St__Stephen_Bridge_Crane_Rehab_-_Specifications.docx

SECTION TABLE OF CONTENTS DIVISION 26 - ELECTRICAL SECTION 26 05 00.00 26

BASIC ELECTRICAL MATERIALS AND METHODS

10/12

PART 1 GENERAL

PART 2 PRODUCTS

PART 3 EXECUTION

-- End of Section Table of Contents -- St Stephen Bridge Crane Rehabilitation 2012

SSBC12

SECTION 26 05 00.00 26

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SECTION 26 05 00.00 26

BASIC ELECTRICAL MATERIALS AND METHODS

PART 1 GENERAL

1.1 OVERVIEW OF WORK

An overview of the electrical work specified in SECTION 26 05 00.00 26 and SECTION 41 01 20.73 26 BRIDGE CRANE ELECTRICAL REHABILITATION includes the removal of the bridge crane controls, motors, operator control station, and wiring on the St. Stephen bridge cranes, and the design, fabrication, factory testing and field testing, furnishing, and installation of electrical and control equipment and associated systems. The equipment and associated systems includes motors, limit switches, complete control systems including radio control, conduit, wiring, load cells and indication, and auxiliary devices required to replace and enhance the cranes' electrical power, and control systems.

1.2 APPLICABILITY

This SECTION applies to sections of Division 26, and Division 41 of these specifications unless specified otherwise in the individual sections.

1.3 REFERENCES

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

ASTM INTERNATIONAL (ASTM)

ASTM D 709 (2001; R 2007) Laminated Thermosetting Materials

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C2 (2012; Errata 2012; INT 1 2012; INT 2 2012) National Electrical Safety Code

IEEE Std 519 (1992; Errata 2004) Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2008) Enclosures for Electrical Equipment (1000 Volts Maximum)

NEMA ICS 6 (1993; R 2006) Standard for Industrial Controls and Systems Enclosures

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2011; Errata 2 2012) National Electrical

Code

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2008; Errata 1-2010; Changes 1-3 2010; Changes 4-6 2011) Safety and Health Requirements Manual

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.

SD-02 Shop Drawings

Fabricated Nameplates

1.5 GENERAL REQUIREMENTS

1.5.1 Rules

All electrical equipment and installation shall be in accordance with EM 385-1-1, NFPA 70, and IEEE C2, except where otherwise specifically indicated on the contract drawings or called for in these specifications. Where equipment is specified to conform to requirements of any code or standard such as UL, NEMA, etc., the design, fabrication and installation shall also conform to the code. Omission of details on the drawings or in the specifications shall not be construed as permitting deviations from Code requirements. NEMA rated and UL listed equipment has been specified when available. Equipment shall meet NEMA and UL construction and rating requirements as specified; no equivalent will be acceptable. The Contractor shall immediately notify the Contracting Officer of any requirements of the specifications or Contractor-proposed materials or assemblies that do not comply with UL or NEMA. International Electrotechnical Commission (IEC) rated equipment will not be considered an acceptable alternative to specified NEMA ratings.

1.5.2 Electrical Requirements

All electrical equipment shall operate on power supplied at the crane. Equipment shall be able to tolerate variations in voltage source of +/- ten (10) percent, and variations in line frequency of +/- two (2) percent, with no degradation of performance or lifespan.

1.5.3 Performance Requirements

All equipment shall comply with IEEE Std 519. Electrical and electromechanical components of the new control system, including variable frequency drives (VFD's), programmable logic controllers (PLC's), radio control systems, and peripheral equipment, shall not cause electromagnetic interference to adjacent electrical and electromechanical equipment and components while in operation.

1.5.4 Type of Equipment and Quality

Materials and equipment shall be of the type normally furnished for crane applications and service and shall be the standard, unmodified, products of

Defective equipment or equipment damaged in the course of installation shall be replaced or repaired as approved by the Contracting Officer.

1.5.5 Environmental Requirements

Communication, control, and protective equipment shall be rated for continuous operation in ambient environmental conditions between -10 and +40 degrees C (+14 and +104 degrees F) at 0 to 95 percent relative humidity, non-condensing. Power equipment shall be rated as required by SECTION 41 01 20.73 26 BRIDGE CRANE ELECTRICAL REHABILITATION. All electrical equipment shall be of an appropriate type, rating, and installation that is resistant to continuous vibration.

