AM_8_Specifications_ _Attachment.pdf

Air Defense Improvements, Unspecified Worldwide 443309

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 22 13.13

BRIDGE CRANES Revised by Amendment 0008

PART 1 GENERAL

1.1 REFERENCES

1.2 DEFINITIONS

1.3 SYSTEM DESCRIPTION

1.3.1 Load and Sizing Calculations

1.3.2 OET Design Criteria

1.3.2.1 General

1.3.2.2 Classification

1.3.2.3 Rated Capacity and Speeds

1.4 SUBMITTALS

1.5 QUALITY ASSURANCE

1.5.1 Manufacturer Qualification

1.5.2 Pre-Delivery Inspections

1.5.3 Certificates

1.5.4 Overhead Electric Traveling (OET) Crane(s)

1.5.5 Welding Qualifications and Procedures

1.5.6 Safety Requirements

1.6 DELIVERY, STORAGE, AND HANDLING

1.7 EXTRA MATERIALS

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 General

2.1.2 Nameplates

2.1.3 Prohibited Use of Asbestos Products

2.1.4 Capacity Plates

2.1.5 Safety Warnings

2.2 STRUCTURAL MATERIALS

2.2.1 Bolts, Nuts and Washers

2.2.2 Bridge Girder or Girders

2.2.3 Bridge Rails or Bars

2.2.4 End Ties and Bridge Girder End Connections

2.2.5 Bridge End Trucks

2.2.6 Trolley Frame

2.2.7 End Stops and Bumpers

2.2.8 Footwalks

2.2.9 Runway Rails

2.3 MECHANICAL EQUIPMENT

2.3.1 Variable Frequency Drives

2.3.1.1 Bridge Drives

2.3.1.2 Trolley Drives

2.3.2 Gearing

2.3.2.1 Gear Reducers

2.3.2.2 Open Gearing

2.3.3 Brakes

2.3.3.1 Hoist Brake Time Delay

SECTION 41 22 13.13 Page 1 W912ER-16-R-0008 Amendment 0008

2.3.4 Wheels

2.3.5 Bearings

2.3.6 Anti-Drip Provisions

2.4 ELECTRICAL COMPONENTS

2.4.1 Control Systems

2.4.1.1 Travel Motion Control System

2.4.1.2 Drive Control System

2.4.2 Power Sources

2.4.2.1 System Supply Voltage

2.4.3 Motors

2.4.3.1 General Requirements for Motors

2.4.3.2 Not Used

2.4.3.3 Motor Enclosures

2.4.3.4 Motor Insulation and Time Rating

2.4.3.5 Bridge and Trolley Motor Insulation and Time Rating

2.4.4 Electric Brakes

2.4.4.1 Not Used

2.4.4.2 Not Used

2.4.4.3 Automatic Stop System

2.4.5 Control System

2.4.5.1 Control Panels

2.4.5.2 Bridge and Trolley Control

2.4.5.3 Drift Point

2.4.6 Pendant Control Station

2.4.6.1 General

2.4.6.2 Operating Pushbuttons

2.4.6.3 Light Indicators

2.4.6.4 Pendant Drive Control

2.4.7 Protection

2.4.7.1 Main Line Disconnect

2.4.7.2 Isolation Transformer

2.4.7.3 Surge Protection

2.4.7.4 Circuit Breakers

2.4.7.5 Overloads

2.4.8 Limit-Switches

2.4.8.1 Bridge and Trolley Travel Limit-Switches

2.4.9 Wiring

2.4.10 Electrification

2.4.10.1 Main Power Electrification

2.4.10.2 Crane Runway Conductors

2.4.10.3 Bridge Span Conductors

2.4.10.4 Pendant Festoon System

2.4.10.5 Pendant Drive System

2.4.11 Special Requirements

2.4.11.1 Warning Horn

2.4.11.2 Accessory Power

2.4.11.3 Receptacles

2.4.11.4 Lighting

2.4.11.5 Electrically-Driven Oil Pump Alarm

2.4.12 Load-Limit System

2.4.12.1 Load-Sensing Electronics

2.4.12.2 Alarm and Indicator Light

2.4.13 Fungus Resistance

2.5 ELECTROMAGNETIC INTERFERENCE SUPPRESSION

2.5.1 Shielded Cable

2.5.2 EMI/RFI Shielded Boxes

2.5.2.1 General

2.5.2.2 Construction

2.5.2.3 Attenuation

SECTION 41 22 13.13 Page 2

2.5.2.4 Finish

2.5.3 Drum Grounding

PART 3 EXECUTION

3.1 EXAMINATION

3.2 ERECTION

3.2.1 Shop Assembly

3.2.2 Mechanical Alignment

3.2.3 Electrical Alignment

3.2.4 Welding

3.2.5 Field Painting

3.3 ACCEPTANCE TESTING

3.3.1 General

3.3.1.1 Test Sequence

3.3.1.2 Test Data

3.3.1.3 Equipment Monitoring

3.3.2 Trolley Travel

3.3.3 Bridge Travel

3.3.4 Bridge Crane Tests

3.3.4.1 Dynamic Load Tests

3.3.4.2 Trolley and Bridge Loss of Power Test

3.3.5 Overload Tests

3.3.6 Acceleration and Deceleration Tests

3.3.7 Grounding Test

3.3.8 Adjustments and Repairs

3.4 SCHEMATIC DIAGRAMS

3.5 MANUFACTURER'S FIELD SERVICE REPRESENTATIVE

3.6 OPERATION AND MAINTENANCE MANUALS

3.7 FIELD TRAINING

3.8 FINAL ACCEPTANCE

3.9 ATTACHMENT

-- End of Section Table of Contents --

SECTION 41 22 13.13 Page 3

SECTION 41 22 13.13

BRIDGE CRANES

Revised by Amendment 0008

PART 1 GENERAL

1.1 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.

