B.08.03 Amendment 0003 41 22 13_REVISED 03.22.203.pdf

ERI: CONSTRUCT ECAOS DABS STORAGE SANEM, LUXEMBOURG

SECTION 41 22 13

BRIDGE CRANES, OVERHEAD ELECTRIC, UNDER RUNNING

02/20

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.

CENTER FOR BUILDING TECHNOLOGIES AND INNOVATION RESOURCES (CRTIB)

CTG 017 Metal construction work

EUROPEAN STANDARDS (EN)

EN 1991-1 Eurocode 1: Actions on structures

GERMAN INSTITUTE FOR STANDARDIZATION (DIN)

DIN EN 15011 (2014) Cranes - Bridge and gantry cranes

DIN EN 15048-1 (2016) Non-preloaded structural bolting assemblies - Part 1: General requirements

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 60034-1 (2017) Rotating Electrical Machines - Part 1: Rating and Performance

IEC 60034-2 (2014) Rotating electrical machines - Part

IEC 60034-32 Rotating electrical machines - Part 32:

Measurement of stator end-winding vibration at form-wound windings

IEC 60204-1 (2016) Safety of Machinery - Electrical Equipment of Machines - Part 1: General Requirements

IEC 60529 (1989+AMD1:1999+AMD2:2013 CSV Consolidated version) Degrees of protection provided by enclosures (IP Code)

IEC 62208 (2011) Empty enclosures for low-voltage switchgear and controlgear assemblies - General requirements

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 8501 Preparation of steel substrates before application of paints and related products

- Visual assessment of surface cleanliness

SECTION 41 22 13 Page 1

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2020; ERTA 20-1 2020; ERTA 20-2 2020; TIA

20-1; TIA 20-2; TIA 20-3; TIA 20-4)

National Electrical Code

UNDERWRITERS LABORATORIES (UL)

UL 943 (2016; Reprint Feb 2018) UL Standard for Safety Ground-Fault Circuit-Interrupters

UL 1004-1 (2012; Reprint Aug 2017) UL Standard for Safety Rotating Electrical Machines - General Requirements

1.2 DEFINITIONS

a. Bridge Crane: That part of an overhead crane system consisting of a girder, end trucks, 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. Lifted Load: The load consisting of the rated load and the weight of lifting devices attached to the crane such as the load block, bucket, or other supplemental devices.

f. Pendant: A control for a hoist and 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. Patented Track: A generic term referring to track built in accordance with DIN EN 15011 utilizing a composite track section incorporating a proprietary bottom flange shape. For this crane system, it is provided for the crane bridge girder and also the crane runway track, if under running.

h. Rated Load: The maximum working load suspended under the load hook.

i. 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 must have been published or copyrighted prior to the issue date of this solicitation and have a document identification number or bulletin number.

j. Trolley Load: The weight of the trolley and its associated equipment

SECTION 41 22 13 Page 2 carried by the trolley wheels.

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 or patented track.

l. Top Running Crane: An overhead electric traveling crane that is supported by end trucks which run on top of supporting rails.

m. Operating Environments:

(1) General Purpose Service: This applies to most cranes and are, in large measure, the manufacturers' standard designs. Cranes should be classified as General Purpose Service if they are operating in routine environments.

(2) Ordnance/Explosives Handling: Cranes handling palletized or unpackaged ammunition, missiles, torpedoes, and other types of ordnance. Minimum requirement of CMAA service class D.

(3) Hazardous (Explosive) Environments: Cranes operating in hazardous environments as defined by the cognizant activity safety office must be equipped with electrical safety features that meet NEC Article 500. The activity safety office must identify the specific Class, Division, and Group, as well as the envelope that the hazard exists, to allow proper design and must list these in this section. Materials for mechanical components must be chosen to minimize the potential for sparking, typically bronze, stainless steel, or aluminum. Hazardous environments are split into two groups: minimum anti-spark protection and maximum anti-spark protection.

(a) Minimum Anti-Spark Protection is used when only the load block enters the explosive area.

(b) Maximum Anti-Spark Protection is used when the hazardous area envelops the entire crane.

1.3 SYSTEM DESCRIPTION

The requirements for the crane runway system and rail supporting structures are specified in Section 05 12 00 STRUCTURAL STEEL, and must conform to CTG 017 .

1.3.1 Crane 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 must not be less than that indicated.

1.3.1.1 General

Include the following: Number of cranes, located in building identified as shown on the drawings, with the capacity expressed in kilograms , for each overhead electric traveling (OET) crane. Also clearly locate and identify each hoist and system components.

SECTION 41 22 13 Page 3

1.3.1.2 Classification

Provide top running bridge overhead electric traveling crane (OET), with under running trolley mounted hoist, service class D for operation in an indoorenvironment, general purpose service, with an ambient temperature range of 5 to 40 degrees Celsius. The crane span must be 29630 meters with a vertical lift of 16.7 meters and as specified herein.