1.5.6 Verification of Dimensions

The Contractor shall verify all dimensions and site conditions prior to sending applicable submittals for Government review. Space available for placement of electrical equipment and enclosures is limited to the dimensions of existing platforms and structural members unless otherwise shown or indicated in these specifications.

1.6 DELIVERY, STORAGE, AND HANDLING

Materials and equipment delivered and placed in storage shall be protected from the weather, humidity and temperature variations, dirt and dust, other contaminants, and physical damage. Equipment shall be shipped as completely assembled and wired as feasible so as to require a minimum of installation work. Any device which cannot withstand the hazards of shipment when mounted in place on the equipment shall be carefully packed and shipped separately. All finished painted surfaces and metal work shall be wrapped suitably or otherwise protected from damage during shipment.

All spare parts and accessories shall be carefully packaged for long-term protection and storage and shall be clearly marked.

PART 2 PRODUCTS

2.1 CABINETS AND ENCLOSURES

a. General construction of cabinets and enclosures housing electrical devices and equipment shall conform to the requirements of NEMA 250 and NEMA ICS 6. Except as otherwise specified, all cabinets and enclosures shall have an environmental enclosure rating of NEMA Type 12 as defined by NEMA 250.

b. Manufacturers of cabinets and enclosures, including custom-fabricated enclosures, shall be UL Certified in the manufacture

enclosure will be accepted as evidence of compliance.

2.2 FACTORY-APPLIED FINISHES

Electrical equipment shall have factory-applied painting systems which shall, as a minimum, meet the requirements of NEMA 250 corrosion-resistance test.

2.3 MANUFACTURER'S NAMEPLATES

Each item of equipment shall have a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place such as VFD's, motors, and separate individual components. The nameplate of the distributing agent will not be acceptable.

2.4 FABRICATED NAMEPLATES

block style.

2.5 MAINTENANCE

2.5.1 Accessories and Tools

For each powerhouse,furnish a complete set of accessories and special tools unique to equipment provided and required for erecting, handling, dismantling, testing and maintaining the apparatus.

PART 3 EXECUTION

3.1 EQUIPMENT REMOVAL

Remove bridge crane controls, motors, limit switches, control switches, conduit unless reused, wire and cable, operator control station and trolley control systems, including mounting brackets and termination boxes. All equipment removed shall become the property of the Contractor and removed from the site in accordance with all local, state and federal regulations.

3.2 EQUIPMENT INSTALLATION

3.2.1 General

Install all work as specified, and in accordance with the manufacturer's recommendations, unless otherwise specified. Provide all necessary interconnections, services, and adjustments required for a complete and operational system. Installation shall provide clear space for operation and maintenance in accordance with EM 385-1-1, NFPA 70, and IEEE C2.

3.2.2 Manufacturer's Technical Services

The Contractor shall work with the equipment manufacturers to make available the services of competent installation technicians during installation, startup, and testing. Technicians shall have the responsibility of checking the installation and making any field adjustments necessary to obtain a working system within the applicable requirements. The manufacturer's representatives shall be responsible for supervision of all testing.

3.2.3 Conduit

turns shall be made using conduit fittings, in order that the conduit may fit close to the crane's framework. All joints shall be threaded, and terminations shall be made at equipment units or components using threading

connections shall be made watertight, rustproof, and electrically conductive by applying a thread compound of colloidal copper and rust

mechanical work of installing conduit shall be completed before installing wire.

3.2.4 Wire and Cable

3.2.4.1 General

Conductor connections shall be terminated at terminal studs or terminal blocks using ring-tongue type indented terminal connectors, except for splices in lighting conductors which are made in junction boxes.

Screw-type terminals shall have lock washers and stud-type terminals shall have contact nuts and either locking nuts or lock washers. Splices shall not be made in any wiring on a panel or in a conduit.

3.2.4.2 Wire and Cable Markers

Single conductors and individual conductors of cables shall be identified with non-metallic tube-type markers at each termination. Markers shall be sized to fit the wire and shall be uniform in position. Wire markers shall be stamped with black wire numbers as indicated on the contract drawings. Cable designations of multiple-conductor cables shall be identified with embossed-aluminum band markers at each termination.

3.3 FIELD-APPLIED PAINTING

Damage areas of the shop coatings due to handling, transporting, erection, or other cause shall be touch up painted in the field. Touch up painting shall be performed so that the paint finish and color matches surrounding surfaces or that the whole surface is repainted. Contractor shall coordinate with St. Stephen Dam on the type of paint used and submit for approval.