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

AGMA ISO 10064-6 (2010A) Code of Inspection Practice - Part 6: Bevel Gear Measurement Methods

AGMA ISO 17485 (2008A; Supplement 2008) Bevel Gears - ISO System of Accuracy (Including Supplement - Tolerance Tables 2008)

ANSI/AGMA 2001 (2004D; R 2010) Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth

ANSI/AGMA 2011 (2014B) Cylindrical Wormgearing Tolerance and Inspection Methods

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

ANSI/AGMA 6113 (2006A; R 2011) Standard for Industrial Enclosed Gear Drives (Metric Edition)

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 (2011) Steel Construction Manual

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2010; Errata 2011) Structural Welding Code - Steel

AWS D14.1/D14.1M (2005) Specification for Welding Industrial and Mill Cranes and Other Material Handling Equipment

ASME INTERNATIONAL (ASME)

ASME B30.10 (2014) Hooks

ASME B30.16 (2012) Overhead Hoists (Underhung)

ASME B30.17 (2006; R 2012) Overhead and Gantry Cranes

SECTION 41 22 13.13 Page 4

(Top Running Bridge, Single Girder, Underhung Hoists)

ASME B30.2 (2011) Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist)

ASME HST-1 (2012) Performance Standard for Electric Chain Hoists

ASME HST-4 (1999; R 2010) Performance Standard for Overhead Electric Wire Rope Hoists

ASTM INTERNATIONAL (ASTM)

ASTM A1023/A1023M (2009; E 2012) Standard Specification for Stranded Carbon Steel Wire Ropes for General Purposes

ASTM A159 (1983; R 2011) Standard Specification for Automotive Gray Iron Castings

ASTM A275/A275M (2015) Standard Test Method for Magnetic Particle Examination of Steel Forgings

ASTM A307 (2014) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength

ASTM A325M (2014) Standard Specification for Structural Bolts, Steel, Heat Treated, 830 MPa Minimum Tensile Strength (Metric)

ASTM A490M (2014a) Standard Specification for High-Strength Steel Bolts, Classes 10.9 and 10.9.3, for Structural Steel Joints (Metric)

ASTM A563M (2007; R 2013) Standard Specification for Carbon and Alloy Steel Nuts (Metric)

ASTM A668/A668M (2015) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM A931 (2008; R 2013) Standard Test Method for Tension Testing of Wire Ropes and Strand

ASTM B438 (2013) Standard Specification for Sintered Bronze Bearings (Oil Impregnated)

ASTM B439 (2008) Standard Specification for Iron-Base Sintered Bearings (Oil-Impregnated)

ASTM B633 (2013) Standard Specification for Electrodeposited Coatings of Zinc on Iron and Steel

SECTION 41 22 13.13 Page 5

ASTM E125 (1963; R 2013) Photographs for Magnetic Particle Indications on Ferrous Castings

ASTM F436M (2011) Hardened Steel Washers (Metric)

ASTM F959M (2013) Compressible-Washer-Type Direct Tension Indicators for Use with Structural Fasteners (Metric)

CRANE MANUFACTURERS ASSOCIATION OF AMERICA (CMAA)

CMAA 70 (2010) Specification for Top Running Bridge and Gantry Type Multiple Girder Electric Overhead Traveling Cranes, No. 70

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2014) Enclosures for Electrical Equipment (1000 Volts Maximum)

NEMA ICS 2 (2000; R 2005; Errata 2008) Standard for Controllers, Contactors, and Overload Relays Rated 600 V

NEMA ICS 3 (2005; R 2010) Medium-Voltage Controllers Rated 2001 to 7200 V AC

NEMA ICS 5 (2000; R 2010) Control Circuit and Pilot Devices

NEMA ICS 6 (1993; R 2011) Enclosures

NEMA ICS 8 (2011) Crane and Hoist Controllers

NEMA MG 1 (2014) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2014; AMD 1 2013; Errata 1 2013; AMD 2 2013; Errata 2 2013; AMD 3 2014; Errata 3-4 2014; AMD 4-6 2014) National Electrical Code

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC SP 6/NACE No.3 (2007) Commercial Blast Cleaning

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910 Occupational Safety and Health Standards

29 CFR 1910.179 Overhead and Gantry Cranes

29 CFR 1910.306 Specific Purpose Equipment and Installations

UNDERWRITERS LABORATORIES (UL)

UL 1004-1 (2012; Reprint Sep 2013) Standard for

SECTION 41 22 13.13 Page 6

Safety Rotating Electrical Machines

UL 1449 (2014;Reprint Mar 2015) Surge Protective Devices

UL 489 (2013; Reprint Mar 2014) Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit-Breaker Enclosures

UL 50 (2007; Reprint Apr 2012) Enclosures for Electrical Equipment, Non-environmental Considerations

1.2 DEFINITIONS

a. Crane Bridge: That part of an overhead crane system consisting of girder(s), end trucks, end ties, walkway, and drive mechanism which carries the trolley(s) and travels along the runway rails parallel to the runway.

b. Crane Runway: The track system along which the crane operates horizontally, including track hangar rods, track connection devices, and runway structural supports.

c. Dead Loads: The loads on a structure which remain in a fixed position relative to the structure.

d. Girder: The principal horizontal beam of the crane bridge. It is supported by the crane end trucks. Normally the crane trolley mounted hoist is suspended from the girder below the crane.

e. Live Load: A load which moves relative to the structure under consideration.

f. Pendant: A control for a hoist and/or a crane. The pendant hangs from the hoist or the crane by a cable at a height that is easy for the operator to reach.

g. Rated Load: For the purpose of this specification the rated load is defined as the maximum working load suspended under the load hook.

Load block and wire ropes, conforming to ASTM A1023/A1023M and ASTM A931 are not included in the rated load.

h. Standard Commercial Cataloged Product: A product which is currently being sold, or previously has been sold, in substantial quantities to the general public, industry or Government in the course of normal business operations. Models, samples, prototypes or experimental units do not meet this definition. The term "cataloged" as specified in this section is defined as "appearing on the manufacturer's published product data sheets. These data sheets should have been published or copyrighted prior to the issue date of this solicitation bearing a document identification number or bulletin number.

i. Top Running Crane: An electric overhead traveling crane that runs on rails on top of support beams. The load is supported by the entire cross-section of the beam.

j. Trolley Mounted Hoist: A combined unit consisting of a wheeled trolley that provides horizontal motion along the bridge girder, and a

SECTION 41 22 13.13 Page 7 hoist suspended from the trolley, that provides lifting and lowering of a freely suspended load.

k. Under running (Underhung) Crane: An electric overhead traveling crane that is supported by crane end trucks suspended below the crane runway. The load is supported by hanging from the lower flange of a beam.