The crane must be radio controlled and operate in the spaces and within the loading conditions indicated. The crane main voltage is 400-volts AC, 50 Hz three phase power source. Control voltage is 48V. Maximum crane wheel loads (without impact) due to dead, trolley, and lifted loads, with the trolley in any position, must not cause a more severe loading condition in the runway support structure than that produced by the design wheel loads and spacing indicated.

1.3.1.3 Rated Capacity and Speeds

Provide crane with a rated capacity of 25000 kg . 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 (maximum) speeds plus or minus 10 percent (in meters/second) for the main hoist, bridge, and trolley at the rated load are specified in the table below. The minimum speed must not exceed the values listed.

Rated Speeds meters/second

Description Minimum Maximum

Main Hoist 0.11 m/min 5.6m/min

Trolley -- 20m/min

Bridge -- 40 m/min

1.4 VERIFICATION OF DIMENSIONS

The Contractor is responsible for the coordination and proper relation of their work to the building structure and to the work of all trades.

Verify all dimensions of the building that relate to fabrication of the crane and notify the Contracting Officer of any discrepancy before finalizing the crane order.

1.5 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 Crane System; G, DO

Complete Schematic Wiring Diagram; G, DO

SD-03 Product Data

SECTION 41 22 13 Page 4

Gear Reducers; G, DO

Hoist Brakes; G, DO

Travel Brakes; G, DO

Couplings; G, DO

Load Block and Hook; G, DO

Hoist and Trolley Units; G, DO

Bridge End Trucks; G, DO

Crane Bridge Girder; G, DO

End Stops; G, DO

Bumpers; G, DO

Crane Runway System; G, DO

Motors; G, DO

Enclosures; G, DO

Circuit Breakers; G, DO

Disconnect Switch; G, DO

Contactors and Relays; G, DO

Fuses; G, DO

Limit Switches; G, DO

Resistors; G, DO

Radio Control System; G, DO

Pendant Push-Button Station; G, DO

Crane Controllers; G, DO

Control Parameter Settings; G, DO

Pilot Devices; G, DO

Warning Devices; G, DO

Floodlights; G, DO

Runway Conductor System; G, DO

Bridge Conductor System; G, DO

Overload Protection; G, DO

SECTION 41 22 13 Page 5

Painting System; G, DO

SD-05 Design Data

Load and Sizing Calculations; G, DO

SD-06 Test Reports

Hook Proof Test

Hook Non-Destructive Test (NDT)

Post-Erection Inspection

Operational Tests

Hook Tram Measurement

Load Tests

SD-07 Certificates

Wire Rope

Crane Runway System

Hazardous Material

Loss of Power Test

Coupling Alignment Verification Record

Overload Test

Brake Adjustment Record

Compliance with Listed Standards

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals; G, RO

1.6 QUALITY ASSURANCE

1.6.1 Manufacturer Qualification

Overhead Electric Crane System, including sub-system components manufactured by vendors, must 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.

The crane design must be accomplished by, or directly supervised by, a registered professional engineer (PE). PE licensing must be by a board or agency authorized to license and register professional engineers. The PE may be a Contractor's regular employee or a consultant. The PE's review and attestation of specification compliance and professional responsibility must be signified by his or her PE original seal and dated signature on the final drawings. The professional engineers must only

SECTION 41 22 13 Page 6 undertake and perform work under this contract in the branch(s) of engineering in which they are licensed.

1.6.2 Pre-Delivery Inspections

Contractor is responsible for performance of quality control inspections, testing, and documentation. Submit all crane test data recorded on appropriate test record forms suitable for retention for the life of the crane.

1.6.2.1 Inspection of Steel Castings

Visually inspect and test load-carrying steel castings using the magnetic-particle inspection method All load bearing components, couplings, shafts, and gears, in the hoist drive train must be rolled or forged steel, except brake drums which may be ductile iron. Methods of repairing the discontinuities is subject to review by the Contracting Officer.

1.6.2.2 Inspection of Hook Assembly

Inspect hook by a magnetic-particle type inspection prior to delivery.

Furnish documentation of hook inspection to Contracting Officer prior to field operational testing. As part of the acceptance standard, linear indications greater than 1/16 inch are not allowed. Welding repairs of hook are not permitted. A hook showing linear indications, damage or deformation is not acceptable.

1.6.2.2.1 Hook Non-Destructive Test (NDT)

Magnetic-particle inspect the hook over the entire area. Acceptance standard is no defects. A defect is defined as a linear indication that is greater than 1.5 mm long.

1.6.2.3 Hook Proof Test

Proof test the load hook. Perform the proof test prior to Hook NDT.

1.6.3 Drawings: Overhead Electric Crane System

a. Submit drawings showing the general arrangement of all components in plan, elevation, and end views. Show all major features of the crane including: hook approaches on all four sides, clearances and principal dimensions, assemblies of hoist, trolley and bridge drives, motor nameplate data, overcurrent protective device ratings, and electrical schematic drawings. Include weights and centers of gravity of major components.

b. Submit shop drawings of all fabricated components. Shop drawing quality must be equivalent to the contract drawings accompanying this solicitation. Drawings must be reviewed, signed and sealed by a licensed professional engineer.

c. Provide integral schedule of crane components on each drawing. The schedule must provide a cross reference between manufacturer data and shop drawings. Components listed on the schedule of crane components must include total quantity, description, original manufacturer, and part number. Distributing agents will not be acceptable in lieu of the original manufacturer.

