Container Crane 2DT2014 Część-3 STS Technical Specification

GDYNIA CONTAINER TERMINAL S.A.
TECHNICAL SPECIFICATION
FOR
QUAYSIDE CONTAINER CRANES
TENDER REFERENCE: 2/DT/2014/2 (GCT)
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2DT2014 Część-3 STS Technical Specification
SECTION C
INDEX
TECHNICAL SPECIFICATION
1. General ................................................................................................................................................................... 9
1-1. Project Description ......................................................................................................................................... 9
1-2. Terminal Site .................................................................................................................................................. 9
1-3. Overriding Requirement of the Purchaser ....................................................................................................... 9
1-4. Project Management ..................................................................................................................................... 10
2. Overall Design Criteria ......................................................................................................................................... 10
2-1. Type of Crane ............................................................................................................................................... 10
2-2. Type of Cargo ............................................................................................................................................... 10
2-3. Operating Environment and Design Aim ...................................................................................................... 11
2-4. Mode of Operation and Performance Target (MMBF) (Mean Moves Between Faults) ............................... 11
2-5. Statutory Requirements and Applicable Standards ....................................................................................... 12
2-6. Minimum Class of Crane .............................................................................................................................. 13
2-7. General Design Criteria ................................................................................................................................ 13
2-7.1 Crane Particulars ......................................................................................................................................... 13
2-7.2. Dimensional Restriction of the Crane ................................................................................................... 15
2-7.3. Quay/Yard Interface.............................................................................................................................. 16
2-7.4 Communication Facility Interface (Radio, Fibre Optic etc.) ................................................................. 17
2-7.5 Auxiliary Electrical Power Interface ..................................................................................................... 17
2-7.6. Climatic Condition ................................................................................................................................ 17
2-7.7. Wind Loading Condition ...................................................................................................................... 17
2-7.8. Load Lifting and Stability Condition .................................................................................................... 18
2-8. Storm Wind Tie-Downs ................................................................................................................................ 20
2-8.1 Design ................................................................................................................................................... 20
2-9. Noise Control ................................................................................................................................................ 20
2-10. Operationally Critical Components........................................................................................................... 21
2-11. Asbestos .................................................................................................................................................... 21
3. Crane Structural Specifications............................................................................................................................. 21
3-1. General Requirement .................................................................................................................................... 21
3-1.1 Design ................................................................................................................................................... 21
3-1.2 Machinery on main structure................................................................................................................. 22
3-1.3 Fittings on Main Structure .................................................................................................................... 23
3-2. Material ......................................................................................................................................................... 23
3-2.1 Material Standards ................................................................................................................................ 23
3-2.2 Machinery Bases ................................................................................................................................... 24
3-2.3 Edge Finish ........................................................................................................................................... 24
3-2.4 Surface Finish ....................................................................................................................................... 24
3-2.5 Draining and Inspection Manholes ....................................................................................................... 24
3-3. Calculations. ................................................................................................................................................. 24
3-3.1 Submission to Purchaser ....................................................................................................................... 24
3-3.2 Design Audit ......................................................................................................................................... 25
3-3.3. Construction Drawings.......................................................................................................................... 27
3-4. Loads ............................................................................................................................................................ 28
3-5. Members Subject to Buckling ....................................................................................................................... 28
3-6. Fatigue Design Criteria ................................................................................................................................. 28
3-7. Connection Design ........................................................................................................................................ 33
3-7.1 Welded Joints........................................................................................................................................ 33
3-7.2 Bolted Joints ......................................................................................................................................... 33
3-7.3 Pin Joints............................................................................................................................................... 34
3-8. Gantry Frame Deflections and Stiffness........................................................................................................ 34
3-9. Camber.......................................................................................................................................................... 35
3-10. Trolley Rails & Rail Fixing ...................................................................................................................... 35
3-11. Workmanship ............................................................................................................................................ 35
3-12. Quality Control of Structural Fabrication ................................................................................................. 38
3-13. Temporary Structures................................................................................................................................ 39
GCT - QUAYSIDE CONTAINER CRANE TENDER REF: 2/DT/2014 (GCT)
3-13.1 Temporary Structures............................................................................................................................ 39

3-13.2 Sea-Fastening ........................................................................................................................................ 39
3-13.3 Voyage Criteria and Calculations ......................................................................................................... 40
4. Functional Systems, Devices & Equipment .......................................................................................................... 42
4-1. Main Hoist .................................................................................................................................................... 42
4-1.1 Main Hoist Drive ................................................................................................................................. 42
4-1.2 Sway Control ....................................................................................................................................... 43
4-1.3 Trim, List, Skew Control ..................................................................................................................... 44
4-1.4 Snag Control ........................................................................................................................................ 44
4-2. Trolley, Trolley Drive, Associated Devices and Operator's Cab .................................................................. 45
4-2.1 Trolley Frame ....................................................................................................................................... 45
4-2.2 Trolley Drive ........................................................................................................................................ 46
4-2.3 Rope Separating System ....................................................................................................................... 47
4-2.4 Trolley Tow Rope Tensioner ................................................................................................................ 47
4-2.5 Power Festoon System (To Trolley) ..................................................................................................... 47
4-3. Gantry Drive ................................................................................................................................................. 47
4-3.1 Gantry Drive ......................................................................................................................................... 47
4-3.2 Stowage Pin .......................................................................................................................................... 49
4-3.3 Wheel Brakes ........................................................................................................................................ 49
4-3.4 H.T. Cable Reel .................................................................................................................................... 49
4-3.5 Boom Collision Avoidance System ...................................................................................................... 50
4-4. Boom Hoist ................................................................................................................................................... 51
4-4.1 Boom Hoist Drive ................................................................................................................................. 51
4-4.2 Boom Latch........................................................................................................................................... 51
4-5. Machinery House, Electrical Control House................................................................................................. 51
4-5.1 Construction .......................................................................................................................................... 51
4-5.2 Fittings, Facilities .................................................................................................................................. 53
4-5.3 Ventilation ............................................................................................................................................ 54
4-5.4 Illumination and Lighting...................................................................................................................... 54
4-5.5 Emergency Lighting System ................................................................................................................. 55
4-5.6 Air Conditioning ................................................................................................................................... 55
4-5.7 Maintenance Hoist ................................................................................................................................ 55
4-6. Operator’s Cab, Control Stations, Checker's Cab ......................................................................................... 55
4-6.1 Control Cab on Trolley ......................................................................................................................... 56
4-6.2 Control Cab Off Trolley........................................................................................................................ 58
4-6.3 Checker’s Cab ....................................................................................................................................... 59
4-7. Personnel Lift................................................................................................................................................ 60
4-8. Headblock ..................................................................................................................................................... 60
4-8.1 Headblock ............................................................................................................................................. 60
4-8.2 Spreader Communication System ......................................................................................................... 61
4-8.3 Baloney Cable ....................................................................................................................................... 61
4-9. Spreader, Hook Beam ................................................................................................................................... 61
4-9.1 Spreader General .................................................................................................................................. 61
4-9.2 Spreader – Twinlift ............................................................................................................................... 65
4-9.3 Hook Beam ........................................................................................................................................... 65
5. Inter-functional Systems & Components .............................................................................................................. 65
5-1. Mechanical System/ Components ................................................................................................................. 65
5-1.1 Bearing, Seals ....................................................................................................................................... 65
5-1.2 Gearing ................................................................................................................................................. 66
5-1.3 Gear Reducers ....................................................................................................................................... 66
5-1.4 Wire Rope Winch Drums...................................................................................................................... 66
5-1.5 Wire Rope Sheaves ............................................................................................................................... 68
5-1.6 Wire Ropes ........................................................................................................................................... 68
5-1.7 Shafts, Axles ......................................................................................................................................... 68
5-1.8 Couplings .............................................................................................................................................. 69
5-1.9 Metal Wheels ........................................................................................................................................ 69
5-1.10 Pins, Pin Brackets ................................................................................................................................. 70
5-1.11 Bolts ...................................................................................................................................................... 70
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5-1.12 Lubrication ............................................................................................................................................ 70

5-2. Hydraulic System/ Components .................................................................................................................... 71
5-2.1 Standards............................................................................................................................................... 71
5-2.2 Components Sources ............................................................................................................................. 71
5-2.3 Operating Condition.............................................................................................................................. 71
5-2.4 Hydraulic Fluid Reservoir ..................................................................................................................... 71
5-2.5 Power Unit ............................................................................................................................................ 72
5-2.6. Valve Mounting .................................................................................................................................... 72
5-2.7 Relief Valve .......................................................................................................................................... 72
5-2.8 Flow Control Valve............................................................................................................................... 72
5-2.9 Check Valve .......................................................................................................................................... 72
5-2.10 Servo Valve .......................................................................................................................................... 73
5-2.11 Control Valve........................................................................................................................................ 73
5-2.12 Solenoid Valves .................................................................................................................................... 73
5-2.13 Piping .................................................................................................................................................... 73
5-2.14 Hoses .................................................................................................................................................... 74
5-2.15 Assembly Test ....................................................................................................................................... 74
5-2.16 Catch Basins ......................................................................................................................................... 74
5-2.17 Filters .................................................................................................................................................... 74
5-2.18 Heat Exchangers ................................................................................................................................... 75
5-2.19 Actuator ................................................................................................................................................ 75
5-2.20 Application for Spreader ....................................................................................................................... 75
5-2.21 Couplings .............................................................................................................................................. 75
5-2.22 Gauges .................................................................................................................................................. 75
5-2.23 Covers ................................................................................................................................................... 75
5-2.24 Hydraulic Fluid ..................................................................................................................................... 76
5-3. Electrical & Electronic System/ Components ............................................................................................... 76
5-3.1 General.................................................................................................................................................. 76
5-3.2 Main Power Supply............................................................................................................................... 77
5-3.3 Power Factor Correction ....................................................................................................................... 78
5-3.4 Harmonics Suppression (if required) .................................................................................................... 78
5-3.5 Protection against Power Surge ............................................................................................................ 78
5-3.6 Protection for Power Dip/Power Failure ............................................................................................... 79
5-3.7 Wiring ................................................................................................................................................... 79
5-3.8 Marking and Identification.................................................................................................................... 81
5-3.9 Conduit and Cable Tray ........................................................................................................................ 81
5-3.10 Electrical Trunking ............................................................................................................................... 82
5-3.11 Motors ................................................................................................................................................... 82
5-3.12 Brakes ................................................................................................................................................... 83
5-3.13 High Tension Panel and Switches ......................................................................................................... 83
5-3.14 Transformers ......................................................................................................................................... 85
5-3.15 Resistors (if any) ................................................................................................................................... 85
5-3.16 Enclosures ............................................................................................................................................. 85
5-3.17 Meter and Counter ................................................................................................................................ 86
5-3.18 Limit Switches ...................................................................................................................................... 87
5-3.19 Space Heaters........................................................................................................................................ 87
5-3.20 D.C. Power Supply ............................................................................................................................... 87
5-3.21 Encoders ............................................................................................................................................... 87
5-3.22 Sensors .................................................................................................................................................. 87
5-3.23 Safety Mechanical Interlock System ..................................................................................................... 87
5-3.24 Name Plates .......................................................................................................................................... 88
5-3.25 Shore Power (Auxiliary) ....................................................................................................................... 88
5-3.26 (Not used). ............................................................................................................................................ 88
5-3.27 Load Cells ............................................................................................................................................. 88
5-4. Crane Motion Controls ................................................................................................................................. 88
5-4.1 Control System - General ...................................................................................................................... 88
5-4.2. Programmable Logic Controllers (PLC) ............................................................................................... 89
5-4.3 Power Supply ........................................................................................................................................ 90
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5-4.4 Discrete I/O Modules ............................................................................................................................ 90

5-4.5 Real Time Clock Module ...................................................................................................................... 91
5-4.6 Motion Control Switches in Operator’s Cab ......................................................................................... 91
5-4.7 Motion Control Switches in Boom Control Station .............................................................................. 93
5-4.8 Motion Control Switches in Ground Level Station ............................................................................... 94
5-4.9 Motion Control Switches in Independent Cab on Girder-Boom ........................................................... 94
5-4.10 Semi-Automatic Operation System (Option) ....................................................................................... 94
5-5. Operational Safety Interlocks........................................................................................................................ 94
5-5.1 Main Motions Interlocks ....................................................................................................................... 94
5-5.2 Cab Access Interlock ............................................................................................................................ 99
5-6. Communications ........................................................................................................................................... 99
5-6.1 Intercom System ................................................................................................................................... 99
5-6.2 Fibre Optic Cable ............................................................................................................................... 100
5-6.3 Public Address System........................................................................................................................ 100
5-6.4 Radio ................................................................................................................................................... 101
5-7. Crane Condition Monitoring System (CCMS) ............................................................................................ 101
5-7.1 General................................................................................................................................................ 101
5-7.2 CCMS Description .............................................................................................................................. 101
5-7.3 Operating Environment and Requirements ......................................................................................... 102
5-7.4 On-Board Crane Condition Monitoring System (On-Board CCMS) .................................................. 103
5-7.5 On-Board CCMS Software Requirements .......................................................................................... 103
5-7.6 On-Board CCMS Hardware Requirements ......................................................................................... 105
5-7.7 Condition Monitoring ......................................................................................................................... 105
5-7.8 Fault Diagnosis ................................................................................................................................... 109
5-7.9 Preventive Maintenance ...................................................................................................................... 110
5-7.10 Equipment Performance Data and Operation Log .............................................................................. 110
5-7.11 Remote Crane Condition Monitoring System (RCCMS) .................................................................... 111
5-7.12 RCCMS Software Requirements......................................................................................................... 111
5-7.13 RCCMS Hardware Requirements ....................................................................................................... 111
5-7.14 Server(s).............................................................................................................................................. 111
5-7.15 CCMS Reporting Format .................................................................................................................... 111
5-7.16 CCMS Data Communication .............................................................................................................. 112
6. Common Items .................................................................................................................................................... 112
6-1. Walkways, Stairs, Ladders and Platforms ................................................................................................... 112
6-1.1 Applicable Code/ Standard ................................................................................................................. 112
6-1.2 Stairway Requirements ....................................................................................................................... 113
6-1.3 Ladder Requirements .......................................................................................................................... 113
6-1.4 Platforms Requirements. ..................................................................................................................... 113
6-1.5 Walkway Handrail Requirements ....................................................................................................... 114
6-1.6 Cab Access Platforms ........................................................................................................................ 114
6-1.7 Cab Window Cleaning Platform ......................................................................................................... 114
6-2. Illumination and Lighting ........................................................................................................................... 115
6-2.1 Walkways, Stairs, Ladder, Cab Access ............................................................................................... 115
6-2.2 Work Area Floodlights ....................................................................................................................... 115
6-2.3 Floodlights on Trolley......................................................................................................................... 115
6-2.4 Emergency Lighting for Escape Routes .............................................................................................. 115
6-2.5 Lighting Control Switches .................................................................................................................. 115
6-2.6 High Pressure Sodium Lamp and Ballast ............................................................................................ 116
6-2.7 Fluorescent Lamps .............................................................................................................................. 116
6-2.8 Boom Latch Area Illumination ........................................................................................................... 116
6-2.9 Aviation Warning Lights..................................................................................................................... 116
6-2.10 Access for Lights Maintenance ........................................................................................................... 116
6-3. Painting and Protective Coating .................................................................................................................. 117
6-3.1 Paint System General NOT REQUESTED / NOT USED. ................................................................. 117
6-3.2 Surface Preparation ............................................................................................................................. 117
6-3.3 Abrasive Blast Cleaning...................................................................................................................... 117
6-3.4 Painting Generally .............................................................................................................................. 117
6-3.5 Paint Systems ...................................................................................................................................... 117
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6-3.6 Galvanising ......................................................................................................................................... 117

6-3.7 Reinstatement of Protective Coatings at Site ...................................................................................... 117
6-3.8 Inspection and Sample Panels ............................................................................................................. 117
6-4. Purchaser’s Logo, Crane Numbers, Signs ................................................................................................... 117
6-4.2 Crane Numbers ................................................................................................................................... 117
6-4.3 Crane Capacity Signs (In Polish) ........................................................................................................ 117
6-4.4 Manufacturer’s Name Plates ............................................................................................................... 117
6-4.5 Other Signs ......................................................................................................................................... 118
6-5. Alarms, Warning, Signals & P.A. System................................................................................................... 118
6-5.1 Gantry Travel Warning ....................................................................................................................... 118
6-5.2 Wind Speed Warning .......................................................................................................................... 119
6-5.3 Main Hoist Overload Warning ............................................................................................................ 119
6-5.4 Premature Twistlock Operation Warning .......................................................................................... 119
6-5.5 By-pass Switch Abuse Warning .......................................................................................................... 120
6-5.6 H.T. Slip Ring Space Heater Indicator ............................................................................................... 120
6-5.7 Electrical Control House A/C Warning .............................................................................................. 120
6-5.8. Public Address/ Warning .................................................................................................................... 121
6-6. Emergency Stop Push Buttons .................................................................................................................... 121
6-6.1 Location .............................................................................................................................................. 121
6-6.2 Type .................................................................................................................................................... 121
6-6.3 Emergency Stop Signs ........................................................................................................................ 121
6-7. Service Outlets/ General Purpose Outlets (GPO’s)..................................................................................... 121
6-7.1 Location .............................................................................................................................................. 122
6-7.2 Type Model - General Purpose Outlets (GPO’s) ................................................................................ 122
6-8. Welding Outlets .......................................................................................................................................... 122
6-8.1Locations .................................................................................................................................................... 122
6-8.2 Make-Model ...................................................................................................................................... 122
6-8.3 Welding Machine ................................................................................................................................ 122
6-9. Fire Extinguishers ....................................................................................................................................... 123
6-9.1 Locations............................................................................................................................................. 123
6-9.2 Type-Model ........................................................................................................................................ 123
6-10. Maintenance Tools and Equipment......................................................................................................... 123
6-10.1 Mechanical Maintenance Tools .......................................................................................................... 123
6-10.2 Electrical / Electronic Maintenance Tools .......................................................................................... 123
6-10.3 Hydraulic Maintenance Tools ............................................................................................................. 123
6-10.4 Special Tools and Equipment/ Jigs ..................................................................................................... 123
7. Project Q.A. and Administrative Requirement ................................................................................................... 123
7-1. Document Submission (Project) ................................................................................................................. 123
7-1.1 Project Organisation Chart (Shop & Site) ........................................................................................... 124
7-1.2 Project Schedule (Shop & Site) .......................................................................................................... 124
7-1.3 Project Progress Report ...................................................................................................................... 124
7-1.4 Quality Assurance Programme/ Manuals ............................................................................................ 124
7-1.5 Daily Plan and Report (Site Work) .................................................................................................... 125
7-1.6 Third Party structural design review ................................................................................................... 126
7-2. Document Submission (Technical) ............................................................................................................. 126
7-2.1 Submission Schedule .......................................................................................................................... 126
7-2.2 Conceptual Design .............................................................................................................................. 126
7-2.3 Drawings and Calculations for the Purchaser's Review ...................................................................... 126
7-2.4 Lubricant List ...................................................................................................................................... 127
7-2.5 Ordered Spare Parts List .................................................................................................................... 127
7-2.6 Crane Delivery Method Statement ...................................................................................................... 128
7-2.7 Site Work Method Statement .............................................................................................................. 128
7-2.8 Commissioning Test Procedure .......................................................................................................... 128
7-2.9 Up-Dated Drawings ............................................................................................................................ 129
7-2.10 Training Programme ........................................................................................................................... 129
7-2.11 Operation Manuals .............................................................................................................................. 131
7-2.12 Maintenance Manuals ......................................................................................................................... 131
7-2.13 As-Built Drawings .............................................................................................................................. 132
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7-2.14 Certification ........................................................................................................................................ 132

7-3. Shop Inspection & Tests ............................................................................................................................. 133
7-3.1 Shop Inspection and Verification ........................................................................................................ 133
7-3.2 Pre-Shipment Inspection and Test ...................................................................................................... 135
7-4. Shipment, Delivery and Site Work ............................................................................................................. 136
7-4.1 Clearance for Shipment ....................................................................................................................... 136
7-4.2 Notification of ETA Site. .......................................................................................................................... 136
7-4.3 Navigation Requirement ..................................................................................................................... 137
7-4.4 Berthing and Roll-off Requirements ................................................................................................... 137
7-4.5 Customs Clearance.............................................................................................................................. 137
7-4.6 Work Permits ...................................................................................................................................... 138
7-4.7 Site Safety and Security ...................................................................................................................... 138
7-4.8 Site Erection Area and Access (NOT USED) .................................................................................... 138
7-4.9 Site Office Communication ................................................................................................................. 138
7-4.10 Test Weight ........................................................................................................................................ 138
7-4.11 Water, Electricity Supply .................................................................................................................... 138
7-4.12 Contractor’s Representatives. ............................................................................................................. 138
7-5. Site Inspection and Tests, Certification ...................................................................................................... 139
7-5.1 Commissioning Tests Application ...................................................................................................... 139
7-5.2 Defects List ........................................................................................................................................ 139
7-5.3 Rectification Report ............................................................................................................................ 139
7-5.4 Commissioning Test ........................................................................................................................... 140
7-5.5 Endurance Test .................................................................................................................................. 140
7-5.6 Acceptance Certification ..................................................................................................................... 141
7-5.7 Access for Remedial Work ................................................................................................................. 141
7-6. Training ...................................................................................................................................................... 142
7-6.1 Training Off-Site ................................................................................................................................. 142
7-6.2 Training On-Site (Operators) .............................................................................................................. 142
7-6.3 Training On-Site (Maintenance) ......................................................................................................... 142
7-7. Spare Parts .................................................................................................................................................. 143
7-7.1 Ordered Spare Parts ............................................................................................................................ 143
7-7.2 Spare Parts for Commissioning Work ................................................................................................. 143
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I. Structural Limit of the Crane – Light Tower
II. Inspection Control Sheets
III. Miscellaneous Detail Drawings
IV. Reference Drawings and Date
V. List of Drawings/ Calculations to be reviewed by the Purchaser (Minimum Requirements)
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Section C. TECHNICAL SPECIFICATION
C (I) Functional Requirement for the Crane
1. General
1-1. Project Description
To carry out the design (if new crane), construction (if new crane), delivery, installation,
testing and commissioning of Two (2) units of not less than 52 tonnes twin-lift capacity
rail mounted container handling quay side crane. The cranes shall be delivered to Gdynia
Container Terminal S.A., Poland in a fully assembled and tested condition.
THIS TECHNICAL SPECIFICATION INCLUDES BOTH OF TYPES OF THE EQUIPMENT:

1. NEW CRANE,
2. USED CRANE.
IN SOME CASES THE TECHNICAL SPECIFICATION APPLIES ONLY TO A NEW CRANE.
IS PERMISSIBLE TO USE EQUIVALENT TECHNOLOGICAL SOLUTIONS TO THOSE

PRESENTED IN THIS TECHNICAL SPECIFICATION. IN ORDER TO PROPOSE
EQUIVALENT TECHNOLOGICAL SOLUTIONS, THE TENDERER SHOULD FILL IN PART
IV DEVIATION LIST OF THE FORM OF TENDER.
1-2. Terminal Site
The crane shall be delivered and installed at Gdynia Container Terminal at

Ul. Engergetykow 5, 81-184 Gdynia Poland (hereinafter referred to as GCT).
1-3. Overriding Requirement of the Purchaser
(1) This Specification forms part of the Agreement. The Contractor’s attention is drawn
to Clause 3-General Requirements of the Conditions of Contract for clarification of
position of this Specification in relation to the overall and overriding requirements of
the Purchaser.
(2) For the purposes of this Contract (including Clause 3 of the Conditions of Contract
and relevant references within the Specification) acceptable routine maintenance
shall be within the following general parameters.
(i) For steel structures and related component parts, fittings and fixings,
acceptable routine maintenance shall be limited to the maintaining of the
paint system as stated below. Reinforcing, cutting out and/or replacement
of any corroded, fatigued or defective steel or its fixings, etc. shall be
Defects remedial works and not maintenance.
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ii) For items of electrical and mechanical equipment, controls, systems,

components, fittings and fixings, acceptable maintenance shall be the
periodic and routine maintenance normally carried out on the various parts
generally undertaken as established practices of the Purchaser or as
specified in the operations and maintenance manual prepared by the
contractor, provided that such maintenance recommendations are
reasonable when compared to industry standards.
iii) The foregoing shall apply notwithstanding any inconsistent requirement or

information in any maintenance instructions provided by the Contractor or
otherwise put forward by the Contractor and any such inconsistent
requirement or information shall not, and shall not be relied on by the
Contractor, to relieve, limit or diminish any obligation or liability of the
Contractor under the Agreement or otherwise including in relation to
Defects.
1-4. Project Management
The Project Manager shall be competent in communicating both oral and written in both
Polish and English. If it is not possible to comply with this requirement then the contractor
shall allow for full-time attendance of suitably qualified translator/ interpreter at all meetings
discussions and for the processing of correspondence.
If during the course of the contract, the Project Management is found to be lacking, the
Purchaser reserves the right to require replacement with a more suitable person. The Project
Manager shall have the necessary authority, within the Contractors organisation, to manage,
direct and control and/ or order the cessation of work the works under the contract, in the
case of unsatisfactory standards of workmanship.
2. Overall Design Criteria
2-1. Type of Crane
The Crane shall be a travelling gantry with a hinged straight boom at seaside, full rope trolley
type or a self-driven trolley type. The crane drive and control shall be supplied with a full AC
inverter drive, fully digitalised control with PLC. The proposed drive and control system
shall be a proven system successfully operating on a similar capacity crane in actual
container handling operations.
2-2. Type of Cargo
The type of Cargo to be handled by the Crane shall be
(1) ISO 20ft and 40ft containers including high-cube, half-height, flat rack containers.
(2) Other types of container with ISO corner fittings at 20', 30’ 40', or 45' position
containers.
10
(3) Not used.