1.3 SYSTEM DESCRIPTION

The requirements for the crane runway and rail supporting structures are to be designed by the Contractor in accordance with the requirements of the bridge crane manufacturer's requirements, specified in Section 05 12 00 STRUCTURAL STEEL, and Section 13 34 19 METAL BUILDING SYSTEMS.

1.3.1 Load and Sizing Calculations

Submit complete list of equipment and materials, including manufacturer's descriptive data and technical literature, performance charts and curves, catalog cuts, and installation instructions. Submit calculations verifying the sizing of the bridge girder, end trucks and travel drives.

Include seismic analysis of bridge girder and end trucks.

1.3.2 OET Design Criteria

Cranes will operate in the given spaces and match the runway dimensions and rails indicated. Hook coverage, hook vertical travel, clear hook height, lifting capacity, and load test weight shall not be less than that indicated.

1.3.2.1 General

Include the following: Number of cranes 1, located in building identified as Maintenance High Bay, with the capacity expressed in 10.2 metric tons, for each OET. Also clearly locate and identify each multiple girder hoist and system components.

1.3.2.2 Classification

Provide crane designed and constructed to CMAA 70 Class C, moderate service requirements for operation in indoor environment with multiple girder hoist system with electric wire rope hoist conforming to ASME HST-4.

1.3.2.3 Rated Capacity and Speeds

Provide crane with rated capacity of 10.2 metric tons. Lower load block or assembly of hook, swivel bearing sheaves, pins and frame suspended by the hoisting ropes are not considered part of the rated capacity. Rated speeds (in meters/second) for the hoist, bridge and trolley at the rated load are as follows:

SECTION 41 22 13.13 Page 8

Rated Speeds meters per second

Description Minimum Maximum

Main Hoist .05 .23

Trolley .25 .64

Bridge .51 .89

1.4 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Overhead Electric Traveling (OET) Crane(s); G M

Crane runway system; G M

Complete schematic wiring diagram; G M

Description of operation.

SD-03 Product Data

OET Design Criteria; G M

Overhead Electric Traveling (OET) Crane(s); G M

Load and Sizing Calculations; G M

Festoon System; G M

Runway Electrification System; G M

Variable Frequency Drives; G M

Bumpers; G M

End Stops; G M

Spare Parts; G R

Framed Instructions; G R

Nameplates; G R

Including all information called for in NFPA 70 , Section 430.7.

Pendant Control Station; G M

Overloads; G M

SECTION 41 22 13.13 Page 9

Limit Switches; G M

SD-06 Test Reports

Acceptance Testing; G M

Hook Assembly; G M

Including Hook Proof Test and Hook and Nut non-destructive Test Report.

SD-07 Certificates

Overload Test Certificate; G M

No Hazardous Material; G M

Loss of Power Test; G M

Crane Runway System; G M

Certificate of Compliance; G M

Including listed Standards.

Wire Ropes; G M

Including Manufacturer's Certificate of Breaking Strength.

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals

1.5 QUALITY ASSURANCE

1.5.1 Manufacturer Qualification

Overhead Electric Traveling (OET) Crane(s) shall be designed and manufactured by a company with a minimum of 10 years of specialized experience in designing and manufacturing the type of overhead crane required to meet requirements of the Contract Documents.

1.5.2 Pre-Delivery Inspections

Contractor is responsible for performance of quality control inspections, testing and documentation of steel castings, hook assembly and nuclear safety as follows. Submit all crane test data recorded on appropriate test record forms suitable for retention for the life of the crane.

Visually inspect and test load-carrying steel castings ASTM A668/A668M using the magnetic-particle inspection method per ASTM A275/A275M .

Reference allowable degree of discontinuities to ASTM E125, and relationship to service loads and stresses, critical configuration, location and type. Methods of repairing the discontinuities is subject to review by the Contracting Officer.

1.5.3 Certificates

Submit an Overload Test Certificate stating that the crane can be periodically load tested to 125 percent (plus 5 to minus 0) of rated load.

SECTION 41 22 13.13 Page 10

Also submit the following certificates:

a. stating that No Hazardous Material is contained within system or components.

b. stating that the system is safe to perform a Loss of Power Test

c. stating that the Crane Runway System conforms to the requirements as specified herein and as specified in Section 05 12 00 STRUCTURAL STEEL.

d. Certificate of Compliance with listed Standards.

1.5.4 Overhead Electric Traveling (OET) Crane(s)

a. Submit shop drawings showing the general arrangement of all components in plan, elevation, and end views; hook approaches on all four sides, clearances and principal dimensions, assemblies of hoist, trolley and bridge drives, and complete schematic wiring diagram with description of operation, and Runway Electrification System. Include weights of components and maximum bridge wheel loads and spacing.

b. Shop drawing quality shall be equivalent to the contract drawings accompanying this solicitation.

c. Provide integral schedule of crane components on each drawing.

Provide maximum wheel loads (without impact) and spacing imparted to the crane runway system track beams. Indicate the crane speeds along the runway, the trolley speeds along the bridge girder, and the multiple girder hoist lifting speeds; all speeds indicated are speeds with hoist loaded with rated crane capacity load.

1.5.5 Welding Qualifications and Procedures

Perform welding in accordance with qualified procedures using AWS D14.1/D14.1M as modified. Written welding procedures shall specify the Contractor's standard dimensional tolerances for deviation from camber and sweep and not exceed those specified in AWS D14.1/D14.1M . Perform all welding indoors. Qualify welders and welding operators in accordance with AWS D1.1/D1.1M or AWS D14.1/D14.1M . Allowable stress values shall comply with CMAA 70.

