19-R-0018_Revision_3.10.pdf

US ARMY CORPS OF ENGINEERS

St. Louis District

PERFORMANCE SPECIFICATION

LD 24 AND LD 25 SERVICE CRANES

PREPARED BY

MOFFATT & NICHOL

PREPARED FOR USACE - MARINE DESIGN CENTER

FEBRUARY 6, 2019

DESIGN REVIEW APPROVED

P. RANTA R. DORNHELM A. BOZORGZADEH

US Army Corps of Engineers St Louis District

Performance Specification LD 24 and LD 25 Service Cranes

Page i

Table of Contents

1. INTRODUCTION

1.1 Project Background

1.2 This Specification

1.3 Project Sites and Site Access

1.4 Definitions

2. CURRENT CRANE SYSTEM FUNCTIONALITY

2.1 General

2.2 Bulkhead Hoist

2.3 Boom Crane

2.4 Cross Travel

3. FUNCTIONAL REQUIREMENTS

3.1 General

3.2 Bulkhead Hoist System

3.3 Boom Crane

3.4 Cross Travel System

3.5 Operating Speeds

3.6 Interlocks

4. GENERAL REQUIREMENTS

4.1 Submittals

4.2 Environmental Conditions

4.3 Seismic Conditions

4.4 Crane Classification and 3rd Party Engineer design review

4.5 Project Management

4.6 Testing Procedures and Documentation

4.7 Acceptance Testing

5. STRUCTURAL REQUIREMENTS

5.1 Structural Design

5.2 Crane Rail and End Stops

6. MECHANICAL REQUIREMENTS

6.1 Truck Arrangements

6.2 Hoist Drum

6.3 Wire Ropes

7. ELECTRICAL REQUIREMENTS

7.1 General

7.2 Main Power System

7.3 Lighting Systems

7.4 Load Measurements System

7.5 Space Heaters

7.6 Anemometer

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7.7 Lightning Protection

7.8 Hour meter

8. ADDITIONAL REQUIREMENTS AND FUNCTIONS

8.1 Operators’ Cabin

8.2 Pendant Control Station

9. MANUFACTURING

9.1 All components of the crane shall be new; no refurbished or second hand components are allowed

9.2 Manufacturing Quality Control

9.3 Surface Preparation

9.4 Painting

9.5 Shop Testing

9.6 Nondestructive Examinations

10. ON-SITE ACTIVITIES

10.1 General

10.2 Installation and Commissioning

10.3 Crane Certification

10.4 Functional Test

10.5 Bulkhead Hoist

10.6 Boom Crane

10.7 Cross Travel

10.8 Interlock Tests

11. SPARE PARTS AND SPECIAL TOOLS

11.1 General

11.2 Special Tools

11.3 Man Baskets

12. MANUALS AND TRAINING

12.1 General

12.2 Operating Instructions and Manuals

12.3 Maintenance Instructions and Manuals

12.4 Maintenance Overview and General Instructions

12.5 Mechanical Maintenance Instructions

12.6 Electrical Maintenance Instructions

12.7 Structural Inspection Manual

12.8 Acceptability of Documentation

12.9 Operator Training

13. WARRANTY

13.1 General

14. SUPPORTING SERVICES

14.1 Service Requests

APPENDIX 1: GENERAL ARRANGEMENTS, CRANE WORKING ENVELOPE

1. INTRODUCTION

1.1 Project Background

1.1.1 The U.S. Army Corps of Engineers (USACE) operates and maintains Lock and Dam systems over the Mississippi River. The objective of this project is to replace the existing lock service cranes for St. Louis District Lock and Dam 24 (LD 24) and Lock and Dam 25

(LD 25).

1.1.2 Additional information can be found from the following documents:

[1] DamNo25_RevisedDrawings.pdf

[2] LD24_Drawings_Dam_1938 Reduced.pdf

[3] LD24 Original crane drawing.pdf

[4] LD25 Original crane drawing.pdf

[5] Bulkhead hoist lifting beam drawings - CRANE_I.pdf

1.2 This Specification

1.2.1 This Specification defines the requirements for design, manufacture, installation, performance, and testing of the LD 24 and LD 25 service cranes. The cranes furnished shall be designed and conform to all applicable codes and requirements, as outlined in this specification. This Specification provides the minimum requirements for the cranes.

The Contractor shall be responsible for sizing, selection, and installation of equipment to provide optimal performance under the conditions described in this specification.

1.3 Project Sites and Site Access

1.3.1 St Louis District Lock Dam 24 (LD 24) and Lock Dam 25 (LD 25) are at following locations:

1.3.1.1 St Louis District Lock Dam 24

1.3.1.1.1 Upper Mississippi River, Clarksville, Missouri (Latitude 39.3754114; Longitude -

90.9072028).

1.3.1.2 St Louis Lock Dam 25

1.3.1.2.1 Upper Mississippi River, Winfield, Missouri (Latitude 39.004856; Longitude -

90.6868296).

1.3.2 Site access is restricted by the USACE; access to the site shall be in accordance with the rules and regulations in place.

1.4 Definitions

1.4.1 Parties:

1.4.1.1 Purchaser: USACE’s representatives and independent engineers retained by the Purchaser.

1.4.1.2 Contractor: The Contractor and the Contractor’s representative and independent engineers retained by the Contractor.

1.4.2 Specifications: These Specifications, including appendices and any clarifications, deviations, or other addenda agreed upon between the Purchaser and the Contractor and incorporated into the Contract.

1.4.2.1 The intent of these Specifications is to provide structural, mechanical, electrical, and functional criteria, dimensions, operating speeds and accelerations, and pertinent details for the design, construction, and installation of a reliable and efficiently functioning lock dam service crane with accessories.

1.4.2.2 Unless specifically stated otherwise, the Specification requirements apply to all cranes and all components, even if the requirement is stated in the singular.