(4) Containers with overheight cargoes through an overheight cargo container lifting
frame currently used in container terminals.
(5) Hatch covers and containers of weight not less than 52 tonnes.
(6) Damaged container with slings and shackles attached to lifting lugs of the spreader.
(7) Heavy lift cargo up to weight of not less than 64 tonnes with a Hook Beam attached
to the headblock. The heavy lift shall be operable through the full hoisting range and
across the full distance of trolley travel.
2-3. Operating Environment and Design Aim
The Crane(s) shall be designed and constructed such that they are suitable for operation and
maintenance on a 24 hours per day basis in all weather conditions. All electrical, electronic,
and mechanical equipment shall be non-hygroscopic, non-corroding and tropicalised for use
in conditions stated in 2-7.6, 2-7.7 and 5-4 of this Specification. Special considerations shall
be given in all aspects of the design for achieving accurate load spotting ability while
ensuring full operational capability and safety for round the clock operations, including
operations under heavy rain (squall conditions) or snow.
2-4. Mode of Operation and Performance Target (MMBF) (Mean Moves Between Faults)
The Crane shall have the option for manually controlled operation or semi-automatic
operation. Under the manually controlled operation, all functions on the Crane shall be
controlled fully by the operator. Under the semi-automatic operation, the functions shall be
aided by the computer system. Details of the semi-automatic operation are defined in Clause
5-4.10-1.
The MMBF of the Crane will be ascertained by the Purchaser after its Commissioning. For
the purpose of ascertaining MMBF the Crane will be put into operation under such
conditions and circumstances as may exist or be required by the Purchaser from time to time
including if the Purchaser elects operation for the purpose of the Purchaser’s business and/or
for the specific purpose of ascertaining MMBF. No credit or allowance shall be given for the
benefit of the Contractor in respect of conditions, circumstances, and operator’s performance.
The MMBF is defined as:
MMBF = Twist Lock Count (TLC) for one week

Number of Breakdowns of a Crane for one week
TLC = One TLC is defined as the operation of twist lock + hoisting + trolley + lowering +
unlock.
The actual MMBF shall be recorded on a weekly basis. Following completion of the Initial
Trial Period, the Intermediate Trial Period and the Final Trial Period for a Crane the MMBF
shall be calculated by dividing the total number of twist lock counts recorded during the final
four-weeks by the total number of emergency breakdowns in the same period.
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2-5. Statutory Requirements and Applicable Standards
The Crane and its mechanisms shall be designed and manufactured to comply in all respects
with the requirements of relevant state or local Polish and/ or Europe on laws, ordinances,
rules, orders, or other legal or regulatory instruments such as, but not limited to, the
following:- (All standards relating to cranes are grouped in Polish Standards Catalogue
under No.53.020.20)
- Wiring Regulations to Polish Standards for electrical installations (PN.60204-

32:2004).
- Local Ordinances and Regulations. (Including safety inspection of Cranes and

Personnel Lift / Elevator tests and certification).TDT requirements.
- Local Power Supply Co. Rules for power supply. (PN-EN 50160:2002)
Where items are not covered by statutory requirements the Crane and other Goods
shall be designed and manufactured to at least the standards as specified in this
Specification, and for items which are not so specified to at least the current
applicable recommendations of the following organisations: -
AWS American Welding Society – Dynamically Loaded Structures
ASTM American Society for Testing and Materials
BSI British Standards Institute
DIN Deutsche Industrie Normen
FEM Federation Europeene de la Manutention
GB Chinese Standard Institute
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronic Engineers
ISO International Standards Organisation
JIS Japanese Industrial Standards
UL Underwriters Laboratory
The Contractor shall be required to submit to the Purchaser a full list of applicable
standards used in the design of the Crane.
12
The Tenderer shall be required to submit to the Purchaser a full list of any other
standards proposed to be used in the design of the Crane for consideration by the
Purchaser. Only one standard shall be applied for any one area of crane design/
construction. It shall not be acceptable to select sections from various codes where
factors/ variables may compromise the design if combined inappropriately.
2-6. Minimum Class of Crane
BS 2573 parts 1 & 2 or FEM shall be used in the design of the crane and its mechanisms.
Structures:
Class of Utilisation U8 (3 million cycles, refer to design cycle
spectrum, clause 3-6(4))
State of Loading Q3
Group Classification A8
Impact Factor 1.4
Duty Factor 0.9
Mechanisms
Mechanisms Class of Utilisation State of Loading Group Classification
Hoist T8 L3 M8
Trolley Travel T8 L3 M8
Gantry Travel T5 L2 M5
Boom Hoist T3 L3 M4
2-7. General Design Criteria
2-7.1 Crane Particulars
(1) Rated Load Not less than 41 tonnes weight of one 20’, 40’ or 45’, 40T
Under spreader: container or weight of two 20’ containers for a totalweight
not less than 52 tonnes .
Not less than 64 tonnes cargo under the Hook Beam
Under headblock: attached to headblock. (From Backreach limit to 56 m
outreach from seaside rail)
(2) Test load for 51,25 tonnes under spreader (SWL X1.25)
overload test 80 tonnes under the Hook Beam Hook. (SWL X1.25)
(3) Container type ISO 20', 30’ 40’ and 45’ ISO containers with ISO corner
fittings at 20', 30’ 40’ or 45' position.
(4) Spreader 20'/30’40'/45' twin-lift spreader. For twin lift spreader

operation, there shall be centre spreaded capability,
telescopic type with corner flippers.
(5) Span (Gantry) 30,480 mm.
13
(6) Outreach from C.L. Not less than 56,000 mm to service limit (to work at least19
of seaside rail wide container vessels)
(7) Backreach from Not more than 25,000 mm to service limit.
C.L. of landside rail.
(8) Lift above top of Not less than 36.0m to the lowest point of twist lock.
seaside rail
(9) Lift below top of Not less than 14m .
seaside rail
(10) Usable inside Not less than 16.9m

clearance between
legs
(11) Clearance height Not less than 15,000 mm

under portal girder
(Above top of
seaside rail)
(12) Overall crane width Not more than 30,000 mm with bumper free condition.
(13) Boom width, or Not more than 16,000 mm

trolley width
whichever the
greater.
(14) Speed: Main Hoist:

These speeds must be Not less than 40 m/min with 65Te rated load under
achieved for Crane spreader.
operation under Not less than 110 m/min minimum with empty spreader.
sustained wind speed Acceleration/ Deceleration time not more than 5 sec
of 20 meter/sec. measured at the motor.
Trolley:
Not less than 180 m/min minimum.
Acceleration/Deceleration time not more than 6.0 sec.
measured at the motor.
Gantry:
Not less than 40 m/min.
Acceleration/ Deceleration time not more than 7.0 sec.
Boom Hoist:
Less than 6 min either way – including the completion of
boom latch locking motion or the boom latch releasing
motion.
(15) Trim adjustment (*) Not less than ± 3 degrees with rated load.
14
(16) List adjustment (*) Not less than ± 3 degrees with rated load
(Spreader horizontal drift allowance in trolleying direction
Not less than ± 150mm max from zero- list position).
(17) Skew adjustment (*) Not less than ± 3 degrees: Speed 0.5 degree per second
minimum.
(*) Note 1 Trim, List and Skew adjustment systems must be capable of
changing attitude of a 41 Te container loading with 1.6
meter eccentricity in load centre.
(18) Gantry rail levels The landside rail is level with the waterside rail level, the
rail profile is A120.
(19) Gantry buffer level. 1,500mm above top of rail.
(20) Trailing cable type Round type
(21) Cable Slot Details Quay Structure.

For details, refer (drawings in Appendix III).
(22) Main power supply cable length to allow gantry travel distance of minimum 450m
from the feeding point in either left or right directions. (for details refer to Appendix III)
(23) The Main Hoist motion with empty spreader shall be allowed together with the
activation of the spreader function when the boom is in the raised condition.
(24) The Trolley motion with empty spreader in slow speed shall be allowed when the
boom is in a raised condition. The range of motion will be between the normal
parking position / storm parking position and the extreme backreach position.
2-7.2. Dimensional Restriction of the Crane
(1) The overall Crane width shall be maximum 30,000 mm for the Cranes bumper to
bumper (free).
(2) The boom width or trolley width, whichever is the greater, shall not exceed 8,0m
either side of the boom centreline.
(3) The absolute maximum projection allowed refer to "Structural Limit of the Crane" in
Appendix I.
(4) The usable inside clearance between legs free of any structure, fittings, machineries
or devices shall be a minimum 16,900 mm.
(5) Trolley rail gauge shall be not less than 6 meters.
15
(6) The cable reel shall be installed so as to avoid any interference with the structure of
the adjacent Crane.
2-7.3. Quay/Yard Interface
(1) Power Supply
(i) The power supply to the crane shall be 15 KV (±10%) 3 phase, 50Hz±2%.
(ii) The high tension trailing cable connection at the power feeding pit on the
quay shall be terminated into specially designed HV junction boxes.
Termination of the cable conductors and fibre waveguide in the plugs at the
feeding pit shall be done by the Contractor. Termination of the Purchaser’s
power supply cable and optics fibre cables into the socket shall also be the
scope of the Contractor. The high tension cable shall be supplied by
contractor with a suitable cable reeling device. A sufficient length of cable to
cover 450 meters gantry travel range from the central feeding point shall be
provided by the Contractor. The Contractor shall bring the Crane trailing
cable end to the feeder pit and shall complete the cable connecting work with
an approved cable joint kit. The supply and installation of the H.V. junction
box and end restraining drum shall be by others. The cable joints made at
Site and high tension wiring shall be subject to the inspection requirements of
the local power supply authority.
(iii) The high tension trailing cable shall be 15 KV ethylene propylene rubber
insulated polychloroprene jacketed round type flexible power cable based on
IECA Pub. S68 - 516 or the equivalent approved by the Purchaser.
The conductor shall be stranded flexible conductor consisting of tinned

annealed copper wires.
The cable shall also carry the fibre- optic cable for the remote CCMS see also
5-6.2.
(2) Gantry Rail
(i) Gantry rail is A120. For details, please refer to Appendix III.
(ii) Up-lift load shall not be applied to the gantry rails.
(3) Stowage Pin
The Contractor shall submit for the Purchaser's review a design of adequate stowage
pins to resist horizontal component of the forces applied to the Crane under its
stowed or tied-down condition. The dimension of the stowage pin shall suit the
socket provided in the quaydeck. The stowage sockets in the quaydeck shall be
installed by others. Typical details of the quaydeck sockets are shown in Appendix III.
16
The Contractor shall be responsible for confirming that the design of the crane
stowage pins suits the installed sockets.
2-7.4 Communication Facility Interface (Radio, Fibre Optic etc.)
The Crane shall be provided with fibre-optics cables and the necessary hardware for data
transmission. Refer to 5-6.2.
2-7.5 Auxiliary Electrical Power Interface
This clause is not used for this project.
2-7.6. Climatic Condition
The Crane shall be designed and constructed to operate safely and efficiently, as required by
the Agreement, climatic conditions in the environment described as follows:-
(1) Ambient temperature -20 deg. C to 35 deg. C

(2) Relative humidity Max. 100%
(3) Dew point Max. 3 deg. C
(4) Wind up to 25 m/sec. without special warning for normal working condition.
(5) Storm/ Gale Wind 42m/ second
More stringent and specific requirements shall apply for individual Crane sub-systems and
components, which are separately specified in each relevant clause of this Specification.
2-7.7. Wind Loading Condition
The entire Crane structure with all of its machinery, components, fittings/accessories, and all
equipment shall be designed and constructed to withstand following wind loading conditions.
(1) For operating wind load condition:
Wind speed of 20 m/s shall be assumed as constant over the total height of the Crane
with boom in fully lowered position or boom in raised and latched position.
(2) For stowed wind load condition:
A wind loading of wind speed up to 42 m/sec. (see Stowed Wind Load Table below)
shall be allowed for the condition that the Crane is out of service, boom in raised and
latched position or boom in fully lowered position, (see table below) and gantry
stowage pins dropped in sockets in the quay. Warnings of high wind conditions are
advised to the terminal by the Port Master for any expected conditions over force 5.
(3) For storm wind load condition: (To be discussed)

A wind loading of wind speed up to 55 m/sec. shall be allowed for the condition that
the Crane is out of service, boom in raised and latched position or boom in fully
17
lowered position, (see table below) and gantry tie-down device shall be locked in the
quay.
2-7.8. Load Lifting and Stability Condition
(1) One side landing
A required operating condition shall include the case of a short side landing of two
20ft - concentric 41 tonnes weight container, in which case a set of main hoist wire
ropes on the landed side is assumed slack and not carrying the load. Calculation for
structural design and mechanical design shall take this case into consideration.
(2) Eccentric container handling
All structural, mechanical and electrical systems and system components shall be
designed to take account of the eccentric forces involved in handling containers in
the single lift operation in the following combinations.
Single lift
(i) 1 off 45ft container weighing not less than 41Te continuous with eccentricity
of 1.2m in longitudinal (gantry) direction and 0.25m in transverse (trolley)
direction.
Twin lift
(ii) 2 off 20ft containers weighting not less than 52 tonnes with eccentricity on
each container of 0.6m in the same longitudinal (gantry) direction and 0.25m
in the transverse (trolley) direction.
(iii) 1 off 20ft container weighing not less than 30.5 tonnes with eccentricity of
0.6m in the longitudinal (gantry) direction and 0.25m in the transverse
(trolley) direction and 1 off 20ft container at 2 tonnes (empty) concentric.
Under conditions (ii) & (iii) the centre distance between containers shall be a
maximum of 7700mm.
(3) Fatigue condition
The structural fatigue calculations shall include the cases that the Cranes will be
continuously handling containers configured as outlined in 2-7.8(2), above and the
Crane must be suitable for and able to perform as required for this. The fatigue lifted
load shall be 32T, and 48T for single or twin lift concentric, i.e. (0.8 times the rated
load).
(4) Dynamic snag load (catch load)
Load cells shall be fitted into the main hoist circuit to give electrical protection
against snagging. The Crane shall not sustain any damage due to dynamic snag load.
18
The Contractor shall submit structural calculations to prove that structures are safe
under dynamic snag load.
It is not acceptable that the Dynamic Snag Load Protection shall rely solely on load-
cell initiated main hoist motor shut-down. i.e. complementary protection, such as
hydraulic cylinder controlled sheave travel (see also 4-1.4) or mechanical brake
release.
(5) Stability
The Crane shall be stable with a reasonable factor of safety (not less than 1.15) and
shall not sustain any damage when a dynamic snag load is applied to the boom at the
maximum outreach position.
(6) The loads and load factors for which stability shall be calculated are specified on the
following table “Stability Combination”. The calculations shall be submitted to the
Purchaser for review and acceptance or rejection.
Stability Combinations
Mode Boom Down
Stability Load Name ST0D ST1D ST2D ST3D ST4D ST5D
Dead Load DL 1.0 1.0 1.0 1.0 1.0 1.0
Trolley Load TL 1.0 1.0 1.0 1.0 1.0 1.0
Lifting System LS 1.0 1.0 1.0 1.0 1.0
Lifted Load LL 1.5 1.0 1.0 1.0
Trolley Load Lateral LATT 1.0
Gantry Load Lateral LATG 1.5
Operating Wind Load OWL 1.0 1.5 1.0 1.0
Stall Torque Load STL 1.15
Collision Load COLL 1.15
Stowed Wind Load SWL 1.5
Typhoon Wind Load TWLC
(Storm)
No. of legs allowed to lift off 0 0 0 1 1ь 1

a. Tie-downs secured.
b. The vertical movement at any stowage pin shall not exceed 35mm.
Stability Combinations
Mode Boom Up
Stability Load Name ST1U ST2U ST3U ST4S ST5S ST6T
Dead Load DL 1.0 1.0 1.0 1.0 1.0 0.9
Trolley Load TL 1.0 1.0 1.0 1.0 1.0 0.9
Lifting System LS 1.0 1.0 1.0 1.0 1.0 0.9
Lifted Load LL
Trolley Load Lateral LATT
19
Gantry Load Lateral LATG 1.5

Operating Wind Load OWL 1.5 1.0
Stall Torque Load STL
Collision Load COLL 1.15
Stowed Wind Load SWL 1.5 1.15
Typhoon Wind Load TWLC 1.3
(Storm)
No. of legs allowed to lift off 0 0 1 1ь 0 a

a. Tie-downs secured.
b. The vertical movement at any stowage pin shall not exceed 35mm.
2-8. Storm Wind Tie-Downs
2-8.1 Design
(1) The Contractor shall submit for the Purchaser's review and the Contractor shall
ensure that the Crane has an adequate storm wind tie-down design to effectively
secure the Crane under the storm wind strength condition as specified in 2-7.7. This
design will suit the dimensional requirements as shown on the drawings in Appendix
III. The complete system shall not inhibit normal crane operations when not in use.
(2) Acceptance of a design by the Purchaser will primarily depend on ease of

application (tieing and untieing) of the device, provided that strength and civil
interface dimensions of the proposed device fully comply with the Purchaser's
requirements.
(3) Other drawings showing the typical cross section and general arrangement of the
quay (crane rail beams and quay deck to the edge of the quay) are attached for
reference in Appendix III.
2-9. Noise Control
(1) Special consideration shall be given to acoustic treatment to reduce noise breakout
from the machinery house via the walls, floors, roof, winch wire rope openings,
ventilation air intake / discharges etc.
(2) The maximum noise level measured 1 metre outside and under the machinery house
shall not exceed 85 dB.
(3) The noise level inside the operator’s cab and the control room within the E- House
section of the Machinery House shall be below 75 dB during operation, with air-
conditioner on, and doors and windows in a closed condition.
(4) The noise level in the E-house section of the Machinery House shall not be greater
than 80dbA with the electrical panels in the operating condition i.e. cubicle doors
closed and all fans operating.
20
(5) The noise level at quaydeck level shall not exceed 85dBA during Trolley Travel
Operation and/ or main hoisting with SWL on the spreader.
2-10. Operationally Critical Components
The Contractor shall submit the inspection and replacement schedule for the operationally
critical components to the Purchaser. The objective is to assist the Purchaser to establish a
standard for maintenance and inspection of operationally critical components (i.e. those
components and structural areas, joints, tension bars where failure could have catastrophic
consequences).
2-11. Asbestos
The Contractor shall ensure there is no asbestos material used on, in or as part of the
construction of the cranes.
Should there be any doubt that there may be asbestos in or on any part of the crane when
delivered to the terminal, then the Purchaser reserves the right to carry out tests for the
presence of asbestos. Should any asbestos be found to be present then the costs of the
testing and removal/ clean-up shall be a charge against the Contractor.
3. Crane Structural Specifications
3-1. General Requirement
Deflection or dynamic oscillation of the structure shall be such that is does not affect the
Crane capacity and operating efficiency may need to strengthen specification with numbers.
3-1.1 Design
(1) The structure shall consist of sections, box or tubular members forming the gantry
frame and boom. The boom shall consist of a twin box girder-type structure.
Cover plates and back-to-back angles or channels shall not be used. Wire rope or
strand shall not be used for structural members. Flattening or crimping of tubing
will not be allowed unless approved in writing by the Purchaser.
(2) The sill beams, legs and portal beams shall form a continuous rigid frame. The
connections between these members shall be bolted or welded and be capable of
resisting all components of force.
(3) The legs of the Cranes shall contain internal access ladders. An adequate number
of appropriately sized manholes shall be provided to allow access for internal
inspection to the interiors of these and any other members large enough to crawl
through. Members that cannot be internally inspected because of size or other
practical reasons shall be sealed by welding. Sealed members shall be pressure
tested during the course of construction at 10kpa pressure using soap film to
demonstrate air tightness.
21
This testing shall be performed by the Contractor and witnessed by the Purchaser
or his representative immediately following fabrication and before painting.
(4) Welded joints are preferable. If the Contractor proposes to use bolted joints, it
shall be made using bolts complying with ASTM A325 or A490.
(5) Fracture critical members or member components, FCM’s, are tension members or
tension components of members whose failure would be expected to result in
collapse of the crane, collapse of the trolley, or dropping the load. Tension
members or tension components include those portions of a flexural member that
are subject to tension stress.
(6) The Contractor shall determine which member or member component is in the
FCM category. All FCM’s shall be identified on the drawings.
(7) FCM’s shall be accessible for periodic structural inspections. Non-fracture critical
members shall be accessible where practical for periodic structural inspections.
(8) Connections shall be detailed to provide a ductile structure capable of withstanding

yielding without brittle failure. Transitions shall be gradual. Changes in thickness
or width shall be achieved using tapered or curved surfaces.
(9) The girder and boom design and Machinery House design shall allow the operator to
escape from the operator's cab to safety, via the walkway of the girder and the boom
at any point of trolley travel range including under the machinery house in an
emergency.
(10) The girder and boom design shall allow trolley wheel replacement works at any
position on girder/boom of the trolley. In addition the Machinery House structure
shall be designed to permit the trolley wheels to be raised/lowered by the Machinery
House maintenance hoist.
3-1.2 Machinery on main structure
The following machinery shall be fitted to the main structure.
(1) Gantry drive machineries.

(2) Gantry buffers.
(3) Power-operated wheel clamps with limit switches.
(4) Cable reel with cable guide and limit switches.
(5) Main hoist sheaves.
(6) Boom hoist sheaves.
(7) Boom latches with limit switches.
(8) Trolley drive sheaves.
(9) Stowage pins with limit switches.
(10) Storm-pin gear for storm/ gale wind.
1 set - gantry structure tie down to the quay. (Provision for turnbuckle length
adjustment range of ±150mm shall be provided).
22
1 set - trolley tie-down (to the girder)

1 set - boom locking device (to the mast structure)
(11) Boom hoist, boom latch and gantry travel control station.
(12) Gantry travel operating station at ground level.
(13) Personnel lift (if applicable).
(14) Trim/List/Skew adjustment devices.
3-1.3 Fittings on Main Structure
The following fittings shall be fitted to the main structure:
(1) Walkways, stairs, ladders and platforms (refer to 6-1).

