Amendment 0006 TechSpecs 20R0004.pdf

PROJECT TABLE OF CONTENTS

DIVISION 00 - PROCUREMENT AND CONTRACTING REQUIREMENTS

00 01 15.00 28 LIST OF DRAWINGS

DIVISION 01 - GENERAL REQUIREMENTS

01 00 00.00 28 GENERAL REQUIREMENTS

01 11 00.00 28 SUMMARY OF WORK

01 11 01.00 28 SUPPLEMENTARY REQUIREMENTS

01 14 00.10 28 PROJECT SITE RESTRICTIONS

01 14 00.90 28 INTEGRATING ANTITERRORISM (AT) AND OPERATIONS SECURITY

(OPSEC)

01 22 00.00 28 MEASUREMENT AND PAYMENT

01 32 01.00 28 PROJECT SCHEDULE

01 33 00 SUBMITTAL PROCEDURES

01 35 29.10 28 GOVERNMENTAL SAFETY REQUIREMENTS

01 42 00 SOURCES FOR REFERENCE PUBLICATIONS

01 45 01.00 28 RESIDENT MANAGEMENT SYSTEM CONTRACTOR MODE (RMS CM)

01 45 04.00 28 CONTRACTOR QUALITY CONTROL

01 51 00.00 28 TEMPORARY UTILITIES

01 55 10.00 28 CONTRACTOR WORK, ACCESS AND STORAGE AREAS

01 57 20.00 28 ENVIRONMENTAL PROTECTION

01 78 00.00 28 CLOSEOUT SUBMITTALS

01 78 23.00 28 OPERATION AND MAINTENANCE DATA

DIVISION 02 - EXISTING CONDITIONS

02 83 33.12 28 LEAD BASED PAINT (LBP) REMOVAL AND DISPOSAL

DIVISION 05 - METALS

05 05 23.17 26 STEEL WELDING AND FABRICATION

05 50 04.00 26 METALS: MATERIALS, PRODUCTS, AND MISCELLANEOUS ITEMS

DIVISION 09 - FINISHES

09 97 02.10 26 PAINTING: STEEL STRUCTURES

DIVISION 26 - ELECTRICAL

26 05 00.00 26 BASIC ELECTRICAL MATERIALS AND METHODS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

41 01 20.16 26 GANTRY CRANE DATA, SPARE PARTS, TESTING, AND TRAINING

41 01 20.17 26 GANTRY CRANE MECHANICAL AND STRUCTURAL REHABILITATION

41 01 20.18 26 GANTRY CRANE ELECTRICAL REHABILITATION

41 01 20.19 26 GANTRY CRANE STRUCTURAL APPURTENANCES

41 01 20.75 26 BELOW-THE-HOOK LIFTING DEVICES INSPECTION AND

CERTIFICATION

-- End of Project Table of Contents --

PROJECT TABLE OF CONTENTS

HLD Powerhouse Intake Gantry Crane Controls Upgrade W912EF20R0004 Amend- 0006 g4ecctgh Line Sections: 41 01 20.17 26 & 41 01 20.18 26 g4ecctgh Line Section: 41 01 20.75 26