1.4.2.3 Will and Shall: These Specifications are written to the Contractor. When a provision of this Specification requires action by the Contractor, the verb “shall” is used. If the Contractor is allowed to exercise an option when limited alternatives are available, the phrasing “either … or …” is used. However, where the words “or approved equivalent” are used, the Purchaser reserves the option of rejecting the proposed equivalent.

Statements provided in the Specification as information to the Contractor use the verbs “may” or “will.” Informational statements typically identify activities or options that “will be taken” or “may be taken” by the Purchaser.

1.4.2.4 Approved Equivalent: Where the term “or approved equivalent” is used, the Contractor may propose an alternative device, item, or manufacturer only if it provides at least equivalent performance, quality, and supportability to that of the specified item.

Proposed alternatives must be provided within 30 calendar days of the contract award to be considered. The Purchaser has no obligation to accept the proposed alternative and the Contractor shall abide by the Purchaser’s decision.

1.4.2.5 Purchaser’s Approval: Where a component, concept, design, or other item is stated as being subject to the Purchaser’s approval, the Contractor shall submit a written request with supporting data for the Purchaser’s consideration of the proposed item and the Purchaser shall respond in writing. Acceptance of the item by the Purchaser shall not relieve the Contractor from responsibility for the design or compliance with these Specifications. Items requiring the Purchaser’s approval may be rejected at any time unless the Contractor has submitted a written request for consideration and the Purchaser has accepted it in writing.

1.4.2.6 The Crane System includes Boom crane, bulkhead hoist and gantry system.

1.4.3 Minimum Criteria

1.4.3.1 The criteria specified herein shall be considered the minimum acceptable. If, in the Contractor’s opinion, any of the criteria specified herein or in the referenced standards is in any way inadequate or insufficient for the intended use, it shall be the Contractor’s responsibility to use more stringent criteria, subject to the Purchaser’s approval.

1.4.3.2 Except where otherwise specified, the Contractor shall furnish all materials, equipment, tools, labor, and incidentals necessary to fully and completely finish the project according to the true intent and meaning of these Specifications and drawings, even though every item or activity is not particularly mentioned or shown in these Specifications or drawings.

1.4.3.3 The Contractor shall remain responsible for adequacy and safety of the design, fabrication, supply, installation, transportation, commissioning, and testing of the equipment specified herein while adhering to the minimum criteria set forth in these Specifications.

1.4.4 Contractor’s Scope of Supply

1.4.4.1 The principal items of work are the following: Design, manufacture, installation, certification, and testing of cranes, including all appurtenances specified and required for a complete installation.

1.4.4.2 All equipment, materials, and labor to manufacture, install, test, transport, and commission are the responsibility of the Contractor.

1.4.5 Applicable Standards

1.4.5.1 The crane manufacturer shall meet or exceed the requirements of the codes, standards, regulations, and procedures, as currently published at the time of manufacture, referenced in this Specification for the design, manufacture, installation, and testing of the crane. In the event of conflict between the Specification and the codes and standards, the more stringent requirement shall govern and be used. Specific codes and standards to be met include:

• Crane Manufacturers Association of America (CMMA): CMAA, Specification No. 70, Class A, (infrequent service) Revised 2015, “Crane Manufacturers Association of America, Inc., Specifications for Top Running Bridge & Gantry Type Multiple Girder Electric Overhead Traveling Cranes.”

• American Society of Mechanical Engineers (ASME): ASME B30.2-2016, “Overhead and Gantry Cranes,” Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist. ASME B30.5 -2011,” Mobile and Locomotive Cranes”. ASME B30.23 - 2016, “Personnel Lifting Systems”.

• National Electric Code (NEC) NFPA 70, Latest Edition including Article 610 Cranes and Hoists.

• Society for Protective Coatings (SSPC).

• Occupation Safety and Health Administration (OSHA), 1910.179 Overhead and Gantry Cranes, OSHA 1926. 1431 Cranes & Derricks in Construction, and OSHA 1926.1501(g)(4) Cranes and derricks.

• USACE Safety and Health Requirements Manual, EM 385-1-1, Section 15 and 16.

• American National Standards Institute, ANSI A1264.1, Safety Requirements for

Workplace Walking/Working Surfaces and Their Access.

• American Society for Testing and Materials (ASTM).

• American Society of Mechanical Engineers (ASME).

• Institute of Electrical and Electronics Engineers (IEEE).

• American Welding Society (AWS): AWS D14.1/D14.1M-2005, "Specification for

Welding of Industrial and Mill Cranes and Other Material Handling Equipment".

• American Gear Manufacturers Association (AGMA).

• National Electrical Manufacturer's Association (NEMA).

• National Fire Protection Association (NFPA).

• International Building Code (IBC).

• USACE EM 1110-2-2610 30 June 2013, Mechanical and Electrical Design for Lock and Dam Operating Equipment.

• USACE EM 1110-2-3200 30 November 2016, Wire Rope for Civil Works Structures.

• American Petroleum Institute, API-2C Specification for Offshore Pedestal Mounted

Cranes.

2. CURRENT CRANE SYSTEM FUNCTIONALITY

2.1 General

2.1.1 This section is for information only; its purpose is to describe current functionality and operational characteristics to the Contractor.

2.1.2 LD 24 has 15 Tainter gates and LD 25 has 14 Tainter gates and 3 roller gates (the roller gates are 40-feet wider than the Tainter gates). When a Tainter or roller gate is taken into maintenance, water flow through the gate is prevented by installing bulkhead gates to the upper pool side of the dam. These bulkheads are lifted using a crane system, subject to replacement in this project. The crane system is located on the service bridge above the gates. Bulkheads are stored at the storage area at the east end of the lock when not in use. The crane system travels on rails mounted on top of the service bridge.

