the travel speed must slow to 25% rated speed. When the stop limit is activated, the gantry or trolley must decelerate to a stop. The gantry or trolley must be able to reverse out of either the slow speed limit or stop limit at rated speed or slow speed (if selected).

h. Emergency Stop Pushbuttons - Verify correct operation of every emergency stop pushbutton (operator chairs, all remote controls, and stop button on control cabinet). To verify correct operation, activate each pushbutton and verify that all power is removed from the crane's motion circuits (the main line contactor opens).

i. Cab Controls - Verify all functions of each cab control (chair) console in both the upstream and downstream operator cabs.

j. Remote Control - Verify all functions of the remote control operation. Demonstrate the "fail-safe" design of the remote (radio) control system, including loss of signal. Verify remote control operation with each remote control that is provided. Verify functionality of all remote controls provided.

k. Monorail Hoist - Verify that the monorail hoist trolley and hoist functions are functional in each direction of travel at both speed points.

l. Slack Line Indication - For each hoist, lower the load blocks to the deck to create a slack line condition. Verify proper annunciation of the slack line condition for each hoist.

m. Hoist Position Indication - Operate each hoists across the full range of travel from upper limit to lower limit and verify position indication for hoists as described in 41 01 20.18 26 GANTRY CRANE

ELECTRICAL REHABILITATION.

n. Auxiliary Hoist Modes of Operation - With the trash rake clamshell attached to the auxiliary hoist load blocks, demonstrate proper operation of the three modes of auxiliary hoist control: Independent

Control, Trash Raking Control, Tandem Control as detailed in Paragraph "Auxiliary Hoist Special Hoisting and Lowering Performances" in Section 41 01 20.18 26 GANTRY CRANE ELECTRICAL REHABILITATION.

Exercise each of the three modes of operation over the entire range of auxiliary hoist travel. While in the Trash Raking Control mode, demonstrate proper ability to adjust the assisting tension provided by the downstream hoist. Verify synchronization performances while operating in the Tandem Control traveling the hoists at up and down a total of at least 20 feet.

o. Operational Limits - Verify correct operation of all operational limits as described in Section 41 01 20.18 26 GANTRY CRANE ELECTRICAL REHABILITATION Paragraph "Operational Limits". Position trolley at various locations and simulate various load cell feedback values within the PLC software to test operational limits. Verify all combinations of trolley position and load cell feedback to ensure that operational limits are functional.

3.7.3 Final Inspection Procedure

Prepare and submit a Final Inspection Procedure . Include the following elements in the procedure, at a minimum:

a. A list of names and contact information for key Contractor personnel who will be involved with the inspections; including the qualified crane inspectors.

b. A checklist of all inspections to be performed.

c. A list of equipment that will be used during the inspections.

d. Sample data sheet(s) or form(s) that inspection data will be recorded on.

3.7.4 Final Inspection Report

Prepare and submit a Final Inspection Report immediately after all final inspections are complete. Include the following elements in the report, at a minimum:

a. A brief narrative summary that describes the inspections that took place.

b. Completed inspection checklist and verification each required inspection was successfully completed.

c. Descriptions of any deficiencies that were discovered during the inspections. If no deficiencies were found, state it in the report.

d. If deficiencies were found, include a description of the means and measures taken to correct the deficiency as well as verification that the deficiency has been corrected and re-inspected.

3.8 ACCEPTANCE TESTING

3.8.1 General

Perform acceptance testing. Acceptance testing consists of three parts:

No-Load, 100% rated load, and 125% rated load.

Provide all personnel and equipment necessary to conduct the tests including, but not limited to, crane operators, riggers, data recorders (personnel), rigging gear, test weights, and measuring instruments.

Performance requirements for testing are defined below. During the process of attaching the test loads to the hoists, verify the brakes are holding the load independently at 50 percent load with no observable slip before proceeding to 100 percent load.

The following tests are not applicable to the monorail hoist or tool hoists. Operational testing of the monorail hoist is required during Initial and Final Inspections per Paragraph "Inspections to be Performed" of this section. Performance and load testing of the tool hoists is required per Section 41 01 20.17 26 GANTRY CRANE MECHANICAL AND STRUCTURAL

REHABILITATION.

Not all requirements of Acceptance Testing are applicable to the tugger hoists; required testing of the tugger hoists is indicated in the following paragraphs only where explicitly cited. Where "crane hoists" is cited, this shall mean the main hoist, actuating hoist, upstream auxiliary hoist, and downstream auxiliary hoist. Where "all hoists" is cited, this shall mean the both tugger hoists in addition to all the "crane hoists".

3.8.2 Performance Requirements

Performance requirements for the rehabilitated gantry crane are defined in Section 41 01 20.18 26 GANTRY CRANE ELECTRICAL REHABILITATION.

3.8.3 Test Sequence

Perform the following tests in the order that is listed. The specifics for each test are specified below:

a. No-Load Performance Test

b. 100 Percent Rated Load Performance Test

c. 125 Percent Rated Load Performance Test

During acceptance testing, all collected data will be reviewed after each test has been completed, and prior to starting the next test. If there are unexpected results or inconsistencies in the data, rerun that portion of the test to verify the data. If repairs or adjustments are needed, take the corrective action and re-run the appropriate portions of the test.

3.8.4 Acceptance Test Procedure

Prepare and submit an Acceptance Test Procedure . Include the following elements in the procedure, at a minimum:

a. A list of names and contact information for key Contractor personnel who will be involved with the test.

b. A step-by-step procedure of each test to be performed. For each test to be performed, include the criteria that must be met for the test to be considered successful.

c. A list of equipment that will be used during the testing. Include up-to-date calibration certificates for each measurement instrument that will be used.

d. Sample copies of the data recording sheets that will be used.

3.8.5 Data Measurement and Recording

For each test, record a full set of calculated and measured readings.

Take measurements at 25% of rated speed, rated speed, and fast speed at no-load (hoists only). Take readings from the digital display unit of the associated VFD. Record values for output voltage, output current, and output frequency. For gantry and trolley drives, take concurrent readings from each motor to ensure that they are operating properly (synchronized). Record load cell indication for each hoist at test loads prescribed (100% and 125% capacity) as well intermediate loads (at a minimum 0, 25%, and 50% capacity) to verify accuracy of the load cells is within specified tolerances of Section 41 01 20.18 26 GANTRY CRANE

ELECTRICAL REHABILITATION.

In the following paragraphs, where operation of the hoist is prescribed to be operated in an "aggressive manner", this shall constitute, at a minimum:

a. Moving the master switch or pendant pushbutton from neutral/off to full speed without any delay.

b. Moving the master switch or pendant pushbutton from full speed in one direction to full speed in the opposite direction without pausing or delaying at any other position.

c. A combination master switch movements or pendant operation consisting of the motions described in the two bullet points above.

d. Quickly moving the master switch or operating the pendant controller between a low speed position and neutral/off in a repetitive manner.

3.8.6 No-Load Performance Test

Perform the following performance tests with no-load attached to the hoist:

(1) Hoist No-Load Performance - For all hoists, raise and lower the load blocks, exercise the entire speed range in each direction at normal speed, slow speed, and fast speed selections. Operate each hoist in an "aggressive manner" and verify proper tuning of the VFD as evidenced by smooth operation and no fault codes.

(2) Trolley Travel No-Load Performance - Operate each trolley in both directions over the entire length of the runway.