THIS PAGE INTENTIONALLY LEFT BLANK

PROJECT TABLE OF CONTENTS

HLD Powerhouse Intake Gantry Crane Controls Upgrade W912EF20R0004 Amend- 0006

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 01 20.17 26

GANTRY CRANE MECHANICAL AND STRUCTURAL REHABILITATION

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

1.2 REFERENCES

1.3 SUBMITTALS

1.4 DESIGN CRITERIA

1.4.1 General

1.4.2 Data, Capacities, Speeds, and Travel

1.4.3 Design

1.4.4 Loading

1.4.4.1 General

1.4.5 Unit Stresses

1.4.5.1 Structural Components

1.4.5.2 Bolts

1.4.5.3 Welds

1.4.5.4 Detailing Requirements

1.4.5.5 Mechanical Parts of the Crane

1.4.5.6 Fatigue Design

1.4.5.7 Wire Rope Stresses

1.4.6 Use of Cast Iron

1.4.7 Connections

1.4.7.1 Shop and Field Connections

1.4.7.2 Welded Connections

1.4.7.3 Bolted Connections

1.5 SUBMISSION OF CRANE DESIGN DATA

1.5.1 General

1.5.1.1 Drawing Index

1.5.1.2 Bill of Materials/Schedule of Equipment

1.5.1.3 Drawings

1.5.1.3.1 Detailed Shop Drawings

1.5.1.4 Product Data

1.5.1.4.1 General

1.5.1.4.2 Type of Equipment and Quality

1.5.1.5 Design Calculations

1.5.1.5.1 Finite Element Analysis (FEA)

1.6 FINAL APPROVED VERSIONS OF CONTRACTOR PREPARED DRAWINGS AND FINAL

CALCULATIONS

1.6.1 Final Approved Versions of Contractor Prepared Drawings

1.7 FIELD MEASUREMENTS

1.8 REHABILITATION PROCEDURE

PART 2 PRODUCTS

2.1 LUBRICANTS

2.1.1 General

2.1.2 Gear Grease

2.1.3 New Lubricating Oil

2.1.4 New Grease

SECTION 41 01 20.17 26

g4ecctgh paragraph 1.4.7.1

2.2 WIRE ROPE FOR AUXILIARY HOISTS AND ACTUATING HOIST

2.3 TOOL HOISTS

2.3.1 General

2.3.2 Hoist

2.3.3 Tool Hoist Wire Rope Lubricant

2.3.4 Wall Mounted Cantilever Jib

2.4 DESICCANT BREATHERS FOR ALL GEARBOXES

2.5 SHAFT COUPLINGS

2.5.1 General

2.5.2 Configuration

2.6 BEARINGS

2.6.1 General

2.6.2 Anti-Friction

2.7 BIRD SCREENS FOR EXPANDED MAIN HOIST WIRE ROPE SLOTS

PART 3 EXECUTION

3.1 CLEANUP AND REMOVAL

3.1.1 Cleanup

3.1.1.1 Cleanup - Environmental Considerations

3.1.2 Removal

3.2 INITIAL PRE-WORK INSPECTION PROCEDURE

3.2.1 General

3.2.2 Open Gear Pre-Work Inspection

3.2.3 Speed Reducer Pre-Work Inspection

3.2.4 In-Service Speed Reducer Oil Test Report

3.2.5 Hoist Machinery Bearings Pre-Work Inspection

3.2.6 Hoist Machinery Bolt Torque Pre-Work Inspection Report

3.3 HOISTS

3.3.1 General

3.3.2 Auxiliary and Actuating Hoist Drums

3.3.3 Shear Blocks

3.3.4 Load Cells

3.3.5 Shaft Couplings

3.4 SPEED REDUCERS

3.5 MAIN TROLLEY AND AUXILIARY TROLLEY DRIVES

3.6 GANTRY DRIVES

3.7 STORM BRAKES

3.8 TUGGER HOISTS

3.9 SHAFT ALIGNMENT

3.10 DYNAMIC BALANCING OF MACHINERY

3.11 TOOL HOIST INSTALLATION AND TESTING

3.11.1 General

3.11.2 Operation Test

3.11.3 Load Test

3.11.4 Testing Report

3.12 MOUNTING BASES

3.12.1 Hoist Bases

3.12.2 Trolley Drive Bases

3.12.3 Gantry Drive Bases

3.13 MISCELLANEOUS ITEMS

3.14 NAMEPLATES AND CAPACITY PLATES

3.14.1 Crane Nameplates

3.14.2 Warning Labels

-- End of Section Table of Contents --

SECTION 41 01 20.17 26

g4ecctgh paragraph 3.12.1

SECTION 41 01 20.17 26

GANTRY CRANE MECHANICAL AND STRUCTURAL REHABILITATION

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

This SECTION covers the mechanical and structural work for the rehabilitation of the 111-ton capacity intake gantry crane at Ice Harbor Dam. Design all new, replaced, or modified systems and components of the crane and submit computations and drawings as stated in Paragraph "Submittals" below. Furnish detailed shop drawings showing all details required to fabricate and install new or modified mechanical and structural equipment. Contractor is responsible for any changes in material or quality which are necessary for products to conform with these specifications while maintaining clearances, fits, and alignment with existing equipment. No items may be considered purely replace-in-kind;

product data submittals, calculations, and drawings are required for all new components or modifications.

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 BEARING MANUFACTURERS ASSOCIATION (ABMA)

ABMA 8.2 (1999) Ball and Roller Bearing Mounting Accessories, Inch Design

ABMA 19.1 (1987; R 1999) Tapered Roller Bearings - Radial Metric Design

ABMA 19.2 (1994; R 1999) Tapered Roller Bearings - Radial Inch Design

ABMA 20 (1996) Radial Bearings of Ball, Cylindrical Roller and Spherical Roller Types Metric Design

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

AGMA 9005 (2002e) Industrial Gear Lubrication

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 (2017) Steel Construction Manual

ASME INTERNATIONAL (ASME)

ASME B30.2 (2017) Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, SECTION 41 01 20.17 26

Top Running Trolley Hoist)

ASME B30.16 (2017) Overhead Underhung and Stationary Hoists

ASTM INTERNATIONAL (ASTM)

ASTM A36/A36M (2014) Standard Specification for Carbon Structural Steel

ASTM A572/A572M (2015) Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

ASTM A992/A992M (2011; R 2015) Standard Specification for Structural Steel Shapes

ASTM D 445 (2006) Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and the Calculation of Dynamic Viscosity)

ASTM D 664 (2007) Standard Test Method for Acid Number of Petroleum Products by Potentiometric Titration

ASTM D 2509 (2003; R 2008) Standard Test Method for Measurement of Load-Carrying Capacity of Lubricating Grease (Timken Method)

ASTM D 4425 (2009) Standard Test Method for Oil Separation From Lubricating Grease by Centrifuging (Koppers Method)

ASTM D 4950 (2008) Standard Classification and Specification for Automotive Service Greases

ASTM D 5185 Determination of Additive Elements, Wear Metals, and Contaminants in Used Lubricating Oils and Determination of Selected Elements in Base Oils by Inductively Coupled Plasma Atomic Emission Spectrometry (ICP-AES)

ASTM D 6304 (2007) Standard Test Method for Determination of Water in Petroleum Products, Lubricating Oils, and Additives by Coulometric Karl Fischer Titration

ASTM E1571 (2011) Standard Practice for Electromagnetic Examination of Ferromagnetic Steel Wire Rope

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015) Structural Welding Code - Steel

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

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

ISO 11171 (1999; Corrigendum 1 2001) Hydraulic Fluid Power - Calibration of Automatic Particle Counters for Liquids - First Edition

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS RR-W-410 (Rev G) Wire Rope and Strand

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

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

Initial Pre-Work Inspection Procedure ; G, HDC

Field Measurements ; G, HDC

Rehabilitation Procedure ; G, HDC

Tool Hoist Testing Plan ; G, HDC

SD-02 Shop Drawings

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

SD-03 Product Data

Submit product data with Crane Design Data design package submittals under SD-05 Design Data.

Lubricants ; G, HDC Submit 30 days prior to initial inspection.