1.5.6 Safety Requirements

Comply with the mandatory and advisory safety requirements of ASME B30.2 , ASME B30.10 , ASME B30.16 , ASME HST-1, ASME HST-4, NFPA 70 , 29 CFR 1910 , 29 CFR 1910.179 , and 29 CFR 1910.306 . Submit analysis and test reports to Contracting Officer for approval.

1.6 DELIVERY, STORAGE, AND HANDLING

Protect all delivered and stored equipment from the weather, humidity, temperature variations, dirt and dust, and other contaminants.

1.7 EXTRA MATERIALS

Submit spare parts data for each different item of material and equipment specified and/or as recommended by the manufacturer, after approval of the detail drawings and not later than three (3) months prior to the date of beneficial occupancy. Include in data a complete list of parts and

SECTION 41 22 13.13 Page 11 supplies, with current unit prices and source of supply. Furnish and deliver one set of manufacturer's recommended spare parts to the site.

Suitably package the spare parts for long-term protection and storage.

Legibly label the packaging to identify the spare parts. Also include a list of the furnished spare parts in the Maintenance manual.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 General

Provide materials and equipment which are standard products of manufacturers regularly engaged in the fabrication of complete and totally functional cranes including necessary ancillary equipment.

2.1.2 Nameplates

Secure nameplates to each major component of equipment with the manufacturer's name, address, type or style, model or catalog number, and serial number. Provide two bridge identification plates, one for each side of bridge. Provide noncorrosive metal identification plates with letters which are easily read from the floor, showing a separate number such as BC-1, BC-2, for each bridge crane.

2.1.3 Prohibited Use of Asbestos Products

Provide materials and products, required for designing and manufacturing cranes, which do not contain asbestos.

2.1.4 Capacity Plates

Two capacity plates indicating the crane capacity in metric tons and tons kilograms are required, one secured to each side of bridge. Fabricate each capacity plate with a steel backing plate and exterior quality/fade-resistant stick-on labels with letters large enough to be easily read from the floor. Place capacity plates in a location visible to pendant operator's position after the crane has been installed.

2.1.5 Safety Warnings

Affix labels in a readable position to each lift block or control pendant in accordance with ASME B30.16 , ASME B30.2 and ASME B30.17 . Submit safety warnings, diagrams and other framed instructions suitably framed and protected for display as indicated by the Contracting Officer as follows:

a. Design and locate the word "WARNING" or other legend to bring the label to the attention of the operator. Provide durable type warning labels and display the following information concerning safe-operating procedures: Cautionary language against lifting more than the rated load; operating the hoist when the hook is not centered under the hoist; operating hoist with twisted, kinked or damaged rope; operating damaged or malfunctioning hoist; operating a rope hoist with a rope that is not properly seated in its hoist drum groove; lifting people;

lifting loads over people; and removing or obscuring the warning label.

b. To avoid operation of crane in the wrong direction, affix the words "FORWARD" and "REVERSE" and accompanying directional arrows in a location on the trolley and bridge which are visible and readable to

SECTION 41 22 13.13 Page 12 the operator from pendant station. The words "FORWARD" and "REVERSE" shall agree with the markings on control pendant. Do not indicate directional arrows on control pendant.

2.2 STRUCTURAL MATERIALS

2.2.1 Bolts, Nuts and Washers

High-strength bolted connections shall be SAE Grade 5 bolts with corresponding lockwashers, ASTM F436M, nuts ASTM A563M, etc., conforming to requirements of AISC 325 bolts. Bolts, nuts and washers ASTM F959M shall conform to ASTM A325M bolts or ASTM A307. Galvanized bolts are not acceptable. Do not use ASTM A490M bolts.

2.2.2 Bridge Girder or Girders

Provide welded structural steel box section bridge girders.

2.2.3 Bridge Rails or Bars

Trolley runway rails, crane girders and other sections shall be straight and true. When loaded with motor driven cranes the deflection of rails shall not exceed 1/800 of the span. Calculate the deflection with the worst case of two loaded bridge cranes located adjacent each other. Make all rail joints flush and true without misalignment of running tread and design to minimize vibration. The gap between adjacent rail ends and the vertical misalignment of running treads shall not exceed 1.588 mm. Level the bridge rail to a plus-or-minus 3 mm at all rail support joints.

Fasten bridge rail to top cover plate, wide flange, or centered on flange or offset near web plate for welded box sections, complete with welded clips. Bolt bridge rail joints using standard joint bars. Stagger rail joints. Provide a positive stop at bridge rail ends to prevent creep.

2.2.4 End Ties and Bridge Girder End Connections

Use welded steel box sections for end ties. Provide full depth diaphragms at girder connections and jacking points. Provide horizontal gusset plates at the elevation of top and bottom end tie flanges for connection to girder ends. Make end connections with high-strength bolts. Use body-bound bolts fitted in drilled and reamed holes to maintain the crane square.

2.2.5 Bridge End Trucks

Provide fixed axle type end trucks fabricated of structural tubes or from structural steel to provide a rigid box section structure. Provide jacking pads for removal of wheel assemblies.

2.2.6 Trolley Frame

Provide trolley frame consisting of two structural steel side frames or trucks welded together with one or more structural steel load girts to form a one-piece unit. Provide pads for the use of jacks or wedges when changing truck wheels. Make all trolley yokes and load bars of drop forged, cast or rolled steel.

2.2.7 End Stops and Bumpers

Fit crane runways and bridge girders with structural steel end stops. Fit

SECTION 41 22 13.13 Page 13 bridge end trucks and trolley frames with shock-absorbing, bumpers capable of decelerating and stopping the bridge and/or trolley within the limits stated by OSHA and MHI CMAA. Provide trolley end stops of sufficient strength to withstand the impact of a fully loaded trolley moving at 50 percent of maximum rated travel speed. When two bridge cranes are on the same runway, one crane shall be fitted with shock-absorbing bumpers on each end of each end-truck, and the other crane shall have shock-absorbing bumpers as per above on one end only of each end-truck which is the opposite end of the adjacent crane. Fit the other end of the end-truck with a structural steel stop to engage the bumpers of the adjacent crane. Provide bridge bumper stops as specified in Section 05 12 00 STRUCTURAL STEEL. Locate stops to permit maximum bridge and trolley travel.

