SECTION 14630 BRIDGE CRANE PART 1 - GENERAL 1.1 SCOPE OF WORK A Fumish all labor, materials, tools, equipment, and incidentals required for a complete and operating installation of the 20-ton electric overhead traveling bridge crane hoist, bridge crane, and appurtenants indicated on the Drawings and as specified herein 1.2 RELATED WORK A B. G Division 5: Metal Fabrications. Division 9: Field Painting Division 16: Electrical Work. 1.3 SUBMITTALS A G. Submit shop drawings and equipment data in compliance with Section 01300, Include erection methods and details. Submit details of crane stops for the bridge cranes. ‘Submit four (4) copies of a Certificate of Compliance with the Department of Labor Occupational Safety and Health Standards (OSHA), Part 1910, Subpart N, Section 190.179, Overhead and Gantry Cranes, at the time that shop drawings are submitted ‘Submit manufacturer's installation instructions ‘Submit manufacturer's field report of installation and equipment testing. ‘Submit operation and maintenance data in compliance with Section 01300. ‘Submit various loads imparted by the crane operation. ‘Submit installation tolerances for orane rail. 4.4 REFERENCE STANDARDS ‘A. Hoist Manufacturer's Institute (HMI); HMI 100-74 for Electric Wire Rope Hoists. B. Crane Manufacturer's Association of America (CMAA): Specification No. 70 for Electric Overhead Traveling Cranes. Contract No. PB467094 PBO6T510 14630 1 Pavaho Storm Water Pumping Station Bridge Cranemoo m J, ‘American Institute of Stee! Construction (AISC) specifications. American Welding Society (AWS) standards. National Electric Code. Occupational Safety and Health Administration Standards of the U.S. Department of Labor. Comply with all Federal, State and City of Dallas, Texas codes and ordinances. Underwriters’ Laboratory (UL) regulations as specified. National Electrical Manufacturers Association. ‘American National Standards Institute. 1.5 QUALITY ASSURANCE ‘A. Qualifications: The crane shall be the product of a crane manufacturer having cranes of the same capacity, size and type as specified, and in successful operation for at least five years. The Contractor shall submit a chronological list of those cranes, including serial number, capacity, span, type of drive, name of owner, and location of each crane. B. Regulatory Requirements’ 1. Equipment furnished under this section shall comply with the applicable requirements of the following: 2. Occupational Safety and Health Administration Standards. 3. CMAA Specifications. 4, Alllstructural steel members of the crane shall be designed in compliance with the specifications of the American institute of Steel Construction, current edition, and any welded construction shall be in accordance with the standards of the American Welding Society. 5. Castings, forgings, stampings, and other structural elements shall have a minimum safety factor of five 6. Conduct plant testing according to manufacturer’s commercial testing procedures. 7. All materials shall be new and unused. C. Services of Manufacturer's Representative: 1. Provide services of manufacturer's factory service engineer specifically trained in the installation, operation, and maintenance of bridge cranes. ‘Submit qualifications of service engineer for approval. 2. Man-hour requirements tabulated below are exclusive of travel time and do not relieve the Contractor of obligation to provide sufficient service to place equipment in satisfactory operations Contract No, PB467094 PBO6T510 14630 -2 Pavaho Storm Water Pumping Station Bridge Crane| | | Senices Provided Minimum | Minimum Time | | By Factory Representative No. of Trips | On Site Per Trip Hours} [4 Supervise installation _.|o(4 | 16 2. Inspect and approve installation” 8 | 3. Supervise initial adjustment 8 | 4. Supervise and assist in testing™ 1 8 [5 Instruct Owner and Owner's Representative in proper startup | 1 16 : 3M" 7 | (a) THE MANUFACTURER'S FACTORY REPRESENTATIVE SHALL BE PRESENT AT FREQUENT ENOUGH INTERVALS TO ENSURE PROPER INSTALLATION, TESTING, AND INTIAL OPERATION OF THE EQUIPMENT (0) THE MANUFACTURER'S FACTORY REPRESENTATIVE SHALL PROVIDE TO THE (OWNER'S REPRESENTATIVE A WRITTEN CERTIFICATION THAT THE SYSTEM HAS. [BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER'S RECOMMENDATIONS. (6) MAYBE DONE UPON COMPLETION OF ITEM 2 IF ACCEPTABLE TO THE OWNER'S REPRESENTATIVE. (6) MAYBE DONE UPON COMPLETION OF