3.4 FIELD-FABRICATED NAMEPLATE MOUNTING

Nameplates to devices and enclosures shall be fastened with a minimum of two (2) corrosion-resisting screws. Adhesive-applied nameplates will not be acceptable.

3.5 FIELD TRAINING

Field training of personnel on the use, operation, and troubleshooting of control system and equipment shall be accomplished in accordance with SECTION 41 01 20.71 26 BRIDGE CRANE DATA, TESTING AND TRAINING, paragraph FIELD TRAINING.

3.6 OPERATION AND MAINTENANCE MANUALS

O&M Manuals shall also include complete original manufacturer's quick-start, reference, programming, and user's manuals, with drawings, logic diagrams, instructions, and troubleshooting tips for each type variable frequency drive, dynamic braking unit, and programmable logic controller used. O&M Manuals shall also include a complete list of programmed settings (a "snapshot" or "download" of settings, current upon acceptance of the crane) and available field-adjustable settings with descriptions for each variable frequency drive provided. The O&M shall also include a detail description on how the control system functions and shall, at a minimum, include the following listed below. The detailed description shall be written by the Contractor and using the original manufacturer's user manuals to meet this requirement will not be acceptable.

f. Stop and Emergency stop function.

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SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT SECTION 41 01 20.71 26

BRIDGE CRANE DATA, TESTING AND TRAINING

PART 1 GENERAL

PART 2 PRODUCTS (Not Used)

PART 3 EXECUTION

SECTION 41 01 20.71 26

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SECTION 41 01 20.71 26

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SECTION 41 01 20.71 26

BRIDGE CRANE DATA, TESTING AND TRAINING

10/12

PART 1 GENERAL

1.1 GENERAL INFORMATION

This SECTION covers capacities, inspections, acceptance testing, and personnel training for the St. Stephen 135-ton powerhouse bridge crane. The bridge crane shall be tested and certified at the rated capacity.

1.2 REFERENCES

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

ASME INTERNATIONAL (ASME)

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

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.

SD-01 Preconstruction Submittals Rehabilitation Procedure; G HDC Final Inspection Procedure; G HDC Acceptance Test Procedure; G HDC Test Weight Plan; G HDC SD-06 Test Reports

Initial Post-Rehabilitation Inspection Report; G HDC Preliminary No-Load Performance Test Report; G HDC Final Inspection Report; G HDC Acceptance Test Report; G HDC

Shaft Alignment Report; G HDC SD-07 Certificates Craftsmen;

Water Bag Cleanliness Certification; SD-10 Operation and Maintenance Data Operating Manual; G HDC SD-11 Closeout Submittals Training Manuals; G HDC

1.4 DATA, CAPACITIES, SPEEDS AND TRAVEL

1.4.1 Definitions

Rated capacity of the main hoists is defined as the rated capacity of the hook. Rated capacity of the bridge crane is defined as the rated capacity of both main hoists. The rated capacity of the auxiliary hoists is defined as the rated capacity at the hook. Rated hoisting speed is defined as the speed when raising at rated capacity. Rated bridge travel speed is defined as the travel speed when traveling at rated capacity. Rated travel speed of the trolley is defined as the travel speed when operating at rated capacity.

1.4.2 Data, Capacities, Speeds, and Travel

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

1.4.2.1 Powerhouse Bridge Crane

a. Rated Capacity, Tons (2,000 pounds)...................... 135 b. Total Bridge Travel, Feet, approx........................ 241 c. Total Trolley Travel, Feet, approx....................... 36.5 d. Rated Bridge Travel Speed, Feet Per Minute............... 67.7 e. Rated Trolley Travel Speed, Feet Per Minute.............. 28.1

1.4.2.1.1 Main Hoists, one (1) per trolley

1.4.2.1.2 Auxiliary Hoists, one (1) per trolley

1.4.3 Speed Control Point Definition

Five (5) speeds shall be used for defining speed points in normal operation:

d. Speed Point Four. Eighty percent (80%) of full rated speed.

e. Speed Point Five. One hundred percent (100%) of full rated speed.