2.2.8 Footwalks

Set the location and construction of footwalks conforming to ASME B30.2 .

A full-length structural platform is required on the driver's side of the bridge. Provide checkered steel flooring for platform, double member handrail and a suitable toe-guard, with 760 mm clearance in front of control equipment. Minimum 380 mm clearance is required in front of bridge machinery. To give access to the opposite side of the trolley, bridge conductors, or other equipment, mount a footwalk twice the length of the trolley on the opposite side of the crane. Provide a cross-over footwalk over an end tie between the two girder footwalks. Mate the drive side footwalk with the crane access platform. The length of the drive side footwalk shall be along the entire length of the bridge. Provide safety handrails for footwalks.

2.2.9 Runway Rails

Provide runway rail size as specified in Section 05 12 00 STRUCTURAL STEEL.

2.3 MECHANICAL EQUIPMENT

2.3.1 Variable Frequency Drives

2.3.1.1 Bridge Drives

Provide bridge drive arrangement as specified in CMAA 70, consisting of a single electric motor mechanically connected through gear reduction and drive shafts to the drive wheels or separate drive motors at each end of bridge. Acceleration and deceleration shall meet the requirements specified in this section. Gears shall conform to applicable AGMA standards. Gear reducers shall be oil tight and fully enclosed with pressure or splash type lubrication. Bridge-travel limit-switches are optional.

2.3.1.2 Trolley Drives

Provide complete trolley drive arrangement with a minimum of two wheels driven by an integral electric motor. Provide drive mechanism which runs in totally enclosed oil bath. Limit switches are optional for drive mechanism. Provide acceleration and deceleration controls meeting the requirements specified in this section.

2.3.2 Gearing

Provide enclosed gear reducers type gearing. Gears and pinions shall be

SECTION 41 22 13.13 Page 14 spur, helical, or herringbone type only, and be forged, cast or rolled steel. Open-type gearing is not acceptable, except for final drives.

Provide gears and pinions with adequate strength and durability for the crane service class and manufactured to ANSI/AGMA 2001 Quality Class 6 or better precision per AGMA ISO 10064-6 , AGMA ISO 17485 , ANSI/AGMA 2011 , or

ANSI/AGMA 2015-1 .

2.3.2.1 Gear Reducers

Provide gear reducers which are integral components of standard hoists or hoist/trolley units of manufacturers regularly engaged in the design and manufacture of hoists or hoist/trolley units for Class A, B or C cranes.

Provide gear reducers designed, manufactured and rated in accordance with ANSI/AGMA 6113 (for trolley drives only), as applicable. Except for final reduction, provide the gear reduction units with fully enclosed in oil-tight housing. Design gearing to AGMA standards and to operate in an oil bath. Operation shall be smooth and quiet.

2.3.2.2 Open Gearing

Provide gears and pinions possessing adequate strength and durability for the crane service class and manufactured to ANSI/AGMA 2001 quality class 6 or better precision per AGMA ISO 10064-6 , AGMA ISO 17485 , ANSI/AGMA 2011 , or ANSI/AGMA 2015-1 . Enclose open gears with safety guard removable covers over openings for inspection and access for grease lubrication.

2.3.3 Brakes

a. In addition to the requirements of CMAA 70, provide shoe, disc, or conical type brakes with thermal capacity suitable for class and service specified in this section. Shoe, disc, and conical brakes shall be spring-set and electrically-released by a continuously rated direct acting magnet. Provide brakes which are self-aligning and easily adjusted for torque setting and lining wear. Brake lining material shall be asbestos free. Provide cast iron brake wheels conforming to ASTM A159 or the manufacturer's standard high-strength ductile cast-iron brake wheels, provided that the material exhibits wear characteristics in the form of powdered wear particles and is resistant to heat-checking. Disc brakes shall be totally enclosed and have multiple discs with stationary releasing magnets. Provide brake torque easily adjustable over a 2:1 torque range.

b. Provide bridge braking system with a spring-applied and electrically-released single shoe, disc, or conical brake for each bridge drive motor. Provide braking system which automatically sets when controls are released or power is interrupted. Make provisions to facilitate easy brake adjustment. Provide brakes with a torque rating of at least 50 percent of bridge drive motor rated torque.

2.3.3.1 Hoist Brake Time Delay

Provide one of the hoist holding brakes with a time-delay setting (from 1 to 3 seconds). The time-delay shall be initiated upon releasing the control pushbutton or returning the master switch to OFF. Operation of mainline POWER-OFF pushbutton or power failure shall result in each hoist brake's setting without any time-delay.

SECTION 41 22 13.13 Page 15

2.3.4 Wheels

Provide wheels manufactured of rolled or forged steel. Provide double-flanged Bridge and trolley wheels. Trolley and bridge wheels shall have straight treads. Equip wheels with self-aligning double-row spherical roller-bearings of capacity as recommended by bearing manufacturer for design load of trolley or bridge.

2.3.5 Bearings

All bearings, except those subject to a small rocker motion, shall be anti-friction type. Provide a means for lubrication for bearings not considered lifetime lubricated by the manufacturer. Equip equalizer sheaves with sintered oil-impregnated type bushings in accordance with ASTM B438 or ASTM B439.

2.3.6 Anti-Drip Provisions

Design cranes to preclude leakage of lubricants onto the lifted loads, floor, or external grounds. Fit all equipment and components which cannot be made leak-proof with suitable drip pans. Drip pans shall be manufactured of steel and designed to permit removal of collected lubricant.

2.4 ELECTRICAL COMPONENTS

2.4.1 Control Systems

Provide controller with overload protection in conformance with the requirements of NEMA ICS 2 or NEMA ICS 3 . Mechanically and electrically interlock contactors that are used for starting, stopping, and reversing.