ITEMS 2 AND 3 IF ACCEPTABLE TO THE OWNER’S REPRESENTATIVE (e) INSTRUCTION MAY BE GIVEN UPON COMPLETION OF ITEM 4, PROVIDED THE TEST 1S SUCCESSFUL AND THE 08M MANUALS HAVE BEEN SUBMITTED TO AND ACCEPTED BY THE OWNER'S REPRESENTATIVE 1.6 SYSTEM DESCRIPTION ‘A. The 20-ton, radio controlled, top running, double girder bridge crane shall include motor driven hoist, trolley, bridge, and crane rails for pump station service. The crane shall also include walkway on either side with a crossover to get from one walkway to the other. B. The bridge crane will be utilized for removing and replacing pumps, motors, and other heavy equipment from the concrete volute rotating element floor level at elevation 393.0 +/- 1.7 DELIVERY, STORAGE, AND HANDLING ‘A. After the crane equipment has been assembled and tested in the manufacturer's shop, the equipment shall be prepared for shipment. Shipment preparations shall include steps necessary for protection during shipment, storage, and erection. Apply an anticorrosion compound such as grease, petroleum jelly, or heavy oil on such parts and components that will be subjected to the weather in storage, B. Prior to the actual date of delivery, the crane company's representative shall contact the Contractor, visit the construction site, and issue instructions for storage of the equipment to prevent damage. Contract No. PB467094 PBO6T510 —14630-3. Pavaho Storm Water Pumping Station Bridge CraneUpon delivery to the job site, receipt and storage shall be the responsibility of the Contractor. Storage, care, and maintenance shall be in accordance with the manufacturer's recommendations. If the equipment must be stored for an extended period of time, the Contractor, at his expense, shall wire and furnish electrical power to each crane electrical system and energize the heaters in the motors for protection against condensation. Such wiring shall follow the manufacturer's recommendations. 1.8 ENVIRONMENTAL CONDITIONS A. Bridge crane system shall be suitable for indoor service. 1.9 MAINTENANCE A B, Provide spare parts as listed in the manufacturer's recommended spare parts list. Provide all special tools required for normal maintenance. Tools shall be packaged in a steel case, clearly and indelibly marked on the exterior to indicate equipment for which tools are identified. Provide the Owner a list of all spare and replacement parts with individual prices and locations where available. Prices shall remain in effect for a period of not less than one year after final acceptance. Furnish a supply of all required lubricants in sufficient quantities for one year's, operations. PART 2- PRODUCTS 24 ACCEPTABLE MANUFACTURERS A Manufacturer: Subject to compliance with requirements, provide products of one of the following: Harnischfeger Corporation, P&H Cranes, Dallas, Texas. Gaffey Inc. of Texas. Anchor Crane & Hoist Company, Dallas, Texas. Shaw-Box Crane & Hoist Division, Dresser Industries, Inc. Muskegon, Michigan. BONe 2.2 GENERAL DESIGN CONDITIONS A General: General design top running, double girder conditions applicable to crane and hoist are as follows: 1. Electric overhead bridge crane (20-ton Bridge Crane) a. __ Electric overhead bridge crane shall be designed by the manufacturer. All design calculations shall be submitted to the Engineer for review and approval. Installation Condition: Bridge crane and hoist shall be designed for installation and setting conditions shown on the drawings. Crane lift, overhead clearance, side clearance, end stops, and other pertinent details are shown on the drawings. Contractor must coordinate placement of Crane stops with River Gauge pipe. Contract No. PB467084 PBO6T510 14630 -4 Pavaho Storm Water Pumping Station Bridge CraneCranes, which require greater clearances than that shown, will not be acceptable. C. Electrical: Bridge crane, trolleys, and hoists shall be electrically operated and controlled on 480 volt, 3 phase, 60 hertz, A.C. current, three-wire grounded neutral feed system. The crane and appurtenances shall be designed for indoor service. Electrical enclosures shall be NEMA IV. 1, The crane and hoist system shall be furnished with a manually operated main line fused disconnect switch near the crane and hoist power ‘connection point with provisions for locking in the "off position. 