Shaft Couplings ; G, HDC

Desiccant Breathers ; G, HDC

Gantry Reducer Bearings ; G, HDC

Tool Hoist Product Information ; G, HDC

SD-05 Design Data

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

Crane Design Data ; G, HDC

Bolt Tension Chart ; G, HDC

Design Package Submittals ; G, HDC

Cantilever Jib Analysis ; G, HDC

Tool Hoist Design Data ; G, HDC

SD-06 Test Reports

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

Tool Hoist Test Report ; G, HDC

Speed Reducer Pre-Work Inspection Report ; G, HDC

Open Gear Pre-Work Inspection Report ; G, HDC

Hoist Machinery Bolt Torque Pre-Work Inspection Report ; G, HDC

Hoist Machinery Bearings Pre-Work Inspection Report ; G, HDC

In-Service Speed Reducer Oil Test Report ; G, HDC

Shaft Alignment Report ; G, HDC

Balance Quality Report ; G, HDC

Dynamic Balancing Report ; G, HDC

SD-07 Certificates

Wire Rope Certificates ; G, HDC

Registered Professional Mechanical Engineer ; G, HDC

Registered Professional Structural Engineer ; G, HDC

SD-11 Closeout Submittals

Final Approved Versions of Contractor Prepared Drawings ; G, HDC

Final Calculations ; G, HDC

1.4 DESIGN CRITERIA

1.4.1 General

Perform all rehabilitation work as specified and shown.

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

1.4.2 Data, Capacities, Speeds, and Travel

Data, capacities, travel distances, and rated speeds of the crane are as per Section 41 01 20.16 26 CRANE DATA, SPARE PARTS, TESTING, AND TRAINING.

1.4.3 Design

The contract drawings indicate the general arrangement and outline of the gantry and other pertinent features. Furnish the detailed design in conformity with the design criteria and other requirements specified herein. Submit design calculations and detailed shop drawings as per the requirements in Paragraph "Submission of Crane Design Data" and in accordance with the requirements of Section 01 33 00 SUBMITTAL PROCEDURES.

1.4.4 Loading

1.4.4.1 General

Base the design loads and speeds on the rated capacities specified in Section 41 01 20.16 26 CRANE DATA, SPARE PARTS, TESTING, AND TRAINING.

For the purpose of design of structural and mechanical parts, loads resulting from the maximum torque of the motors are defined as 200 percent of the rated full-load torque of the motor.

1.4.5 Unit Stresses

1.4.5.1 Structural Components

Allowable stresses in structural parts (except bolts and welds) for new or modified structural components are defined as the lesser of 45% of the yield or 75% of AISC 325 allowable stresses for ASTM A36/A36M, ASTM A992/A992M or ASTM A572/A572M grade 50 steel. Allowable stresses in structural parts not carrying primary loads must be designed to 100% of AISC 325 allowable stresses.

1.4.5.2 Bolts

Allowable stresses in bolts must be no more than 75% of AISC 325 allowable stresses. Allowable stresses in structural bolts not connecting members carrying primary loads must be designed to 100% of AISC 325 allowable stresses.

1.4.5.3 Welds

Design welded joints in accordance with the applicable provisions of AWS D1.1/D1.1M , except that allowable stresses in welds must be no more than 75% of AISC 325 allowable stresses. For designs where fatigue must be considered, allowable stresses must be the lesser of 75% of AISC 325 allowable stresses or the allowable stresses based on fatigue design provisions. Allowable stresses in welds not connecting members carrying primary loads must be designed to no more than 100% of AISC 325 allowable stresses.

1.4.5.4 Detailing Requirements

The detailing of structural components and connections must conform to the requirements of AISC 325 .

1.4.5.5 Mechanical Parts of the Crane

Design new or modified mechanical parts of the crane for rated load, with a factor of safety of 5 based on the ultimate strength of the materials, provided that each part or component, excluding wire rope, must be proportioned to withstand the stresses produced by the maximum torque of the motors with resultant stresses not exceeding 75 percent of the yield point of the materials involved.

1.4.5.6 Fatigue Design

Fatigue design must be addressed for conditions resulting in high numbers of load cycles inclusive excessive vibration. Use stress concentration factors where applicable. Reduce allowable stresses to compensate for repeated cycles of loading as necessary. For ancillary features, provide bracing and support such that excessive vibration does not occur during normal crane usage.

1.4.5.7 Wire Rope Stresses

For hoisting ropes, the maximum stress resulting from the rated load must be used and must take into consideration the overall efficiency of the hoist tackle in the blocks, wire rope fittings/connections/sockets, and other parts. The stresses must not be greater than 1/5 the nominal breaking strength of the rope. In addition, the rope tension resulting from the maximum torque of the motor selected must not exceed 0.7 of the nominal breaking strength of the rope.

1.4.6 Use of Cast Iron

Cast iron of a class less than 30 must not be used for any parts of the crane except for counterweights. Cast iron of class 30 or higher may be used for gear cases. Brake shoes and brake wheels must conform to materials specified in Section 41 01 20.18 26 GANTRY CRANE ELECTRICAL

REHABILITATION.

1.4.7 Connections

1.4.7.1 Shop and Field Connections

Accomplish all connections by either welding or bolting. Riveted connections are not permitted. For connections fabricated complete in the shop, design welded connections at all locations practicable. For connections which must be completed in the field, provide bolted connections. Field welding will not be accepted without written approval from the KO, with the exception of field welding required to install new shear blocks as shown and specified Field welding is not acceptable, excluding equipment mounting and when shop welding is not practical .