2.4.1.1 Travel Motion Control System

Provide AC inverter duty, totally enclosed non-ventilated (TENV), squirrel cage induction type bridge and trolley and hoist drive motors. All motors shall have 60 minute duty rating minimum. Provide Class H insulation with Class B temperature rise.

2.4.1.2 Drive Control System

Provide static reversing, adjustable frequency controllers for the trolley and bridge infinitely variable electric drives. Provide dynamic braking.

Provide minimum two step infinitely variable speed control for the bridge and trolley and hoist functions, controlled via pendant pushbuttons. The trolley, and bridge brakes shall set after associated controller decelerates motor to a controlled stop. Size the bridge and trolley controllers to provide sufficient starting torque to initiate motion of that crane drive mechanism from standstill with 0 to 131.25 percent of rated load on the hook and not produce any hook rollback. Drive motors shall run smoothly, without torque pulsations at the lowest speed, and be energized at a frequency not exceeding 60 HZ.

2.4.2 Power Sources

2.4.2.1 System Supply Voltage

Design cranes to be operated from a 415 volt, three-phase, 50 Hz, alternating current system power source. Design energy isolating devices

SECTION 41 22 13.13 Page 16 for such machine or equipment to accept a lockout device in accordance with NFPA 70 .

2.4.3 Motors

2.4.3.1 General Requirements for Motors

a. Provide motors designed specifically for crane and hoist duty.

Provide drain holes at low points near each end. Provide inspection and service covers with gaskets. Hardware shall be corrosion-resistant. Provide motors conforming to the requirements of NFPA 70 , NEMA MG 1 and UL 1004-1 .

b. Motor heaters shall energize when mainline contactor is de-energized, and water heaters de-energize when mainline contactor is de-energized. Provide motors 15 kW and larger with a suitable heater to prevent condensation during long periods of inactivity. Motor heater shall be an integral component of the hoist and motor manufacturer.

c. Provide one embedded thermal sensitive device in hoist motor windings. Device and associated circuitry shall serve as an alarm activating an amber signal or pilot light visible to control stations when motor temperatures become excessive. Establish set point below the Class B insulation temperature limit. Thermal-sensitive device and associated circuits shall be self-restoring (automatic reset).

Two-speed, two-winding motors with a solid-state control are not allowed for creep-speed use.

2.4.3.2 Not Used Bridge and Trolley Drive Motors

Provide ac crane type single-speed; single-winding bridge and trolley drive motors.

2.4.3.3 Motor Enclosures

Provide motor enclosures that are totally enclosed, fan cooled (TEFC) drip-proof and conform to NEMA 250.

2.4.3.4 Motor Insulation and Time Rating

2.4.3.5 Bridge and Trolley Motor Insulation and Time Rating

Provide bridge and trolley drive motors with an insulation which has a Class H rating based on 125 degrees C motor temperature rise above 40 degrees C ambient with frame size selection based on continuous rating.

2.4.4 Electric Brakes

2.4.4.1 Not Used Brakes

a. Electric-hydraulic bridge and trolley brakes shall be dc shunt magnet type equipped with hydraulic actuators manually-operated with a foot-operated master control unit in the operator's cab, and electrically released with the operation of the mainline contactor POWER-OFF pushbutton or power failure.

b. Provide remote control bleeders operable by pushbutton and foot pedal except for power-assisted brake systems. Remote control bleeders

SECTION 41 22 13.13 Page 17 shall be complete with pushbutton clearly labeled and located in operator's cab where the operator can easily depress the pushbutton and pump the brake simultaneously. In lieu of the combination electric-hydraulic brakes, separate hydraulic and electric brakes may be provided. Design hydraulic brake system to ensure equal pressure at each brake cylinder.

2.4.4.2 Not Used Hoist Brake Time Delay

Provide one of the hoist holding brakes with a time-delay setting (from 1 to 3 seconds). The time-delay shall be initiated upon releasing the control pushbutton or returning the master switch to OFF. Operation of mainline POWER-OFF pushbutton or power failure shall result in each hoist brake's setting without any time-delay.

2.4.4.3 Automatic Stop System

Provide fail-safe spring set electrically-controlled brakes when power is interrupted. Brakes shall be released with a mainline contactor POWER-OFF pushbutton or a master switch for the associated drive. Brakes shall automatically stop when there is a power failure. Design electric system to be mechanically released. Provide enclosures for electrical-controlled brake components conforming to NEMA ICS 6 Type 3R, and NEMA ICS 8 .

Provide direct current shunt magnetic shoe brakes with an electrical forcing circuit for rapid release of brake. Each shunt coil brake shall be circuited for both conductors to open simultaneously when the brake is de-energized.

2.4.5 Control System

Provide a separate controller for each motor; a duplex type for 2-motor bridge drives and a quadraplex type for 4-motor bridge drives on ac central cranes. When 2-motor bridge drives are furnished and dc magnetic control is required, provide dc series-connected motors. When 4-motor bridge drives are furnished and dc magnetic control is required, provide dc series-parallel connected motors . Provide overload protection conforming to NEMA ICS 2 and NFPA 70 . When contactors are used for starting, stopping and reversing, contactors shall be mechanically and electrically interlocked.

2.4.5.1 Control Panels

Fabricate control panels of solid sheet steel designed and constructed to conform to requirements of NEMA ICS 6 Type 3R. Hinge and equip control panel doors with gaskets and fitted with key-lock handle design, complete with a single key to open all locks.

2.4.5.2 Bridge and Trolley Control

a. Provide bridge and trolley main control systems with minimum of two speeds in each direction with an electrically-operated, full-magnetic, across-the-line reversing type starter . Use centrifugal switches in control circuit to prevent the plugging of trolley or bridge drive motors; arrange each switch to set the associated drive's brake while attempts are made to plug. Provide the bridge and trolley main control system with reduced voltage starting for all speed points.

SECTION 41 22 13.13 Page 18

2.4.5.3 Drift Point

Provide a trolley and bridge main control systems with a drift point between OFF and first speed control point in each direction or have a separate pushbutton.