SECTION 41 22 13 Page 7

1.6.4 Design Data: 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 reviewed, signed, and sealed by a registered professional engineer verifying the load cases, sizing of the bridge girder, end trucks, travel drives, motors, overcurrent protection, and conduit. Provide a list of all codes and standards, design assumptions, equations, specified efficiencies, limits, factors of safety, component ratings, and sources of values used. Include free body diagrams or sketches of each load case.

Include seismic analysis of crane.

1.6.5 Certificates

All certifications shall be dated and shall bear the original signature (above the printed name) of the authorized representative of the Contractor or the manufacturer of the items or equipment being certified.

Each certification shall clearly identify the crane, the drives, components, and location (as applicable) to which it applies:

a. Submit a Wire Rope Certification with the wire rope manufacturer's certification that the rope meets the published breaking strength or the actual breaking strength of a sample taken from the reel and tested. Certification shall be traceable to the hoist, crane, and reel.

b. Submit a Crane Runway System Certificate stating that the new crane will operate properly on the runway. For runways provided by Contractor, include statement certifying runway has been aligned, as applicable. If runway is existing and if the crane(s) cannot operate without restriction, the Contractor shall indicate crane limitations.

c. Submit a Hazardous Material Certificate that the crane does not contain hazardous material including asbestos, lead, cadmium, chromium, PCBs, or elemental mercury. Products required for the designing and manufacturing of cranes must not contain the prohibited materials.

d. Submit a Loss of Power Test Certificate stating that a test may be performed in which power is removed from the crane while the hoist, bridge, and trolley are in operation to simulate a loss of power.

e. Submit a Certificate of the Coupling Alignment Verification Record.

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

g. Submit a Certificate of the Brake Adjustment Record. Provide a brake adjustment record and installation/maintenance manuals for each brake on the crane. Each brake measurement must have a tolerance traceable to the associated brake manual or documentation provided by the brake manufacturer, location of measurements, and the actual brake setting.

Changes made to settings of the brake, at any time, will void the record.

h. Submit a Certificate of Compliance with Listed Standards.

SECTION 41 22 13 Page 8

1.6.6 Welding Qualifications and Procedure

Welding must be in accordance with qualified procedures as modified.

Written welding procedures must specify the Contractor's standard dimensional tolerances for deviation from camber and sweep and not exceed those specified Welders and welding operators must be qualified.

1.7 CRANE SAFETY

Comply with the mandatory and advisory safety requirements of local regulations, and all applicable provisions of NFPA 70 . Where personal fall arrest anchorages are provided, design anchorages in accordance with local regulations.

PART 2 PRODUCTS

2.1 MATERIALS

Materials or assemblies furnished or installed as part of this project must be procurable within Europe and maintainable using certified local labor and replacement material and assembly parts. Certified local labor and replacement material and assembly parts must meet the servicing and technical requirements prescribed by the manufacturer and contract documents in order to keep warranties in force.

2.1.1 System Description 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. Material will be free from defects and imperfections that might affect the serviceability and appearance of the finished product. All material must be new and unused. Subject to compliance with project requirements provide lifting equipment system: 25000 kg (28t) double girder crane with 29630 m span and two wire rope hoists for spreader bar.

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 the 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 Capacity Marking

Mark the rated capacity in kg units on each side of the crane on the bridge girder. Capacity marks must be large enough to be clearly visible from the floor. Individual hoist units must have their rated capacity clearly marked on their bottom block, and additionally labeled on the hoist body. Rated capacity must include all accessories below the hook, such as load bars, magnets, and grabs, as part of the load to be handled.

2.1.4 Safety Warnings

Affix labels in a readable position to each lift block or control station.

Submit safety warnings, diagrams and other instructions suitably framed

SECTION 41 22 13 Page 9 and protected for display as indicated by the Contracting Officer as follows:

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.

2.2 STRUCTURAL REQUIREMENTS

Structural requirements must be in accordance with Eurocodes , as applicable. Structural steel materials must conform to the standards permitted. Skewing and other applicable lateral loads must be considered in the design.

2.2.1 Structural Connections

High-strength bolted structural connections must be designed and installed in accordance with DIN EN 15048-1 . Bolts must be of material in compliance with Eurocodes, CTG 017 and local regulations. Galvanized bolts are not acceptable.

Welded connections for the crane must be performed in accordance with CTG 017 and DIN EN 15011 . Welded connections to the building must be performed in accordance with Eurocodes . Allowable stress values must comply with Eurocodes .

2.2.2 Crane Bridge Girder

Provide a bridge girder of rolled steel shape conforming to DIN EN 15011 or patented track, as applicable. For ordnance handling cranes, the bridge girder must be of patented track. Intermittent ("skip") welds on bridge girder elements (e.g. web and flange interfaces) are prohibited.