Avoid combining welds and bolts in the same connection. When bolts are used in combination with welds, bolts should not be considered as sharing loads in combination with the welds and the welds should be designed to carry the entire load. Connections that are welded to one member and bolted to another are permitted.

1.4.7.2 Welded Connections

Design welded connections in accordance with the applicable provisions of AWS D1.1/D1.1M , except that allowable unit stresses in paragraph "Unit Stresses" apply.

SECTION 41 01 20.17 26

g4ecctgh

1.4.7.3 Bolted Connections

Design of bolted connections in accordance with Section 05 05 23.17 26

STEEL WELDING AND FABRICATION, 05 50 04.00 26 METALS: MATERIALS, PRODUCTS,

AND MISCELLANEOUS ITEMS and as follows:

a. Machine bolts or fitted bolts must be used for assembly connections on machine parts, frames, attaching machine parts, and similar items.

b. Utilize structural bolts as defined in section 05 50 04.00 26 METALS: MATERIALS, PRODUCTS, AND MISCELLANEOUS ITEMS for structural bolted connections carrying primary loads, guardrails, gates, and similar structural items.

c. For all bolted connections, provide installation (torque) requirements in the design documents and on the shop drawings.

d. Coupling bolted joints must be assembled per manufacturer's instructions with manufacturer-supplied or recommended hardware.

1.5 SUBMISSION OF CRANE DESIGN DATA

1.5.1 General

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

a. Drawing Index

b. Bill of Materials/Schedule of Equipment

c. Drawings

d. Product Data

e. Design Calculations

Crane Design Data for a complete crane rehabilitation must be submitted in a logical order with the major components submitted first and the lesser components submitted afterwards. Examples of Crane Components or Systems include, but are not limited to those listed below:

1. Tugger Hoists

2. Tool Hoists on Wall Mounted Jib Booms with Winches

3. Shear Blocks

4. Storm Brakes

5. Wire Rope

6. Speed Reducer Breather Installation

7. Lubricants, Flushing, and Lubrication

8. Gantry Drive Rehabilitation (Including Storm Brakes)

All submittals for Crane Design Data must be uniquely categorized into Design Package Submittals and must be named based off the Crane Components or Systems. For example: "Crane Design Data - Tugger Hoists". A list of proposed design package submittals with schedule of submittal dates must be submitted no later than 30 calendar days after receipt of notice to proceed.

All mechanical computations and drawings submitted as part of the Crane

Design Data must be stamped and signed by a registered professional mechanical engineer who has done the design himself/herself or supervised and reviewed work if done by other engineers.

All structural computations and drawings submitted as part of the Crane Design Data must be stamped and signed by a registered professional structural engineer who is either licensed as a structural engineer and who has done the design himself/herself or supervised and reviewed work if done by other engineers.

Crane design data must be submitted no later than 90 calendar days prior to the 'crane taken out of service date' specified in FAR Clause 52.211-10.

1.5.1.1 Drawing Index

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

1.5.1.2 Bill of Materials/Schedule of Equipment

Bill of materials or parts lists must be included on the drawings, consisting of descriptive name (e.g. "new main hoist machinery base"), total quantity, manufacturer, part number, material type, size, and weight of item or equipment; or bill of materials must be drawings that are part of the drawing set, having a title block, border, and sheet number compatible with the drawing set. Bill of materials must provide a cross reference between manufacturer data and shop drawings.

1.5.1.3 Drawings

Submit design drawings for a complete crane rehabilitation for each major system and/or component for each crane as a whole. Drawings must be easily readable in half size format. Weights of items must be included on the drawings. Show assembly views and all details required for a complete crane rehabilitation, including but not being limited to layout and installation of all machinery. Each drawings which labels components with numbers from a Bill of Materials on a separate drawing must have a note referencing the drawing number of that Bill of Materials. Drawings must include detailed locations of all drilling required in structural members. Provide detailed drawings of any replaced components. Label components with descriptive names (e.g. "Auxiliary Trolley Tool Hoist Reinforcement"). Reference drawings used in the development of the Contractor prepared drawings must be noted on the drawing by listing the Resource drawing 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.

1.5.1.3.1 Detailed Shop Drawings

Detailed shop drawings must be submitted for approval prior to fabrication of all components. Drawings for individual components must reference an assembly drawing of the entire crane which shows clearances where pertinent. Each component must be labeled with an appropriate descriptive name (e.g. "Main Hoist Gear-Side Drum Bearing Stand"). When detailed drawings are submitted, they must be submitted with arrangement drawings and bill of materials/parts lists. Detail drawings for metalwork and machine work must include catalog cuts, templates, fabrication and assembly details and type, grade and class of material as appropriate.

1.5.1.4 Product Data

1.5.1.4.1 General

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

1.5.1.4.2 Type of Equipment and Quality

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

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

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

1.5.1.5 Design Calculations

Design calculations for new, replaced, and modified mechanical and structural components must be submitted for approval. Design calculations for new/replaced/modified components (or system of components) must be submitted concurrently with the drawings and product data specific to the designed component (or system of components). Calculations must include an introductory narrative paragraph describing the methodology for the analysis including the failure theories used and/or the codes and standards referenced, a list of assumptions made, equations, specified efficiencies, limits, factors of safety, component ratings, sources of values used, free body diagrams, or sketches of each load case.

Calculations must show that the rehabilitated crane meets the capacities and speeds as listed in Section 41 01 20.16 26 GANTRY CRANE DATA, SPARE

PARTS, TESTING, AND TRAINING.