2.4.6 Pendant Control Station

2.4.6.1 General

Provide NEMA Type 3R pendant control station. Hold physical size of pendant to a minimum. Provide a separate cable of corrosion-resistant 3.2 mm wire. Attach pendant station to an auxiliary girder and hang vertically with bottom of pendant at 1 m above floor. Do not support weight of pendant by control cable.

2.4.6.2 Operating Pushbuttons

Provide heavy-duty, dust-and-oil-tight type operating pushbuttons with distinctly-felt operating positions which meet requirements of NEMA ICS 2 .

Pendant control buttons shall be momentary pushbuttons. Provide recessed type pushbuttons (except the POWER-OFF button) to avoid accidental operation. Make diameter of buttons a size which will make operation possible with a thumb while holding the pendant with same hand. Provide nameplates adjacent to each pushbutton. Provide barriers on pendant between various pushbutton functions, except on elements mounted in junction box. In a multi-speed application, dual-position pushbuttons shall have a definite click-detent position for each speed. Design and manufacture pushbuttons not to hang up in control case. Pendant shall include a separate set of pushbuttons for each motion and for POWER-ON POWER-OFF. Provide the following pushbuttons:

POWER-OFF.

POWER-ON.

Hoist-up.

Hoist-down.

Gantry-North.

Gantry-South.

Trolley-East.

Trolley-West.

2.4.6.3 Light Indicators

Provide pilot lights meeting heavy-duty requirements of NEMA ICS 5 .

Provide one red pilot light to indicate excessive hoist motor temperature on pendant station. Provide a blue pilot light to indicate that the main contactor is energized, and a white pilot light to indicate that power is available on the load side of crane disconnect switch. Provide a bright red mushroom head for the POWER-OFF pushbutton. Provide a 2-position selector switch to select between normal and VFAC drive. Provide a single green pilot light to indicate all VFAC drive functions are engaged.

2.4.6.4 Pendant Drive Control

Provide a 3-position momentary contact spring-return to OFF toggle switch to control the motorized trolley for pendant.

SECTION 41 22 13.13 Page 19

2.4.6.5 Transfer of Control Stations

Provide pendant with a green pilot light to indicate that control has been transferred to pendant station from cab with key lock-out.

2.4.7 Protection

2.4.7.1 Main Line Disconnect

Provide a main line disconnect consisting of a combination circuit breaker (50,000 AIC) and non-reversing starter, starter without overloads (mainline contactor) in NEMA Type 3R enclosure. Control circuit of mainline disconnect shall cause all crane motions to stop upon mainline undervoltage, overload, control circuit fuse failure, or operation of POWER OFF pushbutton. Equip mainline disconnect with energy isolating devices designed to accept lockout devices.

2.4.7.2 Isolation Transformer

Provide an SCR drive type isolation transformer specifically designed for cranes, with a continuous rating which will exceed that required of the sum of rated full-load full-speed KVA of hoist plus 50 percent of rated full-load full-speed KVA of trolley and bridge motors plus the rated KVA of controls. Multiply the total KVA by 1.05 (efficiency factor). Connect the isolation transformer to the load side of mainline disconnect of the transformer. Supply crane dc static control electric power distributed on the crane through this isolation transformer.

2.4.7.3 Surge Protection

Provide surge suppressors meeting the requirements of UL 1449 . Provide three metal oxide varistors on the line side of each SCR drive isolation transformer to provide transient over-voltage protection.

2.4.7.4 Circuit Breakers

Provide circuit breakers meeting the requirements of UL 489 .

2.4.7.5 Overloads

Alternating current circuit overload relays shall be of the ambient compensated, automatic reset, inverse time type located in all phases individual motor circuits. Arrange overload relays to de-energize the associated motor on an overload condition.

2.4.8 Limit-Switches

Provide heavy-duty quick-break double-pole double-throw type gear limit switches conforming to NEMA ICS 2 . The geared limit-switch interruption of a motion in one direction shall not prevent the opposite motion.

Geared limit-switches shall reset automatically. Provide NEMA Type 1 limit switch housings. Limit-switches shall interrupt power to the primary control systems.

2.4.8.1 Bridge and Trolley Travel Limit-Switches

Provide runway (track-type) limit-switches for crane bridge and trolley motions to stop the bridge and trolley motions, respectively. Install limit-switch actuators on building and trolley frame to actuate the

SECTION 41 22 13.13 Page 20 limit-switches and stop the crane bridge or trolley prior to contacting the trolley frame bumpers. Locate trip mechanism for trolley motion on crane runway to trip the switch before the bumper contacts the stop.

Locate trip mechanism for bridge motion on crane runway to trip switch before bumper contacts the stop. When the switch is tripped, permit the switch opposite travel in the direction of stop and then automatically reset.

2.4.9 Wiring

Provide wiring complying with Article 610 of NFPA 70 . Number or tag wires at connection points. Make all splices in boxes or panels on terminals boards or standoff insulators. Base motor loop, branch circuit and brake conductor selection on NFPA 70 for 90 degrees C conductor rating on indoor cranes, and for 75 degrees C conductor rating on outdoor cranes.

Conductors in the vicinity of resistors and conductors connected to resistors shall be Type 5RML.

2.4.10 Electrification

2.4.10.1 Main Power Electrification

Main power electrification system shall provide power to crane starter/disconnect circuit breaker.

2.4.10.2 Crane Runway Conductors

Provide covered conductor bar type crane runway conductor system designed and manufactured to meet UL requirements. Provide rigid or flexible self-closing type protective cover designed to cover all live conductors and shaped to prevent accidental contact with conductors. Provide heavy-duty sliding shoe type collectors compatible with the electrification system. Provide two tandem designed collector heads for each conductor rail to provide redundancy.

2.4.10.3 Bridge Span Conductors

Provide festooned type consisting of a support rail, electrical cables, junction boxes, cable cars and accessories or rigid conductor/collector type located within enclosure bridge span conductor system. Cable loops shall not drop below the hook high position. Provide corrosion resistant outdoor crane bridge festoon system hardware.