(2) Lighting for operation and for walkway, stairs ladders and platforms (refer to 6-2).
(3) Aviation warning lights (refer to 6-2.9). One pair on top of the mast structure. One
pair at the tip of the boom.
(4) Wind vane for anemometer at a high level where least affected by turbulence caused
by own crane structure during operation.
(5) Intercom system (refer to 5-6.1).
(6) Travel warning device. Warning gong speaker plus flashing strobe light at each of
4-corners.
(7) 2 speakers fitted at quay level on waterside and landside facing inside of the Crane.
(8) Welding outlet (refer to 6-8).
(9) Service outlet (refer to 6-7).
(10) Emergency stop buttons (refer to 6.6).
(11) 2-CO2 fire extinguishers, 5kg capacity at ground level.
(12) 2-angled face warning reflector signs on the landside sill-beam facing the backreach
area in English and Polish stating 'BEWARE OF OVERHEAD LOAD'.
(13) Cab window cleaning platform at near the rear end of girder, which is accessible
from the operator's cab or back reach girder.
(14) Provision shall be made in the design / construction of the horizontal member to
incorporate lugs to carry a twist lock or stacking cones platform supported off the top
of the sill member and the subject lugs, via tension members.
3-2. Material
3-2.1 Material Standards
The whole of the materials used in the Crane shall be new, of the best quality and suitable for
the duty intended. Mill certificates shall be obtained and records strictly maintained to match
these to the various Crane sections produced during crane manufacture. The steel materials
for all the stressed members shall be selected from the materials which specification includes
the notch toughness requirement for service in an environment with temperatures in the
range -20~+35°C. Charpy testing shall be on a “per-plate” basis and the coupons shall be cut
transversely to the direction of rolling.
The steel used for the manufacture of the Crane shall conform as a minimum to one or more
of the following standards most recent issue.
23
American Standard
Deutsche Industries Norman (DIN)
British Standards (BS)
Japanese Industry Standards (JIS)
EU Standards (EN)
3-2.2 Machinery Bases
All main drive machinery bases (Motors, brakes, gearboxes, bearing housings/pedestals, etc.)
shall be machined, after all fabrication work on the area is completed, to ensure flatness, and
to avoid assembly problems within each functional sub-assembly.
All machinery mounts shall have adjustable locking screws for horizontal adjustment
(forward and backwards, side to side) for the purposes of the equipment alignment.
3-2.3 Edge Finish
All plate edges shall be ground with a grinder or other suitable power tool to eliminate any
sharp edges or burrs from cutting work.
3-2.4 Surface Finish
Provision shall be made to protect structural surfaces and any other surfaces where weld
spatter can be detrimental to the performance of the crane i.e. windows, hand railing,
trunking, electrical boxes paint systems etc., from welding spatter.
3-2.5 Draining and Inspection Manholes
All the structure shall be designed to drain water effectively. Any draining water shall not
affect safety of operations or maintenance work during heavy rain conditions. No water traps
or pounding shall be allowed in any part of the crane structure.
Appropriately, sized manholes shall be provided in all unsealed members to provide for
internal inspection. The manholes shall be positioned such to allow access from each end of
any unsealed member and particular attention for safety shall be given to those areas where
manholes directly access onto or from vertical ladders.
3-3. Calculations.
3-3.1 Submission to Purchaser
Wheel loads, for seaside rail 1000 [kN/m] and for landside rail 750 [kN/m], , stability
calculations, gantry buffer loads, braking capacity and distance calculations for all motions,
and peak power consumption calculations shall be submitted for Purchaser's review prior to
commencement of detailed design.
Other data or design calculations at various stages of design shall be submitted from time to
time as requested by the Purchaser as part of review process.
24
3-3.2 Design Audit
The Purchaser reserves the right to carry out a detailed structural and mechanical audit of
the design proposed by the Contractor.
To facilitate this audit, the contractor shall supply, in logical order, and in complete
packages, all relevant information on major elements and functional drives. This shall
include
- Relevant drawings to show how the loads are being transmitted into the structure,
to permit an integrated design audit.
- Relevant calculations.
- Sufficient drawings to show how components elements make up the conceptual
design (clause 7.2. refers)
- Calculations to justify the selection of proprietary items such as hoist, trolley,
gantry and boom hoist components e.g. motors, couplings reducers brakes etc.
Provided that the Design information packages incorporate all relevant information,
calculations and component selection data, the Purchaser shall endeavour to have relevant
comments back to the contractor within three weeks of submittal.
Failure to supply all relevant information sufficient to enable the auditor to confirm fitness
for purpose will, of necessity, extend this period. The purchaser will not be responsible for
any delays that may occur from the necessity to amend proposed designs.
For the guidance of the Contractors design office staff, the Design Auditor will be
following a procedure generally described as follows:-
3-3.2.1 Calculations
(1) Assemblies shall be analysed with the aid of an appropriate computer program.
(2) The mathematical model shall accurately simulate the real structure. When
ancillary members are attached to the structure, these members must either be
accurately modelled or the connecting details shall be designed to allow for
compatible deformations. The size of joints shall be taken into account. If a joint is
modelled as pinned, it shall either be actually pinned or connected with a flexible
element capable of flexing as required without overstress. The effect of axial load
shall be included in the analysis of such flexible components.
(3) The boundary conditions at the gantry rails shall be selected to suit the various load
cases.
For vertical loads:

The wheels shall be modelled as free to spread perpendicular to the rails and free to
move parallel to the rails.
For horizontal loads perpendicular to the gantry rails:
25
The wheels may be considered to be restrained in the direction perpendicular to the

rails, at both the landside and waterside rails, and free to move parallel to the rails.
For horizontal loads parallel to the gantry rails:

For operating conditions, the loads due to driving or braking shall be taken
according to driving and braking forces developed at each corner. The wheels shall
be free to spread parallel and perpendicular to the rails. For stowed conditions, the
horizontal loads shall be taken to the stowage pins. Stowage pin prying action, if
any, shall be included in the analysis.
(4) The Effect of the horizontal forces parallel and perpendicular to the rails shall be
included in the calculation of truck and equalizer forces.
(5) Load paths shall be developed for all details. The calculations shall contain free
bodies showing these load paths.
(6) For load combinations where one leg lifts off, proper boundary conditions shall be
used and the gantry frame shall be checked for stresses using the allowable stress
for the corresponding stress combination.
(7) Calculations based on the analysis of the preliminary structural design may not
need to be revised to suit the final design unless there is significant discrepancy
between the preliminary and final designs. After the design is complete and all
changes have been made, a final computer analysis shall be run to verify that the
design revisions do not significantly increase the calculated stresses. The allowable
stresses for the verification analysis shall be the stated allowable stresses plus 3 %.
(8) The calculations shall be retained for information only and may or may not be
reviewed by the Purchasers Representative. At least the following items shall be
included in the calculation brief to the Design Auditor to facilitate the audit process
(provided by the Contractor).
Table of Contents.
General description of computer programs used with definitions of any special

terminology.
Listing of the governing specifications.
Listing of all loads.
Listing of load combinations and corresponding allowable stresses.
Calculations for determining the magnitude of each design load.
If a dynamic analysis is used to determine impact load, this analysis may be

submitted separately.
26
Dynamic analysis for one boom hoist rope failing.
Sketches showing computer input data including geometry, node numbers, member
numbers, global axis, local axis, member properties and boundary restraints.
Stress calculations for members.
Stress calculations for joints and other details.
Cumulative damage analysis.

Gantry frame buckling analysis.
Buckling analysis of plate elements, including stiffener sizing.
Stability calculations.
Computer output for the gantry frame and boom including the following
information:
Echo of input data, including descriptive sketches.
Member forces for each of the specified individual loads. For moving loads, results
need not be given for all members for each moving load position. However,
maximum and minimum forces and the corresponding moving load positions shall
be provided for all members.
Displacements at appropriate joints for each of the specified individual loads.
Sum of forces at each node. Computer results will not be accepted if this summary
shows significant around-off error.
Period and mode shape for the lowest gantry frame mode of vibration excited when
the trolley stops and starts.
Period and mode shape for the lowest gantry frame mode of vibration excited when
the gantry stops and starts with the trolley located midway between the gantry rails.
Support reactions for each of the specified individual loads.
Cumulative damage ratios at critical zones of each connection or change of section.
The Contractor shall be required to work closely with the Design Auditor appointed by the
Purchaser and provide any information that they may require in order for them to carry out
their design audit obligations.
3-3.3. Construction Drawings
27
The Contractor shall also provide three (3) copies of the drawings showing construction
details to enable supervision of the fabrication and construction by either the Purchasers
representatives or Third Party Surveyors.
Drawings forming part of the design packages, forwarded for audit purposes shall be
provided in AutoCAD drawing format so that they can be reproduced clearly upon receipt,
to permit accurate examination and assessment.
[The Purchaser warrants that it will respect commercial confidentiality of drawings

provided and will only use them for the purpose of assessing the design.]
3-4. Loads
(1) The design shall incorporate all loads and load combinations pertinent to all in
service and out of service conditions of the crane. The loads due to temperature
effects, erection stresses, and others based on the Contractor's experience shall be
included in the analysis if they cause significant stresses. If rational analysis
indicates loads larger than specified, the larger loads shall be used.
(2) The Contractor shall comply with BS2573: Part 1: 1983, Rules for the Design of
Cranes for calculation of stresses in structural components.
3-5. Members Subject to Buckling
(1) The design of columns, beam columns, frames and beams subject to lateral buckling
shall be in accordance with the AISC Specification. The design of flat plates, curved
plates, and plate stiffeners shall be in accordance with a recognized method that
considers the combined effect of shear, compression and flexure. The effects of
biaxial stresses shall be included. Criteria given in FEM is acceptable.
(2) For all structural plates, the ratio of the minimum clear dimension, b, to thickness, t,
shall not exceed 60, i.e. 60 ≥ b/t.
(3) The local buckling criteria given in the AISC and AISE standards are unacceptable
because biaxial and combined stress effects are ignored. The choice of a practical
method of calculation is left to the Contractor who shall state the origin of the
method chosen.
(4) Tension field action may be included for evaluating pure shear resistance during
overload and stowed conditions, provided the tension field shear panels are designed
for a factor of safety against collapse of at least 1.25. Tension field panels shall be
assumed to have zero capacity to resist bending, bearing or axial stress.
3-6. Fatigue Design Criteria
(1) Fatigue design shall generally conform to the requirements of BS 5400: Part 10
(1980), except as modified in this section. Modifications to BS 5400 pertain
primarily to the deletion of provisions that apply to bridges only, insertion of
28
design load spectra applicable to container cranes, and the addition of provisions
for tubular joints. The criteria stated in this section shall take precedence over the
design criteria in AWS D1.1 – latest version.
(2) When not specified in BS 5400, the requirements and recommendations in BS

7608 shall be followed, except where specifically excluded in the specification.
Some of the exceptions to BS 7608 are:
2.1 BS 7608 “B.6.2.1 Misalignment” The AWS 1.1-latest version requirements

shall apply.
2.2 BS 7608 “Table 6 Type 6.2, 6.3”: The 4 to 1 taper shall be required if class
E, or D, is assigned. Otherwise the taper may be 2.5 to 1 as specified in the
AWS D1.1-latest version and the joint class may be F or lower. Class D
details are difficult to achieve since small attachments will degrade the
classification. Generally class D details are impractical. Class E details are
practical if care is taken not to degrade the joint. Class E details are
practical locally, but are generally impractical for an entire member. Class
E and D details should be used with caution. Class G details shall not be
used.
2.3 BS 7608 “Table 7 Type 7.6” and “Table 10 Type 10.3”: Stiffeners shall
support the component of stress due to the bend in the main plate. The
stiffener centerline shall intersect the point where the main plate centerlines
intersect.
2.4 BS 7608 “Table 11” all types: Eccentric lap joints shall not be used to
transmit axial stress.
2.5 BS 7608 “4.3.2. Effect of material thickness”: The correction on stress

range specified below, in section 4.5.11 of the code shall govern.
(3) The load spectra for development of the stress cycle spectra shall be as described in
this section. The specified loads and cycles represent the effects of the actual
anticipated operating conditions. The fatigue lifted load (LLF), lifting system (LS)
and trolley load (TL) shall be used for the fatigue calculations of the gantry frame
and boom.
(4) Definitions for move and cycles:
i) One move: Lift the container from the ship, travel the trolley and set the
container on the wharf; or the reverse operation.
ii) Single Cycle: Lift the container from the ship, travel the trolley and set the
container on the wharf with the lifting system supported by the container,
pick the lifting system, return to the ship, set the lifting system on the next
container and prepare to lift the container from the ship; or the reverse of
the above. There is one move per single cycle.
29
WS Rail
LS Rail
30.48 m
A 0.75 x 106 Moves A 1.0 x 106
B 0.75 x 106 Moves B 1.0 x 106

C 0.75 x 106 Moves C 1.0 x 106
D 0.75 x 106 Moves D 1.0 x 106
3.0 x 106 Total Moves
(All Single Cycles)
20 m
30 m
40.0 m 40 m
45.0 (to full backreach) 56 m (to full outreach)
Design Cycle Spectrum
N.B. Heavy Lift Range – 45m backreach

- 56 m outreach
Frequency of Heavy Lift – 1 Lift/month
30
(5) ALLOWABLE CUMULATIVE DAMAGE
JOINT DETAILS
NFCM FCM
Detail Class K1 K2
BS5400: Part 10 m (t/cm2)m (t/cm2)m
W 3.0 2.57x105 1.68x105
G 3.0 4.00x105 2.65x105
F2 3.0 7.72x105 4.57x105
F 3.0 1.11x106 6.71x105
E 3.0 1.96x106 1.10x106
D 3.0 2.61x106 1.61x106
C 3.5 7.23x106 4.52x106
B 4.0 1.67x107 1.09x107
TUBULAR JOINTS
NFCM FCM
Detail Class K1 K2
2
AWS D1.1 m (t/cm )m (t/cm2)m
T-A 5.8 4.56x107 1.52x107
T-B 4.4 3.41x106 1.14x106
T-C1 4.1 2.01x106 6.69x105
T-C2 3.6 6.55x105 2.12x105
T-D 3.3 3.68x105 1.23x105
T-E 3.2 2.02x105 6.72x104
T-F 4.6 2.36x105 7.85x104
T-DT 4.4 3.71x104 1.23x104
T-ET 3.4 1.04x104 3.45x103
T-FT 4.2 1.57x104 5.22x103
T-K1 4.5 4.13x102 1.38x102
T-K2 4.3 2.59x102 8.13x101
NFCM is Non-Fracture Critical Members
FCM is Fracture critical Members
T preface is used to distinguish AWS D1.1 tubular class from BS5400 class.
(1) Fluctuating stresses and the number of cycles of each fluctuation shall be
determined from the stress spectra. Stress cycle value and counting shall be done
by the “reservoir method”. See BS 5400: Part 10, 1980 or BS 7608 “Annex F
Cycle counting by the reservoir method”.
(2) The applied cumulative damage at each critical point shall be calculated using
Miner’s rule.
(3) The allowable cumulative damage for each joint classification K1 or K2 is given in
the tables above. K2 values shall be used for fracture critical members. K1 values
shall be used for non-fracture critical members.
31
(4) The values tabulated for BS 5400: Part 10 details are identical to those given in BS
5400. The values tabulated here for AWS D1.1-latest version tubular details are
close, but not identical, to those given in AWS D1.1-latest version. The tabulated
values given here shall be used.
(5) When a detail does not match a standard detail, two alternative methods may be
used to determine the fatigue class:
(i) Alternate 1: Prepare a stress analysis of the detail and compare the results to
a stress analysis of a typical standard detail which is most similar to the
actual detail. The standard detail shall be of usual proportions, similar to
the detail used in the development of the test data. The peak stress in the
proposed detail shall not exceed peak stress in the standard detail. Criteria
in BS 5400: Part 10, BS 7608, or the AWS D1.1-latest version tubular
details shall be used for comparing proposed detail to the standard detail.
(ii) Alternate 2: Conduct tests in accordance with BS 7608 “Annex E Fatigue

testing and the use to test data to define design stresses”.
(6) For a plate thickness or nominal bolt diameter, t, greater than 30 mm and, for plates,
where the coefficient m is less than or equal to four, a reduced allowable
cumulative damage, K1’ and K2’ shall be determined as follows.
m
4
30
K’1 = K1 x
t
(7) Fatigue detail Class G shall not be used on FCM’s. All FCM details shall be F2 or
better. Smooth transitions shall be provided at changes in section on FCM.
(8) Some typical acceptable and unacceptable details are shown in Appendix IV.
(9) Special calculations shall be made for members in series. FCM’s in series shall be
verified to have the design reliability of at least 0.977. A single FCM subject to the
design (allowable) cumulative damage, K2, has a reliability of 0.977. If two or
more members are in series as links of a chain, the combined reliability of the
series of FCM, the series of links, is the product of the reliability of each link. For
example, if there are three links with reliabilities of 0.990, 0.999, and 0.991, the
combined reliability would be 0.990 x 0.999 x 0.991 = 0.980.
(10) The reliability of elements in series shall be determined using fundamental

principles of reliability analysis. The forestays, backstays and tension zones of the
frame are in series. The reliability of the series shall be at least 0.977. When a
detail occurs on two sides, both sides shall be included in the series. The effects of
bending shall be included.
32
(11) The link shall be the element closest to the test sample used to determine the BS
5400 values. The lowest class detail shall be used to determine the reliability of
each link.
(12) For the series calculations, the values in the Table 4.2 “Fatigue Detail Reliability”
shall be used to determine the reliability of each link. This reliability will be a
factor in the calculations for the series. Linear interpolations shall be used between
ratios.
Fatigue Detail Reliability
DETAIL RATIO L/K2

1.0 0.8 0.6 0.4
W 0.977 0.994 0.999 1.000
G 0.977 0.994 0.999 1.000
F2 0.977 0.992 0.999 1.000
F 0.977 0.993 0.999 1.000
E 0.977 0.991 0.998 1.000
D 0.977 0.993 0.999 1.000
C 0.977 0.993 0.999 1.000
B 0.977 0.994 0.999 1.000
T-X 0.977 0.993 0.999 1.000
(13) Joints other than tubular joints shall be classified in accordance with BS 5400: Part
10 or BS 7608. Tubular joints shall be classified in accordance with AWS D1.1 –
latest version.
(14) Calculation of stresses and corresponding stress range shall conform to Section 6
of BS 5400: Part 10 or BS 7608, and for tubes, AWS D1.1 – latest version for
tubular joints.
3-7. Connection Design
Connections shall be designed to resist artificial local loads imposed by a stress equal to
the average of the allowable and the calculated stress, but they shall be designed for not
less than 75% of the allowable strength of the member. Notice that whenever the
calculated stresses are less than 50% of the allowable stress, the 75% requirement applies.
3-7.1 Welded Joints
Stresses at weld throats shall be calculated as the vector sum of the individual stresses
applied to the weld throat. For fatigue design when calculating the stress range, the vector
difference of the greatest and least vector sum stress may be used instead of the algebraic
difference. Welded joint design shall conform to BS 5400: Part 10, BS 7608, and for static
loads only AWS D1.1 – latest version.
3-7.2 Bolted Joints
33
Bolted joint design shall conform to BS 5400: Part 10, BS 7608, and to the AISC
Specification using 0.9 times AISC allowable values. Prying action due to distortion of
the connection details shall be considered. Bolts subject to fluctuating tensile stress shall
be checked according to BS 7608. Bolts governed by fatigue strength shall comply with
ASTM A325.
3-7.3 Pin Joints
Eye bars and pin connected members shall be designed in accordance with the AISC
Specification using 0.9 times AISC allowable values, and shall be checked for fatigue
using either the allowable net section stress range for Class F details or the stress
concentration factors and the stress range for Class B details at the face of the hole. If the
net section is governed by fatigue, then all other proportions shall be increased on a basis
consistent with the AISC requirements.
3-8. Gantry Frame Deflections and Stiffness
3-8.1 Deflection shall be defined as the calculated distance the point in question moves
from the unloaded state to the loaded state relative to the global coordinate
system. All secondary effects, including catenary action may be neglected. Note that
since all secondary effects are neglected, the actual deflections will exceed the
calculated deflections.
3-8.2 The calculated vertical deflection at the maximum outreach due to a parameter load
equal to (TL + LS + LL) applied at the maximum outreach shall not exceed 300
mm. The effect of catenary sag in the forestays may be neglected.
3-8.3 The calculated horizontal deflection at the maximum outreach in the gantry travel
direction due to a parameter load equal to 0.05*(DL + TL + LS + LL) applied in the
gantry travel direction at the maximum outreach, shall not exceed 300 mm.
3-8.4 Frame stiffness shall also be evaluated by applying a parameter lateral load equal to
0.30*(TL + LS + LL) in the trolley travel direction at the boom elevation and
calculating horizontal displacements at the trolley girder support connections. The
calculated deflections shall not exceed 50 mm parallel to the boom.
3-8.5 Calculated torsional rotation of a mono-girder boom measured at boom tip with LLE
at maximum outreach shall not exceed 0.15°.
3-8.6 The structural stiffness of the gantry frame shall be adequate for proper operation of
the crane for all design load cases. Ratio of the crane structure natural period of
oscillation in the trolley travel direction and natural period of the hanging load shall
be designed to prevent the frame from experiencing magnified dynamic
displacements due to trolley motion. The natural period of the first mode of vibration
in the direction parallel to the trolley travel motion shall be less than 1.5 s.
Boom Hoist Failure
34
The Boom structure shall be designed so that the Boom is able to be hoist on one set of
falls only. In the event, that the other set fails, the design load shall include the effect of
shock loading due to one rope breaking. The allowable stress shall be 1.5 times basic
allowable stress.
3-9. Camber
(1) The trolley runway/ girder beam shall be cambered so that the trolley path is
approximately level when the trolley travels from the backreach to the outreach
maximum position.
At the design stage the Contractor shall submit the load case used for the camber
calculations for review by the Purchaser.
3-10. Trolley Rails & Rail Fixing
(1) The trolley rails shall consist of a standard rail section and shall be fitted to the girder
and the boom through rail clips and a fastening system.
(2) The rail joints shall be welded and ground smooth except for the joint at the
girder-boom transition. The Contractor shall adopt a weld procedure and heat
treatment, if necessary, such that the variation in hardness across the width of the
weld shall not exceed 10% of the basic rail head hardness. The hardness of the rail
shall be not less than 300BHN. The joint at the girder-boom transition shall be
designed to minimise the impact of trolley wheels crossing over the joint and
maximise the life of the rail ends.
(3) Rail sections 2 metres long shall be provided on either side of the boom hinge joint
and shall be designed for ease of replacement. The rail or a section of the rail on the
boom shall have stoppers to prevent falling of the rail when the boom is raised. This
section of rails shall be connected to the trolley rail by welding.
(4) In addition the access of maintenance personnel to the boom joint area to safely
effect repairs is of prime importance and the access design shall be approved by the
Purchaser.
3-11. Workmanship
(1) The whole of the structural fabrication and assembly shall be done in a through,
workmanlike manner and shall follow the best modern practices in the manufacture
of high-grade structures. The work shall be performed by workmen suitably skilled
in their particular trades.
(2) Welders, welding operators and tackers shall be certified, under proper welding
procedure being performed, by an independent testing laboratory within 6 months
prior to performing such work. The certifying laboratory will be approved by the
Purchaser.
35
The rail shall be harder than the trolley wheels by at a minimum of 20% i.e. if the
trolley wheel x BHN then the hardness of the rail shall be harder by a factor of 1.2 as
minimum.
(3) Certification of the qualifications of each individual welder shall be submitted by the
Contractor. Welds installed using unqualified procedures or welding performed by
non-certified welders shall be subject to removal by the Contractor at his own
expense.
(4) The Contractor’s Quality Assurance team shall be required to keep an accurate log of
the qualified welders on the job. This log will be subjected to examination at any
time by the Purchaser or his site representative.
(5) Welding procedures may be AWS prequalified or they shall be qualified in

accordance with AWS by the approved testing laboratory.
(6) Written procedures for all welded joints shall be submitted to the Purchaser.
Procedures shall identify required inspections that may be critical to the specific
welds. Procedures shall be identified on t he drawings and shall be made available to
all appropriate shop personnel. Procedures shall be prepared in a manner such that
shop personnel can understand and use them without referencing the applicable
codes.
(7) These requirements shall apply to all welding, burning, cutting and grinding on the
crane structure. This includes welds for erection attachment, whether or not they are
removed, and electrical clips and conduit supports.
(8) The Contractor’s Quality Assurance team will ensure that all correct welding
procedures are strictly followed by the welding personnel. Any welding work being
seen to not meet accepted procedures shall be stopped immediately and logged as a
non-conformance report. Continuation of this welding will then be subject to
approval by the Purchaser’s representative on site.
(9) The Contractor’s Quality Assurance team will ensure that all welding during low
temperatures is carried out, as far as practicable, within an enclosed canopy to
provide a controlled environment. The use of correct pre-heating procedures and
welding electrode heater or warmer is essential and will be closely monitored by the
Purchaser’s Representative.
(10) To facilitate removal/ replacement or regular maintenance, all unpainted metal

surfaces shall be treated with an appropriate approved anti-corrosion treatment
i) Structural Pins– “Copper kote”, “Copper-slip”, “Moly-slip”, or