1.5 QUALIFICATIONS

1.5.1 General

Data showing that craftsmen meet the following qualifications shall be submitted for approval:

1.5.2 Qualified Craftsmen

Craftsmen shall possess the following:

a. Have experience and knowledge in performing work on bridge cranes of similar size and capacity as the St. Stephen bridge crane.

b. Have performed work on bridge cranes of similar size and capacity as the St. Stephen bridge crane for at least five (5) years.

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

1.5.3 Qualified Crane Electricians

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

1.6 REHABILITATION PROCEDURE

A complete rehabilitation procedure for all work done shall be submitted and approved before any work will be allowed to start. The procedure shall include, but not be limited to the following:

a. Step-by-step rehabilitation procedure. The level of detail for this procedure shall include all work steps necessary to completely demolish equipment specified to be removed, disposal, clean-up and surface preparations. Features of work with special removal/installation plans (for example operator cab, bridge trucks, etc). Include details of the steps necessary to completely install-shim-align and make machinery ready for operation.

b. Schedule and sequence of work.

c. Types of equipment used on site including work platforms, cranes, scissor lifts, etc.

All components that can be fabricated and/or assembled prior to removing the crane from service shall be furnished prior to the crane being turned over to the Contractor and on-site work commences. At minimum, the following components shall be completely fabricated and/or assembled and factory inspected and tested (unless otherwise approved by the Contracting Officer) prior to removing the crane from service:

1.7 TEST WEIGHT PLAN

A test weight plan for 100% rated load performance test shall be submitted for approval and shall contain the following:

d. Load measuring devices such as water flow meters and load indicators shall have calibration certificates issued within the last two (2) years. Include copies of calibration certificates with the test weight plan.

e. Test loads shall be plus 5 percent, minus 0 percent. Load on the powerhouse erection floor shall not exceed 1,000 lbs. per sq. foot.

Contractor shall submit water bag cleanliness certification at least 10 days prior to start of testing. Information included as part of the bag cleanliness certification shall be the storage locations and all locations bags have been used since last certification, invasive species removal verification, and cleaning techniques after usage.

Failure to provide an acceptable bag cleanliness certification shall require the Contractor to provide complete containment, clean-up and disposal of all water used during the load testing procedure, including

testing shall be replaced to keep spilled water to a minimum.

1.8 OPERATING MANUAL

A copy of an Operating Manual shall be provided. The Operating Manual shall include load ratings of crane; crane make, model, serial number, year of manufacture, year of rehabilitation, manufacturer's name and rehabilitation's name; operating instructions; and warnings.

a. After all rehabilitation work is completed and the crane has been completely reassembled, adjusted, lubricated, and otherwise made ready for operation, the Contractor shall perform initial post-rehabilitation inspections and preliminary no-load performance testing for themselves as quality control, correct any deficiencies, and repeat portions of inspections and tests to verify corrections prior to performing the final inspections and acceptance tests for the Government. The following shall be submitted for approval and approved before performing the Final Inspection:

1. Initial Post-Rehabilitation Inspection Report

2. Preliminary No-Load Performance Test Report

(The "Final Inspection" is the post-rehabilitation inspection that is witnessed by the Government.)

b. The Contractor shall allow the Government two (2) full business days to review the Initial Post-Rehabilitation Inspection Report and Preliminary No-Load Performance Test Report prior to start of the Government witnessed final inspections and acceptance tests. "Two (2) full business days" constitutes the Government receiving the reports electronically, not later than 0800 hours of the first date of review, to allow all Government reviewers adequate time to review the reports.

c. The final inspection and acceptance tests shall be performed by the Contractor and witnessed by the Government representatives, unless waived in writing.

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

ii. The final inspection and no-load testing/acceptance tests shall occur on separate days, unless otherwise approved by the Government.

iii. The main hoist 100 and 125 Percent Rated Load Performance Tests shall be coordinated with Project. The auxiliary hoist load tests may be completed during normal project work duty hours.

iv. Coordination of schedule for the testing shall be made with the Contracting Officer.

v. The Contractor test materials and personnel shall be on-site and ready for testing prior to Government witness representatives arrival.

d. The Final Inspection Report shall be provided to the Contracting Officer and witnessing Government personnel for approval before starting the acceptance tests.

e. Notify the Contracting Officer, a minimum of 14 calendar days in advance, the dates of the final inspections and acceptance tests.

f. Notify the Contracting Officer, a minimum of three (3) business days in advance, any revisions of the dates of the final inspections and acceptance tests.

g. Final touch-up painting may be performed after completion of acceptance testing.