2. Equip each motor and control cabinet with space heaters. Motor space heater shall maintain the temperature 10 to 15 degrees above ambient Space heaters in control cabinets and panels shall remain on at all times, except when mainline contactor is engaged, to prevent condensation. 3. Control Panel(s) shall also include mainline magnetic contactor, contactors for the control of the hoist, trolley and bridge and a control transformer. 4. Fumish an adjustable time delay relays for each (hoist, trolley and bridge) motion as follows: a. 2 speed, one relay 5. __ Provide adjustable upper and lower geared limit switches on hoist. D. Electrical Conductors: Furnish enclosed Howell Corporation safety insulated type copper conductors (SAF-T-BAR) for runways. The conductors shall have at least 110-ampere continuous duty rating and sized for maximum voltage drop of one percent at any point on the runway. The current collector and conductor system shall be complete with power feeds, intermediate hanger clamps, expansion joints, angle support brackets, and all other required items for a complete installation. Trolley conductors shall be festooned across the bridge by a track festoon system, E. End Stops: Furnish rubber end stops on crane. Contractor to coordinate end stops with River Gage. F. Bearings: use anti-friction ball or roller bearings throughout. Bearings shall have a B-10 bearing life at 10,000 hours and permanently lubricated. G. Gearing: Crane and hoist to be designed with high quality long life gearing and type using the least number of gears and pinions to accomplish the needed reduction under sustained loads. Drives shall have alloy steel heat treated gearing designed to AGMA Class 11. All gearing shall be enclosed in gasketed gear cases designed to retain oil lubricants. Spring back oil seals shall be used wherever possible. H. Lubrication: All gear trains shall be enclosed in oil-tight housing with oil level sight gauge where applicable, 1 Painting: Thoroughly clean crane of all rust, mill scale, and foreign substances prior to painting. Apply a prime coat followed by two finished coats of high visibility yellow before shipment from manufacturer's plant. Purchased items such as hoists, reducers, and motors may be furnished with supplier's standard finish if such painting consists of at least one prime coat and one finish coat of paint. The hoist load block shall be painted with alternate yellow and black stripes. Repair Contract No, PB467094 PBO6T510 —14630-5 Pavaho Storm Water Pumping Station Bridge Cranepaint scratches and surface damage after equipment has been erected and final adjustments made. J. Bridge Assembly: Bridge Assembly: The bridge girders are to be squared to the end trucks, and braced for welding and drilling. After welding or drilling, the entire crane is to be re-checked to insure the accuracy of span, square and wheel alignment. K. Bridge Girders: Bridge shall be of the double girder design with fabricated plate box section as appropriate to capacity and span. Trolley rails will be ASCE rails. L. Bridge End Trucks: Bridge end trucks shall be fabricated from high strength ASTM A500 grade structural tubing, reinforced with gusset plates and stiffeners as required. Reinforced machined bearing seats to be provided, assuring positive alignment of bridge axle assemblies. Trucks shall be designed to prevent excessive drop in the event of axle failure. Rail sweeps shall be furnished on leading bridge wheels to clear rails of any obstructions. M. __ Bridge Drives: Crane bridge shall be furnished with a dual drive (CMAA Type A- 4) arrangement utilizing drive motors connected to self contained speed reducers. The speed reducers in turn will be connected directly to extended shafts of wheel axles. N. Bumpers: Bridge and trolley shall be provided with energy absorbent polyurethane bumpers, which comply with OSHA and CMAA. Suitable end stops to be provided by the purchaser. ©. Trolley Frame: The trolley frame shall be fabricated steel weldment. Load girts, shall be fabricated built up sections. P. Trolley Drives: Trolley shall be furnished with a dual drive (CMAA Type A-4) arrangement utilizing drive motors connected to self contained speed reducers. The speed reducers in turn will be connected directly to extended shafts of wheel axies. Q. Trolley Whee! Assemblies: The trolley wheel assemblies to be rotating axle type with cast alloy steel wheels hardened to 321 BHN as a minimum, and alloy steel heat-treated axles