“Molybonum di-sulphide”
ii) Bearings, housings – grease
iii) Tapped holes - “Never-Seize”
iv) Bolts – “Never-Seize”
36
(11) A325 and A490 bolts that are 22m (7/8) in diameter or less may be tightened to the
required tension by any standard method. A325 and A490 bolts greater than 7/8”
(22mm) diameter shall be tightened to the required tension by the calibrated
wrench method only. The following supplemental requirements shall apply in
addition to the requirements of the Specifications to structural joints using ASTM
A325 or A490 Bolts:
(i) Hardened washers shall be placed under the both the head and the nut.
(ii) The Contractor shall notify the Engineer if the highest and lowest torqueses
measured during wrench calibration vary by more than 10 percent of the
lowest torque, so they may develop the appropriate solution. If the range
exceeds this tolerance, flied tightening may be erratic.
(iii) The “snug tight” tension shall be approximately 15 percent of the specified
tension and shall be achieved using a calibrated wrench.
(iv) The sequence of bolt tensioning shall be shown on the drawings.
(v) After the snug tight condition is achieved, an initial tension of 75 percent of
the final tension shall be developed in all the bolts. Only then shall the final
tension be developed.
(vi) The final tension shall be verified by testing 10 percent of the bolts after all
the bolts are tensioned. If the verification indicates loss of tension in some
bolts, the Contractor shall notify the Purchaser. The Purchaser and the
Contractor will develop the appropriate action.
(vii) The flange contact bearing surfaces shall have at least 75% of the bearing
cross-sectional areas in contact. The outer surface of the flanges shall fit
within 0.010in. (0.25mm) for 75% of the length of the edge and not more
than 1/32in. (1mm) for the remaining 25% of the length.
(viii) Bolt tension may be verified at locations selected by the Purchaser’s

Representative. Bolt tension verification shall be performed by the
Contractor in the presence of the Purchaser’s Representative and in such a
manner that the torque wrench gage can be read during verification.
(12) Weld Testing and Inspection
All welds shall be subjected to inspection by methods and extent, reflecting the
critical nature of the welded connection.
Welds shall meet the requirements for cyclically loaded structures of AWS D1.1-
latest version. The specific method of weld inspections shall be shown on the
drawings. Weld inspection procedures shall be submitted to the Purchaser.
Testing, which shall be at the Contractors expense is required as follows:-
37
Weld Type of Testing/ Acceptance Criteria

Inspection
All Welds 100% Visual AWS 1.1 – latest
version
Full Penetration Butt Welds 100% UT AWS 1.1 – latest
(Compression) 1 X RT Exposure ≈ version
400mm Per weld
Full Penetration Butt Welds 100% UT and AWS 1.1 – latest
(Tension – as determined by 10% of length RT or version
stress levels due to 1 X Exposure per weld
operating loads, length ≈ 400mm which
combinations. ever is the greater
Full Penetration Butt Welds 100% UT and AWS 1.1 – latest

in Tension Bars (e.g. 100% of length RT version
Forestays)
Fillet Welds or Partial AWS 1.1 – latest
Penetration Welds version
On FCM 100% of length MT
On Non- FCM 10% of length MT
(as nominated by the
Purchasers Representative)
Rejection of any portion of a weld inspected on a less than 100% basis shall
require inspection of 100% of that weld.
Ultrasonic and Radiograph testing of tension welds shall be done by or under the
direct supervision of an ASNT or PCN Certified LEVEL III person.
3-12. Quality Control of Structural Fabrication
(1) Quality Control shall be the responsibility of the Contractor. The Contractor must
implement a written quality control programme and this programme shall be
submitted to the Purchaser within 1 month of the date of the Agreement.
(2) The quality control programme shall follow the applicable requirements laid out in
7-1.4. For the structural fabrication this shall include but not be limited to the
following:
- Inventory of incoming material, consumables components and machinery.
- Traceability procedures for materials together with traceability

identification codes which shall be serial and indexed to the controlled
manufacturing procedures.
- Cutting, fit up, welding, forming and dimensions of structural components.
38
- Welding and inspection procedures identifying clearly the type and extent
of NDT inspection carried out on the cranes structure.
- Welding and inspection personnel qualification and certification (see 3-11).
- Welding, machining, measuring and inspection equipment maintenance and

calibration.
- Machining, surface finishes, bolt tensioning procedures.
- Procedures for non-conformance reporting and rectification of defects.
- Design and manufacturing drawing control and procedures for revisions,

updates and reissue of drawings
- Procedures for blasting and painting.
A sample of a QA manual that is currently used by the Tenderer/ Contractor shall be

submitted as part of the tender documentation.
3-13. Temporary Structures
3-13.1 Temporary Structures
Connections details of temporary structures (such as lifting lugs, etc) fitted onto
Operationally Critical Components must be reviewed by the Purchaser.
Any temporary attachments welded onto structural members shall be removed in a way
that does not damage the parent plate nor affect the fatigue life of the member, the
temporary attachment shall be gas cut-off, above the surface of the plate and ground block
to flush.
Temporary attachments shall not be removed by force that may “tear” metal from the
parent plate.
If the parent plate as damaged in any way, the defective area shall be welded to fill the
void, ground flush and non-destructively tested by magnetic partied testing method.
3-13.2 Sea-Fastening
At least three months before the intended shipment, the Contractor shall submit sea-
fastening structure connection details to crane structures for the Purchaser’s review,
consideration and acceptance or otherwise. The submission shall also provide details of
the proposed methods for removal of the temporary bracings and fixings. The Purchaser
prefers a system that minimises any “Hot Work” at the site to minimise the risk of damage
to paintwork and the need for extensive paint system repairs.
39
3-13.3 Voyage Criteria and Calculations
The transportation procedures for the assembled crane and crane components shall be
reviewed and approved by the design auditor engaged by the Purchaser and by the
Contractor’s responsible structural engineer.
The calculations shall also be checked in accordance with requirements of Clause 3-3.2.1
except the dynamic analysis is not required and the boundary conditions shall be modified
to suit the voyage conditions. Calculations shall include the analysis of the crane structure,
braced and anchored for shipping, and shall include the analysis of the vessel structure.
Gravity loads shall be applied to the unbraced structure. Environmental loads shall be
applied to the braced structure model.
All workmanship and attachments shall comply with the requirements of this section.
Comprehensive procedures, drawings and calculations shall be submitted. The following

issues shall be addressed:
Quay geometry, water depth and tidal data.
Route and estimated departure date.
External restrictions such as sailing draft, air draft and beam.
Loading and offloading procedures and calculations.
Design environmental criteria. This shall be for at least a 10 year return sea state and one
minute sustained wind speed.
Design ship motions and accelerations.
Wind force on the cargo and the vessel.
Initial Stability including the GM corrected for the free surface effects and static stability.
Stowage arrangement and loading condition.
A description of auxiliary equipment used during the loading and offloading operations.
Pulling and braking forces.
Jacking methods and equipment.
Crane bracing and sea fastening of all cargo.
Deadweight capacity.
Stability during loading, transport and off loading.
40
Ballast calculations.
Static and dynamic deck loads.
The natural roll period of the loaded vessel shall be calculated. If the period is less than the
shortest design wave period, then additional ship motions shall be calculated for a set of
sea states with the mean wave period ranging from the natural roll period minus one
second to the natural roll period plus one second and the significant wave heights, in mm,
of at least 39 times the square of the mean wave period in seconds, but not more than the
design significant wave height. If roll resonance in these alternative sea states results in
more severe design accelerations, then more severe accelerations shall be used.
The design forces shall be those due to the following effects. The linear and rotational
components shall be included.
Gravity
Wind
List
Roll
Trim
Pitch
Heave
The maximum voyage loads shall be combined as follows:-
Ftotal = Fgravity + Fwind + Flist + F trim + Fheave + (F pitch ² + F roll²)⁰⁃⁵
Where Fi is the component stress due to the effect of the subscript load. Pretension loads
in the bracing members shall be included.
The total stress, Ftotal, shall be calculated using the maximum stress, Fi, for each component
force acting in the most adverse direction.
The allowable stresses for maximum voyage condition stress, Ftotal shall be 1.33 times the
basic AISC allowable stresses.
The fatigue damage due to the voyage forces shall be calculated. The intent of the voyage
fatigue requirements is to limit the fatigue damage due to the voyage stresses so the fatigue
life of the member will not be significantly reduced by the voyage.
The calculated stress ranges shall be the maximum stress ranges due to the static and
dynamic effects of the full reversal of roll or pitch conditions, whichever is higher. Wind
does not need to be included. Roll and pitch do not need to be combined.
One stress range shall be calculated for the forces including pitch, and another shall be
calculated for the forces including roll. The maximum of these ranges shall be used to
check cumulative damage. The cumulative damage due to 350,000 cycles of the above
41
stress ranges shall be less than that allowed in Table 4.1. The values for K1 or K2 shall be
selected based on the operating conditions. If, however, a member is a FCM for voyage
conditions, then K1 shall be used for voyage stresses. For temporary members, K1 or K2
values shall be selected based on the voyage conditions.
Alternatively to method defined in the above paragraph, the cumulative damage due to the
cycles in 100 voyage hours of the specified voyage stress ranges plus the cumulative
damage due to the operating condition maybe calculated. The cumulative damage shall be
less than 1.1 times that allowed in the Table allowable Cumulative Damage in Clause 3-6.
4. Functional Systems, Devices & Equipment
4-1. Main Hoist
4-1.1 Main Hoist Drive
The main hoist drive system shall consist of one or two AC motor(s) driving through a
foot mounted gear reducer and shall have the following facilities: -.
(1) The main hoist drive reduction gearbox shall be totally enclosed, oil bath lubricated
type.
(2) Two AC servo operated disc brakes shall be fitted on the high speed pinion shaft.
Each brake shall have a design rating equal to 150% of the full load torque of the
motor, and shall be capable of stopping and holding the maximum rated load from
full rated speed
(3) Overspeed switches shall be fitted to the main hoist drums to shut down the drive and
set the brakes if the load exceeds 115% of rated speed.
(4) Heavy duty, absolute position encoders shall be installed on the main hoist drums.
(5) Acceleration from zero speed to a maximum speed or deceleration to zero speed shall
be smooth and stepless for any load under the headblock. The final speed ramping
characteristic, which will be an “S” shape curve, will be fine tuned at site as part of
the Testing and Commissioning process.
(6) The Main Hoist drive system shall be designed to accommodate frequent inching
during operations.
(7) The main hoist wire ropes to the head block shall not interfere with the stacked on-
deck containers when the crane is working on a single cell to its maximum depth.
Outside wire ropes shall be stationary during hoist and lowering motion.
(8) Any openings on the machinery house wall for the passage of all wire ropes shall be
protected from water ingress. Suitable protection of the wall against sagging ropes
shall be provided.
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(9) Main hoist system shall include an overload warning and tripping system. The
system shall detect the load under the spreader (or the load hook of the hook beam) in
3 levels and activate a warning signal or trip hoisting motion as shown below:
i) 80% load for over 3 sec. Intermittent warning signal.

ii) 100% load for over 3 sec. Continuous warning signal.
iii) 110% load for over 3 sec. Trip hoist motion. Allow lowering motion only.
(10) The load sensing system shall include the installation of compression type load cells.
Pin type load cells will not be accepted. The design of the load cell installation shall
be submitted for the approval (or otherwise) of the Purchasers Representations.
Installations that reduce the sensitivity of the load cell by “moment-arm” effects are
not acceptable, that is full load rated load cells, in compression, shall be provided.
(11) The main hoist drums shall also be fitted with disc brakes, rated such they are able to
arrest a falling load, equivalent to the maximum S.W.L. These brakes shall be
activated by
(i) Drum overspeed

(ii) Any other condition that an unacceptable condition in the Main Hoist drive
e.g. a discrepancy between motor and drum rotation, brake failure or coupling
failures.
It shall be fail-safe, spring-set, thruster released and automatically set by an over

speed condition or loss of power such as an emergency stop.
(12) The Main Hoist shall also be fitted with an auxiliary gearbox and drive motor for the
operation of the main hoist. This shall be arranged through a suitable gear reducer
and the operation of a simple sprocket mounted on an extension to the main input
shaft of the main hoist gearbox. The auxiliary and main drives shall be fully
interlocked. Auxiliary drive selection shall only be possible with a fully fail safe
interlock with all operating safety devices. The chain drive will be manually fitted in
an emergency condition when the auxiliary motor is to be used. The auxiliary drive
system shall be designed to operate for the following load cases.
(i) lower or hoist SWL

(ii) raise headblock and either spreader or heavy lift hook. (i.e. No Load)
This auxiliary motor shall be powered from the 400V shore supply and be controlled
by a separate PLC to provide “interlock” crane protection.
4-1.2 Sway Control
(1) An electronic sway control system shall be provided. The System shall also be
capable of damping the spreader sway for Semi-Automatic Operation System (if
applicable).
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(2) The electronic sway control shall be a closed loop system which verifies the no
sway condition and provides sway correction where required. Sway correction with
a stopped trolley shall not move the load beyond its present sway excursions.
(3) The sway control shall bring the spreader to a stop within +/- 50mm at any lifting
height as measured at the bottom corners of the 40’ container or the twist lock of
an empty spreader. It shall be capable of bringing the spreader to a stop to within 2
swings.
(4) Details of the construction and proven performance data of the electronic anti-sway
system shall be submitted with the tender documents.
(5) In addition to the electronic sway control system, a mechanical or electrical sway
damping system for trolley fine-positioning shall be provided. During the trolley
fine positioning, the sway control shall be taken over by the mechanical or
electrical sway damping system and not through trolley speed reference. The
Contractor shall submit the above design for Purchaser’s review.
4-1.3 Trim, List, Skew Control
(1) Each of trim, list or skew motion to be controllable independently from two other
motions up to its maximum angle as specified in 2-7.1(15), (16), (17), from any
attitude of the headblock and under rated load capacity.
(2) One push button switch on the control console shall automatically reset the spreader
position to a 'Zero trim, Zero list, Zero skew' position. The travel from centre to
maximum trim, list or skew shall not be more then Two (2) swings.
(3) A system which restrains the main hoist wire rope in a rope clamp shall be designed
so that the clamp, and the adjacent structural load path, will hold the suspended load
in case the wire rope breaks at one side of the clamp.
(4) Trim, skew and list indicators shall be installed in the cab. Each indicator shall
indicate angle of trim, skew and list.
4-1.4 Snag Control
(1) Snag control shall be provided to limit mechanical and structural loads to their
design limits. The snag control device shall have the following features:
i) It shall be of hydraulic type and absorb energy by fluid flow over relief
valves or by a functionally similar hydraulic circuit. (See also clause 2-
7.8(4).
ii) It shall allow powered reset after a snag incident. Replacement of parts,
manual adjustment or manual charging of an accumulator does not meet the
intent of this requirement. Resetting shall be by keyed switch in the
electrical house.
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iii) Automatic compensation for internal leakage. External leakage is not

acceptable.
iv) Meet all the requirements of the hydraulic section of this Specification.
v) Snag analysis shall consider the activating time of relief valves. Response
time shall be certified by the valve manufacturer.
vi) Snag device shall be set not to trip for any rope load less than 125% of any
operating rope load including design impact and eccentricity.
vii) Electrical Control Supplier/ Designer shall certify motor and brake response
times used in snag analysis. Strip chart recording during the
Commissioning Test shall verify this data.
viii) A convenient means shall be provided for maintenance personnel to

periodically field-verify pressure setting of relief valves. Verification
procedures shall be included in the Maintenance Instruction Manual.
ix) The snag analysis shall investigate all possible snag load combinations to
ensure sufficient energy absorbing capabilities.
The Contractor shall provide a method statement showing the system of design of
the snag control for review by the Purchaser. The requirements of clause 2-7.8 (4)
also refer.
4-2. Trolley, Trolley Drive, Associated Devices and Operator's Cab
4-2.1 Trolley Frame
(1) The trolley frame shall be fitted with hydraulic buffers in the front and rear directions
of motion. These buffers shall be capable of absorbing and dissipating, without
bottoming, the impact energy of collision at full speed with rated load.
(2) The trolley frame shall be fitted with safety drop-stop lugs, which shall prevent the
trolley from dropping off the girder in case of wheel shaft failure. The Trolley
wheels shall be double flanged.
(3) The trolley frame shall have adequate jacking points and free access for the
replacement of trolley wheels at any point on the girder or the boom.
(4) The trolley frame, boom, girders and machinery house floor structure shall provide a
safe emergency access from the operator's cab at any point of trolley travel range
including under the machinery house.
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(5) Trolley wheel, shaft and bearing systems shall be designed to facilitate fast
replacement of components at any point on the girder or the boom.
(6) The trolley frame and cabin shall be provided with a safe maintenance platform
allowing risk free access to all of its component parts for maintenance. This access/
maintenance platform shall be at the backreach of the crane.
(7) The trolley frame shall be equipped with a stowage pin device for the storm/ gale
condition. The stowage pin device shall allow a one-man operation to
engage/disengage pins on both sides of the trolley from the girder. The stowage pin
design shall allow approx. 200mm for trolley positioning. The girder shall be
marked for the operator to spot the storm parking position. Indicating lamp for trolley
stowage pin engage/disengage shall be provided at the Ground Level Station.
4-2.2 Trolley Drive
The trolley drive system shall be full rope driven.
(1) Full Rope Driven Trolley
i) The tow rope drive shall be mounted on a rigid base located in the machinery
house and shall consist of an AC electric motor and brake driving a grooved
drum through a totally enclosed foot mounted helical gear reducer.
The Trolley Drive shall also be fitted with an auxiliary gearbox and drive
motor for the operation of the trolley motion. This shall be arranged through a
suitable gear reducer and the operation of a simple dog clutch mounted on an
extension to the main input shaft of the trolley motion gearbox. The auxiliary
and main drives shall be fully interlocked. Auxiliary drive selection shall only
be possible with a fully fail safe interlock with all operating safety devices.
ii) An AC servo operated disc brake shall be fitted on the high speed pinion
shaft and shall be rated at 150% full load motor torque.
iii) A power operated rope tensioning device shall be provided for the trolley
drive wire ropes. (refer to 4-2.4)
iv) Heavy duty, absolute position encoders shall be installed on the trolley drums.
v) The Control System shall allow for frequent inching operations.
vi) The trolley wire rope system shall allow simple quick adjustment of
squareness of the trolley.
vii) The normal trolley parking position shall be just forward to the seaside of the
landside rail. The storm parking position may be set at another position,
provided proper access walkways are provided for the position.
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4-2.3 Rope Separating System
(Not used).
4-2.4 Trolley Tow Rope Tensioner
(1) A hydraulically operated towrope tensioning system shall be provided and shall
maintain proper rope tension during normal operation and compensate for unequal
rope stretch. The tensioning device shall be designed for continuous operation.
(2) The design and installation of the hydraulic system shall meet the requirements
outlined in 5-2.
4-2.5 Power Festoon System (To Trolley)
(1) The Power and Communication cabling between the main structure and the Trolley
shall be carried in a PowerFestoon System.
(2) The design of the system shall be carried out by the system supplier and shall be
specified to meet the required speeds in the marine environment prevailing, paying
particular attention to the issues of temperature and snow and ice. (It may be
necessary to make provision for heating within the cable groupings or with shielding
canopy making of stainless steel).
(3) The supporting structure and girders shall be sufficiently rigid to avoid unacceptable
levels of vibration or noise.
(4) The cabling incorporated in the arrangement shall be purpose – constructed for use in
such Power Festoon installation.
(5) The whole installation shall be in accordance with the manufactures

recommendations in regard to clearances, bending radii and towing arm detail.
4-3. Gantry Drive
4-3.1 Gantry Drive
(1) The gantry drive motors and brake system shall provide sufficient thermal capacity,
torque and traction for all operating conditions.
(2) The gantry drive and motors shall be capable of accelerating, driving a distance of
450m and decelerating with and against the operating wind load of 25m/s without
injurious heating of any part, and provide power to not less than 50% of wheels.
(3) The brake capacity must be sufficient to stop the crane without sustaining any
damage in the event that an emergency stop button is pressed during full-speed
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gantry travelling, with 25 m/s tail wind with the container at full outreach and at mid-
height of lift.
(4) The Gantry Motor drive arrangement shall be the conventional motor/ coupling-
brake/ reducer arrangement mounted onto the side of the gantry travel bogies.
The coupling-brake assembly shall have sufficient guards to provide adequate

