412213.13 overhead cranes top running.pdf

F5W61607 Combined Support Maintenance Shop - Phase II Ohio Army National Guard Rev. 0 Defense Supply Center Columbus, Ohio 30 January 2009 Bid Final

OVERHEAD CRANES - TOP RUNNING 412213.13 - 1

SECTION 412213.13 - OVERHEAD CRANES - TOP RUNNING

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This Section includes top-running overhead cranes as follows:

1. 15-ton capacity cranes: 1H2, 2H1, 2H2 and 3H1.

2. Optional Bid Item: 15-ton capacity crane 1H2A.

3. Optional Bid Item: 15-ton capacity crane 2H1A.

1.3 SUBMITTALS

A. Shop drawings prepared and sealed by a professional engineer registered in the State of Ohio.

B. Structural/mechanical/electrical calculations prepared and sealed by a professional engineer registered in the State of Ohio.

C. Product Catalog Data.

D. Design Data.

E. Test Reports.

1. Final Inspection Report including as-built survey showing rail elevations and rail to rail dimensions.

2. Load Test Reports.

F. Operation and Maintenance Manuals.

1.4 QUALITY ASSURANCE

A. Bridge cranes shall comply with Specifications for Top Running Bridge and Gantry Type Multiple Girder Electric Overhead Traveling Cranes – CMAA Specification No.

70.

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B. Bridge cranes, bridges, and trolleys shall comply with:

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

C. Hoists shall comply with:

1. ASME HST-4 – Performance Standard for Overhead Electric Wire Rope Hoists.

D. Installer Qualifications: An authorized representative of crane manufacturer for installation and maintenance of units required for this Project.

1. Maintenance Proximity: Not more than 2 hours' normal travel time from Installer's place of business to Project site.

2. Installer's responsibilities include fabricating and installing cranes and providing professional engineering services needed to assume engineering responsibility.

3. Engineering Responsibility: Preparation of data for cranes, including Shop Drawings, based on testing and engineering analysis of manufacturer's standard units in assemblies similar to those indicated for this Project.

E. Manufacturer Qualifications: A qualified manufacturer with a minimum of 10 years in the field of manufacturing bridge cranes. Provide list of five projects similar in scope, with names of Architects, Contractors, with the years and locations of installations.

F. Source Limitations: Obtain cranes included in this Section through one source from a single manufacturer.

G. Design to comply with AISC S329 - Manual of Steel Construction - Allowable Stress Design Specifications.

H. Steel fabrication shall be free of kinks and sharp bends. Shear and chip neatly and accurately. Provide square/true corners. Straightening is only permitted if it will not change material properties or cause fabrications scars.

I. Flame Cutting: May be used so long as surfaces are sufficiently ground or machined to remove slag, objectionable notches, and all evidence of cooling checks.

J. Welding in accordance with AWS D14.1, done by AWS Certified Welders.

1.5 SITE CONDITIONS

A. Reference Structural Drawings for Seismic Risk Zone.

B. Electric power will be supplied as 480 VAC, 3 Phase.

C. Items specified in this Section will not be located or operated in areas classified as hazardous areas.

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PART 2 - PRODUCTS

2.1 TOP RUNNING BRIDGE CRANES

A. General: Cranes shall be complete systems including rails, bridges, trolleys, drives, electrification bars, hoists, electrical panels and controls, and radio controllers.

B. Basis-of-Design Product: 15 Ton Crane manufactured by OMI Crane Systems, Inc., Royse City, TX or a comparable product by one of the following manufacturers:

1. Morris Material Handling, LLC, Oak Creek, WI.

2. R&M Materials Handling, Inc., Springfield, OH.

3. Whiting Corporation, Monee, IL.

C. Spans and travel shall be as shown on the drawings. Spans and travel shown on equipment schedules are approximate.

D. Hook heights shall be as indicated on equipment schedules.

E. Maximum speeds shall be:

1. Hoist: 20 ft per minute.

2. Trolley: 65 ft per minute.

3. Bridge: 75 ft per minute.

F. Crane supplier shall provide and install ASCE rails of appropriate size for crane capacity and application. Rails shall be mounted on support beams provided by others.

G. Crane supplier shall provide stops at end of rails.

H. Runway electrification shall be conductor bar and collectors and shall include a grounding bar as well as current bars. The bar shall be totally enclosed on three sides.

I. A warning horn shall be provided on the crane that emits a continuous series of alternating tones whenever the bridge or the trolley are in motion.