with high quality anti-friction spherical roller bearings mounted in bolted bearing housings. Wheels to be double flanged and heat-treated with straight tread R. Hoist: Hoist shall be “built -up” type consisting of a base mounted speed reducer, flange mounted motor -brake unit, rope drum, and drum tail bearing. Hoist shall be double reeved for true vertical lift S. Hoist Drums: All drums are to be made from seamless hot rolled steel tubing half depth grooved for optimum wire support. Drum shall have bolt-on end support for ease of drum maintenance/ removal. Drum shaft to be directly mounted into the gearbox to eliminating coupling requirements. There shall be not less than two wraps on the drum in the lowest hook position. The drum diameter to rope diameter shall be no less than 20:1. Contract No, PB467094 PBO6T510 14630 - 6 Pavaho Storm Water Pumping Station Bridge CraneT. Hoist Bottom Blocks: The bottom block shall be designed for easy maintenance and built to withstand harsh working environments. The shape of the block frame shall be designed to keep the cable in the sheave groove even when in the slack position to minimize cable damage and jamming. Hook shall be forged steel, rotated on a thrust bearing and with safety latch. The sheaves are forged or hot rolled steel, and supported by roller bearings, U. Walkway: Crane shall have full length walkway along each side of the girder for service access to trolley and control panels. A crossover shall also be provided to ‘connect both walkways. Platform shall have checkered steel plate flooring, double member handrail and suitable toe guard, V. Motor Controls: Motor control shall be designed with Safety and Reliability in mind. In addition to a manual safety power disconnect, a magnetic mainline disconnect operable from the festooned pushbutton station shall be provided. Auto-Reset thermal overload protection or temp switches shall be provided for all motors. All wiring and conduit is to be installed in accordance with NEC requirement. W. Control: Variable speed AC adjustable frequency control shall be provided for the bridge, and trolley. Hoist control shall either be 2-step magnetic control or 2- step variable frequency. Control to be housed in NEMA 12 enclosures. X. Motors: All motors are to be TENV or TEFC crane and hoist duty with anti- friction bearings and Class *F” insulation. The motors are to be designed and manufactured in accordance with NEMA standards. Hoist motors shall be 60 minute rated, bridge and trolley motors to be 30 minute rated. Y. Brakes: DC rectified disc type brakes shall be furnished for hoist, bridge and trolley. Brakes shall be per OSHA requirements. Hoist brake shall have a minimum rating of 250% motor torque. Bridge and trolley brakes shall have minimum rating of 100% motor toque. Z. Limit Switches: Separate adjustable upper and lower type limit switches shall be provided. In addition there shall be a weight operated over-travel control type limit switch provided. ‘AA. Wiring: All wiring in raceways and on panels will be type THHN-THWN or XHHW, with insulation rated at 90 degrees C. Resistor wiring will be SMRL. Crane will be wired in accordance with the National Electrical Code. BB. Radio Control: Crane shall be provide with Hand Held Remote Radio Control system with the following functions and features. on/off Mainline Contactor Bridge 2-Step Reversing Trolley 2-Step Reversing Hoist 2-step Reversing Warning Horn Auxiliary Contract No, PB467094 PBO6T510 —14630-7 Pavaho Storm Water Pumping Station Bridge Cranece. Dp. EE. FF. GG. HH, Pushbutton Station: Festooned pushbutton station enclosures are to be durable, and supplied for the operating environment specified in accordance with NEMA standards. Pushbuttons are to be the reversing “Deadman” type with spring retum to the off position. Pendant Messenger: Festooned type flat cable system with flexible flat insulated cable from heavy-duty carriers running in a “C" track, Bridge cross Conductors: Bridge span conductor system shall have flat covered flexible festooned cables with heavy-duty carriers and will run on a °C’ track. Mainline Collectors: The crane shall be provided with a collector bracket and three (4) tandem shoe collectors. Runway Conductors: Runway conductor system shall be a 4-conductor Safety enclosed rigid bar type. Supplier of crane is responsible for matching the collectors to the system. Paint the capacity of crane in large block black letters on both sides of the bridge and block. 