1.5.1.5.1 Finite Element Analysis (FEA)

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

Present FEA in report format. FEA report must include clear indication of all load scenarios, visual and narrative description of load location and application, boundary conditions / fixtures, global mesh attributes, detailed mesh attributes where mesh refinement is required, reasoning for mesh refinement, verification that actual material is consistent with material used in the model, narrative explanation of any peak stresses noted, and narrative explanation of any peak deflections noted. Submit electronic files for any FEA performed (in the FEA software file type).

Accompany any FEA data submitted with sample written calculations that support the FEA analysis.

1.6 FINAL APPROVED VERSIONS OF CONTRACTOR PREPARED DRAWINGS AND FINAL

CALCULATIONS

1.6.1 Final Approved Versions of Contractor Prepared Drawings

Final Approved Versions of Contractor Prepared Drawings for the Intake Gantry Crane must be submitted. Final approved versions of Contractor prepared drawings must be submitted in accordance with Section 01 78 00.00 28 CLOSEOUT SUBMITTALS. Contractor prepared drawings must be updated if there are any outstanding comments. Modifications to approved Contractor prepared drawings made during fabrication and installation must be immediately recorded for inclusion into final versions of Contractor prepared drawings. A set of 11 by 17 inch final approved versions of Contractor prepared drawings must be inserted in the Operation and Maintenance Manuals, see Section 01 78 23.00 28 OPERATION AND MAINTENANCE DATA for requirements on the O&M manuals.

1.6.2 Final Calculations

Final Calculations must be submitted and approved prior to start of acceptance testing. All design calculations must be assembled with a table of contents and submitted for review to verify that all calculations have been assembled and to verify that they have incorporated all outstanding comments and changes to the design. When final calculations are submitted, each section must include reference to submittals where that section was approved with a "B" code or better. They must be called "Final Calculations." Upon approval of the final calculations, they must be inserted as a separate section in the Operation and Maintenance Manuals, see Section 01 78 23.00 28 OPERATION AND MAINTENANCE DATA for requirements on the O&M manuals. Submit one electronic copy, in the form of a bookmarked, page-numbered PDF on a marked DVD.

1.7 FIELD MEASUREMENTS

Field verify all elevations, dimensions, deck clearances and coordinates of existing features indicated on the contract drawings that affect the specified work. Before performing any design work, Contractor must become familiar with all details of the work, verify all dimensions in the field, and submit a letter describing the results of this verification including discrepancies to the KO. See contract drawings for identification of crane clearances, deck clearances, and dimensions to field measure (list of dimensions and clearances to field verify is not all inclusive).

1.8 REHABILITATION PROCEDURE

Submit a complete rehabilitation procedure for all work done on this job for approval before any work will be allowed to start. The procedure must include, but not be limited to the following:

a. Step-by-step rehabilitation procedure.

b. Schedule and sequence of work.

c. Types of equipment used on site, such as work platforms, cranes, and scissor lifts, for example.

d. Methods of removing and reinstalling components, including but not limited to main hoist drums and trolleys, if applicable.

e. Work area restrictions.

All components that can be fabricated and/or assembled prior to removing the crane from service must be furnished prior to the commencement of on-site work.

See Section 01 35 29.10 28 GOVERNMENT SAFETY PROCEDURES for the requirements on safety precautions during the rehabilitation.

PART 2 PRODUCTS

2.1 LUBRICANTS

2.1.1 General

For new and existing equipment, lubrication must be provided for gear trains and gear- or grid-type couplings, and other mechanical operating parts. The Government will provide lubricating oil for the existing speed reducers as detailed in paragraph 2.1.3 SPEED REDUCERS. Submit product data for approval for all lubricants to be replaced on the crane that are not provided by the Government. At a minimum, submit product data for lubrication for the following equipment:

- wire rope, for tool hoists, auxiliary hoists, and actuating hoist

- all gantry drive open gears

- all hoist open gears

- all replaced couplings

Lubricants must be acceptable to equipment manufacturers and must be compatible with lubricants already in use on the crane.

2.1.2 Gear Grease

Grease lubrication must be provided for all open gears.

For hoist open gears, trolley and gantry drive gears, lubricants must be compatible with what is currently used at the Project unless otherwise specified. The Project currently uses high film strength Chevron open gear grease.

2.1.3 New Lubricating Oil

New speed reducer lubricating oil will be provided by the Government for use by the Contractor to fill the speed reducers once inspection and flushing have been completed. Existing lubrication oil for the speed reducer is Chevron Meropa EP 150 gear oil.

2.1.4 New Grease

a. General purpose grease must be NLGI No. 2 high temperature Lithium complex type meeting the highest performance categories of ASTM D 4950

Automotive Grease Classification System, GC-LB. The grease must provide extreme pressure (EP) performance and be rated for high Timken O.K. load of 70 pounds minimum per ASTM D 2509 . The mineral oil viscosity must be 400 cSt at 40 degrees C and 24.3 cSt at 100 degrees C. The general purpose grease must be proven through thorough grease compatibility testing submitted for approval to be compatible with what is currently in use, unless otherwise approved by the COR.

b. Gear- or grid type couplings must use grease that is highly resistant to separation, with high viscosity and low bleed rates.

Minimum specifications include viscosity of 715 cSt at 40 degrees C and 38 cSt at 100 degrees C, NLGI Grade as recommended by coupling manufacturer, Timken extreme pressure (EP) O.K. Load of 40 pounds per ASTM D 2509 . Centrifugal separation must be K36s 2/24 maximum per ASTM D 4425 . Existing couplings must be cleaned of old grease before packing with new. All gear- or grid-type couplings must use long term grease (LTG) that has been proven through thorough grease compatibility testing submitted for approval to be compatible with what is currently in use, unless otherwise approved by the COR.