2.4.10.4 Pendant Festoon System

Provide pendant festoon system consisting of a support rail, cables, junction boxes, cable cars and accessories. Cable loops shall not drop below the hook high position. Provide pendant control car with NEMA Type 3R junction box. Pendant festoon shall be independent of trolley motion.

Provide corrosion resistant outdoor crane pendant festoon system hardware.

2.4.10.5 Pendant Drive System

Provide pendant festoon system with a motor-drive system capable of driving the pendant control car at .64 m/s. Control of pendant motor drive shall be from the pendant.

SECTION 41 22 13.13 Page 21

2.4.11 Special Requirements

2.4.11.1 Warning Horn

Provide a solid-state electronic warning horn on the crane. Accompany any bridge or trolley motion by a continuous series of alternating tones. The warning horn shall not sound when the crane is in the VFAC drive mode.

2.4.11.2 Accessory Power

Use three-phase 208Y/120 volt ac power supplied via a circuit breaker and isolation transformer from the line side of the main line disconnect for lighting and accessory circuits on the crane. Provide the circuit breaker with a NEMA Type 3R enclosure. The enclosure shall have provisions to lock the breaker in the OFF position. Provide each circuit breaker pole with individual thermal and magnetic trip elements and the enclosure cover with a button for mechanically tripping the circuit breaker. Supply three-phase 480 volt delta primary and 208Y/120 volt wye secondary general lighting transformer from the accessory circuit breaker and feed a 208Y/120 volt UL listed circuit breaker panelboard and a heater circuit breaker/combination starter. The panelboard shall supply branch circuits for utilization of various accessories such as receptacles, lighting, panel internal lighting, and control enclosure which meets NEMA requirements. Provide transformer and panelboard with the same NEMA classification as the circuit breaker.

2.4.11.3 Receptacles

Provide single-phase, 120-volt 15-amp, grounded, duplex type receptacles complete with metal weather-proof enclosure with self-closing weatherproof receptacle cover. Provide a receptacle on the trolley at each end of the front bridge walkway in the vicinity of bridge travel drive motors.

Provide several receptacles in the vicinity of the control equipment equally spaced every 3 m.

2.4.11.4 Lighting

Provide control panels with a 120-volt lamp fixture with an unbreakable lens and switch. Provide floodlights to illuminate the work area under the crane and drum area on crane, controlled from crane control station.

Provide metal halide industrial floodlight luminaries. Totally enclose each floodlight, vapor-tight design, gasketed and provided with a heat-resistant and impact-resistant glass lens. Space and attach floodlights to underside of crane to provide uniform lighting.

2.4.11.5 Electrically-Driven Oil Pump Alarm

Provide electrically -driven lubricating pump complete with an audible alarm and red light for indication of pump malfunction. Make location of alarm the factory standard location.

2.4.12 Load-Limit System

Provide a load-limit visual/audible system for the main hoist to inform the operator that the preset load has been exceeded. The load-limit system shall consist of a load-cell, load-sensing electronics, overload indicator lights, overload alarm bell and alarm cut-out switch. Mount load cell to receive the load from equalizing sheave pin or upper block sheave pin. Provide adjustable alarm setpoint.

SECTION 41 22 13.13 Page 22

2.4.12.1 Load-Sensing Electronics

Provide NEMA Type 3R enclosures for load sensing electronics. Provide adjustable alarm setpoint.

2.4.12.2 Alarm and Indicator Light

Provide an overload alarm light to indicate a load greater than the preset maximum. Overload alarm shall be indicated with a red light and clearly labeled "OVERLOAD". Also provide a bell to indicate when an overload condition exists. Make provisions to turn off the bell from pendant station.

2.4.13 Fungus Resistance

Coat electrical connections such as terminal connections, circuit connections, components and circuit elements with fungus-resistant varnish. Do not treat components and elements which are inherently inert to fungi or hermetically sealed. Do not treat elements whose operation will be adversely affected with the application of varnish.

2.5 ELECTROMAGNETIC INTERFERENCE SUPPRESSION

2.5.1 Shielded Cable

Provide shielded type pendant and festooned cables of braided tinned-copper. Ground each cable shielding with a single connection to equipment grounding conductor.

2.5.2 EMI/RFI Shielded Boxes

2.5.2.1 General

Boxes designed to house electronic and electrical control equipment, instruments, metering equipment, etc., in installations where electromagnetic compatibility and/or system security is required shall protect interior components from stray radio frequency (RF) fields and contain RF signals produced by interior components.

2.5.2.2 Construction

Design Electromagnetic Interference/Radio Frequency Interference (EMI/RFI) shielded boxes to meet UL 50 Type 12 and Type 13. Construct the shielded boxes of 1.897 mm steel with seams continuously welded and ground smooth, without holes and knockouts. Cover gasket shall be a combination of woven plated steel mesh and oil-resistant gasket which will provide an EMI/RFI seal as well as an oil-tight, dust-tight and water-tight seal between cover and body. Attach gasket to cover with oil-resistant adhesive.

Provide stainless steel cover clamps and screws which are quick and easy to operate on three sides of hinged cover for positive clamping.

2.5.2.3 Attenuation

Design EMI/RFI shielded boxes to provide maximum shielding of electric and magnetic components of radiated RF energy. Provide RF filters to suppress conducted radio frequency in cables and conductors. Provide shielded boxes with attenuation greater than 60 db at 14.5 KHz to greater than 100 db at 1 MHz for magnetic fields and greater than 100 db from 14.5 KHz to

SECTION 41 22 13.13 Page 23

430 MHz for electric fields.

2.5.2.4 Finish

Provide zinc-plated EMI/RFI shielded boxes in accordance with ASTM B633 SC3/Type II to provide corrosion-resistant conductive surfaces for gasket contact area and conduit entries. The finish coat shall match the crane finish.

2.5.3 Drum Grounding

Provide a copper ring/collector assembly to ground each drum. Provide electrically-bonded ring to drum. Collector shall be stationary and connected to equipment grounding conductor system with a No. 8 AWG copper wire.

PART 3 EXECUTION

3.1 EXAMINATION

After becoming familiar with all details of the work, and before performing any…