3.2 INITIAL POST-REHABILITATION INSPECTION

The initial post-rehabilitation inspection is the same inspection as the final inspection, except that it is a trial inspection that the Contractor performs by themselves to make sure the crane is ready to undergo the final inspection and acceptance test procedure in the presence of the

Procedure shall be submitted and approved prior to performing the initial post-rehabilitation inspection. The Government approved Final Inspection Procedure shall be used for the initial post-rehabilitation inspection, except that the gear alignment verification checks do not need to be

inspections, including any corrective action taken and re-inspection results, shall be recorded in the Initial Post-Rehabilitation Inspection Report. Any anomalies shall be corrected and re-inspected prior to the submittal and acceptance of the Initial Post-Rehabilitation Inspection Report. See paragraph FINAL INSPECTION.

3.2.1 Additional Requirements

The following tests, data results and supplementary reports shall be included with the submittal of the Initial Post-Rehabilitation Inspection Report.

3.2.1.1 Shaft Alignment

3.3 PRELIMINARY NO-LOAD PERFORMANCE TEST

The Preliminary No-Load Performance Test is the same test as the No-Load Performance Test, except that it is a trial test that the Contractor performs by themselves to make sure everything performs satisfactorily prior to performing the acceptance tests in the presence of the Government representatives. The Preliminary No-Load Performance Test need not be witnessed by the Government. The Acceptance Test Procedureshall be submitted and approved prior to performing the Preliminary No-Load

paragraphs EQUIPMENT MONITORING and NO-LOAD PERFORMANCE TEST.

3.4 FINAL INSPECTION

3.4.1 General

a. The "Final Inspection" is the post-rehabilitation inspection that is witnessed by the Government. The Government representatives will not attend the final inspection until the following have been completed:

(1) Submittal and approval of Initial Post-Rehabilitation Inspection Report.

(2) Submittal and approval of Preliminary No-Load Performance Test Report.

b. The Final Inspection Procedure shall be used for the final inspection. The final inspection shall be performed by designated crane inspectors. The findings shall be recorded in the Final Inspection Report. Any anomalies shall be corrected and re-inspected prior to acceptance of the Final Inspection Report.

c. The inspection shall be witnessed by the Government representatives, unless waived in writing.

d. The Final Inspection Report shall be prepared and given to the Contracting Officer on-site for review. Upon on-site approval of the Final Inspection Report, the acceptance tests may be performed. The Final Inspection Report shall be included in the Operation And Maintenance Manual.

3.4.2 Final Inspection Procedure

The Final Inspection Procedure shall be prepared by the Contractor and used to record findings and results of the inspections. Operational tests shall be performed at no-load. The final inspection shall include the following:

a. A checklist of all work to be performed under this contract shall be prepared. During inspection, verify that all work has been performed.

b. Perform inspection in accordance with ASME B30.2, Overhead and Gantry Cranes (periodic inspection).

c. All incidental equipment including load cells, locking and indicating devices, and lights shall be checked for proper operation.

d. Verify that all brakes have been adjusted and burnished; and brake torques have been verified.

e. Verify that the crane has been cleaned up.

f. The main and auxiliary hoist load blocks shall be raised and lowered through the full range of normal travel exercising all five (5) drive speed control points in each direction at normal speed, microspeed, and ultra-lift speed. The load blocks shall be stopped below the limit switch upper setting. In slow speed (first speed, normal) only, proper operation of upper limit switches shall be verified. At minimum, the lower limits for the main hoist load blocks shall be verified for proper operation of lower limit switch by jumpering the contact or tripping the lever type limit switch. The main hoist lower limit shall also be physically verified by lowering each block to the lowest elevation achievable (if possible by removing access hatches). Lower limits for the auxiliary hoist load blocks shall be verified for proper operation of lower limit switch by physically lowering each block to the required elevation in the powerhouse to trip the limit

in each direction.

g. The trolleys shall be operated the full distance of the rails in each direction, exercising all five (5) drive speed control points in each direction at normal speed and microspeed. Brake operation shall be verified in each direction. Proper operation of travel limit switches shall be verified.

h. The bridge shall be operated the full distance of the runway in each direction, exercising all five (5) drive speed control points in each direction at normal speed and microspeed. Brake operation shall be verified in each direction.

i. For all hoists, while slowly lowering the load blocks (normal speed and microspeed), the main power source shall be disconnected by pressing the "Emergency Stop" button on the operator control station, verifying that there are no more than four (4) brake wheel revolutions, and that the brakes will set.

j. For each of the trolleys and bridge, with the load blocks raised to clear obstructions and the trolley and bridge traveling in slow speed, the main power source shall be disconnected by pressing the emergency stop button on the operator control station, verifying that the trolleys and bridge will stop, and that the brakes will set.

k. Tandem operation for both main hoists and both trolley drives shall be demonstrated for proper operation.

l. Remote control operation for the hoists, trolley drives and bridge drives shall be demonstrated for proper operation.