2.3 20-TON BRIDGE CRANE A Crane Information Form: The information outlined in the following data shall be included in the design, fabrication, and operation of the crane. Data is as follows: 1. Type of Crane: Double girder, dual gear motor with brakes, top-running crane. Service: Class A Standby (Infrequent) Service. Capacity: 20-tons. Span: See Drawings. Lift of Hook: Minimum 42:- 435,00 to elevation 393.00. Clearances: As shown on the drawings. Length of Runway: See drawings. Vertical Settings: Top of crane concrete beam 435.00. Design Factor: Design all material with a minimum safety factor of 5 based on the ultimate strength of the material. 10. Speeds: Provide two speed operations as follows: a. Main Hoist: 15/5 feet per minute. b. Trolley Travel: 50/25 feet per minute with soft start. c. Bridge Travel: 100/50 feet per minute with soft start. RON " - See Drawings, from raised elevation END Runway/Track: 1. Runway rail shall be in accordance with ASTM 759. 2. Runway rails shall be spliced by bolting. Splices on opposite rails shall be staggered 3. Runway rails shall be attached to the concrete corbel by using anchor bolts and clamps. All hardware, including splices, end stops, or other items necessary to furnish a complete system shall be provided as required for the system. Contract No. PB467094 PBO6T510 1460-8 Pavaho Storm Water Pumping Station Bridge Crane4. Clamp spacing shall not exceed 3'-0", and shall be staggered. 5. Submit details of fastening runway rails to corbel. 6. Provide crane stops at end of runway rails. C. Crane Controls: Crane operation and control systems for two-speed motors shall be designed for remote controlled operations as follows: 1. Remote control shall be thermoplastic enclosed pushbutton units for two- speed operation of the hoist, bridge, and trolley. Control unit to be yellow color with laminated legend plates. Control to be housed in Nema 12 enclosure. The assembled pendant to have pushbuttons to perform functions as follows: a. System () One pushbutton - (ii) One pushbutton - b. Hoist Module with: () One pushbutton - "UP" (i) One pushbutton - "DOWN" cc. Bridge Module with: () One pushbutton - "FORWARD" (i) One pushbutton - "REVERSE" d. Trolley Module with: (One pushbutton - "NORTH" travel (i) One pushbutton - "SOUTH" travel e. Speed: (i) One push button - "SLOW" speed (li) One push button - "FAST" speed 2. The crane shall be completely wired for manual pendant control before shipment. All wiring shall be of the type and sufficient size to safely carry the load. It shall be completely enclosed in conduits and weatherproof fittings. The control system and circuits are to be installed with all wiring, reversing contactors, limit switches, accessories, devices, and appurtenances ready for operation. 3. Protection Limit Switches: In addition to the limit switches provided for b bridge travel, trolley travel, and hoist travel, furnish and install a limit switch system for protection against damage as follows: a. Limit switch at each end of a runway. D. Bridge Crane Construction: Specifications for construction of the 20-ton crane are as follows 1. Bridge Beams. Design the bridge beams in accordance with the latest Specifications of the Crane Manufacturers Association of America (CMAA No. 74), of structural steel shapes, constructed in accordance with AISC Specifications. Beam deflection not to exceed 1/600 of the span under rated full load. Brace the bridge beam to maintain squareness with the end trucks. Provide a beam of adequate lateral stiffness with minimum lateral moment of inertia of 1/20 that of the vertical moment of inertia. Beam spacing shall be as required to meet travel and performance requirements specified herein. Contract No. PB467094 PBOGT510 —14630-9 Pavaho Storm Water Pumping Station Bridge Crane2, Bridge End Trucks. Bridge End Trucks: Bridge end trucks shall be fabricated from high strength ASTM AS00 grade structural tubing, reinforced with gusset plates and stiffeners as required. Reinforced machined bearing seats to be provided, assuring positive alignment of bridge axle assemblies. Trucks shall be designed to prevent excessive drop in the event of axle failure. Rail sweeps shall be furnished on leading bridge wheels to clear rails of any obstructions. 