2.2 WIRE ROPE FOR AUXILIARY HOISTS AND ACTUATING HOIST

Field-verify wire rope length and diameter; for estimating purposes, approximately 680 feet of 5/8-inch diameter wire rope is needed for each auxiliary hoist and approximately 160 feet of 5/8-inch diameter wire rope is needed for the actuating hoist.

a. Wire rope must conform to the requirements of FS RR-W-410 , Type I, Class 3, 6x37 or 6x19 to match wire rope currently in service, construction optional, extra improved plow steel or extra extra improved plow steel, pre-formed, regular lay, uncoated, independent wire rope core. The wire ropes must be lubricated, both IWRC and the strands, during manufacture. All new hoist wire ropes must be the same size as existing wire ropes. Wire rope must be manufactured by a domestic wire rope manufacturer. Kinking of rope will be cause for rejection. A single broken wire in a "valley" between two strands will be cause for rejection.

b. Wire rope certificates must be submitted for review as well as included in the Operation and Maintenance Manuals, including but not limited to: chemical analysis of the wire, type and grade of wire rope, and wire rope tensile strength test-to-failure to verify the wire rope meets or exceeds FS RR-W-410 standards for nominal strength. Tensile strength test data must include but is not limited to certificate of calibration for the tensile testing machine, explanation of procedure, and results. The test must meet or exceed the requirements of paragraph 4.4.1.1 of FS RR-W-410 , using suitable tension testing equipment and qualified personnel, both furnished by the Contractor.

c. All new wire rope must be 100 percent tested with a magnetic flux leakage testing instrument for pre-existing wire rope defects, prior to installation. The magnetic flux leakage test must be performed in accordance with ASTM E1571. The measured LF value per ASTM E1571 must be approved by the wire rope manufacturer. Submit wire rope magnetic flux leakage test results (prior to installation) for approval at least 30 calendar days before installing the wire rope. A second magnetic flux leakage test must be performed after the wire rope is installed, and the results must be included in the Initial

Post-Rehabilitation Inspection Report, see SECTION 41 01 20.16 26

CRANE DATA, TESTING AND TRAINING.

d. Manufacture the wire rope with a lubricant on the core and outer strands. Wire rope lubricant on the outer strands must be an environmentally acceptable lubricant (EAL), clearly meeting EPA requirements. Examples of how to clearly demonstrate these requirements have been met are:

i. Wire rope lubricant is officially represented as being Vessel-General-Permit-compliant by the manufacturer.

ii. Wire rope lubricant is certified to have met the testing requirements in Appendix A of the Vessel General Permit (VGP) for biodegradation, toxicity, and non-bioaccumulation.

iii. Wire rope lubricant is OSPAR-approved.

iv. Wire rope lubricant has been granted EAL certification by the European Ecolable (EEL).

2.3 TOOL HOISTS

2.3.1 General

Provide two tool hoist assemblies, rated for 200 pounds each with the wire rope at its outer layer, and with sufficient wire rope length to lift from the intake deck to the elevation of (1) the auxiliary hoist trolley walkway and (2) the main hoist trolley walkway. Each hoist assembly must consist of a wall mounted jib boom mounted to the trolley with an electric wire rope hoist. The contract drawings show the required coverage and clearances above existing guardrails for the tool hoists. Electrical requirements for the tool hoists are provided in Section 41 01 20.18 26

GANTRY CRANE ELECTRICAL REHABILITATION.

Submit information including but not limited to detailed drawings and design calculations for each tool hoist assembly as a part of the Tool Hoist Design Data submittal.

2.3.2 Hoist

For each tool hoist, provide an electric winch attached to the fix end of the jib. Hoist must be operated by a control pendant. Hoist must be constructed from aluminum or steel with a corrosion-resistant coating. The hoist must incorporate upper and lower limit switches, a motor controlled brake and possess an IP55 rating or higher for weather resistance .

Covers must be provided over the gears for safety and exposure to outdoor conditions. Hoist drum must be designed for multiple wraps of wire rope.

The wire rope must be stainless steel.

Provide a galvanized steel housing permanently affixed to the end of the tool hoist jib boom to serve as a shelter or "doghouse" for the tool hoist. Submit detailed drawings and calculations for the hoist housing as a part of the Toll Hoist Design Data submittal. Submit Tool Hoist Product Information that details the electric winch to be installed.

2.3.3 Tool Hoist Wire Rope Lubricant

Tool hoist wire rope lubricant must be an environmentally approved lubricant (EAL). Wire rope lubricant on the outer strands must be an environmentally acceptable lubricant (EAL), clearly meeting EPA requirements. Examples of how to clearly demonstrate these requirements have been met are:

i. Wire rope lubricant is officially represented as being Vessel-General-Permit-compliant by the manufacturer.

ii. Wire rope lubricant is certified to have met the testing requirements in Appendix A of the Vessel General Permit (VGP) for biodegradation, toxicity, and non-bioaccumulation.

iii. Wire rope lubricant is OSPAR-approved.

iv. Wire rope lubricant has been granted EAL certification by the European Ecolable (EEL).

Submit product data for the tool hoist wire lubricant as a part of the Lubricants product data submittal.