If the girder is notched to fit over the end trucks, reinforce the girder ends with vertical and horizontal stiffeners. Splices in the unsupported length of the girder are prohibited.

For patented track girder, submit manufacturer's standard published tables that verify the crane bridge girder is sized in compliance with all specification requirements. When standard published tables are not available, provide calculations for the strength design and deflection of the bridge. Patented track girder must be of welded steel construction and fabricated by a manufacturer regularly engaged in the production of this type of beam.

2.2.3 Bridge End Trucks

Provide bridge end trucks conforming to DIN EN 15011 , as applicable.

Configure end trucks with a feature that limits end truck movement to 25.4 mm in the event of wheel or shaft failure.

2.2.4 End Stops and Bumpers

Fit bridge girders with structural steel end stops. Locate stops to

SECTION 41 22 13 Page 10 permit maximum trolley travel. Fit bridge end trucks and trolley frames with shock-absorbing bumpers capable of decelerating and stopping the bridge and trolley within the limits stated by DIN EN 15011 , as applicable. Ensure bumpers and end stops conform to local regulations.

Bumpers must fully engage end stops. Mount bumpers so that there is no direct shear on mounting bolts (if any) upon impact. Bumpers must provide adequate clearance between the crane and surrounding structure when compressed to preclude damaging equipment. When more than one crane is located and operated on the same runway, bumpers shall be provided on their adjacent ends or on one end of one crane. Fit the other end of the end-truck with a structural steel stop to engage the bumpers of the adjacent crane. Ensure bridge bumpers are properly aligned with runway end stops. Metal to metal contact at the bumper to end stop connection is not permitted.

2.2.5 Crane Runway System

Provide the complete runway track suspension system that is required to hang the crane runway track at its indicated location from the structural supports indicated on the drawings. Provide runway and support structure for underrunning crane of rolled steel shapes or patented track girders conforming to DIN EN 15011 .

For rolled steel shapes, locate splices under structural support members.

For patented track girders, perform splices as necessary in accordance with the manufacturer's recommendations and requirements. Align ends of lower T-section to minimize the horizontal gap on the running surface to not greater than 1/16 inch and not greater than a vertical difference of 1/32 inch for the wheel running surface alignment for a smooth crossing by the wheels. Splice assemblies must be from the same manufacturer as the patented track and located under structural support members. Submit manufacturer's standard published tables that verify the crane runway track is sized in compliance with all specification requirements. When standard published tables are not available, provide calculations for the strength design and deflection of the beams.

Runway support structure must be designed, fabricated, and installed such that runway rails meet the alignment tolerances of DIN EN 15011 , as applicable. Provide means to allow for vertical adjustment of the runway track both before and after the system has been put in operation so that track can be erected and maintained level. Brace runway to restrain the track against damaging lateral and longitudinal movements. Where the runway track is suspended from hanger rods, provide means preventing the hanger rod nuts from backing off the rods. Allowable stress in hanger rods is 20 percent of the minimum specified ultimate strength of the material used.

2.2.6 Seismic Forces

Perform a seismic analysis as a part of the design of the crane in accordance with EN 1991-1 and National Annexes. The seismic analysis must be included in the DIN EN 15011 extraordinary load case (Case 3), as applicable.

For project locations beyond the scope of EN 1991-1 and National Annexes, a widely accepted design standard may be used for seismic analysis.

SECTION 41 22 13 Page 11

2.3 MECHANICAL REQUIREMENTS

Provide steel shafts, gears, keys, and couplings. Cast iron and aluminum used to support components of the hoist power transmission train must be ductile. Gray cast iron load bearing parts are prohibited.

All mechanical components must be accurately aligned and positively secured to maintain the alignment. Parts must not be forced into position to obtain apparent alignment.

2.3.1 Threaded Fasteners

Fasten base-mounted and flange-mounted components and all mechanical connections subjected to calculable loads with lubricated fasteners, washers, and nuts in compliance with local regulations. Match bolt and nut threads. Oversize tapping is not permitted. Bolt and nut threads must conform to CTG 017 . Bolts and screws may be installed into tapped holes provided that adequate thread engagement is provided to develop the full designed connection strength.

2.3.2 Hoist

Provide hoist conforming to DIN EN 15011 service class D or better, double reeved, except as modified and supplemented in this section. Standard commercial hoist and trolley units (packaged hoists) must be electric wire rope hoist conforming to IEC standards and local regulations. For custom hoist shafts, the fatigue design factor must be a minimum of 1.5.

Configure trolley such that the trolley frame contacts the trolley stops and prevents the trolley from dropping more than one inch in the event of an axle or wheel failure.

2.3.2.1 Hoist Brakes

Equip the hoist with two holding brakes, each with a minimum torque rating of 125 percent of the rated load hoisting torque. Provide a brake configuration with two electro-mechanical or thruster brakes. A mechanical load brake may be utilized in lieu of one of the hoist holding brakes provided it stops and holds 125 percent of the hoist's rated load and does not require the load to be raised before being lowered.