2.1.3 The crane system has two functions: 1) lifting and transporting bulkheads, and 2) lifting service equipment and materials to and from the storage yard. The crane system has two major components: 1) an electric powered hoist for lifting bulkheads; and 2) a diesel generator powered system for travel movement on the service bridge, and boom crane for lifting equipment and materials to and from the service bridge.

2.2 Bulkhead Hoist

2.2.1 The procedure for placing bulkheads starts with latching the lifting beam to the bulkhead, lifting a bulkhead from the storage area to a travel position, travelling the bulkhead to the gate, lowering the bulkhead in the upstream guide slots, unlatching the lifting beam, and lifting the lifting beam back to the travel position. The lifting beam / bulkhead is supported by guides in the travel position, see Appendix 1. This process is repeated until the bulkheads are above water level. Removing the bulkheads is performed in reverse order. The bulkhead hoist system has lifting capacity of 82,000 lbs.

at LD 25 and 72,000 lbs. at LD24.

2.2.2 LD 25 hoist system has a rigging function that provides approximately 2 feet in / out movement, this is needed due to different types of bulkheads and bulkhead locations.

The existing LD 24 hoist system does not have this capability.

2.3 Boom Crane

2.3.1 The boom crane has a maximum outreach of 70 feet and maximum lifting capacity of 12,000 lbs. The boom crane is equipped with winch and auxiliary winch.

2.4 Cross Travel

2.4.1 The crane system cross travels on a pair of rails on top of the service bridge. Cross travel is powered through a diesel generator and power is transferred to wheels over a shaft arrangement. All eight (8) wheels are driven. Current system speed is approximately 3 miles per hour (mph). The rail gage at LD 24 is 10’ 2.5” while that at LD 25 is 12’ 2.5”.

3. FUNCTIONAL REQUIREMENTS

3.1 General

3.1.1 The replacement bulkhead design results in bulkhead lift requirements that exceed the capability of the existing systems. This section defines the minimum requirements for the replacement crane system.

3.1.2 Crane system design life shall be 25 years.

3.2 Bulkhead Hoist System

3.2.1 The bulkhead hoist system shall be operated with wired pendant controller at the east side of the service bridge and shall have sufficient length to operate the hoist from off-board the crane.

3.2.2 The hoist lifting distance below top of the rail is 59’ 5’’. The lifting beam and bulkhead shall be lifted to a home position where they are supported and secured for safe gantry travel. The details of home position are subject of design review and it can be different from top of the rail.

3.2.3 Hoist drums shall operate simultaneously at the same speed, maintaining the lifting beam in a leveled position.

3.2.4 The LD 25 hoist shall have rigging range of 2 (two) feet from the home position. The LD 24 hoist shall have rigging range of 6 (six) inch from the home position.

3.2.5 The bulkhead hoist lifting capacity at LD 24 shall be 160,000 lbs, which is equal to the Safe Working Load (SWL). The bulkhead hoist lifting capacity at LD 25 shall be 120,000 lbs, which is equal to the Safe Working Load (SWL).

3.2.6 Bulkhead hoist lifting speed with rated load shall be 1 ft/min.

3.2.7 The bulkhead hoist lifting system shall be designed to work with lifting beams provided by the Purchaser.

3.2.8 Bulkhead hoist home position is at the top of the lifting height in a supported travel position. The hoist can be at the home position with or without lifting beam.

3.2.9 Bulkhead hoist shall be provided with load indication and load limiting devices.

3.2.10 In addition to operating brake, the bulkhead hoist system shall have emergency brake to prevent falling of the load and stopping lowering motion, in case of power loss or other failure.

3.3 Boom Crane

3.3.1 The boom crane shall have telescopic retractable hydraulic boom.

3.3.2 The boom crane shall have a minimum 50-foot reach with a load of 12,000 lbs when fully extended.

3.3.3 The boom crane lifting distance below top of the rail is 59’ 6”. The lifting distance above top of the rail is minimum 30’.

3.3.4 The boom crane shall have 360-degree revolving range.

3.3.5 The boom crane shall have a main winch and an auxiliary winch. Auxiliary winch lifting capacity shall be 10,000 lbs.

3.3.6 Boom crane shall be rated for man basket operations with limited speeds, and shall be explicitly stated in user manuals.

3.3.7 The home position is the boom in stowage position or retracted completely. Home position shall be designed to allow safe travel during cross travel or safe lifting when operating the bulkhead hoist. The boom crane shall be in the home position for safe travel or bulkhead lift.

3.3.8 The boom crane/operator’s cab shall be provided with continuous load indication, maximum permissible load and actual load, snag control, boom angle, boom length, and load limiting devices.

3.4 Cross Travel System

3.4.1 Cross travel shall move the crane system along the rails on top of the service bridge.

3.4.2 The gantry truck shall be secured with parking brake(s) when movement is stopped.

3.4.3 The gantry may utilize the existing wheel stops provided the new truck wheels are the same diameter as the existing. If the truck wheels are a different diameter than the existing, then new wheel stops of appropriate size shall be provided. The wheel stops shall be the non-slip type suitable for end-of-rail application.

3.5 Operating Speeds

3.5.1 The bulkhead hoist shall be capable of lifting or lowering the bulkhead sections at a minimum full lifting speed of 1 ft/min. Hoist shall have variable speeds starting from creep speed (25% from the full speed) to full speed.

3.5.2 The crane system shall be capable of cross-traveling with the bulkhead and lifting beam the full length of the service bridge at a nominal 3 mph. The crane system shall be capable of cross-traveling at a reduced speed to suit environmental conditions.

3.5.3 The boom crane line speed shall be minimum 220 ft/min.

3.5.4 The boom crane Slewing speed shall be 0-4.0 rpm

3.5.5 The boom extension time shall be maximum 130 seconds, elevating time to maximum elevation shall be maximum of 90 seconds.