protection from inadvertent contact with hands but at the same time permitting ease
of access for inspection and maintenance.
(5) The motor shall drive through a totally enclosed, oil lubricated, helical and/or spiral
bevel gearing.
(6) The gantry trucks shall be equipped with safety lugs to support the truck in case of
wheel or wheel shaft failure.
(7) Each truck and equalizer beam shall have proper jacking points to facilitate jacking
for simple removal of any wheel without dismantling trucks or equaliser beams.
Jacking load and position shall be approved by the Purchaser to prevent overloading
of quay structure.
(8) Wheels and gearboxes shall be fitted with robust safety guards. The guards or covers
shall have inspection windows.
(9) Rail scrapers shall be provided in front of the outer and inner wheels at each corner.
(10) Hydraulic Buffers or bumpers shall be installed at 4-corners of the crane. These shall
be capable of absorbing and dissipating the impact energy of collision at full
travelling speed. For details of the existing buffer system please refer to Drawings in
Appendix III.
(11) The Gantry Travel Motor Control shall be fitted with a detection system based on the
contactless signal/ sensor principle such as laser, infrared or ultrasonic sensors to
detect the presence of an adjacent crane.
The system shall provide two levels of protection
(i) Adjacent crane within 2 times the normal stopping distance- slow down to
creep speed.
(ii) Adjacent crane within stopping distance – immediately bring the crane to the
zero – speed condition.
(12) Limit switches to prohibit gantry travel motion when the stowage pins are inserted
into the ground socket shall be provided.
(13) Gantry motion shall be prohibited whenever the hoist motion is activated.
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(14) A key-lockable switch shall be located in the ground level control panel to control the
release of all the gantry and wheel brakes to facilitate moving a crane with an
adjacent crane.
4-3.2 Stowage Pin
(1) Hand operated stowage pins shall be provided and shall be designed to hold the crane
under the wind conditions shown in 2-7.7 (2) & (3). The design to size the pin and its
supporting structure shall not consider the restraining force of the wheel brakes or the
braking force of the motor brakes.
(2) The arrangement of the stowage pins shall suit the sockets provided by others in the
quaydeck.
(3) A suitable latching or retaining device shall be provided for securing the pins in their
raised and lowered position, to ensure that the pin is in either the fully raised or fully
engaged position.
(4) The design of the pin raise/lower system shall reflect the ease of manual operation in
one man requiring a minimum of force to complete either the engaging or
disengaging of the pin.
(5) Cam or roller lever type limit switches shall disable the gantry drive unless all
stowage pins are in the raised position.
4-3.3 Wheel Brakes
(1) These wheel brakes shall be designed to be capable of holding the crane under a
30m/sec. sustained wind with gantry brakes released and stowage pins in the
disengaged condition.
(2) For wheel brake interlocks, release time and method of operation refer to 5-5.1(5).
(3) Hand pumps for manually releasing the rail brakes shall be provided.
4-3.4 H.T. Cable Reel
(1) Cable Reel
(i) The cable reel shall be installed within the restricted dimensions as set out in
2-7.2. The drive control system of the cable reel shall be designed to
minimise abrupt starting, braking and excessive slack / tension in the cable
when the Crane passes the cable feed point. Sensors to detect the above
conditions shall be provided.
(ii) Cable guide wheels shall be installed near the gantry trucks to keep the high
tension cable close to the ground level. The cable shall be laid inside the
cable slot within a total wheel base of gantry trucks in one corner.
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(iii) The system especially the high tension slip ring components shall be well
protected from weather, having an IP rating of not less than 55
(iv) The cable reel drive machinery and slip ring area shall be isolated by fencing
or other means and to permit to access of authorised persons only. High
tension warning signs shall be provided and fitted to the entrance of the
fenced area.
(v) A suitably sized space heater shall be provided for the slip ring enclosure.
An indicator light indicating functioning or malfunction of the space heater
shall be installed near the cable reel machinery and shall clearly visible
from ground level. The slip ring enclosure shall have hinged, sealed and
lockable access panels on both sides to provide for easy access for servicing
and maintenance.
(vi) Limit switches to control gantry motion near the travelling limit (limited by
cable length) shall be provided.
(vii) An override switch shall be provided to allow operation of the cable reel
drive. This switch shall be enclosed in a lockable and weatherproof box
mounted at ground level in the proximity of the cable plough arrangement.
(2) HT Trailing Cable
(i) The composite cable shall incorporate not less than eight (8) numbers of low
loss silica glass optical fibre waveguides. The cable reel mechanisms shall
incorporate low loss connecting devices that allow the use of all waveguide
simultaneously linking the equipment on the crane to external devices. The
standard for the waveguide shall be 60/125 micron.
(ii) The optical waveguide shall be terminated with standard connectors unless
otherwise specified. The composite cable shall be separated into power and
optical fibre cables for termination work in the junction boxes at the turn-over
pits as well as the cable reel on the Crane.
4-3.5 Boom Collision Avoidance System
The Crane shall be fitted with a Boom Collision Avoidance System (BCAS), to minimize
the risk of the boom coming into contact with any obstruction, ship superstructure or radar
mast, during gantry travel.
The system shall have wire ropes on both sides of the boom to protect the crane in both
directions. Such wire ropes through the sensors shall be connected to the PLC to over-ride
the gantry travel motion in case an obstruction is encountered
The operation of the system shall be recorded appropriately on the crane CCMS.
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The Contractor shall submit basic details of his proposed system with his tender, however,
the design shall be finalized along with the development of the crane control system.
4-4. Boom Hoist
4-4.1 Boom Hoist Drive
(1) The boom hoist drive reduction gearbox shall be a totally enclosed oil bath lubricated
type.
(2) The drive assembly shall include one (1) Thruster operated calliper disc brake on the
high speed pinion shaft and one (1) fail safe, spring set disc type friction brake
mounted on the boom hoist rope drum flange. The calliper disc brake shall be rated
at 150% of full load motor torque. The disc type friction brake shall be rated to be
capable of arresting and holding the boom in any position during full speed operation
either up or down motion. This disc brake shall be activated in the event of either
mechanical or electrical component failure or breakdown such as overspeed of the
drum, excessive or less motor torque, loss of electrical power operation of a boom
hoist emergency stop button or any other condition deemed to be unacceptable e.g.
“coupling slippage”.
(3) The Boom shall also be fitted with an auxiliary gearbox and drive motor for the
operation of the boom hoist. This shall be arranged through a suitable gear reducer
and the operation of a simple dog clutch mounted on an extension to the main input
shaft of the hoist gearbox. The auxiliary and main drives shall be fully interlocked.
Auxiliary drive selection shall only be possible with a fully fail safe interlock with all
operating safety devices.
(4) An overspeed switch shall be fitted to the boom hoist drum to shut down the drive
and set the brakes if the load exceeds 110% of rated speed.
(5) Heavy duty, absolute position encoders shall be installed on the boom hoist drum.
(6) All openings in the machinery house wall for the passage of the boom hoist wire
ropes shall have protection for rope slapping and from water ingress. Excess water on
the ropes shall be suitably trapped on entry to the machinery house and drained to a
suitable location.
4-4.2 Boom Latch
IF APPLICABLE
4-5. Machinery House, Electrical Control House
4-5.1 Construction
(1) The machinery house shall be designed to provide a weatherproof protected area for
the location of the major machinery and electrical control equipment on the crane.
51
The major electrical control equipment shall be housed in a separate air conditioned
room (the control panel room) within the machinery house.
(2) The machinery house shall be constructed to maintain an environment suitable for
the reliable operation of the mechanical and electrical components. The walls shall
be insulated with fibre glass or wool insulation bats and covered with a sheet metal
cladding. Heating shall be provided in the electrical control room to ensure that the
minimum temperature does not fall below dew point. The outside surface of the
machinery house shall be flat, corrugated sheeting is not acceptable. Air exchange
fans maybe used to remove hot air.
(3) The floor of the electrical control room shall be completely fitted out with a rubber
mat rated at 1000 volts to provide anti-static protection. Ample space provided for
accommodating all the hardware equipment for Crane Condition Monitoring
System outlined in 5-7.
All electrical cables installed underneath the floor shall be accessible for inspection
and shall be laid out in an orderly arrangement and supported suitable on structures
i.e. ladders or trays cable support so that cables do not rub against adjacent cables
with the movement/ vibration of the structure (see also section on electrical
installation).
(4) The access doors shall be metal sliding doors with non-corrosive hardware locks and
safety glass windows in upper panels. The door shall be self-closing. Drip shield
shall be provided over the door. The locations of doors shall be at the front and the
rear wall of the machinery house.
(5) An access with permanent ladders to the top of the roof shall be provided. Handrails
along the perimeter of the roof shall be provided.
(6) Equipment or permanent ladders shall be provided for accessing lights and other
fittings on the ceiling for maintenance work.
(7) Ample maintenance space around each piece of machinery shall be provided for its
adjustment, inspection and removal or replacement.
A storage area for lubricants in drums and pails shall be provided the base, of which
shall be raised above the adjacent floor level and surrounded by a seawall with
facilities for draining into portable receptacles.
(8) A hatch shall be provided in the deck with its size permitting the removal of the
largest piece of equipment within the machinery house to the ground level with the
aid of the maintenance hoist.
The hatch cover shall be a sliding type with adequate handles for opening and closing
by one or two persons easily. If necessary the removal may be designed to be
effected by using the maintenance hoist. The position of the hatch shall allow for
adequate personnel access to all four sides in the opened position. Socketed,
52
removable hand rails shall be provided around the hatch opening. Purpose built
storage facilities for the hand rails when not in use shall be provided adjacent to the
hatch.
A separate hatch opening on the floor of its position in between two main girders
shall be provided to lift components to and from the top of the trolley with the
maintenance hoist. This hatch shall also be used by the operator to escape from the
cab via the trolley into the machinery house.
(9) A work bench shall be provided in the machinery house.

The bench shall be approximately 1800 x 700 and shall be fitted with a 150mm vice.
(10) One steel locker with door lock shall be installed in the machinery house to store
drawings tools, wear gauges, first aid kit box, cleaning materials, etc.
In addition one steel locker with door lock shall be provided inside the Control Panel
Room.
(11) A working table (table top size minimum 750mm x 1200mm) and a chair shall be
provided in the Control Panel Room.
(12) The machinery house shall be provided with an access walkway around all four sides
to allow for ease of maintenance.
(13) The Crane shall be installed with a compressed air reticulation system for the purpose
of operating air-tools or cleaning. The system shall be fed by a compressor mounted
in the machinery house and shall have a capacity to deliver a sustained free air flow
at a rate of not less than 14.7 litres /sec at a pressure of 10 bar.
The airlines shall run from ground level (land-side) to the cable reeler area, the
Machinery House, the backreach area, front reach area and the A-frame.
It may be necessary to utilise a manually fitted flexible connection at the boom hinge
point.
Each take-off point shall be fitted with a shut-off valve, air dryer and a quick-connect
fitting.
4-5.2 Fittings, Facilities
The machinery house shall contain main machinery and a fully air conditioned Control Panel
Room. Push button switches for the main control circuit, the main motion power source, and
the lighting control switches shall be installed outside the Control Panel Room.
Special consideration shall be given to acoustic treatment to reduce noise breakout from the
machinery house via the walls, floor, roof, winch wire rope openings, ventilation air
intake/discharges, etc.
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(1) Main machinery in machinery house.

The Machinery house shall contain following main equipment:
i) Main high tension power supply source, switch panels and their remote
control switches.
ii) Main hoist drive machinery.
iii) Boom hoist drive machinery.
iv) Trolley drive machinery.
v) Main hoist, trolley, gantry and boom hoist motion drive control panels,
cubicles, etc. located in the Control Panel Room.
vi) Transformers.
vii) Auxiliary power source panels.
viii) Auxiliary motor starter and control panels.
In addition to above (1), the following equipment and fittings shall be installed in the
machinery house:
i) Lighting in order to produce sufficient lighting for maintenance work.

ii) A minimum of two (2) ventilation fans (with filtration to prevent water
ingress) See 4-5.3
iii) Maintenance hoist, (refer to 4-5.7).
iv) Intercom unit (refer to 5-6.1).
v) Specific meters and counters (refer to 5-3.17).
vi) Fire extinguisher, 3-CO2, 5kg capacity.
vii) Welding outlet (refer to 6-8).
viii) Service outlet (refer to 6-7).
ix) Ballast bank for all the high pressure sodium lamps, or similar type lamps on
the Crane (refer to 6-2.6).
x) Central switch panel for Crane lighting (refer to 6-2.5).
xi) Work bench.
xii) Locker.
xiii) 300 Amp A.C. welding transformer with 75m welding lead.
xiv) Harmonics Suppressor (if required).
xv) Two (2) air conditioners for Control Panel Room.
xvi) Two (2) 220v hand lamps (guarded type with hook) complete with 10 m of
cable and plug.
4-5.3 Ventilation
Effective removal of hot air from Ventilation shall be provided by not less than two fans
mounted in the roof or high in the wall of the machinery house.
4-5.4 Illumination and Lighting
Internal illumination in the machinery house and electrical control room shall be provided by
fluorescent type lighting and shall be arranged to provide uniform illumination in all areas of
not less than 120 lux.
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4-5.5 Emergency Lighting System
Emergency lighting operated by individual rechargeable batteries shall be provided in the

machinery house to the following levels:
*50% Lighting in Control Room

*20% Lighting in Main Machinery House Area
The batteries shall have capacity to power the emergency lamps for at least two hours. The
lamps shall be turned on automatically when the electric power supply to the crane is cut off.
Battery chargers to keep the batteries in continuously charged condition shall also be
provided.
4-5.6 Air Conditioning
The Control Panel Room shall be well insulated to keep the inside temperature to below 25
deg. C at all times. Warning of failure of the system shall be indicated as shown in 6-5.7.
The system shall be the “Reverse-cycle” type to provide for heating in the winter period. To
reduce the frequency of cutting in/cutting out of the air conditioners, a temperature sensor
shall be installed in parallel with the main control of the air conditioners. The air conditioner
main circuit shall be powered on with the activation of the main motion control source, and
powered off with 30 minutes time delay after the main motion control source is cut off.
Duplicate air conditioning units shall be provided to ensure that the failure of one unit does
not stop the crane operation. Each unit shall be rated to maintain the set conditions
independently of the other.
The air conditioning units shall be supplied by an internationally reputable supplier and be
designed and constructed for use in a harsh marine environment particularly in relation to
material selection and anti-corrosion treatments. The refrigerant used in the system shall be
non-harmful to the environment.
4-5.7 Maintenance Hoist
(1) A maintenance hoist which can vertically lift any component in the machinery house
and lower it to ground level shall be installed in the machinery house.
(2) All the motions of the hoist shall be operated by electric motors, controlled by a
pendant switch with ample cable length for handling loads in various locations.
(3) Hoisting and lowering speed for the light load shall be controlled automatically to
higher speed to shorten the operating time.
(4) The pendant switch shall have push buttons for slow speed hoisting and lowering to
allow fine inching control.
4-6. Operator’s Cab, Control Stations, Checker's Cab
55
4-6.1 Control Cab on Trolley
(1) Operator's cab shall be constructed of mild steel, double bottom, double ceiling and
double wall, and weather proof, fully air conditioned and heated. Minimum inside
floor width of the cab to be 2500mm, and length (fore & aft) 2500mm excluding
bottom glass frame.
(2) The design of the cab shall allow the operator to clean inside and outside of all the
glasses safely, from either within the cabin or via a maintenance platform at the
backreach.
(3) Cab access shall be from a hinge door in the rear of the cab. The door shall be self
closing (‘pull out’ type) and fitted, with a latch to keep the door in open position.
(4) Cab shall be fitted with a permanent escape ladder and access to the trolley top deck
to facilitate evacuation in an emergency.
(5) Cab windows to provide as much views as possible. It shall be protected from the
glare of the sun and condensation. The method of protection shall be submitted and
approved by the Purchaser. Window glass shall be scratch resistant that meets the
requirements of BS6202, class A, Safety Glass with both surfaces being flat, parallel
and fine polished, giving clear undistorted vision. Fine screen type roll up sunshades
shall be fitted on all upper windows. The mounting of the glass in the frame shall be
such that the glass cannot fall from the frame, in the event of failure of the rubber
seal.
(6) Shields shall be fitted above the windscreen to prevent wire rope lubricants from
splashing onto the glass.
(7) Particular attention shall be given to isolating the operator from shocks and vibration.
The connection of the cab supports shall incorporate an effective anti-vibration
system. The cabin/ chair/ control consoles shall incorporate design features as are
provided in the Ergo Cab design concepts i.e. designed such that they reduce the
strain/ loads on the operators lower back.
(8) The operators cab shall be bolt mounted to the trolley and fitted with safety drop
stop lugs, which shall prevent the cab from dropping off the trolley in case of
support failure
The anti-vibration mounts shall be a proprietary product specifically designed for the
purpose.
(9) Cab Fittings
The operator's cab shall be fitted with following fittings and shall not obstruct the
operator's views required for crane operations.
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i) One right-hand and one left-hand control consoles (refer to 5-4.6). The
consoles together with the chair shall be ergonomically laid out to minimize
fatigue of the operator. These may be combined with the operator's chair.
(Refer to Appendix IV). (See also 4-6-1(7) above)
ii) One upholstered operator's chair with air cushioned seat. The chair shall be
fitted with a head rest.
The chair height and position (fore and aft movement) shall be adjustable to
best suit each operator, the backseat shall also be adjustable.
The chair shall be equipped with a retractable safety belt to restrain the
operator during an emergency stop condition with the trolley travelling at
maximum speed.
The position and height of the arm rest of the operator’s chair shall be
adjusted independently.
iii) Spreader 'Landed', 'Locked', ‘Unlocked' and spreader position indicator

(20’/30’40’/45’) LED-indicating lamps shall be mounted in the lower front
part of the cab.
iv) External
Window wipers and washers: Wipers and washers to ensure that the
operational view angle required for operation can be cleaned. Wipers and
washers shall be fitted to front and side windows.
Internal – Demisters to lower front and “floor” windows hot air nozzles shall
be arranged to cover full glass area of nominated windows.
v) Communication equipment (refer to 5-6.1).
vi) Digital spreader height and load indicator.
vii) Anemometer (refer to 6-5.2).
viii) A split-system reverse-cycle air conditioning unit with a minimum 18000

BTU/ HOUR capacity.
ix) Service outlet (one 13 amp., 230v, 50Hz)
ix) Fluorescent lights shall be provided. One switch shall be mounted at the door
and one within reach of the seated operator.
x) Foot rests for the operator (positions to be easily adjustable to suit individual
operator).
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xi) 24 V (5 Amp.) and 12 V D.C. (10 Amp.) outlets for radio communication
equipment. Both D.C. sources shall be stabilised within + 2.5% and - 10% of
the rated voltage.
xii) 2.5 KW capacity oil filled type heater with manual heat level adjuster
(independent of air conditioning unit).
xiii) Safety bars wherever necessary to prevent accidental falling of the operator or
maintenance staff.
xiv) Siren foot switch.
xv) Fault code and message panel.
xvi) Isolating switches to isolate:
- Power circuit to head block/spreader.

- Control circuit to head block/spreader.
xvii) Trim, List, Skew angle indicator.
xviii) 1 no. - 5kg CO2 fire extinguisher. (Outside of cab at / near the entrance door).
xix) A wall mounted hinged pull down seat with upholstered swab for use by
operator instructor during training period.
xx) CCTV screen to monitor the boom latch operation.
4-6.2 Control Cab Off Trolley
(1) Boom/ Gantry Control Station
i) A totally enclosed control station sized for a standing operator shall be

located in a position so that the operator can directly watch the movement of
the boom, boom latches, ship's structures, and the ground around waterside
gantry trucks. The control station shall contain the boom and gantry motion
controls as outlined in 5-4.7
ii) The control station shall be provided with a door with weather seals
incorporating a fixed safety glass window. The walls and roof shall also
incorporate fixed safety glass sized as large as is practical in order to provide
an all round view. Access to clean all widows is to be considered.
iii) The fittings inside the station shall include a ceiling light, communication
equipment (refer to 5-6.1) and one service outlet, 13 amp, 230v, 50Hz.
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iv) This control station shall also be fitted with the screen of a CCTV system that
will enable an operator to confirm visually that the boom is latched
effectively.
v) This control station shall also be fitted with a terminal point

for connection of the diagnostic programmer unit by maintenance staff staff
for accessing all information from CCMS system.
(2) Ground Level Station
A gantry control box weatherproof to IP55 shall be installed at the ground level near
the landside stowage pin structure facing inside of the crane. This box shall be
stainless steel, with a hinged lockable glass fronted door and shall contain the
controls and switches to control the functions outlined in 5-4.8.
4-6.3 Checker’s Cab
(1) A checker's cab fabricated in mild steel shall be provided under the landside sill
beam or other safe location nominated by the Purchaser. The checker’s cab shall be
bolt mounted to the sill beam and fitted with forklift pockets.
(2) The following shall be provided:
i) 2 - Service outlets with ground, 230V, 1-phase, 13 Amp capacity.
ii) 1 – Ventilation fan
iii) Fluorescent lighting
iv) Stabilised DC
24V (5 Amp.) and 12V (10 Amp.) power supply for communication.
v) 1 hand set for communication with other areas within the Crane as specified
in 5-6.1.
vi) Fibre optic link refer to 5-7.2 (2) and 5-7.16.
(3) The checker’s cabin shall also have the following features:
i) Sliding Windows on both sides of the cabin to facilitate cross ventilation.
ii) A wall mounted shelf, about 1200 × 600 to act as a desk and a height
adjustable, seat mounted off the opposite wall and capable of being swung
back to the corner when not in use.
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iii) An exhaust fan and a vent panel in the door, to provide ventilation in
inclement weather and a 1000W capacity oil filled type heater with manual
heat level adjustment.
4-7. Personnel Lift
IF APPLICABLE
(1) The personnel lift shall have a capacity for three persons plus an allowance for tool
kits. The model shall be approved by the Purchaser and shall meet the requirements
of all relevant regulations and all applicable laws within the European Community.
4-8. Headblock
4-8.1 Headblock
(1) The headblock shall be designed to be compatible with longitudinal and transverse
twistlock dimensions details of which are provided at Appendix IV.
(2) Fittings
The major fittings on the head block shall include:
i) Main hoist sheave blocks. Arrangement to minimize the spreader rocking

motion.
iii) A man-cage to carry two men standing with a robust steel plate top and steel
mesh side walls for sheave and rope protection and inward opening pipe
doors on seaside and landside. Necessary access ladders which connect to the
ladders on the spreader shall be fitted.
iv) A set of manual twist locks with operating handle and linkage. The twist
locks shall be positively locked in either 'Locked' or Unlocked' position,
which will be clearly indicated on the frame to be seen from outside.
Limit switches shall be fitted to indicate to the crane control system that
either the locked or unlocked condition has been selected.
v) An electrical connector for the feeder cable for the spreader.
vi) Anti-sway or trim/list/skew devices, if any.
vii) Limit switches, junction boxes, etc.
viii) An open top steel box for stacking cones (about 1 tonne).
ix) One (1) Emergency Stop push button station.
x) A dummy plug and socket for baloney cable end protection. Refer to 4-8.3 (4).
(3) All the fittings shall be securely fitted to the head block to withstand frequent impact
of landing.
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(4) Headblock design to allow full access to the spreader terminal boxes and spreader
hydraulic unit specifically solenoid valves while the spreader is engaged to the
headblock.
4-8.2 Spreader Communication System
(1) The communication between the trolley and the headblock shall via the baloney cable
with a CANopen system.
(2) Gateway shall be provided on the headblock and trolley. The trolley gateway shall
convert and transmit all the status and conditions of the spreader to the crane PLC.
4-8.3 Baloney Cable
(1) The baloney cable shall have at least 28nos. 2.5 mm² conductor wires.
(2) All the wire connection shall be designed to withstand frequent impact of landing.
(3) The cable shall be terminated at both ends in a prescribed plug and socket assembly
to be approved by the Purchaser.
(4) At the Headblock end a dummy plug/socket arrangement shall be provided attached
to the headblock to provide protection for the cable end connection when the
Spreader is disconnected. Electrical interlocking shall be included to permit hoist
motion without the Spreader.
The Contractor shall also supply one portable Testing and Maintenance Control
Panel, make of stainless steel and water proof to IP55 as minimum. This panel, when
connected to a suitable power supply, shall enable full simulation and operation of all
functions of the spreader in workshop and at site.
4-9. Spreader, Hook Beam
4-9.1 Spreader General
The Contractor shall supply one all hydraulic twin lift expanding spreader rated at 65 tonnes
for each crane supplied.
The spreader shall have the following general requirements: -
(1) Spreader Frame
i) The structural frame shall be designed and constructed to have adequate

safety factors to provide a fatigue life of not less than 2 million load cycles.
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ii) The bottom plate of the twist lock box shall have hardness of Hs26 or more to
reduce wear.
iii) Access ladders from both sea and land sides to the man cage on the head
block shall be fitted to the main frame.
iv) Flared guides shall be provided at four corners of upper surface of the frame
where the frame is connected to the headblock. Size of flare to be
approximately 150mm.
(2) Spreader Twist Lock
i) The twist lock shape shall fit ISO corner fittings.
ii) Twist locks shall be floating type and fitted with sleeve type twist lock guides. A
grease nipple shall be fitted at a suitable position on the sleeve to inject grease
in between the sleeve and the twist lock shank. Spherical washer and split
ring type bearing collar (collet type) load bearing system shall be provided to
support twist lock loads.
iii) Twist lock mounting system shall be designed to withstand frequent landing of
the spreader and headblock on twist locks during handling of hatch covers
and top tier containers.
iv) Twistlock movement from 'Unlock' position to 'Lock' position shall be prohibited
by mechanical and electrical interlock unless all twist locks are confirmed to
be fully inserted into corner fittings and the spreader is fully landed onto a
container or containers (or hatch cover).
v) Twistlock movement from 'Lock' position to 'Unlock' position shall be prohibited

by a mechanical and electrical interlocks unless complete landing of the
spreader is confirmed.
vi) Main Hoist motion is to be prohibited unless physical positions of all of the twist
locks match the 'Lock' or 'Unlock' command switch position on the control
console. A method of direct twistlock sensing is preferred.
vii) For indication lamp in the cab, refer to 5-4.6(6).
viii) The solenoid valves for twistlock control shall be

fitted at both topside end beams to minimise hydraulic hoses on the
telescopic mechanism. The solenoid valves shall be protected by covers to
prevent water ingress but shall not obstruct any maintenance accessibility.
Each solenoid shall be marked clearly for each function to facilitate trouble
shooting and minimise downtime. Each solenoid shall be protected by
individual fuse and all fuses shall be installed in the driver’s cabin.
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ix) A twistlock counter shall be provided on the spreader. For function refer to 4-
9.1(8).
(3) Spreader Flipper
i) The flipper drive and structure shall be designed and constructed to have
ample gathering capability of the flipper to displace the spreader by 150mm
and stop swaying in 3 seconds.
ii) Flipper operating time (arm up and down) shall be less than 5 sec maximum
one way.
vii) Flipper shall be capable of withstanding impact of

mis-landing of the spreader where only one lowered flipper lands on the top
of a container.
(4) Spreader Telescoping
i) Telescoping guide shoes or rollers shall be designed to allow easy and quick
access and simple adjustment.
The guide shoes or rollers must be able to be replaced without dismantling

telescopic beams from the main frame.
ii) Extension and retraction to the nominated twistlock separation dimensions