"Fail-safe" design of the remote (radio) control system as specified in SECTION 41 01 20.73 26 paragraph CONTROL PANEL SUPERVISION shall be demonstrated, including loss of signal.

m. Not Used.

n. All powerhouse "Emergency Stop" pushbuttons and "Emergency Stop" pushbuttons on the VFD consoles shall be operated to ensure all power is removed from the bridge crane when activated.

i. Speed Control Test. All speed control points shall perform as defined in paragraph 1.4.3 "Speed Control Point Definition."

3.5 ACCEPTANCE TESTS

3.5.1 General

a. Acceptance Testing will not occur until the following conditions are met:

(4) On-site approval of the Final Inspection Report.

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

3.5.2 Test Sequence

The crane shall be tested according to the sequence provided in the approved Acceptance Test Procedure, which shall include the requirements specified in the No-Load Performance Test, 100 Percent Rated Load Performance Test, and 125 Percent Rated Load Performance Test.

3.5.3 No-Load Performance Test

a. During the test for each condition specified below, a full set of calculated and measured readings shall be recorded for load float and each speed point in each direction for each hoist and travel motion. Calculated readings shall be taken from the digital display unit of the associated Variable Frequency Drive (VFD) and shall include output voltage, output current and output frequency. Measured readings shall be taken from the output terminals of the associated VFD and shall include true rms voltage and true rms current. All speeds shall be computed based on output frequencies for all speed points. Data recorded shall be included in the Acceptance Test Report.

tests shall be performed at no-load:

(1) Main Hoist No-Load Performance. For all main hoists, the load block shall be raised and lowered exercising all five (5) drive speed control points at normal speed, microspeed, and ultra-lift speed (raising only in ultra-lift).

(2) Auxiliary Hoist No-Load Performance. For all auxiliary hoists, the load block shall be raised and lowered exercising all five (5) drive speed control points at normal speed, microspeed, and ultra-lift speed (raising only in ultra-lift).

(3) Trolley Travel No-Load Performance. Each trolley shall be operated exercising all five (5) drive speed control points in each direction at normal speed and microspeed.

(4) Bridge Travel No-Load Performance. The bridge shall be operated exercising all five (5) drive speed control points in each direction at normal speed and microspeed. A full set of readings shall be taken for each drive motor individually to ensure that they are operating properly (synchronized).

(5) Tandem No-Load Performance. Main hoist tandem operation shall be raised and lowered exercising all five (5) drive speed control points at normal speed and microspeed. Trolley tandem operation shall be performed (while mechanically unlocked) exercising all five (5) drive speed control points in each direction at normal speed and microspeed. Trolley tandem operation shall be performed (while mechanically locked) exercising the fifth drive speed control point in each direction.

(6) Tandem Synchronized Performance. Main hoists and trolleys (while mechanically unlocked) shall be tested for Tandem Synchronized Performance at full rated speed and microspeed.

(7) Main Hoist HMI Positioning Verification. The main hoist position information as displayed on the Human Machine Interface (HMI) shall be verified for accuracy.

(8) Positioning Accuracy Verification. The positioning accuracy for hoists, trolleys and bridges shall be verified.

(9) Anti-Skewing System: Verify ability to acquire and maintain laser distance measurements and provide specified system function at all speeds. Test in both directions.

c. Final Operational Test. The Contractor shall operate the bridge crane, traversing the entire length of the track. The Contractor shall note all significant noises from the bridge drive and track, as well as any issues with crane tracking and any defective items found during the test. All observations (and measurements where applicable) shall be compared to the findings of the Operation Test Report.

Results of the No-Load Performance Test shall be included in the Acceptance Test Report, submitted for approval.