3. Trolley Drives: Trolley shall be furnished with a dual drive (CMAA Type ‘A.4) arrangement utilizing drive motors connected to self contained speed reducers. The speed reducers in tur will be connected directly to extended shafts of wheel axles 4. Bridge Drive. Bridge Drives: Crane bridge shall be furnished with a dual drive (CMAA Type A-4) arrangement utilizing drive motors connected to self contained speed reducers. The speed reducers in turn will be connected directly to extended shafts of wheel axles. 5. Hoisting, The hoisting mechanism shall be integral with the trolley frame. The hoisting mechanism shall consist of a winding drum, reduction gearing, motor, solenoid operated multiple disc brake on the motor pinion shaft, and an automatic load brake of the Weston type. Each brake must be capable of holding capacity loads independently of each other. a. The winding drum shall be a steel weldment, and shall have right and left hand deeply machined cable grooves to provide a true vertical lft. The drum capacity must be such that all hoisting cable may be accommodated without overlapping. b. The winding drum and load sheave diameter shall be not less than 24 times the hoist rope diameter based on using 6 x 37 preformed cable in accordance with E.0.C.1, specifications. 30 to 1 drum-to- cable ratio is required only if using 6x 19 cable. c. Hoisting ropes shall be of proper design and construction for crane service. The rated capacity load divided by the number of parts of rope shall not exceed 20 of the published breaking strength of the rope. d. The hoist shall have an automatic upper limit switch to prevent hook overtravel. Provide an automatic lower limit switch to prevent overloading the bridge crane and hoist. Provide a 2-element field adjustable upper and lower hook travel lift switch. fe. The hoist gear train shall consist of helical gearing for quiet operation. All reduction gearing shall be totally enclosed, and shall operate in oil baths in sealed housings. 7 Drop forged heat-treated steel hook shall swivel 360° on a shielded roller thrust bearing. Provide spring latch on hook 6. Motors. All motors shall be totally enclosed and have anti-friction ball bearings suitable for crane service. They shall have a 30-minute rating with a temperature rise in accordance with the latest NEMA standards for the class F insulation and enclosure used. Full load motor speeds shall not exceed 1750 R.P.M, 7. Wiring. All wiring shall be completely enclosed and capable of safely carrying the rated electrical load. The bridge conductor shall be safety type bars as specified, Contract No. PB467094 PBO6T510 14630- 10 __Pavaho Storm Water Pumping Station Bridge CranePART 3 - EXECUTION 3.1 INSTALLATION ‘A. Allcrane equipment, apparatus, and devices shall be set in place as indicated on the Drawings. All runways shall be set dead level at true height and equal distance (parallel). Before final setting, all clearance line requirements shall be checked and verified, 3.2 TESTING ‘A. After installation, and as a prerequisite to acceptance, run a full operational test ‘on each complete crane and hoist system using a load equal to 125 percent of rated capacity. Testing procedures shall be as recommended by the ‘manufacturer and approved by the Engineer. Such testing shall be conducted in the presence of, and witnessed by, the Owner's and manufacturers authorized representatives. Testing and associated costs shall be at the expense of the Contractor. Failure of any part of the crane and hoist system and/or appurtenants in the operational test shall be corrected and the system retested at the sole expense of the Contractor. B. _Fumish the labor and weights required for testing the capacity of the hoist. C. Upon final completion and testing, the Contractor and manufacturer shall issue a certification to the Owner that the crane and hoist system are in compliance with the Owner's and OSHA's safety requirements, 3.3. USE OF COMPLETED SYSTEM ‘A. After installation and testing, hoist system may be used for construction purposes only with the written permission of the Owner. B. Use of the system shall not affect the warranty period stipulated in the Conditions of the Contract. C. Any damage to the system due to usage during construction shall be repaired at the Contractor's expense. END OF SECTION Contract No. PB467094 PB06T510 14630- 11 __ Pavaho Storm Water Pumping Station Bridge Crane