3.6 Interlocks

3.6.1 The crane system shall have, in addition to specifications mentioned in section 1.4.5.1 , the following interlocks and other limitations to functionality based on safety regulations.

3.6.1.1 Bulkhead Hoist and rigging functions shall not be allowed if any of the following conditions apply:

3.6.1.1.1 Gantry is not in parked state.

3.6.1.1.2 Boom crane is not in the home position.

3.6.1.1.3 Detection of overload.

3.6.1.1.4 Wind exceeds safe operating limits.

3.6.1.2 Boom crane functions shall not be allowed if any of the following conditions apply:

3.6.1.2.1 Bulkhead hoist is carrying a load or hoist is not in home position.

3.6.1.2.2 Gantry truck is not in parked state.

3.6.1.2.3 Detection of overload.

3.6.1.2.4 Wind exceeds safe operating limits.

3.6.1.3 Gantry truck functions shall not be allowed if any of the following conditions apply:

3.6.1.3.1 Bulkhead hoist is not in home position; only inching mode shall be available.

3.6.1.3.2 Boom crane is not in home position.

3.6.1.3.3 Wind exceeds safe operating limits.

3.6.1.3.4 Crane system is plugged in to utility power.

3.6.2 Other Requirements

3.6.2.1 The crane system shall be sized to resist all overturning forces with appropriate factors of safety. Overturning factor of safety shall not include any physical connection to the crane rail, which shall be provided as redundant overturning system.

3.6.2.2 The crane shall be provided with clearly visible label plates indicating safe working loads (SWL). Warning plates shall also be provided as shown on the drawings. All label and warning plates shall be in accordance with OSHA and CMAA No. 70 Specifications.

3.6.2.3 The crane shall have power connection to energize block heaters and charge of batteries, when the crane is parked and not operating.

4. GENERAL REQUIREMENTS

4.1 Submittals

4.1.1 The Contractor shall submit design concepts to the Purchaser for design review purposes. The concepts shall be presented in writing and shall be supported by calculations, layouts, sketches, and typical previous designs and details. The Contractor shall create document registry where all individual documents are listed and progress of submittals are tracked, example of the document registry is shown in Table 4-1. The Contractor shall include all information that he believes will help describe the concepts.

The final design drawings, specifications, and calculations shall be sealed by a Professional Engineer registered in the United States. A day means a calendar day. The submittals shall include, as a minimum but not limited to, the following with the given schedule:

4.1.1.1 Submittals no later than 20 days after Notice to Proceed (NTP):

4.1.1.1.1 The Contractor shall submit the following submittals no later than 20 days after NTP:

• Project Management Plan

• Project Schedule

• Quality Control Plan, including but not limited to, list of sub-assemblies for The

Purchaser’s inspection during manufacturing phase.

4.1.1.2 Submittals no later than 60 days after NTP

4.1.1.2.1 Structural Concepts: Crane system, including but not limited to, stability analysis and wheel load calculations shall be submitted for Purchaser’s review and approval.

4.1.1.2.2 Mechanical Concepts: Description of how the Contractor intends to meet the concept requirements shall be submitted. Specifically:

• General arrangement drawings showing dimensions and clearances

• Welded steel construction gantry frame, trucks, wheels, and drive system assemblies with parking brakes

• Bulkhead hoist construction

• Boom crane manufacturer’s specification packet, if standard boom crane model is used. Otherwise all documentation, including calculations, fabrication drawing, component selections and manufacturing procedures to support design review are required.

• Operators’ cabin arrangements

4.1.1.2.3 Electrical Concepts: Specifically:

• Electrical arrangement of the crane system

• Electrical single-line diagram

• Scheme for electrical isolation of drives

• Preliminary drive and motor sizing

• Preliminary brake sizing

• Main power disconnect and transfer switch

• Preliminary power demand

• Diesel generator sizing and manufacturer’s specification packet

• Crane overload capacity switch

4.1.1.3 Submittals no later than 120 days after NTP or 30 Days Prior to Site Delivery, whichever is earlier:

4.1.1.3.1 Final design documents including drawings, specifications, calculations, non-destructive examination procedures, operating manual, maintenance manual and fabrication construction schedule.

4.1.1.3.2 Description of site work program, resources, and timeline.

4.1.1.3.3 Detailed transportation, offloading, commissioning plan.

4.1.1.3.4 A crane-testing program, including hydraulic, electrical, and other equipment, in sufficient detail to demonstrate no-load, load, and overload tests on the entire crane and components.

4.1.2 No delivery shall be scheduled until minimum of 14 days after final approval of all required submittals by the Purchaser.

4.1.3 The Contractor shall provide as-built documentation no later than 30 days after final acceptance.

Table 4.1 Example: Submittal Registry

Item Submittal Due date

NTP+

Date

Submitted Date

Reviewed General documentation

1 Project Management Plan 20

2 Project Master Schedule (monthly update)

3 Quality control plan 20

4 Site work program description 120

5 Transportation and lifting plan 120 6 Offloading plan 120

7 Crane Installation Plan 120 8 Crane Erection Drawings 120 9 Crane testing program 120

10 Non-destructive examination procedures

11 Operating Manual 120 12 Maintenance Manual 120

Item Submittal Due date

NTP+

Date

Submitted Date

Reviewed 13 Spare Part List – class 1 120 14 Spare Part List – class 2 120 15 Manufacturing quality control reports, including nondestructive examinations