For cranes with two electro-mechanical or thruster brakes, designate each brake as primary or secondary with the primary brake being the brake mounted closer to the motor. Provide the primary brake with a non-time delayed setting and secondary brake with an adjustable setting time delay, set between one to three seconds after the primary brake in any stopping condition. Do not use an uninterruptible power supply (UPS) to create the secondary brake time delay.

Electro-mechanical or thruster brakes must be adjustable to 50 percent of its rated capacity, and must have an externally accessible means of manual release.

2.3.2.2 Load Block and Hook

The load block must be constructed of steel and designed to prevent metal-to-metal contact of moving parts. The block must be fully enclosed, concealing the sheaves and wire ropes, except for wire rope slots and drain holes. The design must preclude the wire rope from being cut, SECTION 41 22 13 Page 12 pinched, crushed, or chafed in case of two-blocking. The block must be clearly marked with the capacity in kilograms on both sides.

Provide an unpainted single barbed forged steel hook complying with DIN EN 15011 and local regulations. Hook dimensions must be as shown on the drawings. Fit hook with a safety latch designed to preclude inadvertent displacement of slings from the hook saddle. The hook and hook nut must be removable without unreeving of the hoist or disassembly of the block. Provide hook nut with a removable type set screw or other similar fastener, installed in a plane parallel to the longitudinal axis of the hook shank. Do not weld hook nut. Hook must be free to rotate through 360 degrees when supporting the test load up to 125 percent of the rated capacity. Upper hooks of hook suspended hoists shall be of non-sparking materials.

2.3.2.3 Wire Ropes

a. Wire rope must conform to DIN EN 15011 and be tested as required by local regulations. The wire rope must be in a double reeved configuration with the equalizing method perpendicular to the running sheaves. Provide wire rope with a minimum design factor of 5 to 1 based on the load experienced at rated capacity and minimum breaking strength of the wire rope.

b. Provide hoisting ropes with improved plow steel, extra improved plow steel, or extra-extra improved plow steel, regular lay, bright, and uncoated with an independent wire rope, wire strand, or otherwise, steel core. Hot-dipped galvanized wire rope is not permitted.

c. Hoisting rope end connections, other than drum connections, must be speltered sockets with forged steel terminals or swaged fittings installed in a fashion that provides 100 percent of the breaking strength of the wire rope. Anchor hoisting rope ends on the drum by means of swaged fittings or by clamping with hoisting rope ends neatly and securely seized with corrosion resistant wire. Provide proof of Wire Rope breaking strength. Wedge sockets or aluminum swages are not permitted on wire rope end connections.

2.3.2.4 Drum

Provide drum made of steel. Design the drum such that all hoisting rope is wound in a single layer and so that not less than two dead wraps of hoisting rope remain on each anchorage when the hook is in its extreme low position. Drum grooving must be machined right and left hand beginning at the ends and grooving toward the center of the drum. Minimum drum groove depth must be 0.375 times the rope diameter.

Provide minimum drum groove pitch either 1.14 times the rope diameter, or the rope diameter plus 3 mm, whichever is smaller. Minimum drum pitch diameter must be 18 times the rope diameter. Do not paint, coat or galvanize the surface of the drum which comes in contact with wire rope.

2.3.2.5 Sheaves

Provide steel sheaves. Machine or grind the grooves to contour and rim toughen, flame, or induction harden to not less than 320 BHN. Minimum pitch diameters must be 18 times the rope diameter for running sheaves and no less than 12 times the rope diameter for equalizer sheaves. Provide sheave groove depth of not less than 1.5 times the hoisting rope

SECTION 41 22 13 Page 13 diameter. Do not paint wire rope contact surfaces of sheaves.

2.3.3 Drives

Provide travel assemblies with at least one quarter of all wheels driven for the crane and a minimum of one driven wheel on each side of the flange. No 3-bearing shaft configurations are allowed. The travel drive arrangement will be the contractor's design of choice.

2.3.3.1 Bridge Drives

Acceleration and deceleration must meet the requirements specified in DIN EN 15011 . Provide bridge travel limit switches.

2.3.3.2 Trolley Drives

Provide a motor-driven trolley arrangement. Provide trolley travel limit switches.

2.3.4 Travel Brakes

Provide brakes with an externally accessible means to manually release the brake.

2.3.4.1 Bridge Brake

Provide bridge drive with an electro-mechanical brake conforming to the requirements of DIN EN 15011 or non-freecoasting mechanical drive capable of stopping the motion of the bridge within a distance in meters equal to 10 percent of the full load speed in meters per minute when traveling at full speed with a full load. Provide brakes with a minimum torque rating per DIN EN 15011 according to the applicable environment, but not sized larger than 150 percent of the drive motor rated torque.

2.3.4.2 Trolley Brake

Provide trolley drive with a non-coasting mechanical drive or an electro-mechanical brake conforming to the requirements of DIN EN 15011 capable of stopping the trolley within a distance in meters equal to 10 percent of the rated speed in meters per minute when traveling at rated speed with rated load.