shall be controlled and maintained by the spreader control system.
iii) The operating time for extension or retraction shall be less than 20 sec. for
20'-30’, 30’-40' & 40’-45’, and 40 sec. for 20'-45'.
The telescopic movement shall allow approx. 3 seconds slow speed period
after start and before stop of the motion to minimise impact at start and stop
on the drive system.
(5) Spreader Landing Probe
i) The landing probes shall positively detect the landing of the spreader on a
container or on a hatch cover which are handled by twist locks.
ii) The landing probe (pin) shall be arranged to detect landing on a flat circular
surface area of 150mm diameter around twist lock hole.
iii) The landing probe diameter shall be 40mm minimum.
iv) The hole for the landing probe on the bottom plate of twist lock box and the tip of
the landing probe shall be chamfered to a minimum of 4mm in radius. (To
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prevent jamming of the probe due to mushrooming of hole edge and the top
of the pin.
v) The landing probe position shall be sensed by proximity switches or lever type
limit switches, which shall be located to accurately indicate spreader landed
and container lifted conditions.
(6) Spreader Lifting Lugs
Lifting lugs for handling a damaged container or an odd shaped cargo with slings and
shackles shall be fitted at four corners near each twist lock and 2 each at about one
third point from each end of the main frame (total 8 lugs on a spreader).
Capacity of lugs shall be minimum 15.0 Te/ each lug. The capacity shall be clearly
indicated by painting near each lug.
(7) Spreader Protection
i) All mechanical and electrical components fitted on the spreader shall be protected
from frequent impact and vibration of operation.
All fasteners shall be anti-loosening type.
ii) All the electrical cables connected to the moving parts of the spreader shall be
properly protected from damage due to interference.
iii) All the electrical parts including solenoid valve shall be protected from the
weather.
iv) Each individual proximity switch for twist lock "Locked" or "Unlocked" position
sensing shall be connected to the I/O unit to prevent any mis-indication and
unsafe movement of twist locks caused by short circuit of any of the failed
proximity switches. Such short circuit status of any failed proximity switch
shall immediately prohibit main hoisting or lowering function until a new
replacement proximity switch is in place. A method of direct twistlock
sensing is preferred.
(8) Spreader Meters and Indication
i) A twistlock operation counter shall be fitted on the spreader. A counter is also

required to record actual number of boxes loaded and unloaded by the crane.
As such the counter shall be designed to register one count when the
following combinations of motion is detected
“locked….hoisted….trolley….lower….unlock….” This counter shall be part
of the PLC function.
ii) A spreader operating hour meter shall be fitted on the spreader (motor
running hour).
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4-9.2 Spreader – Twinlift
The center twistlock housing shall be retracted (raised) when not in use. In this position
the twist lock and corner plunger limit switches shall be by-passed. When in twinlift mode,
the center twistlock housings center gap can be adjusted from 0 to 1600mm either unladen
or when be lifting two laden 20ft containers. The operator shall be able to adjust the center
gap by means of a single axis joystick or switch. A memory system to capture the center
gap separation at both seaside and landside shall be provided. Two push buttons labeled
‘Store’ and ‘Memory’ shall be provided near the centre gap separation joystick. When a
desired centre gap separation is achieved by the operator, the ‘Store’ button followed by
the ‘Memory’ button is depressed. This action associates the separation distance with the
memory location. Whenever a memory button is depressed the centre gap separation will
return to the distance as captured by the memory location. The spreader shall be capable of
handling single 20, 30 and 40 ft containers.
(1) The spreader shall be supplied with all necessary electrical and mechanical controls for
the handling of containers.
(2) Twinlift sensors shall be fitted to the spreader to detect, when in the 40ft operating
mode, that the spreader is not connected to two separate 20ft containers. If twin
20ft containers are present then the sensors should prevent the main hoist operating
in the ‘raise’ mode until the correct twin or single 20ft condition is selected and
reached.
(3) The motion of the retractable centre twist lock housing shall be synchronized.
(4) These requirements are in addition to those defined in 4-9.1.
(5) Twin twenty detection system (TTDS) shall be provided to prohibit lifting up two
twenty foot containers by the spreader at 40 foot status.
4-9.3 Hook Beam
IF APPLICABLE
5. Inter-functional Systems & Components
5-1. Mechanical System/ Components
5-1.1 Bearing, Seals
(1) All bearings used throughout the Crane shall be supplied from an internationally
recognised and approved manufacturer of bearings. All bearings shall have
standardised equivalents across a range of manufacturers.
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(2) All bearings shall be anti-friction type except for the shafts or pins with a limited
small angle rotation such as the gantry truck equalizer pins or equalizer sheaves. For
all types of bearings, an effective means of lubrication and sealing shall be provided.
(4) Bearing housings or retainers shall be a split type or bolt-down type to facilitate fast
inspection and replacement work.
5-1.2 Gearing
(1) Gears shall be of helical or herringbone type and designed in accordance with the relevant
BS, AGMA or DIN standards.
(2) The durability rating for the main hoist, trolley and boom hoist drives shall be based on a
minimum service factor of 1.5 for rated load and rated speed and a wear factor of 0.7.
Calculations to substantiate reducer selection shall be provided (clause 3-3.1 also refers).
(3) All other gearing shall be selected or designed for a minimum service factor of 1.0.
(4) The gearing for all main drives shall be totally enclosed in a split, oil tight steel box with
oil bath lubrication
(5) All open gears for the auxiliary drive systems shall be properly covered or guarded with
covers or guards for safety. The cover or the guard shall be easily removable and have
adequate ports to check and lubricate the gears.
(6) Oil or grease tray of a removable type under each open gear shall be provided to receive
excess lubricant. Prevention against overflow of oily water out of such trays during
rainy operational condition shall be taken into consideration in the design.
5-1.3 Gear Reducers
(1) The gearboxes shall be fitted with effective gear inspection windows and sight glass
type oil level gauges. The gear boxes shall be free from oil leakage. A dip stick type
oil level gauge system is not allowed.
(2) The gearboxes shall be designed to allow easy replacement of gears or gear shafts
without removing the whole gearbox assembly from its mounting base.
(3) Drain pipes with shut off valves and end plugs shall be fitted to each gearbox for
draining lubricant. An appropriate drain receiving space for each drain outlet shall be
provided.
5-1.4 Wire Rope Winch Drums
(1) The main hoist, trolley and boom hoist drums shall be of rolled welded steel
construction, statically balanced and complete with machined grooves for single
layer winding of wire ropes.
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(2) The grooves on the drum shall be pitched so that there is clearance between the
turns of rope on the drum and also clearance between the part of the rope leading
onto, or leaving the drum, and the adjacent coil.
(3) The bottom of the grooves should have a circular arc over an angle of not less than
120 degrees and the radius of the groove should be neither less than 5% nor more
than 7½% larger than the nominal radius of the rope.
(4) The diameter of the drum at the bottom of the groove shall not be less than 30
times the nominal rope diameter.
(5) The maximum angle of fleet between the rope and a plane perpendicular to the
longitudinal axis of the drum shall preferably not exceed 2 degrees. However 2.5
degrees may be accepted in the lightly loaded condition
(6) The drum shall be flanged at both ends.
(7) The wire ropes shall be secured to the drum by suitable clamping devices. The
design of this device will be subject to review by the Purchaser during the design
stage.
(8) The length of the hoist drum and wire ropes shall be such that when the headblock
is at its lowest specified point at least three full turns of rope shall remain on the
drum. When the load is at its highest possible point at least one empty groove shall
separate two adjacent ropes, depending on the drum configuration.
(9) With the boom in the fully lowered position there should be at least three full turns
of each rope remaining on the boom drum, and in the fully raised position at least
one empty groove shall separate the two ropes.
(10) The trolley wire rope drums (if applicable) shall retain at least three full turns for
each rope end when the trolley is either at the boom end or in the back reach. Three
empty grooves minimum shall be maintained between different ropes mounted on the
same drum.
(11) The Purchaser shall examine the designs proposed and determine suitability in
terms of the recommendations in ISO4308-1:2004 “Cranes and lifting appliance-
Selection of wire ropes” and ISO4309:2004 “Cranes-Wire ropes-Care, maintenance,
installation, examination and discard”.
(12) Oil or grease tray of a removable type adequately segmented for easy removal by
hand shall be provided under each wire drum to receive excess lubricant.
(13) Steel pipe type strong duty wire rope guards shall be fitted at mid level of the wire
rope winch drum to protect the wire ropes from entanglement when spreader is at it’s
utmost height emergency position.
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The clearance between main hoist wire ropes and the surface of the guards shall be equal to
half of the wire rope diameter.
5-1.5 Wire Rope Sheaves
(1) All wire rope sheaves shall be of cast steel or forged steel construction with
smoothly machined grooves. Fabricated or gravity cast sheaves are not acceptable.
(2) The bottom of the grooves should have a circular arc over an angle of not less than
120 degrees, have an included angle of 52 degrees and the radius of the groove
should not be less than 7½% or more than 15% larger than the nominal radius of the
rope with 11% being the optimum.
The supplier is to furnish specific details of the proposed sheave profiles.
(3) Minimum designed life of the sheave, specifically the groove and bearing retainer,
shall be 20,000 hoist operating hours.
(4) The pitch diameter shall be at least 30 times the wire rope diameter. An equalizer
sheave may have a smaller diameter provided that the small radius will not reduce the
safety factor of wire rope below the specified value.
(5) The maximum angle of fleet between the rope and a plane perpendicular to the axis
of the sheave shall preferably not exceed 2 degrees, however 2.5 degree may be
accepted in a lightly loaded rope condition e.g. Boom Hoist at upper limit.
(6) The surface of the groove of the sheave shall have a hardness value of minimum 321
on the Brinell Scale. The groove of the sheave shall be through-hardened to a depth
of at least 5mm.
(7) All running sheaves shall be fitted with anti-friction roller bearings with grease
fittings for pressure lubrication.
(8) In the locations where the wire ropes can jump or ride off the sheave, rope guards
shall be fitted.
5-1.6 Wire Ropes
(1) The factor of safety shall not be less than 6 for main hoist, boom hoist, and trolley
travel.
(2) Wire rope lubricant shall be carefully selected to minimise the dripping problems.
(3) For the dead end fixing, cotter socket is specifically not allowed.
5-1.7 Shafts, Axles
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(1) Shafts and axles shall be designed to include acceptable allowances and finishes for
stress concentrations at fillets, keyways and lubrication holes. All splines, gear teeth, or
threads shall run out smoothly or shall be undercut and surface finish shall be
uniformly smooth and free from defects.
(2) For any long driving shaft the tensional deflection shall not affect the coupling or
gearing associated with the shaft.
(3) Gearing axle brackets shall be a split type or a bolted type for simple removal of axle
and bearing.
(4) Shafts shall be properly covered or guarded for safety.
5-1.8 Couplings
(1) All main drive couplings shall be supplied by an internationally recognised

manufacturer.
(2) All main driving shafts shall be fitted with flange type flexible couplings. All coupling
bolts shall be locked with a proper anti-loosening system.
(3) Couplings shall be properly covered or guarded for safety. The cover or the guard shall
allow easy access for lubrication of the coupling without removing entire cover or
guard.
(4) For any spline couplings, a visible wear indicator with a maximum wear limit mark
shall be provided.
(5) In the event of a Hoist drum coupling failure, the release of the drum and rated load is
not acceptable. The Contractor shall submit to the Purchaser for approval a fail to safe
method for preventing such an occurrence.
5-1.9 Metal Wheels
(1) Gantry and trolley wheels shall be double flanged type forged steel wheel with
hardened tread.
(2) The designed life of the trolley wheels shall be a minimum of 25,000 operating hours.
(3) The designed life of the gantry wheels shall be a minimum of 10,000 operating hours.
(4) Wheels
Gantry and Trolley wheels shall be inspected by visual and UT methods to ensure that
the outer tread and flanges are free from any deleterious defects or flaws. Small
spherical defects less than 3mm in diameter may be accepted in the outer rim depth of
20mm, provided that they are not grouped or localised. Cracks or linear defects in this
rim will be grounds for rejection.
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In the core area, beneath the rim, discontinuities may be accepted but it will be subject
to the consideration and approval, or otherwise, of the Purchasers Representatives
following submission of the UT reports on defects present.
5-1.10 Pins, Pin Brackets
(1) An adequate lubrication system shall be provided for all pins and pin joint locations
in order to prevent seizure within the life of the crane.
(2) Suitable access and extraction facilities shall be provided for all removable pins. This
shall include jacking and or pulling.
(3) In order to facilitate ease of lubrication and to reduce the possibility of hardening
lubricant causing blockage, all pins shall be supplied with single straight drilled
lubrication holes. These holes shall be angled from the centre point of the pin end and
exit at the point of lubrication on the pin surface.
(4) The use of oil-less bushes shall not be acceptable.
(5) To ensure that the alignment of machined bores is maintained during the final
attachment process, cheek plate brackets shall be first welded into a stable single
assembly, prior to machining of the bore and subsequent welding onto the main
structure. Alternatively, side cheek plates may be welded on singly and then line-bored
in-situ.
The design of the assembly and the weldment shall be such that the distortion from the
welding process shall not compromise the alignment of the pin bore.
5-1.11 Bolts
(1) All bolts are to be manufactured to ISO-metric standard and shall conform at least to
the requirements of ASTM A375 or A490.
(2) Tightening torque for all fitting bolts shall be clarified by the Contractor in the form of
a bolt list clearly indicating bolt location, size, material and quantities.
(3) Structural bolts shall be tightened in accordance with the A.I.S.C. bolt tightening
method. Any other bolt tensioning method proposed must be submitted to the
purchaser’s representative for approval before adoption. The bolt tension may be
checked at location selected by the Purchaser’s representative. The checking at these
locations shall be done by the contractor and in such a manner that the torque wrench
or indicator can be read and verified.
5-1.12 Lubrication
(1) All the moving parts shall be effectively lubricated.
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(2) All the Contractor's designated lubricant shall be locally available in Poland. The
lubricants initially filled in manufacturer's shops shall be pre-approved by the Purchaser
for their compatibility with those lubricants to be used by the Purchaser.
(3) Any excess lubricant shall be trapped in removable trays or receivers.
5-2. Hydraulic System/ Components
5-2.1 Standards
Hydraulic systems shall be designed in accordance with relevant international Standards. As a

minimum all components must be capable of operating continuously i.e. pumps, valves etc.
5-2.2 Components Sources
All components shall be sourced from internationally approved suppliers and the hydraulic
systems shall use components, which are readily available in Poland.
5-2.3 Operating Condition
Under conditions of continuous operation, the pump inlet temperature of the fluid must not
exceed 65 degrees C. The equipment shall operate efficiently in an ambient temperature range
of -20 degrees C. to plus 35 degrees C. The system shall incorporate fluid over temperature
protection which shall operate to indicate the fault and stop the operation of the pump. Such
Hydraulic shut-down shall register as a fault to the crane control system and render the crane
fail-safe.
5-2.4 Hydraulic Fluid Reservoir
The type of hydraulic fluid for the initial fill by the Contractor must be pre-approved by the
Purchaser.
All Hydraulic reservoirs/storage tanks shall be provided with adequate drainage facilities to
permit the draining of the hydraulic fluid into waste oil receptacles through shut-off valves
which can be easily accessed. Space shall be provided around and below the drain valve to
allow this essential maintenance work without spillage.
(1) The capacity of the fluid reservoir shall be sufficient to contain all the fluid that can
flow from the system into the reservoir. The fluid level shall be maintained at a safe
working height to prevent cavitations in the pump during the operating cycle.
(2) Reservoirs shall be equipped with clearly viewed flush mounted or protected fluid level
indicators. They must be provided with markings indicating high level when pumps
are stopped and low level when the pumps are in operation.
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Reservoirs shall be constructed to prevent entry of foreign matter, including fluid

contamination and moisture.
(3) Both fluid intake and return points shall terminate sufficiently below the minimum
fluid level to prevent aeration.
5-2.5 Power Unit
(1) Positive displacement pumps and motors are preferred.
(2) Means and good access shall be provided for filling and draining pump and motor
casings in accordance with the manufacturer’s specifications.
5-2.6. Valve Mounting
Wherever possible, valves shall be mounted so that their removal and replacement can be made
without disconnecting pipe fittings. Adjustable valves shall be such that their settings, when
made, will be maintained against vibration.
5-2.7 Relief Valve
A pressure relief valve capable of relieving the maximum flow at the outlet of the pump shall
be provided on the delivery side of the pump and there shall be no other valve between the
pump and the relief valve.
Relief valves shall reseat within 3% (maximum) of cracking pressure, and shall have a rated
working pressure of not less than 150% of operating pressure. Relief valves subject to
changeable back pressure shall be externally drained. Wherever possible, relief valve shall
be used as safety reliefs and shall be set a minimum of 10% higher than maximum operating
pressure. Solenoid operated directional valves shall have oil immersed or wet pin solenoids.
Each solenoid shall have means for external mechanical actuation for testing. If internally
drained, tank ports will not be subjected to more than 7Mpa or maximum pressure allowed
by manufacturer, whichever is less. External drain lines shall be designed to minimize
pressure surges and reduce backpressure. Four-way valves shall spring center or spring offset
to a failsafe position upon electrical failure.
5-2.8 Flow Control Valve
Variable flow control valves shall show the direction of operation for increase and decrease of
throughput.
Flow control valves shall be pressure and temperature compensated over the full range of
flow for which the valve is rated. Flow setting shall be adjustable and shall have facilities
for locking when proper flow setting is reached. Flow control valves must be adjustable to
zero flow.
5-2.9 Check Valve
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Check valves may be either ball type or piston type. Swing checks shall not be used. Check
valves shall be spring loaded closed and have zero reverse flow.
5-2.10 Servo Valve
Servovalves shall be rated for maximum operating flow with a maximum pressure drop of
3MPa across both ports combined. Servovalves shall have non-bypass type 3 micron
absolute full flow filters on their supply lines. Each servo valve shall have externally
adjustable null.
5-2.11 Control Valve
All control valves shall be subplate mounted or cartridge type. Shut off valves, check valves
and needle valves may be line mounted. Maximum flow rates and pressures through valves
shall not exceed manufacturer’s rated flow and pressure, valves at 24V.
5-2.12 Solenoid Valves
(1) All solenoid valves shall be 24 volt 50 cycles and shall be replaceable without
disassembling the valve or removing it from the subplate or manifold.
(2) All solenoid valves shall be protected from weather.
(3) Valves including specifically solenoid valves shall be readily accessible to allow
for any adjustment, operational check, or manual operation in an emergency.
(4) Solenoids shall have continuous rating and be equipped with an LED indicator for
indicating fault.
(5) All solenoids shall be fitted with an independent surge absorber to absorb high
voltage spike due to ‘close’ and ‘open’ of highly inductive load solenoid.
(6) Solenoid valves shall be equipped to provide remote signals to operator’s cab /
computer control and to central data collecting point.
5-2.13 Piping
(1) Welded joints in hydraulic pipe work shall not be allowed when the diameter of pipe
is less than or equal to Ø30mm.
(2) All rigid piping shall be securely supported to minimize vibration or movement. The
length and method of supporting flexible piping shall be such as to avoid sharp flexing
and straining, particularly at the end fittings. The spacing between adjacent rigid pipes
and between rigid pipes and the surrounding steelwork etc. shall be sufficient to allow
the pipe couplings to be secured with ease and without damage to adjacent pipes or
couplings.
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All the piping shall be securely fixed to the structure and shall withstand internal and
external vibration and impact.
(3) Piping between actuating and control devices shall be as short as possible and pipes
must be removable without dismantling equipment, components or adjacent piping.
5-2.14 Hoses
(1) Flexible hoses and couplings shall be in accordance with the requirements of the
relevant international Standards and shall be of an approved type and manufacturer.
(2) Flexible hose shall be protected from mechanical damages due to interference with the
adjacent structure, equipment, or any moving parts.
(3) Where the pressure adjustment is critical, a pressure gauge port with shut off valve
shall be provided in the line so that the pressure can be checked without disconnecting
the lines.
(4) Hoses shall be designed for burst pressures of 70 Mpa and shall be tested at 35 Mpa.
5-2.15 Assembly Test
After assembly, the system shall be hydrostatically tested to 150% maximum pressure.
5-2.16 Catch Basins
(1) All hydraulic power units will have catch basins to collect leakage for the power unit
and its components. The basin shall be sized to a minimum of 10% of the reservoir’s
volume.
(2) Catch basins shall be fitted with a manual valve equipped with drains. The drains
shall either be accessible from crane walkways, machinery decks, the wharf, or from
the trolley. Space shall be provided for a container to accept the drained fluid.
Where the catch basin is compartmentalized, the various compartments shall be
piped together to form a single drain point.
5-2.17 Filters
(1) Filters shall be full-flow, non-bypass type complete with visual condition monitoring.
The filter may generally be fitted either in the intake, pressure, or return lines and shall
have a 10 micron nominal filtration rating. When the filter is installed in the pressure
or return lines the pump intake shall be fitted with a wire mesh screen (100 mesh or
finer).
(2) The filter shall be easily accessible for element replacement purposes without having to
drain the reservoir and/or system.
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(3) A suitable magnet should also be fitted in the bottom of the reservoir between the
return side of the reservoir and the suction strainers. Magnets shall be easily removable
for cleaning.
5-2.18 Heat Exchangers
Heat exchangers shall be installed and shall be air/ oil type sized to limit the maximum
reservoir oil temperature to 48 deg C. All heat exchangers shall be provided with bypass
valves to limit maximum operating pressure to 700 KPa or less.
5-2.19 Actuator
All actuators shall be laid out to allow easy removal and reinstallation.
5-2.20 Application for Spreader
(1) The hydraulic system capable of operating twist locks, flippers, etc, shall be
mounted on the spreader.
(2) A system to enable the hydraulic oil to be flushed out from the spreader
hydraulic circuit shall be provided.
(3) One unit of spare hand-operated hydraulic pump with appropriate

capacity shall be provided for emergency maintenance purpose.
5-2.21 Couplings
(1) Quick release couplings shall be provided and ample space provided between
couplings for coupling and uncoupling of hoses.
(2) The quick release couplings shall be match marked with ferrules on the connecting
ends.
5-2.22 Gauges
(1) A delivery pressure gauge shall be provided. The gauge shall be connected via a fail
to-safe valve and damping loop, and rigidly mounted on a structure. It can only be
read by operation of a fail safe valve.
(2) An oil level gauge on the reservoir shall be provided at a location convenient for
inspection by direct eye-sight.
5-2.23 Covers
Any cover for the hydraulic system must be manufactured in order to allow prompt and
direct access to manually check the solenoid valves. This should be allowed without the need
to remove the whole cover.
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5-2.24 Hydraulic Fluid
The type of hydraulic oil for the initial fill by the Contractor shall be pre-approved by the
Purchaser.
5-3. Electrical & Electronic System/ Components
5-3.1 General
(1) The Contractor shall be responsible for the safe and reliable operation of all
equipment in accordance with the requirements of this Specification. The electrical
installation shall provide reliable power for the rapid precise handling of containers
in continuous loading and unloading operations.
(2) All electrical installations shall be adequately earthed to protect electrical

equipment from damage during lightning storm. Lightning arrestors shall be
provided at the tip of the boom and mast structure of the Crane. It shall be
connected directly to the ground and insulated from the structure. The structure of
the Crane shall be electrically bonded to the rail.
(3) The supply of the Electrical Equipment shall be from the one manufacturer/
supplier.
The Supply of the hardware and equipment and the Integration of the system shall
be the responsibility of the Electrical Equipment supplier.
The Contractor shall, allow for the following:-
- In the case that the installation of the cabling is to be by others, the electrical
equipment supplier shall examine the installation, cable identification and
terminations and prepare a report on the cable installation and terminations. A
copy of this audit report shall be handed to the Purchasers Representative prior
to the testing and commissioning activities at the Contractors site.
It shall be a prerequisite of electrical testing commencing, that the cable

installation and terminations shall be in a condition and to a standard of
workmanship that is acceptable to the electrical equipment supplier.
- Attendance at site for the duration of the testing and commissioning activities
to facilitate the immediate correction or amendment or modification of the
control programme or equipment settings or adjustments.
- Minor adjustments at site of the motor/ driving characteristics of the various

functions, to accommodate terminal operator’s performance criteria.
[N.B. Speeds and accelerations as specified elsewhere in this specification shall be

used in the calculation of motor power requirements and also to test the capability
at site.]
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The minor adjustments may be required to “soften” the acceleration of drives to

enhance operator comfort.
(4) The electrical installation shall be carried out in strict accordance with the
following relevant codes of practice.
- EN 60204-1
- EN 60204-2
- EN954-1
- EN60439-1
- EN292-1
- EN292-2
- EN50081-1
- EN50081-2
- IEC 61800-1
- IEC 61800-2
- EN13135:2004
(5) The Crane shall be equipped with a monitoring system to provide instantaneous
information on the following variables relevant to the Power Supply System
• Volts V
• Current A (Drawn by the crane)
• VA
• Watts W
• var
• kWH
• kvarh
• kVAh
• Power Factor P.F.
• Frequency Hz
5-3.2 Main Power Supply
(1) Supply Voltage
A.C. 15KV ±10%