14 days after examination

16 Testing and commissioning reports, including crane certification documentation

14 days after completion of the tests

17 As-built documentation 14 days after hand over to operation

Structural design and calculations

18 Load calculations to the service bridge superstructure

19 Stability calculations 60

20 Crane system structural calculations 60 Mechanical design and calculations

21 General arrangements 60

22 Color scheme 60 23 Gantry truck arrangements and calculations

24 Bulkhead hoist arrangements 60

25 Lifting beam sheave arrangements 26 Stick boom crane arrangements 60

27 Operators cabin and control devices 60

28 Man basket design 60 Electrical design and calculations

29 Electrical arrangement of the crane system

30 Lighting plan 31 Electrical single line diagram 60

32 Arc flash hazard analysis report 60 33 Scheme for electrical isolation 60

34 Electrical motor sizing calculations 60

35 Brake sizing calculations 60

36 Main power disconnect/transfer switch

37 Power demand calculations, including generator calculations

38 Crane overload capacity switch 60

4.2 Environmental Conditions

4.2.1 The crane must be designed to work under the following ambient conditions:

4.2.1.1 Temperature range -20°F to 120°F.

4.2.1.2 Maximum operating wind speed of 30 mph.

4.2.1.3 The recommended wind speed (3 second gust at 33-ft) for the cranes in the stowed position is 115 mph, Exposure D at elevation 90-ft above ground (water) level. The appropriate topographic effects with wind from the downstream direction, with river at the minimum lower pool levels, shall be accounted for in the design of the crane. Wind analyses shall be per ASCE 7-10.

4.2.1.4 Humidity, condensing 100%.

4.3 Seismic Conditions

4.3.1 The crane in the stowed position shall be designed to be stable and able to withstand the MCE as described in ASCE 7-10. The site classification shall be taken as D (stiff soil).

The seismic risk category is II. Mapped acceleration parameters at the two sites shall be taken from the USGS website or ASCE mapped peak ground acceleration.

4.3.2 The crane shall be seismically designed for maximum seismic load to survive an International Building Code (IBC) specified earthquake for the region. CMAA No. 70 level three (3) stress case shall be used for designing the crane for the assumed seismic load.

4.4 Crane Classification and 3rd Party Engineer design review

4.4.1 The cranes shall be designed and constructed in accordance with the Crane Manufacturers Association of America Specification No. 70, Class A, Duty Cycle (standby or infrequent service).

4.4.2 The Contractor shall hire a 3rd Party Engineer for design review and validation of calculations, these include structural, mechanical and electrical engineering. 3rd Party Engineer shall provide an independent review of structural, mechanical and electrical engineering for The Purchaser. The Contractor shall provide 3rd Party Engineer’s qualifications for The Purchaser’s approval. The Purchaser has right to reject use of 3rd Party Engineer proposed by The Contractor based on qualifications.

4.5 Project Management

4.5.1 The Contractor shall nominate a Project Manager, who will be the single point of contact in all project related matters during the duration of the project.

4.5.2 The Contractor’s Project Manager shall present the Project Management Plan.

4.5.3 The Project Management Plan shall include, as a minimum, the following:

4.5.3.1 Engineering schedule

4.5.3.2 Project organization/work breakdown structure

4.5.3.3 Submittal schedule

4.5.3.4 Management of workmanship and quality control

4.5.3.5 Management of fabrication and transportation

4.5.3.6 Management of site activities

4.5.3.7 Management of testing program

4.5.3.8 Instructions and manuals

4.5.3.9 Document management

4.5.3.10 Commissioning and test procedures

4.5.4 The Contractor’s Project Manager shall facilitate regular project status meetings. These meetings are facilitated as conference calls at a minimum bi-weekly interval. The Contractor Project Manager shall publish minutes of the meeting within five days after each meeting.

4.5.5 The Contractor shall facilitate design review meetings prior to start of manufacturing.

The Contractor shall present design concepts for structural, mechanical, and electrical parts of the crane during the design review meetings; therefore, these meetings must be face-to-face or via a video conferencing tool such as Web-Ex or Skype.

4.5.6 The Contractor shall facilitate delivery and commission meetings a minimum of 30 days prior to the start of delivery. The Contractor shall present time schedule, site-requirements, offloading plan, commissioning, and acceptance plan for Purchaser’s approval during the delivery and commission meeting; therefore, these meetings must be face-to-face or via a video conferencing tool such as Web-Ex or Skype.

4.6 Testing Procedures and Documentation

4.6.1 The Contractor shall provide testing procedures for factory testing, non-destructive examination procedures and results, pre-shipment function test, commissioning test, and acceptance testing for The Purchaser’s review and approval.

4.7 Acceptance Testing

4.7.1 The Contractor shall perform all tests required for certification to the satisfaction of the Certifying Agency at LD 24 and LD 25.

5. STRUCTURAL REQUIREMENTS

5.1 Structural Design

5.1.1 The contractor shall submit a rational structural analysis and computations for each lock and dam site for the Purchaser’s review. The rational structural analysis shall include but not be limited to, analysis of crane stability and an analysis of the maximum live load effects imposed by the crane to the service bridge.

5.1.1.1 The Contractor shall consider all industry standard load cases in addition to the load cases specified in 5.1.1.2 and 5.1.1.3.

5.1.1.2 Additional Load Case 1: Bulkhead hoist carrying SWL maximum bulkhead load with lifting beam along each bridge span to be placed in bulkhead slot. Maximum operating wind load on live load shall be considered to maximize the wheel load on the upstream girder. The Contractor shall provide load effects results comprising of one set of results including live load impact and one set of results not including live load impact.

5.1.1.3 Additional Load Case 2: Crane is centered over each bridge span picking the bulkhead out of the upstream bulkhead slot. Maximum operating wind load shall be considered to maximize wheel loads on the upstream girder. Impact on the picking load shall be considered based on industry standards. The Contractor shall provide load effects results comprising of one set of results including live load impact and one set of results not including live load impact.

5.1.2 For each load case, the following maximum live load effects, defined in Table 5.1 through Table 5.3, shall not be exceeded at each critical location for the span identified.

The enveloped results of load effects from all load cases shall be documented for each girder and optimized against the load criteria defined in this performance specification.