2.3.4 Wall Mounted Cantilever Jib

For each tool hoist, provide a wall mounted cantilever type, monorail-boom jib to support the wire rope hoist. The jib boom must be comprised of a head assembly, a boom assembly, and a column assembly. The jib is conceptually shown on the contract drawings with required clearances. The jib must meet the requirements shown on the drawings, including those for guardrail clearances, and the following requirements:

a. The jib must have a load rating equal to or greater than the rating of the hoist plus the weight of the hoist. Provided that the jib is custom fabricated for installation as a part of this job, submit detailed design calculations with the Tool Hoist Design Data submittal. If the jib is commercially available off the shelf or otherwise pre-engineered, detailed design calculations of the jib are not required, but product data for the commercially available jib must be submitted. For both commercially available and custom fabricated jibs, submit detailed designs for the mounting of the jib to the crane structure. The detailed design of the jib (if required) and the detailed design of the jib mounting must both be reviewed and stamped by the contractor's registered structural professional engineer.

b. Mount the jib to the side of the main and aux trolley machinery housing as shown on the contract drawings. Provide analysis for the connection to the crane.

c. The jib must be capable of being manually rotated 180 degrees. The rotation mechanism must be able to be locked or otherwise parked in a position that allows un-obstructed lowering of the hook to the intake deck. The jib must have two locking positions - one in parked position and one perpendicular to the trolley. Provide stops for each jib to prevent the jib from contacting the when being placed in the stowed position.

d. Jib size and mounting location must be such so that hoist can reach the limits of coverage shown on the Contract Drawings. The jib base must not block or otherwise obstruct the walkway.

2.4 DESICCANT BREATHERS FOR ALL GEARBOXES

Each speed reducer on the crane (e.g. main hoist, auxiliary hoist, main trolley, auxiliary trolley, actuating hoist, gantry drives) must have a breather which removes dirt and moisture from the incoming air. The incoming air must first pass through a desiccant bed to remove the moisture, and then pass through a filter to eliminate the solid contaminants before entering the reservoir. Outgoing air must pass directly to the atmosphere through a check valve. The breather must also provide visual indication of the desiccant and filter condition.

Desiccant silica-gel breather units must contain approximately 1.0 lb of silica-gel desiccant and shall be capable of absorbing at least 6.0 fluid oz of water. The minimum airflow through the breather must be at least 15

CFM = 112 GPM.

2.5 SHAFT COUPLINGS

2.5.1 General

Use flanged-type shaft couplings, consisting of a pair of coupling halves. Select coupling sizes such that the couplings are capable of developing the full strength of the shafting which they connect. Select couplings using a service factor of at least 1.5, based on the torque developed at rated load. Provide couplings with the following salient features:

a. Make couplings and fasteners from steel.

b. For flexible coupling halves, use flanged sleeve, single-engagement, gear type, with fully crowned gear teeth.

c. Fasten coupling halves together with shrouded bolts with self locking nuts. Couplings with sleeves held in place, or retained, by snap rings will not be permitted.

d. On flexible couplings, provide a Buna-N o-ring seal to exclude foreign debris and retain lubricant. Couplings must be oil tight under both static and operating conditions.

e. Provide bores, with keyways, sized for an interference fit with the given shaft size.

f. Etch or engrave each coupling half with the manufacturer's name and part number.

2.5.2 Configuration

Shaft coupling configurations, consisting of two coupling halves, are defined as follows:

(1) Rigid - Both coupling halves are rigid

(2) Flex/Rigid - One coupling half is rigid, one is flexible

(3) Flexible - Both coupling halves are flexible

Determine coupling configuration in accordance with the recommendations of the coupling manufacturer. Clearly show coupling configuration on the shop drawings. Brake-wheel-coupling assemblies which consist of bolting brake wheel and coupling halves together are not allowed.

2.6 BEARINGS

2.6.1 General

Except where otherwise specified, antifriction bearings may be of the roller, ball, or sleeve type. Bearings must be so designed as to be easily replaceable and must be placed as close as possible to the points of loading. Where feasible, bearing bases for gear trains must be made in one piece to ensure that alignment and spacing will be maintained. Where welded construction is employed for bearing housing assemblies, pedestals or base spacers, the weldments must be stress relieved and the mounting surface and toe bottom of the bases machined flat and parallel to each other. Bearing fits must be as recommended by the manufacturer for the application. Bearing bases and pillow blocks must have solid steel bases (not cast iron) and must be held securely in place by one of the methods described in paragraph Bolted Connections.

2.6.2 Anti-Friction

Anti-friction bearings must be of standard types most suitable for the respective application and must have both inner and outer races. Ball and roller bearings must conform to the applicable requirements of the ABMA 19.1 , ABMA 19.2 and ABMA 20. The manufacturer's published ratings must be used in determining the bearing capacity. Bearings, except as noted below, must have a L-10 life of 5,000 hours and must be designed for the loads and speeds resulting from the crane performance specified in SECTION 41 01 20.16 26 . For wheel bearings, one bearing on each wheel axle must be of the fixed double-thrust type. The other bearing must be arranged to allow for expansion or float of the axle. On other bearings where thrust occurs, unless the design is such that the thrust on a bearing can be determined, the full thrust load must be added to each bearing on the shaft or axle. See Paragraph "Axles" for thrust load requirements. Bearings must have oil tight enclosures and, except for sheave bearings, must have double lipped seals; a synthetic rubber spring loaded element to retain the grease and another synthetic rubber element to exclude foreign matter.

(a) For bearings on the machinery deck for the hoist drums only, Contractor may choose to meet the requirements of paragraph (b) below, or to use an eccentric locking collar, self-aligning double row spherical roller bearing, with an external nut to eliminate axial movement.

(b) For all other bearings, including but not limited to crane wheel axle bearings: Fixed bearings must be secured against a shaft shoulder by means of a locknut and bearing lockwasher as described in ABMA 8.2 .

Floating bearings must be secured against a shaft shoulder by means of a retaining ring or locknut and lockwasher, except that floating bearings at intermediate points on long shafts may be secured with a tapered sleeve and locknut and lockwasher.