50 Hz±2%
3-phase
(2) Main drives A.C. Motor voltage and control power voltage to be proposed by the
Contractor.
(3) A.C. Motors A.C. 380 V 3-phase 50 Hz
(4) Lighting A.C. 220 V 1-phase 50 Hz
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General & floodlight A.C. 380 V 3-phase 50 Hz
(5) Alarm, intercom and other accessories A.C. 220 V 1-phase 50 Hz
(6) Window wiper and washer. D.C. 24 V.
(7) Radio communication equipment, stabilised D.C. 24 V, 5 amp and D.C. 12 V, 10

amp. These circuits shall be powered by a UPS that has the capacity to provide power
for at least 30 minutes in the case of mains power failure.
(8) Welding outlet A.C. 380 V 3-phase 50 Hz.
5-3.3 Power Factor Correction
Power factor under any working condition shall be controlled between 0.9 lagging and unity.
An automatic power factor correction device shall be installed on the crane to meet the
requirement. Details of the system proposed shall be provided as part of the Tender
submission. The system shall be fully integrated with the crane electrical system and shall be
supplied by the crane electrical equipment supplier.
5-3.4 Harmonics Suppression (if required)
(1) The harmonic current and the total, individual odd and individual even harmonic
voltage distortion values shall be suppressed within the permissible values during the
Crane Commissioning Test. The Contractor shall measure harmonics of each Crane
and submit the report to the Purchaser to demonstrate harmonics are within the
permissible values. (See Decree from Ministry of Economy and Labour dated 20th
December 2004 regarding detailed connection conditions of companies to public
supply.)
(2) The harmonic current generated by each Crane which referred to the 15KV level at
the point of common coupling shall not exceed the limits stated in the table in
Appendix IV.
5-3.5 Protection against Power Surge
All electrical and electronic equipment shall be protected by transient surge suppressor
installed as close as possible to each equipment which requires protection from the surge in
power and control circuit. Any electrical apparatus or device on the Crane which may
introduce a surge shall be properly designed to suppress surge within its own environment
and shall not cause any interference to other equipment or control functions of the Crane.
The following are, whilst not limited to, particular areas which require special attention in
terms of the transient surge suppression.
(1) The automatic power factor correcting device and the harmonic suppression device
shall be designed to be of solid state device without contactor to eliminate the surge
generated during 'on' and 'off' of the contactors which may cause a transient surge in
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the control circuit and in turn may create erroneous signals to trip off the main drives
operating circuitry.
(2) All rectifiers from A. C. to D. C. shall be protected by surge absorber on the A. C.

side as well as the D. C. side to have a clean D. C. output and with a suitable diode to
maintain the voltage at optimum level.
(3) All A. C. contactors, D. C. contactors and relays shall be connected in parallel with
suitable surge absorber to absorb transient surge due to make and break of coils
contact and minimize the disturbance of voltage to the sensitive areas within the
Crane.
(4) Critical items such as Programmable Logic Controllers, computers and I/O modules
shall be protected from external transient surge by independent surge absorber on
their power supply line.
(5) Any other items considered vulnerable to any transient surge must be properly
protected from transient surge to minimise interruption of Crane operation.
5-3.6 Protection for Power Dip/Power Failure
(1) The high voltage power supply electrical circuit of the crane shall be properly
designed to minimise crane recovery time in case of power supply failure in a form of
short duration voltage dip or a complete loss of high voltage power supply
(2) The A.C. Inverter Drive for the Crane shall be designed so that in case of power
supply voltage dip or a complete power failure when boom is lowering at full speed
or when main hoist is lowering at full speed with wide range of Empty spreader to
full load under spreader, the entire control system shall not fail and worst case is only
to trip out the under voltage protection relay as fitted on the Inverter Drive. All fuses
and Insulated Gate Bipolar Transistors (IGBT) shall not burn off under any condition
during real life operations. If any fuse or any IGBT should fail, the Contractor shall
take all responsibilities to change the design to cope with the above described
condition.
(3) The A.C. line low voltage power supply to the converter shall be connected in series
with A.C. current limiting reactors to limit the short circuit current if there is any
such condition when boom is lowering or main hoist is lowering at full speed with
and without load under spreader. An adequately sized Moulded Case Circuit Breaker
shall be connected in series to trip out the circuit in such case to minimise damages.
(4) The Contractor shall demonstrate to the Purchaser by switching off the high voltage
power supply when boom is lowering at full speed or main hoist is lowering at full
speed with empty spreader or full load under spreader. Nothing shall burn out except
trip off the undervoltage relay as fitted at A.C. Inverter.
5-3.7 Wiring
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(1) A minimum wire size shall be 2.5 mm², except for factory wired panels which may
include smaller size wires. For factory fitted pig tail wires for control components of
its size smaller than 2.5 mm², the length must be limited to less than one (1) meter.
(2) Cabling shall be connected only at the terminal blocks in panels, control box, joint
box, or at the terminal of electrical equipment. Cables shall not be joined other than
at proper terminals.
All conductor wires of 4 mm² or smaller shall be terminated at terminal strips and at
components having spring type terminals with spade or ring tongue crimped
solderless lugs, of the appropriate size and shape determined by the conductor
diameter.
(3) All the wires shall be run in trunking or conduit. It is preferable that as much as
possible the wires are so designed and installed inside the crane box structures. All
wires which run through holes or windows in the structure must be protected from
insulation damages due to mechanical contact with structures. Control and signal
wires shall be separated from power wires to avoid any interference causing false
signals. High tension cables shall be run independently. Multi-core cables may be
run on cable trays with adequate cable clamps and mechanical protection covers.
Covers shall be fabricated from marine grade stainless steel.
[See also Clause 4-5.1(3) for specific requirements in relation to cable installation
within and underneath the Machinery House floor.]
(4) At least 10% of control wires as spare wires shall be installed on all routes and
specifically labelled as such. Minimum core size shall be 2.5 mm². 10% spare
communication wires shall be run to each communications point and operations
station.
All spare wires shall be terminated in the terminal block.
(5) Vertical long distance wiring shall be restrained to prevent wire breakage due to
suspension of self weight of wires or cables.
Cable runs shall be fully supported adequately in either conduits cable trays or on
cable ladders.
Plastic cable tie shall only be acceptable in fully enclosed areas such as machinery
house cable trays/ ladders or within junction boxes.
For all external cables in cable trays or ladders cables shall be supported with cable
clamps or plastic coated stainless steel cable tie.
Vertical cable runs shall be supported by mechanical cable clamps.
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Cables restrained in vertical or inclined metal (galvanised) conduits, shall be clamped

mechanically with a stainless steel clamp at the top end to minimise relative
movement between the inner surface of the conduit and outer protection of the cable.
(6) Wiring on the trolley, headblock and spreader shall be designed to withstand
continuous vibration and impact.
(7) Each wire shall be cut to an adequate length to avoid any kinks or sharp bends, and
fitted with terminal lugs and marked at both ends with ferrule with number
corresponding to the number in schematic diagram. Tape or indelible markers are
specifically not allowed.
(8) Optical fibre core cable may be applied for control signal transmission with the
Purchaser's approval.
5-3.8 Marking and Identification
(1) All conductors (internal and external to panels) shall be suitably labelled at both ends
with hot foil printed, plastic tubing wire markers in accordance with electrical
drawings and wire schedules. All terminal blocks shall be properly marked as to
block number and terminal number per drawings.
(2) All terminal blocks shall be properly marked with the block number and terminal
number as shown on the drawings.
(3) Groups of cables entering junction boxes, cabinets, panels and pull boxes shall be
tagged as to location of the other end.
(4) All panels, boxes and cabinets shall be marked on the outside using engraved plastic
name tags fastened with stainless steel screws containing unit number and general
function, name or description.
(5) Individual control devices in cabinets shall be labelled by number description in

accordance with the drawings using durable, heat resistant labels with permanent
markings, and fixed in a manner designed to combat extreme hot and cold conditions
over long periods.
(6) Major control cabinets shall be labelled with engraved plastic description tags
fastened with stainless steel screws.
(7) The method securing cables within the control panels shall utilise a proper and
correct method of attachment. The use of self adhesive pads to secure the cables to
the panel walls shall not be acceptable.
5-3.9 Conduit and Cable Tray
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(1) Rigid conduit, with pull boxes at appropriate locations, shall be water proof and
continuous. Inside of the conduit must be smooth, and inner edges of both ends must
be rounded smooth.
(2) Flexible conduit (Kopex heavy duty or equal approved type) with proper fittings shall
be used between end of rigid conduit and pull box or terminal box of motors, brakes,
limit switches and all other independently installed electrical equipment which
require adjustment, realignment or removal for maintenance or are subject to
vibration.
(3) Rigid conduits shall be rigidly fastened to the crane structures.
(4) All conduits shall be contained within the Crane structure profile for protection.
(5) No conduit is to be installed across /above walkways or working platforms or in any

way that could be considered to impede safe passage, access, safety of operation etc.
(6) For conduit runs of more than 6 metres a pull wire shall be left in place.
(7) A drain hole shall be provided at the lowest point in each junction box.
(8) Ladder type open electrical cable tray shall be hot dipped galvanised finished and
fixed to the structure using stainless steel bolts and nuts. The type and fixing of the
cable tray shall be reviewed by the Purchaser.
Any cut edges on the hot dip galvanised cable tray or ladders shall have the sharp
edges removed by grinding or filing and the raw surface area protected by a zinc rich
primer immediately after suitably cleaning with clean solvent and, prior to any
degradation by rust.
5-3.10 Electrical Trunking
(1) Electrical trunking and trunking covers shall be free from sharp edges or sharp
corners to protect the cabling. Covers shall be fabricated from marine grade stainless
steel.
(2) Trunking shall have appropriate partitions to separate power and control wires, and
be fitted with restraining devices to prevent excessive cable movement in the
trunking.
(3) Trunking shall be designed to prevent water ingress. Nevertheless, the trunking shall
be designed so as not to trap any water inside in case of water ingress.
5-3.11 Motors
(1) Motor terminal box shall face an open space for ease of maintenance.
(2) All the main motors shall be fitted with space Heaters.
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(3) Motors shall be sized according to FEM 3rd edition Booklet 4 (Selection of Motors).
The minimum rating and duty of the motors, designated according to IEC 34-1
standard, shall be as follows:
Motors Minimum Ratings required

Main Hoist motors Continuous rating, duty type S1.
Boom Hoist motors S2 duty type, 60 minutes rating.
Trolley travel motors Continuous rating, duty type S1.
Gantry travel motors S2 duty type, 30 minutes rating.
The nominated motor duty shall be required as a minimum, the contractor/ electrical
equipment supplier shall assess the required rating for the actual calculated loadings
relevant to design proposed.
The Contractor shall submit calculations and selected classifications to the

Purchaser’s Representative for approval.
(4) All exposed moving parts of motors shall be adequately guarded.
(5) All motors for the main hoist, boom hoist, trolley travel and the gantry travel
system shall be individually tested in the motor factories, and the reports of such
tests shall be submitted with the commissioning reports of each crane.
(6) All DC (if applicable) motors shall be provided with commutator end covers which
are transparent to provide a simple means of inspecting the condition of commutators
and brush gear without removing the end covers.
5-3.12 Brakes
(1) Ample space shall be provided around brakes for inspection and maintenance works.
(2) Brake discs shall be dynamically balanced.
(3) Brake discs shall not sustain damages due to an emergency stop operation.
(4) Main hoist and trolley brakes shall be a peak impact damping type approved by the
Purchaser. The deceleration shall be accompanied electrically and re-generatively
with the brakes applied only when the motion has slowed down to essentially
stopped condition.
(5) Brake units on major drives shall be provided with brake lining auto wear
compensator.
(6) Brake Linings to be of non-asbestos material.
5-3.13 High Tension Panel and Switches
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(1) The power shall be separated for auxiliary power and main motions power. Three 15
KV vacuum circuit breaker switches shall be provided.
i) One VCB in-comer

ii) One VCB for auxiliary power
iii) One VCB for main motions (Hoist/Gantry, Trolley/Boom power supply).
(2) The Contractor shall submit the tripping characteristics of the 15KV switches for the
Purchaser’s review.
(3) The system shall be designed to indicate and log within the CCMS and PLC, the
tripping of any vacuum circuit breaker. All vacuum circuit breaker protection shall be
digital type.
(4) Remote control on-off switches with indicator lights for above (1) iii) (main motions)
to be fitted at entrance position of machinery house as far as possible from physical
switch gear body to switch on/off the power. Operation of this switch shall be
allowed only when the motion control circuit power is off.
(5) Remote control on-off switches with indicator lights for above (1) ii). (auxiliary
power) to be fitted inside the Gantry Control Box on the ground level (refer to 5-4.8).
(6) Pulse counters shall be installed for each 15 KV switch gear shown in 5-3.13 where
vacuum circuit breakers are used. These counters to count one for 'ON' and 'OFF' for
the purpose of maintenance.
(7) The following protection shall be provided
i) Over current protection

ii) Overvoltage and undervoltage protection (setting to be adjustable)
iii) Earth fault protection
iv) Door opening-tripping interlock
(8) The Metering Panel shall be fitted with the following,
i) Voltage meter
ii) Current meter with peak memory
iii) Frequency meter
iv) Power factor meter
v) Power Meter including peak power indication. (at high voltage switchgear
panel)
(9) High Voltage switch gear tools to be hung inside a wall mounted box fitted with
transparent front cover. Each tool shape to be painted on inside wall of the box on its
position for easy identification of any missing tool. Test probe shall be included in
the tool.
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(10) High voltage warning signs in English and Polish to be installed on each panel
stating 15KV HIGH VOLTAGE – DANGER.
(11) Proper space shall be provided around the panel for maintenance of switchgear.
5-3.14 Transformers
(1) All transformers shall be located indoors.
(2) The main transformers shall be dry type and guarded by a wire mesh barrier with a
lockable door and warning signs for high voltage.
(3) An auxiliary transformer of minimum rating of 150 KVA shall be installed for
essential supply when the Crane is not in operational condition.
(4) The Contractor shall submit the load curves for all transformers for the Purchaser’s
review. The load curves shall define the power consumption at the different loading
conditions.
(5) The location of transformers shall be selected not to raise panel temperature.
(6) An interlock system shall be provided on cables/cages to provide high voltage

personnel protection.
5-3.15 Resistors (if any)
(1) Any resistor shall be installed in a position where it will not raise the temperature of
electronic control components.
(2) Resistor banks, if any, shall be fenced off to avoid accidental contact by maintenance
staff. The fence shall be provided with an access door with a lock, and warning signs.
5-3.16 Enclosures
(1) All electrical enclosures, terminal or distribution boxes in locations exposed to the
weather shall be manufactured in stainless steel to a minimum IP55 standard.
(2) Stainless steel bolts or screws shall be used throughout to secure the covers and these
shall not penetrate into the box. All panels shall be accessible and removable from
the front.
(3) Control panels shall be of steel construction with full access from the front. Each
panel shall be equipped with lights with switch controls inside the panel for
facilitating maintenance work.
(4) Panels with electronic control units shall be designed to maintain the inside air
temperature below 40 deg. C at all times. Any air inlet for cooling air shall be
equipped with air filters.
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(5) Each motion control panel shall be fitted with motor RPM meters, ampere meters
and volt meters which indicate motor current, reference voltage and motor voltage.
(Alternatively this information maybe made available from the “Touch
Screen“ associated with the PLC.)
(6) All control panels, layout drawings shall be submitted and reviewed by the Purchaser
before manufacturing.
5-3.17 Meter and Counter
(1) All meters shown in (2) below shall be enclosed in a purpose built single cabinet
mounted within the machinery house at a height not exceeding 1.7m from the floor
level and not below 1.2m from the floor level. The cabinet shall be glass fronted and
illumination shall be provided by switched fluorescent light with an on/off timer
circuit of 15 minutes. The position of the cabinet shall be approved by the Purchaser.
(2) The following individual meters and counters shall be installed in the machinery
house cabinet in addition to ordinary meters on the control panels. The display for all
meters shall be of LCD type. Please also refer to 5-3.16(5) above.
i) Operation hour meter for main motion power source, main hoist, trolley
travel, gantry travel & boom hoist.
ii) Twist lock counter (For function refers to 4-9.1(8)).
iii) Main hoist brake counter
iv) Trolley brake counter
v) Net handling hour meter showing hours [main hoist + trolley – see appendix
IV
vi) Main vacuum circuit breaker switching frequency.
vii) Rail brake operating frequency.
(3) In the operator's cab the following meters shall be provided,
i) Anemometer with adjustable interlock alarm function.

ii) Spreader height indicator with adjustable height setting and contacts for
interlocks.
iii) Trim, List, Skew meters.
iv) Load Indicator in tonnes.
(4) On the spreader mechanical type meters shall be provided (unless otherwise specified)
as follows
i) LCD Twist lock counter (For function refer to 4-9.1(8))

ii) Operating hour meter (motor operating hours)
iii) All indications, annunciation, alarm and performance to have the facility for
remote indication and control.
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5-3.18 Limit Switches
(1) All the limit switches shall be independently accessible easily and quickly for
adjustment and maintenance or replacement.
(2) Application of proximity switch shall be 'fail-to-safe' application. Short circuit status
created within the switch at the time of failure of a proximity switch must prevent
further motion which is controlled by the switch, and such short circuit fault must be
registered for fault tracing.
(3) Lever type limit switches (if used) shall be “Omron” type.
(4) Proximity switches (if used) shall be Sick or Pulsotronic type.
5-3.19 Space Heaters
(1) Space heaters shall be fitted to the following locations
i) 15KV slip ring enclosures

ii) All main function AC and if applicable DC motors
iii) All control panels
(2) A LED indication light shall be installed external to each space heater location in
order for the maintenance team to easily identify that the space heaters are
functioning correctly.
5-3.20 D.C. Power Supply
The DC power supply shall be able to self regulate the output DC voltages to a constant
value against variations in the input AC supply voltage. There shall be sufficient cooling /
heat dissipating ability for the DC power supply.
5-3.21 Encoders
Electronic absolute encoders shall be used for position feedback for main hoist, trolley travel,
list and trim systems.
5-3.22 Sensors
All sensors installed on the spreader shall be wired in parallel.
5-3.23 Safety Mechanical Interlock System
Mechanical interlocking shall be provided for all main High Voltage circuit breakers,
switches, electrical enclosures etc., on each crane to ensure that access to the live parts of the
devices cannot be gained until the incoming supply is proved to be de-energised and a safety
key has been retained by the person requiring safe access.
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5-3.24 Name Plates
Electrical equipment shall be supplied with a nameplate immediately adjacent and

symmetrical to the equipment. These nameplates shall contain appropriate inscriptions or
identification markings to convey all relevant information appertaining to the characteristics
of the equipment.
5-3.25 Shore Power (Auxiliary)
Shore Power supply shall be provided to the following auxiliary systems.
a) Manlift
b) Walkway lights and emergency lightings
c) Aviation lights
d) Machinery house lighting
e) Communication system
f) UPS
g) Emergency mechanism (if any)
5-3.26 (Not used).
5-3.27 Load Cells
The load cells to be incorporated in the crane construction shall be the “pin type” and shall
be installed such that their sensitivity is not reduced by the installation arrangement.
5-4. Crane Motion Controls
5-4.1 Control System - General
The Crane control system design shall be based on a control system consists of
Programmable Logical Controllers (PLC) designed to the latest industrial standards. The
Programmable Logical Controllers are to be installed in the machinery house and operator's
cab which are operated in following environment and operating conditions.
(1) Environment - The entire system shall be designed and operated in hot and humid
atmosphere where installations are subject to prevailing heavy condensation and high
fungi. Equipment shall also be treated so as to resist attacks and entry of bugs and
mites such as termites, beetles, fly, etc. All components shall be tropicalised-treated.
(2) Degree of Protection - A minimum IP class (IEC 144 and 529) of IP41 is required for
all in house, enclosed installations. Equipment of installations at open, exposed
atmosphere shall have an IP class of IP55 as a minimum degree of protection. Finger
protection against electrical hazard to operators or maintenance personnel shall be
provided according to the latest industrial standards.
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(3) Ambient Temperature - The system shall be designed to operate in an ambient

temperature between -200C to +400C. It shall also withstand a storage temperature
range between -100C to +600C.
(4) Relative Humidity - The operating and storage humidity of this system shall have a
range from 8% to 99% (non-condensing).
(5) Vibration and Shock Resistance - The entire system shall be designed and installed
with an adequate vibration and shock resistance of not less than 16.7 Hz at a 3
dimensional amplitude of minimum 3mm in vibration and 10G in shocks.
(6) Operating Voltage - The system shall be designed and operated with a power supply
of 220VAC, single phase with an electrical potential tolerance of ±10% and a
frequency of 50Hz with a frequency tolerance of ±2%. It is expected that harmonics
of 3rd, 5th and 7th order will be superimposed on the supply line frequency.
Therefore, the Contractor shall install harmonic filters and power surge absorbers as
a standard feature. The system shall have a minimum isolation resistance between
external circuits and internal circuits of 50M ohm at 500VDC. An isolation voltage
of up to 1500VAC for 1 minute is also required.
(7) Duty Cycle - The system shall be designed to be operated 24 hours a day for the
whole year round with a mean time between failure (MTBF) at the component level
of not less than 30,000 hours and an operational mean time to repair (MTTR) of not
more than ½ hour per component replacement and module replacement. The
operating availability shall be not less than 99.997% per every continuous duration or
period of 3 months.
(8) One unit of Uninterrupted Power Supply (UPS) with a minimum of 30 minutes shall
be provided to enable the system to back up all status data for an orderly shutdown in
case of power failure so that all previous status data can be retrieved and safe
operation can be resumed when the power is restored.
The UPS shall support the following equipment during power failure :
(i) PLC and discrete I/O modules.