2.3.5 Gearing

Provide gearing of the enclosed gear reducers type. Provide steel spur, helical, or herringbone type gears and pinions only. Gearing must conform to DIN EN 15011 and local regulations. Internal and external gear dimensional tolerances must conform to the applicable AGMA standard for tooth geometry and tolerances. Open-type gearing is not acceptable, except for final drives.

2.3.5.1 Gear Reducers

Gear reducers must be 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 or standard items of manufacturers regularly engaged in the design and manufacture of gear reducers for Class D and E cranes. Gear reducers must be designed, manufactured, and rated in accordance with DIN EN 15011 and

SECTION 41 22 13 Page 14 local regulations, as applicable. Except for final reduction, the gear reduction units must be fully enclosed in oil-tight housing. Gearing must be designed to AGMA standards and operate in an oil bath. Operation must be smooth and quiet.

2.3.5.2 Open Gearing

Provide all gears and pinions with adequate strength and durability for the crane service class and manufactured to DIN EN 15011 Accuracy Grade A8 or better. Open gears must be enclosed with safety guards provided with openings with covers for inspection and access for grease lubrication.

2.3.6 Bearings

All bearings, except those subject only to small rocker motion, must be anti-friction type. Provide permanently lubricated and sealed bearings or provide grease lubricated bearings with means for relubrication through easily accessible lubrication fittings.

Fit all connections subject only to small rocking motion with manufacturer's standard bronze alloy bushings in the pivot pin bore, as applicable. Provide means for relubrication of grease lubricated bushings through easily accessible lubrication fittings or provide oil impregnated type bushings.

2.3.7 Couplings

Chain and continuous sleeve type couplings must not be used. Spline couplings are acceptable as installed on c, d, or p-face assemblies.

Conventional couplings must not be loaded in the radial direction. Brake wheel or brake disc couplings (if used) must be compatible with the required coupling type. Flexible couplings must not be relied upon to compensate for inaccurate alignment. Ends of coupled shafts must be aligned within the recommended installation criteria of the coupling manufacturer.

2.3.8 Wheels

a. Top running trolley and bridge travel wheels are to be straight tread, double flanged, and sized in accordance with DIN EN 15011 recommendations for wheel sizing and flange to rail head clearances.

Wheel material must be of rolled-to-shape or roll-forged steel.

Provide wheels made from non-sparking material. Bronze wheels must have a minimum tread hardness of 225 BHN. Provide steel wheels with a minimum tread hardness of 320 BHN.

b. Under running wheels are to be flanged or provided with side guide rollers. Provide wheel sizing and flange-to-rail head clearances in accordance with DIN EN 15011 recommendations, as applicable. Wheel material is to be steel or ductile cast iron. Minimum tread hardness for underhung wheels that run on patented track is 375 BHN. Minimum tread hardness for wheels running on structural shapes is 320 BHN.

Wheels are to be made of forged steel. Provide wheels of non-sparking material. The minimum tread hardness for bronze wheels is 225 BHN.

2.3.9 Drip Pans

a. The crane must be designed to preclude leakage of lubricants onto the lifted loads or the floor. Equipment or components, which cannot be

SECTION 41 22 13 Page 15 made leak-proof, must be fitted with unpainted corrosion resistant steel drip pans or must have the foundations seal welded to create a dam. Drip pans that utilize liquid sealant to prevent leakage of lubricants are not permitted.

b. The drip pans must be sized to hold the entire gear case fluid capacity, installed under all drive machinery, designed to permit easy removal of collected lubricant. A trolley floor designed to contain any lubricant drips may be used as fluid containment for any equipment that is mounted on it.

c. Provide drip pans fitted around the shank of the hook and extending outward to encompass all possible points of lubrication drips from the load block or wire rope and must be easily removable without disassembly of the hook or load block and shall not interfere with the crane structure during testing of the upper limits.

2.4 ELECTRICAL REQUIREMENTS

The design, selection, rating, and installation of the electrical portions of the crane and its accessories must conform to the requirements of IEC 60204-1 , IEC 60034-32 , the applicable host nation standard, and NFPA 70 , and other requirements specified herein.

The crane manufacturer must furnish and install all electrical equipment on the crane conforming to IEC 62208 , including motors, conforming to IEC 60034-1 , electrically released brakes, switches, crane controllers, panels, operating station, wiring system, cables, and crane electrification.

2.4.1 Motors

Motors must meet all applicable requirements of IEC 60034-1 and UL 1004-1 .

All motors must have a minimum of a 60 minute duty rating and be Totally Enclosed Non Ventilated (TENV), Totally Enclosed Fan Cooled (TEFC), or Totally Enclosed Blower Cooled (TEBC). Provide two speed, AC squirrel cage induction type motor for the hoist. Provide motors with a minimum of Class F insulation. Provide motor overload protection utilizing a thermal sensitive device embedded in its windings.