2.7 BIRD SCREENS FOR EXPANDED MAIN HOIST WIRE ROPE SLOTS

Provide rubber flaps or brushes similar to the existing to cover the expanded wire rope slots for the tugger hoists in the main trolley.

PART 3 EXECUTION

3.1 CLEANUP AND REMOVAL

3.1.1 Cleanup

All components of the gantry crane must be cleaned up during the rehabilitation regardless whether the contaminants were pre-existing or generated during rehabilitation. All grease, oil, dirt, dust, debris, and any other foreign objects must be cleaned up using appropriate cleanup methods. Cleanup methods include sweeping, vacuuming, wiping/washing using soap and water, or solvents. Additional cleanup requirements are specified in other paragraphs.

3.1.1.1 Cleanup - Environmental Considerations

Cleanup methods must be in compliance with Section 01 57 20.00 28 ENVIRONMENTAL PROTECTION. The Contractor must segregate the waste rags to reduce the volume of RCRA waste generated. For example: the first and second wipe rags go in one drum and the rest with PPE in another. The Contractor will not be permitted to use solvents or mixtures of solvents that generate F-listed, P-listed or U-listed waste.

3.1.2 Removal

Remove unused machinery bases, brackets and hangers for the hoist equipment,motor-generator sets, electrical cabinets and related equipment. Verify with Contracting Officer before removal of all equipment. The components must be removed in such a manner that will not damage the base metal. Areas where components are removed must be ground smooth with base material and repainted in accordance with Section 09 97 02.10 26 PAINTING: STEEL STRUCTURES. All work performed in the removal of equipment must be done in accordance with the applicable requirements specified in Section 01 57 20.00 28 ENVIRONMENTAL PROTECTION.

3.2 INITIAL PRE-WORK INSPECTION PROCEDURE

3.2.1 General

Prior to inspection, the contractor must provide inspector qualifications and perform inspections in accordance with Sections 05 05 23.17 26 STEEL WELDING AND FABRICATION and Section 41 01 20.16 26 GANTRY CRANE DATA< SPARE PARTS, TESTING, AND TRAINING. Also prior to inspection, gear grease lubricant product data submittal must be approved. Perform initial pre-work inspection within 90 days of the notice to proceed (NTP). Submit for approval a complete procedure on how the pre-work inspection will be performed. The procedure must include, but not be limited to the following:

a. Step-by-step details on how inspection will be performed.

b. Schedule and sequence of work, including any requests for Project crane operator support to operate hoists for the purposes of inspection.

c. Types of equipment used on site, such as work platforms, cranes, scissor lifts, borescope, calibrated torque wrenches, or stethoscope, for example.

d. Methods of accessing the inside of reducers and open gear trains, including but not limited to methods of removing and reinstalling main hoist gear covers and auxiliary hoist gear covers.

e. Calculated bolt tension chart of bolt torque values, using a Torque Factor "K" of 0.13, for all bolts in all hoist drum bearings and all bolts in all hoist pinion bearings and all bolts holding down hoist reducers. If a thread lubricant is used to install bolts, submit the lubricant type as well as the corresponding torque factor as a part of the bolt tension chart as well as on the Final Approved Versions of Contractor Prepared Drawings.

f. Work area restrictions.

Do not disassemble any components which are part of the hoist load path during any portion of the initial pre-work inspection. For instance, do not split the reducer case during initial inspection.

For all reports resulting from the initial pre-work inspection, provide narrative descriptions of findings, identified photographs with minimum 600 dpi quality and full-width on standard 8-1/2-inch wide documents, and relevant data and measurements.

3.2.2 Open Gear Pre-Work Inspection

For all open gears (i.e. gears not enclosed in speed reducer gearboxes), including gantry drive gears, auxiliary hoist gears, and main hoist gears, pre-work inspection must include but is not limited to: removal of upper gear cover; cleaning of gears and cover; 100% visual inspection of gears and visible portions of shafts, including but not limited to visual inspection for corrosion, wear, pitting, cracks, or distortion; fully re-grease gears with approved gear grease per "Lubricants" submittal;

re-install gear cover. Submit for approval an Open Gear Pre-Work Inspection Report , including but not limited to identified photographs of each open gear, together with narrative description of inspection procedure with particular attention to any findings of concern.

3.2.3 Speed Reducer Pre-Work Inspection

For the main hoist, auxiliary hoists, actuating hoist, and gantry drive speed reducers (but not for any trolley drive speed reducers), perform pre-work inspection. Conduct inspection of interior entirely through the inspection port/plate, using mirrors or a borescope as needed. Pre-work inspection must include but is not limited to the following: While hoist or drive is operating, use a mechanic's stethoscope or equivalent to listen to each reducer bearing and note any findings of concern. To the extent possible without disassembly or draining oil, perform 100% visual inspection of gears, shafts, and housing. Visually inspect for corrosion, wear, pitting, cracks, distortion, leaking bearing seals, or bent shafts.

Note the size and type of inspection cover gasket and hardware for future replacement. Note the best location for future installation of a desiccant breather. Take a sample of in-service speed reducer oil for analysis. Submit for approval an Speed Reducer Pre-Work Inspection Report , including but not limited to identified photographs of each speed reducer and best locations for breathers for each speed reducer, together with narrative description of inspection procedure with particular attention to any findings of concern. Trolley drive speed reducers may be excepted from the portions of this inspection which are impracticable due to access restrictions.

3.2.4 In-Service Speed Reducer Oil Test Report

Submit In-Service Speed Reducer Oil Test Report for approval. A laboratory analysis for each in-service oil sample from each speed reducer included in the pre-work inspection (all speed reducers except the trolley drives) must be performed in accordance with…