For each span, when computing the maximum live load effects for each load case at each critical location, the Contractor shall model each girder using discrete elements, including nodes at every critical section. For all moving load cases, the moving wheel loads applied to the girders shall start completely off the bridge span at one end and travel along the bridge span until all wheels are off the span.

Table 5.1 Maximum Allowable Crane Live Load Effects (Provided by USACE, St. Louis District)

Table 5.2 Maximum Allowable Crane Live Load Effects (Provided by USACE, St. Louis District)

Table 5.3 Maximum Allowable Crane Live Load Effects (Provided by USACE, St. Louis District)

5.1.3 The weight of the boom crane and bulkhead hoist shall be as light as practical without sacrificing stability and integrity of the structural design or jeopardizing safety of operation. The maximum allowable weight of the crane system (not including weight of lifting beam and maximum bulkhead load or boom crane maximum loads) at LD24 and LD25 shall be 215,000 lbs.

5.1.4 The maximum allowable wheel load, considering weight of the crane system plus weight of lifting beam and maximum bulkhead load or boom crane maximum loads, shall not exceed 52 kips per wheel.

5.1.5 The maximum distance between the ends of the gantry shall not exceed 60 feet, as depicted on the Appendix 1. All structures, equipment, and access fittings shall be within this requirement and as shown on the Appendix 1. Retracted and parked parts of the boom crane shall not extend beyond the ends of the gantry.

5.2 Crane Rail and End Stops

5.2.1 The existing crane rail is not being altered or replaced. Crane design shall be based on the geometry and structural capacity of the existing ASCE 80 lb crane rail and supporting system. Details of the crane rail and supporting system may be found in the reference documents, see Section 1.1.2.

5.2.2 End stops shall be capable of arresting the crane moving at 2-inches / second without sustaining damage or damaging the rail.

6. MECHANICAL REQUIREMENTS

6.1 Truck Arrangements

6.1.1 Truck wheels shall be steel, double flanged, machined treads with treads hardened to Brinnell Hardness Number (BHN) 200 subject to rail hardness testing by the purchaser.

Wheels shall be designed in accordance with CMAA No. 70 guidelines for the loading, class of service, and rail size.

6.1.2 The crane system shall be sized to resist all overturning forces with appropriate factors of safety. Overturning factor of safety shall not include any physical connection to the crane rail, which shall be provided as redundant overturning protection. The Contractor shall provide a mechanism for storm locking and stowage. Storm locking shall be manually activated when crane is parked and is not operating.

6.1.3 Wheel bearings for crane truck shall be designed in accordance with CMAA No. 70 Class A (stand by or infrequent service). The Contractor shall provide system to equalize the load over all wheels.

6.2 Hoist Drum

6.2.1 The bulkhead hoisting drums shall be fabricated of welded steel plate. The drums shall have machined grooves.

6.2.2 The wire rope attachment to the drums shall be designed such that adjustment and replacement of rope may be accomplished without dismantling the drum assembly. The pitch diameter of the drum shall not be less than thirty (30) times the diameter of the hoisting rope. The drum material shall be in accordance with CMAA No. 70. The combined bending and crushing stress for the drums shall not exceed 20 percent of the drum material yield strength, at rated loads.

6.3 Wire Ropes

6.3.1 The size of the hoisting ropes shall be determined from the maximum rope tension resulting from maximum rated load. The rope tension shall not be greater than 20 percent of the nominal breaking strength of the rope. The ropes shall be standard size, of sufficient length to provide for the specified lift, plus fill three (3) extra wraps on the drum and an adequate length for bitter end connection to the drum. Suitable bolt-on rope clamps shall attach the ropes to the circumference of the drum. Where ropes dead end other than on the drum, the rope attachment shall develop the full strength of the rope. As a minimum, rope shall be extra improved plow steel (EIPS) independent wire core (IWRC), type 6x37 strand.

6.3.2 Wire rope selection should be optimized by an analysis of commercial availability and hoist dimensional constraints. The Factor of Safety for the rope shall be at least 5, or higher if required by regulations.

6.3.3 The current lifting beams have sheaves designed for 1-1/8" diameter rope. New sheaves shall be supplied for each lifting beam. Sheaves shall be designed and manufactured by a sheave manufacturer regularly involved in the design and manufacture of sheaves of this size and type. Sheaves shall be designed keeping with the dimensions shown in the lifting beam reference drawings with the exception that the accurately machined grooves should be sized in accordance with the wire rope diameter supplied with the new bulkhead crane. The sheaves shall be designed for a line pull load equal to the rated load of the wire rope with 180 degrees of wrap on the sheave. Material shall be cast iron, ductile iron, cast steel, or forged steel as required by the design. Paint shall be the manufacturer's standard paint system for sheave operation and storage in an outdoor environment and subjected to cycles of submergence in fresh water. Contractor to install the new sheaves on the existing lifting beams prior to any testing requiring the use of the lifting beams

7. ELECTRICAL REQUIREMENTS

7.1 General

7.1.1 Electrical components shall be designed and rated in accordance with applicable NEMA and UL standards.

7.1.2 Contractor shall perform an arc flash hazard analysis on the electrical system and comply with the most recent editions of industry standards and codes, including OSHA 29 Part 1910 Subpart S, NFPA 70-2017, NFPA 70E-2018, IEEE 1584-2002, and EP 385-1- 100.

7.1.2.1 Contractor shall document the arc flash hazard analysis in a detailed report and provide 3 copies to The Purchaser.

7.2 Main Power System

7.2.1 All crane system functions shall be powered by onboard diesel generator as main source of power. Direct electrical connection to 100A 480V 3-phase outlets available on the bridge structure at each bay shall be provided as backup power. Receptacle is Crouse- Hinds 3-wire 4 pole type 3R interlocked Arkite receptacle with enclosed switch (WSP 10352 Model M82). The Contractor shall provide a connection cable between crane and bridge utility power connection, cable length shall be determined during detail design.