J. Hoist, trolley, and bridge shall be electrically powered with variable frequency drives (VFDs) permitting operation in any direction at very slow speed and adjustment of maximum speed, up to specified maximum speed, in the control panel.

K. Hoist shall have mechanical load brake capable of holding rated load stationary for extended periods of time.

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L. Cranes shall be radio controlled.

1. The radio crane control systems shall be complete operating systems including portable controllers, crane mounted receiving and decoding equipment, power supply, and all necessary circuitry to operate the cranes in a safe and reliable manner.

2. The system shall operate in the 450 to 470 MHz band and shall be non-licensed. Frequency Modulation (FM) shall be used to minimize effects of electrical interference.

3. System shall meet or exceed applicable FCC and EIA standards and requirements.

4. The system shall have sufficient RF power and reserve signal strength to provide a nominal operating range of 500 ft.

5. Decoders shall use redundant microprocessors that compare commands before outputs are energized.

6. Radio Control System shall permit all cranes including existing to operate simultaneously, securely, and reliably.

7. Controllers shall be clearly marked indicating crane ID that they control.

Provide one spare controller that can be setup to operate either crane in case of a controller failure.

M. All components shall comply with CMAA 70 – Class C Moderate Service.

N. If Optional Bid Item for additional cranes on the same tracks is accepted, those cranes shall include collision avoidance systems. These systems shall be set to keep at least 18 ft separation between the wheels of the two cranes.

O. Hoist shall comply with ASME HST-4 – Class H3 Duty.

P. Hoist Ropes:

1. FS RR-W-410. Hoisting ropes shall be 6 by 37 class construction, improved or extra improved plow steel, with an independent wire rope core. Maximum hoisting rope fleet angles shall be 4 degrees for drums and 4.75 degrees for sheaves. Hoisting rope end connections, other than drum connections, shall be speltered sockets with forged steel terminals. Provide proof of wire rope breaking strength. Provide wire rope minimum safety factory of 5 to 1 based on the ratio of actual minimum wire rope breaking load to the calculated load on rope when hoist is assumed loaded to rated capacity. Certification from rope manufacturer, verifying provided wire roping breaking strength, shall be submitted to Contracting Officer and approved prior to final acceptance of hoist.

No paint or coatings shall be allowed on the wire rope. Minimum length of the wire rope shall enable the load hook to operate through its full hook lift range and still have a minimum of two full wraps of wire rope around the rope drum.

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PART 3 - EXECUTION

3.1 SHOP ASSEMBLY

A. Shop assemble the cranes to the largest possible extent.

3.2 SITE INSTALLATION

A. Erect the cranes within 30 days of the units arriving on-site.

B. The Contractor shall provide as-built survey data upon completion of the primary structure (including roof decking and roofing) in order for the Crane supplier to provide adequate tolerance/adjustment for connecting and leveling all crane rails.

The Crane Contractor shall identify and verify all critical dimensions prior to final fabrication/delivery of project cranes.

C. Crane supplier shall furnish all personnel and supervisory services necessary to install and make fully functional each crane and monorail hoist and the radio control system.

3.3 FIELD QUALITY CONTROL

A. Post-Erection Inspection: After erection, the Contractor and the Contracting Officer shall jointly inspect the crane, bridge and hoist systems and components to determine compliance with specifications and approved submittals. Contractor shall notify Contracting Officer 14 days prior to the inspection. Provide a report of the inspection indicating the crane is considered ready for operational tests.

B. Operational Tests: Provide operation tests for each crane unit. After erection and inspection, test the hoist, bridge, and trolley as specified. Perform the 125 percent rated load test with the bridge and trolley located to obtain maximum loads on the bridge and runway girders. Test the system in service to determine that each component of the system operates as specified, is properly installed and adjusted, and is free from defects in material, manufacture, installation and workmanship.

Rectify all deficiencies disclosed by testing and retest the system or component to prove the crane is operational. Contractor shall furnish test loads/rigging, operating personnel, instruments and other apparatus necessary to conduct field tests on each crane.

C. Test Data: Record test date on appropriate test record forms suitable for retention for the life of the cranes. Record operating and startup current measurements for electrical equipment (motors and coils) using appropriate instrumentation, such as clamp-on ammeters. Compare recorded values with design specifications or manufacturer's recommended values; abnormal differences, those greater than 10 percent from manufacturer's or design values, shall be justified or appropriate

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adjustments performed. In addition, high temperatures or abnormal operation of any equipment or machinery shall be noted, investigated and corrected. Record hoist, trolley and bridge speeds during each test cycle.