3.5.4 100 Percent Rated Load Performance Test

brakes are holding properly at 50 percent load before proceeding to 100 percent.

tests shall be performed using a test load of 100 percent of rated load:

(1) Hoist Loss of Power Performance. For all hoists, while slowly (first speed control point, normal) lowering the test load, the "Emergency Stop" pushbutton shall be pressed to verify that, with the test load, there are no more than four (4) brake wheel revolutions and that the brakes will set. For all hoists, while slowly (first speed control point, microspeed) lowering the test load, the emergency stop pushbutton shall be pressed to verify that, with the test load, there are no more than four (4) brake wheel revolutions and that the brakes will set.

(2) Hoist Performance. For all hoists, the load block shall be raised and lowered exercising all five (5) drive speed control points in each direction at normal speed and microspeed.

(3) Trolley Travel Performance. Each trolley shall be operated exercising all five (5) drive speed control point in each direction at normal speed and and exercising all five (5) drive speed control points in each direction at microspeed.

(4) Bridge Travel Performance. The bridge shall be operated exercising all five (5) drive speed control point in each direction at normal speed and and exercising all five (5) drive speed control points in each direction at microspeed.

(5) Trolley Tandem Travel Performance. Trolley tandem shall be operated (while mechanically unlocked) exercising all five (5) speed control points in each direction at normal speed and exercising all five (5) drive speed control points in each direction at microspeed. Trolley tandem shall be operated (while mechanically locked) exercising the first drive speed control point in each direction at normal speed.

(6) Main Hoist Tandem Performance. Main hoist tandem shall be raised and lowered exercising all five (5) drive speed control points at normal speed and microspeed. All hoist position information shall be verified via the HMI.

c. Bridge travel performances shall be verified at 100 percent rated load of the crane, with both main hoists of the crane being loaded simultaneously, and shall be tested at normal speed and microspeed.

Results of the 100 percent rated load performance test shall be included in the Acceptance Test Report, submitted for approval.

3.5.5 Acceptance Test Report

The Acceptance Test Report shall be submitted for approval and inserted as a separate section in the Operations and Maintenance Manual.

3.6 EQUIPMENT MONITORING

During the Final Inspection, performance testing, and Acceptance Test, improper operation or poor condition of safety devices, electrical components, mechanical equipment, and structural assemblies shall be monitored. Observed defects critical to continued inspection or testing shall be reported immediately to the Contracting Officer and inspection or testing shall be suspended until the deficiency is corrected. After corrective action has been taken, the tests shall be continued or rerun as directed. The following inspections shall be made:

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

POWER OFF pushbuttons, shall be tested and inspected separately to verify proper operation of the brakes.

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

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

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

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

i. Inspection covers shall be removed from gear reducers for inspection of gearing after all testing.

j. Inspection covers shall be removed from hoist drum and pinion gears for inspection after all testing.

3.7 MANUFACTURER'S SERVICES

Equipment manufacturers shall make available the services of competent installation technicians during installation, startup, and testing. Technicians shall have the responsibility of checking the installation and making any field adjustments necessary to obtain a working system within the applicable requirements.

3.8 NOT USED

3.9 FIELD TRAINING

3.9.1 General

All Contractor administered training must occur during the normal Government schedule. The Government will not take final acceptance of the crane until all training has been completed.

3.9.2 General Operation and Maintenance

3.9.3 Solid State Maintenance Training

b. The Contracting Officer shall be given at least two (2) weeks advance notice for training covering the systems listed. It shall be the Contractor's responsibility to coordinate the training sessions with the Project to ensure minimum conflicts with ongoing Project work.

3.9.4 Training Materials

The Contractor shall provide training materials for 10 employees per class. The Government will provide the training location. The Contractor shall submit training manuals and documentation to the Contracting Officer for approval at least 30 days prior to scheduled classes and shall furnish three (3) copies of the approved training materials at the completion of the training to the Contracting Officer for the Project files. Training shall include both lecture and hands-on type of work. Where audio/visual materials are used in training classes, three (3) copies of such materials shall be furnished to the Contracting Officer for use in future Project office training. Draft copies of the Operation and Maintenance (O&M) Manuals shall be provided as reference material for use with the training manuals. Copies of Contractor prepared drawings shall be included with the draft O&Ms.

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SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT SECTION 41 01 20.73 26

BRIDGE CRANE ELECTRICAL REHABILITATION

03/10

PART 1 GENERAL

PART 2 PRODUCTS

System

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