7.2.2 The generator shall have seismic bracing.

7.2.3 A manual transfer switch will be used to switch between onboard generator power and external bridge utility power.

7.2.4 The Contractor shall provide power plan, including generator calculations for The Purchasers review and approval.

7.3 Lighting Systems

7.3.1 The crane shall be supplied with a permanent lighting system to cover the crane work areas, ladders, walkways, and platforms.

7.3.2 Lighting fixtures shall be LED type with color temperature 4000K or less, and shall be designed for outdoor crane service. Lighting fixtures shall be waterproof marine type, selected and mounted for high resistance to weather, vibration and corrosion. The operator shall have ability to adjust lights manually to provide optimal light aiming.

Light fixtures may have portable clamps to accommodate adjustment.

7.3.3 Additional lights shall be provided for nighttime access, operation, and/or maintenance.

Lighting shall achieve the following target lighting levels, minimum:

7.3.3.1 Operational areas under bulkhead hoist: 200 lux (20 fc)

7.3.3.2 Operational areas of boom crane: 100 lux (10 fc)

7.3.3.3 Areas around the crane at the service bridge 50 lux (5 fc)

7.3.3.4 Inside the Cab: 100 lux (10 fc)

7.3.4 The Contractor shall provide a lighting plan for Purchaser’s review and approval.

7.4 Load Measurements System

7.4.1 The bulkhead hoist and boom crane shall be equipped with load measurement system(s). Load measurement system(s) shall visualize current load in numeric value and activate visual and audible overload warning and shutdown on overload situation.

Bulkhead hoist load shall be visualized in pendant control station and operators cabin.

Boom crane load shall be visualized in operator’s cabin. The load measurement system adjustments, calibration or other applicable changes shall be performed by the manufacturer or contractors qualified technician.

7.5 Space Heaters

7.5.1 The crane system shall be equipped with block heaters to accommodate winter conditions. For operating temperature range see section 4.2.

7.6 Anemometer

7.6.1 The anemometer shall be all weather type, suitable for a marine environment and be able to withstand winds to 150 mph.

7.6.2 The anemometer shall be able to monitor wind velocity between 0 mph and minimum 130 mph with an accuracy of +/- 2 percent over the full range.

7.6.3 The anemometer shall be suitable for rugged crane service. It shall be insensitive to crane vibrations and insensitive to a waterfront environment. The anemometer shall be installed at the tip of the boom.

7.6.4 The anemometer shall activate a warning signal when wind exceeds 20 mph. Warning signal thresholds shall be adjustable by a parameter.

7.6.5 The actual wind speed, direction, and active warnings shall be displayed at the operators’ cabin.

7.7 Lightning Protection

7.7.1 All crane frame and bolted and pinned joints shall have highly flexible copper conductors across the joint.

7.7.2 Tandem grounding sliding shoes shall be provided on the crane rails at the four corners of the crane.

7.7.3 Install lightning arrester in switchgear

7.7.4 A lightning rod at the boom tip and top cross tie shall be a minimum 4 foot in length and no device shall be in a 40-degree cone envelope of the rod.

7.8 Hour meter

7.8.1 Crane shall be equipped with 5-digit electromechanical hour meter measuring operating hours. Hour meter shall monitor operating time under generator and external bridge utility powered operation, not including when crane system is plugged in for parking.

8. ADDITIONAL REQUIREMENTS AND FUNCTIONS

8.1 Operators’ Cabin

8.1.1 The enclosed boom crane operators’ cab shall be installed on top of the crane frame and oriented such that the operator’s view provides optimal visibility.

8.1.2 Operators’ cabin shall have HVAC with thermostatic control.

8.1.3 Operators’ cabin shall comply with OSHA defined noise levels.

8.1.4 Audible and visual alarm indicators/controls and safety warning devices. Audible alarm shall be provided with a manual shut-off switch, overload warning and start of cross travel.

8.1.5 Operators’ cabin shall have windshield wipers and window defoggers.

8.1.6 Operators’ cabin shall have electrical duplex outlet (120 VAC, 20 Amp).

8.1.7 Operators’ cabin shall have a fire extinguisher.

8.1.8 Access to the operators’ cabin shall comply with OSHA requirements for safety, as a minimum. Access to the operators’ cabin shall be via permanent ladders and attached to gantry truck. Ladders shall be arranged on the lower pool side of the gantry truck.

Operators’ cabin shall have a door, either sliding type or swinging type. In case of swinging type of door, it shall open outwards. Access shall be in accordance to ANSI A1264.1.

8.1.9 Operators’ cabin shall have a fixed radio installation operating at various frequencies, including local communication channels, marine, and emergency bands. Radio shall be provided with noise cancelling headset with hot mic functionality.

8.1.10 Stick boom outreach and safe working load (SWL) shall be indicated with drawing installed in operators’ cabin.

8.2 Pendant Control Station

8.2.1 Bulkhead hoist and gantry travel shall be controlled from the pendant controller located on the east side of crane system. Pendant controller shall have fixed cable installation and it shall have sufficient reach allowing operator to stand next to the crane system and observe and control bulkhead hoist operation and gantry travel motion.

8.2.2 Pendant controller shall be rated for outdoor use.

9. MANUFACTURING

9.1 All components of the crane shall be new; no refurbished or second hand components are allowed.

9.2 Manufacturing Quality Control

9.2.1 (QC) shall be the responsibility of the Contractor. Any inspection performed by The Purchaser shall be only as verification of the Contractor’s own program and is not to replace any portion of the Contractor’s program. The Contractor shall assign for the duration of the project, a senior QC person to be accountable for the quality of all work in all disciplines, including design, documentation, manufacturing, commissioning, testing, and delivery. The Purchaser shall have right to visit manufacturing site(s) without restriction during the fabrication, The Purchaser shall notify The Contractor minimum 48 hours prior to the visit.