D. Test Hook: Measure hook for hook throat spread before and after load test. Establish a throat dimension base measurement by installing two tram points and measuring the distance between these tram points, plus or minus 1/64-inch. Record this base dimension. Measure the distance between tram points before and after load test. An increase in the throat opening by more than 5 percent from the base measurement shall be cause for rejection.

E. No-Load Test: Raise and lower the hook through the full range of normal travel at rated speed for three complete cycles. Raise and lower the hook, testing other speeds of the crane. Verify proper operation of hoist limit switches. Operate the bridge and trolley in each direction the full distance between end stops. Operate through the entire speed range and verify proper brake operation.

F. Load Tests: Perform for each crane. Perform the following tests, as specified, with test loads of 50, 100 and 125 percent of rated load. If the hoist is equipped with an overload limit device, disconnect it to allow the hoist to lift the test load. Proof test the overload limit device after it is reconnected. Submit a copy of load test certification from the Crane Manufacturer.

1. Static Load: 125 percent only. Check entire structure, holding brake and hoisting components as follows: Raise the test load approximately one foot.

Hold the load for 10 minutes. Rotate the load and hook to check bearing operation. Observe lowering that may occur indicating a weakness in the structure or malfunction of hoisting components or brakes.

2. Dynamic Load Tests: Raise and lower the test load through the full lift range.

Lower the load to the floor, wait 5 minutes, then raise and lower the load through two more cycles. As a minimum, operate in each speed for each test load. In addition, the dynamic test of load sequence number 2 (100 percent of rated load) shall be repeated for 10 cycles at rated speed, in order to demonstrate proper operation and repeatability of all functions without component overheating or malfunction. Completely stop the machinery at least once in each direction during each cycle to ensure proper brake operation. The hoist shall not be stopped for more than 15 seconds prior to commencing the next cycle.

3. Hoist Load Brake (at 125 percent only): Raise test load approximately 5 feet.

With the hoist controller in the neutral position, release by hand the holding brake. The load brake should hold the test load. Again with the holding brake in the released position start the test load down (first point) and return the controller to the "off" position as the test load lowers. The load brake should prevent the test load from accelerating.

4. Hoist Loss of Power Test (at 125 percent only): Raise the test load to approximately 8 feet. While slowly lowering the test load (first point), disconnect the crane's power source. Verify that the test load does not lower and that the brake is set.

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G. Trolley: Operate the trolley the full distance of the bridge rails in each direction with a test load of 125 percent of rated load on the hook (one cycle). Check proper functioning of all drive speed control points. Verify proper brake action.

H. Bridge: With a test load of 125 percent of rated load on the hook, operate the bridge for the full length of the runway in one direction with the trolley at the extreme end of the bridge, and in the opposite direction with the trolley at the opposite extreme end of the bridge (one cycle). Check proper functioning of all drive speed control points.

Check for any binding of the bridge end trucks and verify proper brake action. Record deficiencies. Secure from testing if deficiencies are found.

I. Rated Travel Tests: Repeat travel tests for trolley and bridge with a test load of 100 percent of rated load. Repeat the test for 5 cycles at rated speed to demonstrate proper operation and repeatability of all functions without the overheating or malfunction of any components. Completely stop the machinery at least once in each direction during each cycle to ensure proper brake action. The machinery shall not be stopped for more than 15 seconds prior to commencing the next cycle.

J. Trolley Loss of Power Test: With a test load of 100 percent of rated load, raise the test load approximately midway between the trolley and any permanent obstruction on the operating floor. Starting at a safe distance from walls or other obstructions, attain a slow speed (first point) of trolley travel. While maintaining a safe distance from obstructions, disconnect the main power source at the wall mounted safety switch (disconnect) to simulate a power failure. Verify that the trolley stops and that the brake sets properly. Measure the distance required for the trolley to stop.

K. Bridge Loss of Power Test: With a test load of 100 percent of rated load, raise the test load approximately midway between the trolley and any permanent obstruction on the operating floor. Starting at a safe distance from walls or other obstructions, attain a slow speed (first point) of bridge travel. While maintaining a safe distance from obstructions, disconnect the main power source at the wall mounted safety switch (disconnect) to simulate a power failure. Verify that the bridge stops and that the brake sets properly. Measure the distance required for the bridge to stop.

3.4 DEMONSTRATION

A. Engage a factory-authorized service representative to train Government's maintenance personnel to adjust, operate, and maintain cranes and controls. Refer to Section 01820 "Demonstration and Training".

END OF SECTION 412213.13