2.4.2 Controls

Provide static reversing, variable frequency drives (VFD) for the bridge, trolley and hoist electric controls. Provide static reversing, VFD, speed regulated, closed loop, flux vector electric controls for the hoists. For feedback, provide hoist motors with encoders. The hoist controller must enable the drive motor to develop full torque continuously at zero speed.

The hoist secondary brake shall be controlled separate from the primary and connected to different output (within the drive) from the primary brake. VFD controllers must meet IEC 60034-2 and at a minimum, provide under-voltage protection, electronic instantaneous over current protection, DC bus over voltage protection, and be able to withstand output line to line shorts without component failure. Select bridge and trolley drives such that the continuous rating of the controller is not less than the motor full load current. Select hoist drives such that the continuous rating of the controller is not less than 100 percent of the motor full load current. All hoist drives must have a motor over-torque limit to lock out the hoist and prevent gross overload of the associated hoist. Provide dynamic braking for each electric drive that is sized per

SECTION 41 22 13 Page 16

VFD manufacturer's requirements. Submit VFD Control Parameter Settings.

Provide speed control which is infinitely variable for each function, controlled via radio control system. Provide controls designed such that the maximum speed of each function will be limited to 25 percent of rated speed when a slow speed switch is actuated on the controllers. Energize a yellow/amber light/indicator while in slow speed mode.

The hoist, trolley, and bridge brakes must set after the associated controller decelerates the drive motor to a controlled stop. The hoist, trolley, and bridge, controllers must be sized to provide sufficient starting torque to initiate motion of that crane drive mechanism from standstill with 0 to 125 percent of rated load on the hook. The hoist controller must prove torque before release of the brakes and enable the drive motor to develop full torque continuously at zero speed. Motors must operate smoothly at all speeds without torque pulsations and must only be energized within the frequency range of 50-60 Hz at rated speed.

Provide two-speed magnetic controls for the bridge drive, trolley drive, and hoist drive. Controllers must meet the requirements of IEC 60034-32 .

Ensure that an energized drive motor initially rotates only in the direction selected by the operator by activating the corresponding direction; i.e., is not overhauled. For AC squirrel cage motor controllers, the requirements for general-purpose controllers, must be met.

The use of definite purpose contactors is prohibited. If IEC contactors are used, the application cannot exceed the contactor manufacturer's AC3 ratings for the contactor at a minimum.

On hoist function roll-up must be less than 1/8 inch measured at the hook block and roll-back must not occur over the entire load range.

Use of Uninterruptible Power Supplies (UPS) is prohibited. Feed control circuits from a single phase, air cooled, double wound transformer with a grounded metal screen between the primary and secondary windings of the transformer.

Provide a main line contactor. Energization of the main line contactor must be controlled by the POWER-OFF/POWER-ON switch/pushbutton on all controllers. Upon actuation of the POWER-OFF pushbutton; power to all drive motors, brakes, and controls must be removed. The mainline contactor must not be able to be energize while the POWER-OFF pushbutton is actuated. The POWER-OFF pushbutton circuitry must be independent of all controls or any other electronic devices.

2.4.3 Protection

Protection must not be less than that required by IEC 60204-1 , IEC 60034-32 , DIN EN 15011 , NFPA 70 , UL 1004-1 , and UL 943 . Provide disconnect switch or enclosed type circuit breaker readily accessible to the crane operator for the crane disconnect. Provide an On/Off button that removes power from the motors, brakes and control circuit on all radio controllers.

Provide for lockout/tagout of all hazardous energy sources. Provide product data for all circuit breakers and fuses.

2.4.4 Resistors

Provide resistors with natural convection cooling sized as recommended by the VFD OEM and fabricated of corrosion resistant metal; the use of "wire

SECTION 41 22 13 Page 17 wound" type resistors is prohibited for segments of 8 ohms or less. Mount resistors in substantial, ventilated enclosures constructed entirely of non-combustible materials. Provide resistors with terminals fitted in the coolest position in the enclosure.

2.4.5 Transients and Harmonics Protection

Provide contactors and relays with appropriate Metal Oxide Varistors (MOV) or resistor-capacitor (R-C) surge absorbers installed across the respective coil.

Provide transient protection for electronic drive controllers that is either internal to the drive or via an MOV connected line-to-ground close to the line terminals of the drive.

Provide line reactors rated for continuous duty operation based upon the motor nameplate amperes. With motors of 50 horsepower or greater, harmonics protection must be provided by an isolations transformer or as recommended by the VFD OEM. For a drive motor branch circuit that exceeds 150 feet in length, a reactor must also be connected in series with the controller load (output) terminals to provide standing wave protection or as otherwise recommended by the VFD or motor OEM.

2.4.6 Limit Switches

Limit switches must be rated for the NEC Hazardous Classifications specified in the Classification section of this specification.

Provide primary upper and lower geared limit switches. Geared limits must allow reversing direction to back out of the limit without resetting. The lower limit switch must be set such that there are a minimum of two wraps of rope on the hoist drum.