9.2.1.1 The Contractor shall notify The Purchaser when any component or sub-assembly is ready for inspection. If any sub-assembly of the Cranes should be assembled by the Contractor without such notification or without affording The Purchaser reasonable opportunity to inspect all of its components, The Purchaser shall have the right to require the Contractor to remove or disassemble, in whole or in part, that assembly so proper inspection of its components can be made. The Contractor shall bear the cost of such removal, disassembly and reassembly, and no extension of time shall be granted because of the increased work required.

9.2.1.2 Purchaser may retain independent inspection laboratories and engineers to audit the Contractor's QC and to perform inspections. These inspectors shall have free access to the facilities of the Contractor and his subcontractors or vendors and their design documentation. Inspections by the Purchaser's representative shall be performed using procedures deemed appropriate by the Purchaser.

9.2.1.3 Purchaser will pay for the cost of the inspectors retained by Purchaser. In the event that retest and re-inspections are required due to defective work, the cost of the retest and re-inspection will be at the Contractor's expense.

9.2.1.4 Inspection by Purchaser's representative will be performed in such a manner as to not unnecessarily delay the work. The Purchaser's representative shall not be restricted from photographing or video filming work in progress.

9.2.1.5 Any work, material, or equipment, whether or not in place, not conforming to these specifications will be considered defective and will be rejected by Purchaser's representative. Work performed from drawings or revisions which have not been signed or initialed by the Contractor's responsible Engineer will not be inspected and will be considered rejected. However, Purchaser has no obligation to exercise such authority, and the Contractor shall remain fully responsible for the completion of his work as specified.

9.3 Surface Preparation

9.3.1 Surfaces shall be thoroughly prepared in accordance with SSPC SP-10. Oils and greases shall be removed by suitable solvents.

9.3.2 No coating shall be applied unless the surface has been cleaned and is dry and free from rust, loose mill scale, dirt, oil, grease and other foreign substances.

9.4 Painting

9.4.1 Lead based paint is not acceptable and shall not be used.

9.4.2 The Contractor shall provide color scheme of the crane for The Purchasers approval, color scheme shall cover following parts:

9.4.2.1 Gantry Truck and bulkhead hoist

9.4.2.2 Boom Crane

9.4.2.3 Access ladders Safety Yellow or galvanized

9.4.3 Three types of coatings shall be used for coating the crane system and outfit. The coatings shall consist of a primer coat, an intermediate coat and finish coats, with at least 285-micron total dry film thickness as follows:

9.4.3.1 Primer: One coat of Epoxy Zinc rich primer with a dry film thickness of at least 65 microns.

9.4.3.2 Intermediate: One coat of Epoxy Micaceous iron oxide applied at manufacturer's plant with a dry film thickness of at least 140 microns.

9.4.3.3 Finish: Two coats of polyurethane recoatable finish applied at manufacturer's plant with a dry film thickness of at least 40 microns each.

9.4.4 The paint system shall not crack or flake off within the warranty period.

9.5 Shop Testing

9.5.1 All major components and sub-assemblies shall be shop tested. All permanent conduit and wires shall be installed for the shop test.

9.5.2 The facility shall accommodate a total length of the crane rail to travel the gantry a minimum of seventy-five (75) feet to perform the tests.

9.5.3 The preference is to perform full-scale functional tests prior to delivering cranes to the site. In the event that the facility cannot accommodate the pre-shipment tests, component tests are required to demonstrate sub-component functionality.

9.6 Nondestructive Examinations

9.6.1 The contractor shall provide written non-destructive examination procedures for the examination of components identified in this section. The contractor shall perform non-destructive testing in accordance with CMAA 70 and AWS D14.1. In addition to the requirements of AWS D14.1 Section 10.8.1, all complete penetration welds (CJP) not classified as Joint Class I or Joint Class 2 shall require either radiographic or ultrasonic examination in addition to magnetic particle or dye penetrant examination. All fillet welds shall be tested using magnetic particle or dye penetrant examination in accordance with AWS D14.1 Section 10.16 and 10.17. The inspector responsible for acceptance or rejection of material and workmanship shall be an AWS Certified Welding Inspector (CWI) in conformance to the provisions of AWS QC1, Standard for AWS Certification of Welding Inspectors. Non-destructive examination results shall be documented and submitted to The Purchaser for review and approval.

10. ON-SITE ACTIVITIES

10.1 General

10.1.1 During on-site activities the Contractor shall nominate a Site Manager responsible for all Contractor’s site activities. The Site Manager shall hold daily morning briefings with USACE staff explaining planned work to be performed at the site.

10.1.2 There is an on-going construction program that may impact the LD 25 project. The Contractor shall coordinate timing of crane delivery with The Purchaser in order to minimize interruptions to the current construction program. The construction program may prevent traversing over the full length of the service bridge, as well as limiting the availability of the bulkheads during the construction program. The Contractor shall be prepared to execute the final testing at a later time in the event the current construction program interferes with the completion of final acceptance testing.

10.1.3 Existing crane shall remain at the service bridge until new crane system is fully commissioned and handed over to the operation. Decommissioning of the existing crane is performed by the others. Limitations caused by the existing crane on commissioning tests shall be coordinated with The Purchaser. The Contractor shall return to complete remaining tests after decommissioning of the existing crane in case limitations disallows completion of the tests.

10.2 Installation and Commissioning

10.2.1 The preparation of the site for the arrival of the cranes shall be coordinated between the Purchaser and the Contractor. The Contractor shall submit a Crane Installation Plan and schedule that entails a description of the crane installation and all rigging mooring required for the installation.

10.2.2 The Contractor shall conduct an independent site review and site survey for purposes of design and installation considerations.

10.2.3 To minimize interruption to operations, the crane and equipment shall not be delivered to…