Provide a backup mechanical hook block activated upper limit switch wired independent of the directional controllers and the primary upper limit switch that removes power from the hoist motor, hoist brake and hoist controls conforming to IEC 60034-32 . The backup limit must require hoist resetting prior to operation of the hoist in any direction.

Travel limit switches must be provided for the bridge and trolley motion to slow the crane to 25 percent of its rated speed 10 feet before the bridge end stops and 5 feet from the trolley end stops. Limit switches must be mounted rigidly in a manner so as to protect the switch from misalignment or damage. The target/trip arm must be large enough to provide interception given a misalignment were to occur.

2.4.7 Operator Controls

Provide crane equipped with a radio control system.

If VFD controls are not provided, provide directional contactors with both mechanical and electrical interlocks.

Operator controls must be rated for the NEC Hazardous Classifications specified in the Classification section of this specification.

SECTION 41 22 13 Page 18

2.4.7.1 Pendant Pushbutton Station

2.4.7.1.1 Radio Control System

Provide each system with a belly box type portable transmitter unit and an identical back-up transmitter unit. Provide each transmitter with an adjustable belt or harness to support it when worn by the operator. Only one transmitter at a time can control the crane and there must be no interference from one crane's controller affecting operation of the other cranes in the building. Each transmitter must include: individual infinitely variable spring return joystick motion control levers for each hoist, trolley, and bridge; a maintained contact, keyed switch, marked ON-OFF, for portable transmitter unit power; indication of Battery Power, and indication of Transmitting Status; a red emergency STOP mushroom pushbutton; and a floodlight on/off pushbutton and a maintained slow speed selector switch. The transmitters and all controls must each be clearly and permanently labeled with functionality and direction. Directions for controllers must be in accordance with DIN EN 15011 recommendations. The remote radio control system must be designed to meet the requirements of IEC standards and local regulations. Each radio remote control lever must be in the OFF position before the associated crane function can begin.

The system frequency must be within the unlicensed FCC Part 15 range.

Each control unit must maintain a continuous status signal to the associated receiver during operation. There must be no significant loss in systems efficiency and function at the end of eight hours of continuous battery use. Provide a contact monitoring board with the crane radio system receiver.

2.4.7.2 Bid Alternate Option - Fully Automated Unmanned Bridge Crane Operation

Provide bid alternate option for fully automated unmanned bridge crane system and operation. Option to include manufacturers fully automated unmanned crane management system of remote operator station, local crane management computers and software, server, database, crane laser scanners, crane control positioners, controllers, crane cameras and transponders.

Automated unmanned bridge crane system to be operated from remote operator station, location of remote operator station to be coordinated with WSA if bid alternate is selected. Manufacturer and Installer to fully test and commission bridge crane fully automated unmanned bridge crane system and operation. Manufacturer to provide operation and maintenance data in accordance with specification Section 01 78 23. Manufacturer and Installer to provide up to two week of training WSA operations staff on the use of the fully automated unmanned bridge crane system.

2.4.8 Electrification Systems

2.4.8.1 Runway Conductor System

Provide a rigid runway Conductor Bar System for the runway conductor system, including all necessary cables and hardware to the crane from a wall or column mounted disconnect switch. Provide electrification system with three power conductors and an equipment grounding conductor. The crane must be grounded through the runway electrification system. Provide runway conductors sized for simultaneous motions of the hoist, bridge, trolley mechanisms and any ancillary loads. If there is any way the hook block or wire rope can swing into the runway electrification, provide a guard installed to prevent contact.

SECTION 41 22 13 Page 19

Provide two Collector Shoes (tandem design) for each conductor; each collector shoe must be rated for not less than the runway conductor sizing, so as to provide redundancy.

Provide a Festoon System for the runway conductor system utilizing cables suspended from carriers riding on an I-beam or C-track for the crane, including all necessary cables and hardware to the crane from a wall or column mounted disconnect switch. Provide electrification system with three power conductors and an equipment grounding conductor. Conductors must be fabricated from copper. The crane is required to be grounded through this conductor system. Provide conductors sized for simultaneous motions of the hoist, bridge, trolley mechanisms and any ancillary loads.

Festooned cable loops must not extend low enough to come into contact with any obstructions.

Provide a totally enclosed flexible cable tray electrification system (cable chain) for the runway conductor system, including all necessary cables and hardware to the crane from a wall or column mounted disconnect switch. The cable chain must have three power conductors and an equipment grounding conductor. The conductors must be selected so as to be of the longest length without splices. Conductors must be fabricated from copper, and sized for simultaneous motions of the hoist, bridge, trolley mechanisms and any ancillary loads. The crane is required to be grounded through this conductor system.

2.4.8.2 Bridge Conductor System

Provide Festoon System for the bridge conductor system utilizing cables suspended from carriers riding on an I-beam or C-track. Conductors must be fabricated from copper. A minimum of 20 percent of the festoon control circuit conductors for each electrification system must be spares at the time of crane acceptance. The trolley is required to be grounded through this conductor system. Festooned cable loops must not extend low enough to come into contact with any obstructions.

Provide a Cable Reel System for the bridge conductor system.