(ii) Crane computer system and on-board CCMS.
(iii) Trunk radio
5-4.2. Programmable Logic Controllers (PLC)
(1) The PLCs shall be of cartridge-insert type design with a rack that can provide the
installation of power suppliers, I/O modules (as specified in the related clauses), etc.
in a compact and low operating cost environment.
(2) The PLCs shall be able to intercommunicate with each other through a network
following the Open System Interconnection communication architecture. The PLCs
shall comply with the requirements of IEC 11311 – 1 and 11311 – 2.
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(3) The racks shall be industrial type with a capability of expansion via simple
communication interface between and among the racks. It is preferable to have a
racking system of a minimum slot or cartridge-insert space for at least 8 module
which excludes the slots or cartridge-insert space for the power supply and CPUs.
(4) The racks shall have a back-plate communication design and back-plate power
supply distribution system. This is to achieve maximum feasibility in module
replacement as well as minimize the mean time to repair when it is required.
(5) The PLCs shall have multi-tasking, remote communication capabilities and
supporting interrupts. The input interrupts shall be hard wired to the front of the
logic processor module. When triggered, the logical processor immediately halts the
execution of the main control program and executes the interrupt routine associated
with the given input interrupt.
(6) The PLCs shall have sufficient memory capacity to hold control algorithms for more
than one process plus at least 30% redundant memory capacity. The program shall
be stored in EEPROM and RAM. Facilities shall be incorporated on the PLCs to
enable programming of the EEPROM. There shall be facilities and space provided
for adding memories for future developments.
(7) The controller system shall provide real time display of programs, data and status at
remote sites. The complete cycle time of crane software inclusive of scanning all I/O
modules as well as execution of control modules in one cycle shall not be more than
30 milliseconds.
5-4.3 Power Supply
(1) The power supply unit shall be a high efficiency, low loss, cartridge-insert type
design with a fuse protected, surface mount input plug for connecting the main
supply mounted to this power supply unit.
(2) LED shall be equipped to show the healthy status of the incoming supply and the
outgoing supply. This shall be a standard feature of this power supply unit.
(3) The rating of the power supply shall be at least 25% more than the total normal
consumption of all the modules that are connected or that are going to be connected
in future.
5-4.4 Discrete I/O Modules
(1) The discrete I/O modules shall be designed from the latest industrial standards with
cartridge-insert type installation and the modules are expected to be operated under
an environment which is specified in 2-7.6.
(2) The discrete I/O modules shall be designed to have an I/O points with 8, 16 and 32 in
steps. All the I/O points shall be equipped with screw type fixtures, additional
plug-in interfacing plugs configuration for easy maintenance will be an advantage.
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All solid state output points shall be protected with quick-burnt fuse for system
protection. Replacement of the quick-burnt fuse shall require no dismantling or
disassembly of modules and racks. The I/O modules shall be equipped with LEDs
which show the status of the inputs and outputs.
(3) The maximum signal delay of the 'on' and ‘off' status of the output modules shall not
be larger than 1ms and 9ms respectively. At the same time, the maximum signal
delay of the 'on' and 'off' status of the input modules shall not be greater than 20ms
and 25ms respectively.
(4) The discrete I/O modules shall be equipped with a removable tab for wiring
identification.
(5) There shall be at least 20% spare I/O ports. Space in the cubicles or junction boxes
for adding I/O modules shall be provided.
5-4.5 Real Time Clock Module
(1) The real time clock module shall be industrial type with a cartridge-insert type design.
The real time clock module shall have the following seven date and time functions:
i) Day of the week

ii) Year
iii) Month
iv) Day of the Month
v) Hour
vi) Minutes
vii) Seconds
(2) The real time clock module shall have an accuracy of not more than 60 seconds per
year in temperature range from -20oC - +50oC.
(3) The module shall have the capability to register the event logs together with the time
clock and then send the logs to the communication module when command is
executed.
5-4.6 Motion Control Switches in Operator’s Cab
Control consoles in the operator's cab. (Consoles may be combined with the operator's chair).
Please refer to Appendix IV for layout of consoles.
(1) Main hoist and gantry motion control
One stepless joystick controller of cross slot universal type on a right-hand control
console shall control main hoist and gantry motion. Fore and aft movement for main
hoist lowering and hoisting, left and right movement for gantry travel. Selection of
motions on first-come-first served basis. The controller shall be spring returned,
positively indented at zero notch and release by push down interlock catch
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incorporated into the master controller. Selection of the joystick type and model
shall be approved by the Purchaser.
(2) Trolley motion control
One stepless joystick controller with a straight slot in fore and aft direction on a
left-hand control console shall control trolley motion.The controller shall be spring
returned, positively indented at zero notch and release by push down interlock
catch incorporated into the master controller. Selection of the joystick type and
model shall be approved by the Purchaser.
(3) Other motion controls
Other motion control switches or control buttons for the following motions shall be
ergonomically laid out on the control consoles.
The layout must be approved by the Purchaser.
i) Twist lock 'Lock/Unlock' changeover switch. (Right console)

ii) Flipper select switches to select individual flipper to be activated. (Left
console)
iii) Flipper selector switch for 'All Flippers', 'Land Side', 'Sea Side'. (Left console)
iv) Flipper 'Raise/Lower' changeover switch. (Left console)
v) Spreader 'Extend/Retract' control switch. (Right console)
vi) Spreader 'Trim/List/Skew' joystick control. (Right console)
vii) One push button switch to automatically correct spreader position to 'Zero
Trim/Zero List/Zero Skew' position. (Right console)
viii) Window wiper 'On/Off' switch.
ix) Window washer 'On/Off' switch.
xi) Control power source 'On/Off' push button switch.
xii) Fault reset button (details of faults will be released to the Contractor)
xiii) Other control switches necessary for normal operation.
xiv) Twinlift Controls
xv) Boom and boom latch operation control
(4) Emergency stop push button on the console
Emergency stop push button shall be positioned such that it can be pressed with
either hand in an emergency, or one on each console shall be provided. The button
shall be a mushroom type with raised guard to prevent accidental tripping.
(5) The equipment start-stop switches and selectors on the consoles shall as a minimum
be:
i) Spreader power supply 'On/Off' push button switch.

ii) Spreader control switch (if applicable).
iii) Lighting control switch. (Operational lightings and walkway lights)
iv) Wind speed alarm cancel push button.
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iv) A push button for siren.

v) Operators cab light on/off switch
(6) Indicating lamps on the console.
i) Control power source 'On' indicator.

ii) Main motion power source 'On' indicator.
iii) Spreader position indicator (20' or 40' or 45').
iv) Spreader motor (if applicable).
v) Spreader 'Zero Trim - Zero List - Zero Skew' position indicator.
vi) Stowage pin 'Clear' indicator.
vii) Rail brake 'Released' indicator.
viii) Boom position 'horizontal/up' and boom latch status indicator.
ix) Other indicating lamps as necessary to indicate operable condition with the
lamp 'On'.
x) Overload indicator.
xi) Trolley tie down status indicator.
(7) Interlock override push buttons
For adjustment and maintenance purposes, interlock override push buttons with
cover of approved type shall be installed on the console or near the console apart
from normal operational control switch group.
(8) Labels shall be provided for each push button and indicator in both English and
Polish. The description shall be approved by the Purchaser.
5-4.7 Motion Control Switches in Boom Control Station
(1) The controls shall be located within a cubicle as outlined in 4-6.2 (1). All control
shall be by push buttons, which activates the PLC function in the machinery house to
allow control of the boom, gantry motors, brakes, and latch operating devices from
the control station.
The control shall allow by push button operation, the automatic latching of the boom
and the fixing of the boom typhoon pin.
(2) An on/off position switch for the boom hoist control circuit ('On' for activating the
boom hoist control) shall be installed at the station which will de-activate all other
motion control sources while this switch is in 'On' position.
(3) The gantry motion control shall have a 'Half Speed' command button.
(4) The control station box and all the control switches shall be weather proof.
Automatic acceleration, slowdown and final stop shall be provided for each motion.
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(5) An emergency stop push button and indicating lamps shall be installed in the station
box in addition to the control push button switches. These indication lamps shall
indicate status of boom and boom latch to ensure safe operation.
(6) A hands free intercom telephone unit which allows simultaneous communication
with the operator's cab, machinery house and ground level shall be fitted in the
control station box.
(7) Labels shall be provided for each switch and indicator in English and Polish.
5-4.8 Motion Control Switches in Ground Level Station
From this station, following shall be controlled.
(1) Remote control switch of 15KV power source for auxiliary systems.
(2) Switch on and off the control power.
(3) Gantry travel each direction at inching speed of 5 m/min maximum.
(4) Wheel brake 'Release' and 'Clamp' operation (Anemometer interlock shall be
overridden).
(5) Anchor limit switch overriding for fine adjustment of anchoring position.
(6) Key-lockable switch to lift off all gantry travel brakes, both drive brakes and wheel
brakes.
(7) All labels for switches and indicators shall be in English and Polish.
5-4.9 Motion Control Switches in Independent Cab on Girder-Boom
NOT USED
5-4.10 Semi-Automatic Operation System (Option)
IF APPLICABLE
5-5. Operational Safety Interlocks
5-5.1 Main Motions Interlocks
In addition to all the necessary protection of structural, mechanical and electrical system
components, the following interlocks are required as minimum.
(1) Main hoist operation
i) Main hoist (hoisting or lowering) motion to stop:
a. At upper and lower hoist limits

b. With brake malfunction, or not activated or not in correct position.
c. With over-speed.
d. With motor over-heat.
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e. Lowering within a certain distance of the landside and seaside

sill-beams.
f. Hoisting with an incomplete 'lock' position of twistlock after the
spreader is landed on a load fitted with corner fittings.
g. Hoisting with an incomplete 'unlock' position of twist lock.
h. When the actual position of any of the twist locks is different from the
twist lock switch command.
i. With loss of lub oil pressure if forced lubrication is applied.
j. When the boom is in motion.
k. With overload of cargo (stop hoisting motion, allow only lowering
motion after hoist motion is cut off).
l. With the activation of E-stop.
m. With position check fault.
n. With the spreader interlock incorrect spreader size, unlock & lock
signal interlock, twistlock selector interlock.
o. With the master controller interlock or check fault.
p. PLC / bus transmission error or fault.
q. Hoisting with any ‘holding signal’ on at unlock position of twistlock.
r. Hoisting with any ‘holding signal’ off at lock position of twistlock.
s. With Gantry master or in motion.
t. With the wind speed interlock of level 3 or > 24m/s.
u. Drive unit protection on Over-Voltage (OV), Over-Load (OL),
Under-Voltage (UV) and Over-Current (OC).
v. Motor side protection on Over-speed (OS), OC, and OV.
w. Speed deviation / control check fault.
x. When auxiliary hoist motor in engaged.
y. When snag protection is activated, hoist up is stopped; hoist down is
in slow speed.
ii) Main hoist (hoisting or lowering) motion to slow down, or in slow speed:
a. Hoisting at near the upper hoist limit, with a safety margin for full
deceleration distance under any load condition before hitting the emergency
stop limit.
b. Lowering at near the lower hoist limit, when the head block is at seaside of
seaside sill-beam.
c. Lowering at the spreader height above quay level is about 4m - 6m, when the
head block is at landside of seaside sill-beam. (The height to be adjustable)
d. Hoisting until sag of the wire rope is taken up.
e. With the hoist wire ropes slacked.
f. When received the landing signal.
g. Two seconds of hoisting after the landing signal has been switched off.
h. When manual override button is engaged.
iii) Main hoist hoisting and lowering without load shall be allowed while the boom is in
raised position. Spreader functions shall also be operable for maintenance work.
(2) Trolley operation
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(i) Trolley motion to stop:
a. At travel end limits at max. outreach or at max. backreach.

b. Where the spreader interferes with sill-beams, with 0.5-1 meter
margin. The margin shall be adjustable.
c. Forwards motion at near the seaside end of the girder if the boom is
not in fully lowered position with sufficient slack in Boom Hoist wire
ropes.
d. With brake malfunction, not activated or not in correct position.
e. With motor overheat.
f. When the boom is in motion.
g. When any one or all of the storm stowage pins of the trolley is
engaged.
h. Entrance door protection/interlock.
i. PLC / bus transmission error or fault.
j. With the E-stop activated.
k. Drive unit protection on (UV), OL, and OC.
l. Motor side protection on OS, OC, and OV.
m. With the master controller interlock or check fault.
n. With position check fault.
o. With the wind speed interlock of level 3 or > 24m/s.
p. Speed deviation / control check fault.
q. No boom horizontal signal.
r. Low pressure of rope tensioner (if any).
s. Boom master or in motion.
t. When auxiliary motor is engaged.
u. With gantry master or in motion.
v. With spreader landing signal.
ii) Trolley motion to slow down, or in slow speed:
a. At near the travel limits forwards and backwards with a safety margin
for full deceleration distance before hitting the end limit, when the
boom is in lowered position.
b. For trolleying while the boom is in raised position (between the
normal parking position/typhoon parking position and cab cleaning
platform position only).
c. With activation of any override or bypass function.
d. Move to trolley selection
e. When snag protection is activated.
(3) Boom hoist operation
i) Boom (hoist or lowering) motion to stop:
a. When the trolley is in motion, or positioned on the boom.

b. With over-speed.
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c. With wire rope slack during lowering motion at a position other than
the boom in fully lowered position. (Stop lowering, allow only
hoisting motion after stop).
d. Hoisting at upper limit.
e. Lowering at lower limit at boom horizontal position (with ample
slack in wire ropes).
f. Lowering at boom latched position.
g. With brake malfunction, not activated or not in correct position.
h. With motor over-heat.
i. With motor field loss.
j. While the boom locking device for a typhoon is engaged.
k. With the E-stop activated.
l. Drive unit protection on UV, OL, and OC.
m. Motor side protection on OS, OC, and OV.
n. PLC / bus transmission error or fault.
o. Hoist, gantry and trolley master on or in motion.
p. With the interlock of rope tensioner pressure.
q. Speed deviation / control check fault.
r. Interlock of boom latch and hook signal.
s. With activate of boom latch but the engaged signal was missed or
failed.
t. When auxiliary motor is engaged.
(ii) Boom (hoist or lowering) motion to slow down, or in slow speed:
a. Hoisting at near the upper limit before hitting the boom latch, or start
hoisting from horizontal.
b. Lowering at near the boom lowering limit (boom near horizontal).
c. Lowering to final latching position.
d. Lowering from the upper limit position until boom latches are cleared
completely.
e. When manual override button is engaged.
(4) Spreader Functional Interlocks.
i) Twistlock function
a. Interlock on the zero notch of all master controllers.

b. Interlock on landing delay on signal.
c. Load cell interlock for unlock function.
d. Signal interlock on unlock and lock sensors.
e. Interlock on twistlock selector and twistlock signal.
f. Interlock on holding signal.
ii) The spreader twist lock movement shall be mechanically and electrically
interlocked with spreader landing detection so that 'lock' movement is
prohibited unless all the twist locks are confirmed to be inserted into the
corner fittings.
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iii) The 'premature unlocking' movement of twist locks while suspending the
load shall be prohibited by means of a mechanical and an electrical interlocks.
An audible (through public address speaker system) and visual alarm at
ground level and inside the operator's cab shall be activated by premature
movement of switches to lock or unlock. Any such premature movement of
switches shall deactivate all crane motions.
iv) Telescopic function
a. Interlock on the landing or lock signal.

b. Spreader size selector interlock
v) Spreader oil pump function.
vi) Headblock connect interlock
(5) Gantry travel operation
i) Gantry motion to stop:
a. When the rail brake is engaged.

b. When the stowage pin is engaged to the quay.
c. When the cable reel limit switch for 'Over Paid-out' is activated.
d. With brake malfunction, not activated or not in correct position.
e. With motor field loss.
f. With motor overheat.
g. While the main hoist brake is energised.
h. With boom position other than 'fully' lowered' or 'latched' position.
i. When the cable reel limit switch for ‘slack cable’ is activated.
j. End stopper interlock.
k. PLC / bus transmission error or fault.
l. Drive unit protection on UV, OL, and OC.
m. Motor side protection on OS, OC, and OV.
n. PLC / bus transmission error or fault.
o. With the activate of E-stop
p. With the master controller interlock or check fault.
q. Speed deviation / control check fault.
r. With the wind speed interlock of level 3 or > 24m/s
s. Interlock on gantry collision
t. Boom master or in motion.
u. Over-Tension of trailing cable.
v. Cable reel motor fault.
w. With trolley master or in motion
ii) Gantry motion to slow down, or in slow speed:
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a. To half speed when the gantry motion is controlled by the control box
at the ground level or the Boom/Gantry control station, or close to or
inside the interfered (common) zone.
a. When the Crane is approaching to its travelling limit.
b. When the Crane is approaching the end stopper.
c. When manual override is engaged.
(6) Wind Speed-Rail Brake Interlock
NOT USED.
5-5.2 Cab Access Interlock
Mechanical and electrical interlock shall be provided at the access gate to the operator’s cab.
The interlock protection shall provide least the following functional constraints with the
fitting of a Fortress type locking system. Gate or gates can only be opened when:
i. The ‘Control-on’ switch is in the ‘OFF’ condition, AND

ii. The trolley access way is carefully aligned with the cabin access way platform.
Similarly the ‘Control-on’ can only be activated when all gate or gates are in the closed and
locked conditioned, and trolley travelling can only be performed under such condition.
A similar level of protection shall also be provided on any access way to the boom area from
girder.
5-6. Communications
5-6.1 Intercom System
(1) A voice communication system which allows simultaneous or selective

communication among the machinery house, control panel room, ground level and
boom control stations, personnel lift (if applicable) and operator's cab shall be
installed.
The communication system shall be similar to those supplied by “Giatronics” or

“Clearcall” or equivalent and shall allow for the volume at any station to be
adjustable, from that station.
2 - Hand sets in machinery house (1 inside the panel room)

1 - Hand set in operator's cab
1 - Hand set in boom control station
2 - Hand sets at ground level, one on land-side beside the
gantry control station and one in the checker's cab.
1 - Hand set on A-frame platform
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1 - Hand set on boom girder platform

1 - Hand set on backreach platform
Care shall be exercised in the layout/ installation of the “Intercom” cabling to avoid
any interference from adjacent “Power” Cables.
5-6.2 Fibre Optic Cable
(1) The fiber optic communication module shall be rack mounted design and the
connecting device (between Crane’s optics cable networks to the optics cable
network outside the Crane) shall support the use of multi mode fiber optic cable
(50 micron core / 125 micron cladding). All optical fiber waveguide shall be
terminated with connectors. The plug and socket assembly for the optics fiber cable
shall be of IP55 protection.
(2) The fiber optic communication module shall support a fiber communication
distance of a minimum of not less than 2500 meters in a continuous 60/125um
fiber optic cable.
(3) The fiber optic cable allowable transmission loss in the cable shall be less than the
following:
Multi-mode cable: 3.0 dB/km at 850 nm wavelength
(4) Tests to measure and confirm the fiber optic waveguide requirements above shall
be conducted during the acceptance, testing and commissioning stage. The
Contractor shall provide the test procedures, all instruments, equipment and
qualified personnel for carrying out the tests.
(5) The power supply for the fiber optic communication modules shall be back plated
supply with LED indications for the active status of the output or receiving
channels.
(6) The insulation and sheath material shall be halogen free and low smoke tested in
accordance with IEC 754-2 and IEC 1034-3.
(7) The Contractor shall submit the proposed selection of cables and their test
certificates to the Purchaser for review prior to ordering of the cables.
5-6.3 Public Address System
(1) Loud speakers
Two loud speakers pointing down shall be mounted on the trolley or near the
operator's cab. An amplifier and a goose-neck type microphone shall be installed in
the operator's cab. The volume adjuster shall be installed in a lockable box to
prevent unauthorized volume adjustment.
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5-6.4 Radio
The Contractor shall supply a radio system, with base units fitted to both Operators and
Checker’s Cabins. The brand name and model shall be approved by the Purchaser.
5-7. Crane Condition Monitoring System (CCMS)
5-7.1 General
The Contractor shall supply, deliver, install and commission a Crane Condition
Monitoring System (hereinafter referred to as the CCMS). The design of the CCMS shall
facilitate future expansion in terms of capacity and functional features. The CCMS
hardware and software shall be modular in design and construction to facilitate future
expansion. There shall not be major re-configuration of the hardware and software
modification and development. System expansion shall not be limited by the capacity of
individual On-Board CCMS, RCCMS and PLCs.
The Crane Condition Monitoring System shall be installed in the following locations:
(1) In the electrical room inside the machinery house of each Crane (hereinafter
referred to as the On-Board Crane Condition Monitoring System, On-Board
CCMS).
(2) ln the maintenance base at the Engineering office building (hereinafter referred to
as the Remote Crane Condition Monitoring System, RCCMS).
5-7.2 CCMS Description
The On-Board CCMS and RCCMS shall incorporate alarm/fault monitoring and graphics
display, the condition status monitoring with graphics display, the fault diagnostic
functions, Crane operation and shall allow access to the programming logic and software.
These functions must be able to be downloaded as a softcopy and printed as a hardcopy.
The CCMS shall consist of but not be limited to the following elements:
(1) One (1) set of On-Board CCMS on each crane. This shall consist of a personal
computer with monitor, key boards and necessary associated peripherals and
software. All hardware and software required for interface to the communication
network and peripheral devices shall be included and reviewed by the Purchaser.
(2) Provision shall be provided at the checker’s cab to allow engineering personnel to
access the On-board CCMS via a computer notebook.
(3) One RCCMS unit shall be provided with the Crane purchased. This shall consist of
a personal computer together with monitor, key board and necessary associated
peripherals and software. All hardware and software required for interface to the
communication network and peripheral devices shall be included.
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(4) A laser jet printer to be installed in the Engineering office and its associated
peripherals for printing necessary information from the RCCMS.
(5) One RCCMS server and the standby server shall be provided with the Crane for
access to the cranes under the same drive system.
(6) The Contractor shall provide technical training for the engineering staff of the
purchaser as part of the crane supply contract. The training program shall be
submitted in the tender proposal. This training shall be conducted by a Polish
speaking personnel who is represented as the representative of the Contractor.
(7) The Contractor shall provide 6 sets, cost free, reproducible maintenance manual,
operator manual, and spare part manual to the Purchaser.
(8) The Contractor shall submit a quotation upon practical completion date of the On-
Board CCMS and RCCMS to the Purchaser for a ordered spare part list of the On-
Board CCMS and RCCMS for an operation period of 5 years continuously.
(9) The Contractor shall also bind to guarantee a spare parts availability not less than 5
years beyond the practical completion of this contract.
(10) The CCMS shall have proper documentation of circuit diagrams, source codes,
hardware and software and associated peripherals.
(11) The design overview of the CCMS is shown in Appendix IV. The Contractor shall
submit within two (2) months after the date of award of contract, the CCMS
system architecture for review by the Purchaser.
5-7.3 Operating Environment and Requirements
The CCMS shall be designed and operated in the following environmental condition:
(1) Environment
An environment as described in Clause 2.7.6. The CCMS shall be designed and

operated in hot and humid atmospheres where installations are subject to prevailing
heavy condensation and light fungi. Equipment shall also be treated to resist
attacks and entry of insects. The components shall be tropicalised treated.
(2) Degree of Protection
A minimum IP class (according to IEC 144 and 529) of IP41 is required.

Equipment of installations of open atmospheres shall have an IP class of minimum
of IP55. Finger protection against touching the electrical potential terminals shall
also be required.
(3) Ambient Temperature (Environment)
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The system shall be designed and operated in an ambient temperature between -20
deg C to 40 deg C.
(4) Relative humidity
The operating and storage humidity shall have a range from 8% to 99% (non
condensation).
(5) Operating Voltage
The system shall be designed to operate under a voltage supply of 230VAC, single
phase with a supply tolerance of +/-10% and a frequency of 50Hz with a tolerance
of +/-2%.
(6) Duty Cycle
The system shall be designed and operated 24 hours a day for the whole year round
with a Mean Time Between Failure (MTBF) at component level of not less than
30,000 hours and a Mean Time To Repair (MTTR) of not more than 1 hour per
component replacement. The operational availability shall be of not less than
99.997% per every continuous duration or period of any 3 months. The operational
availability is defined as follows:
Operational Availability, Ao%
= ((Toc -Tem) / Toc) x 100%
Toc (hrs): Total occupied time (system is turned ‘ON’)

Tem (hrs): Total time for emergency maintenance
5-7.4 On-Board Crane Condition Monitoring System (On-Board CCMS)
(1) General Specification
The On-Board CCMS is located in the electrical room and the checker’s cab of the
Crane. The On-Board CCMS is designed to provide a diagnostic and condition /
status real time monitoring of the crane control system. The On-Board CCMS shall
consist of the necessary sensors and transducers to be installed on each crane and
with in conjunction with the PLCs to provide continuous monitoring, diagnostics,
data collection on the Crane’s operating systems. The system shall also provide
crane operational data that is used to determine crane performance, maintenance
scheduling, spare part details and daily/shift reports.
5-7.5 On-Board CCMS Software Requirements
(1) The On-Board CCMS and RCCMS operating system shall be real time, multi-
tasking, multi-user operating system. The operating system shall allow the On-
Board CCMS and other programs to run simultaneously and allow the user to
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access any software without affecting the real time condition monitoring of the
crane control system and the communication link between the On-Board CCMS
and the RCCMS.
(2) The Contractor shall develop a user interface software to meet the following
requirements :
i) The software shall be able to run on Windowsoperating platform. The

operating platform and user interface software has to be approved by the
Purchaser. All back-up copies of the software shall be stored in the CD-
ROM or USB storage device.
ii) The software shall be commercially available software and it shall serve as
an interface to display on the screen all the captured data from the On-
Board CCMS. The software shall be able to generate but not restricted to
historical trend charts/files, trending, alarm management and fault logging,
crane maintenance and performance report, planned maintenance
information. The Purchaser will release the reporting format and details to
the Contractor and the Contractor shall comply with the same as part of the
Works. The capacity of the memory shall be able to store not less than 500
fault messages together with the related fault records and at least 3 years of
historical productivity data / information. The software shall be able to
download or export data files to other commercially available software such
as Microsoft Access, Microsoft Excel, and Microsoft Words or etc. The
export data files shall include but not be limited to ”txt”, “xls”, “doc”
format.
iii) The proposed structure of the database system for storing the CCMS data
and information has to be reviewed and approved by the Purchaser.
iv) The software shall allow engineers to access (read and write) the PLC
ladder diagrams, Boolean logic and other software codes. Forcing-on and
forcing-off of switches, contacts and relays on the PLC ladder diagram shall
be available on the On-Board CCMS. Key switch and password shall be
available to authorized personnel to carry out any modifications as
described above. There shall be three (3) levels of security for accessing to
different levels of CCMS software. The exact details will be released to the
Contractor by the Purchaser and the Contractor shall comply with the same
as part of the Works.
v) The On-Board CCMS shall be able to copy or upload PLC software

programme to each PLC within 10 minutes. The On-Board CCMS shall be
able to download all data files which shall include all real time information
of the CCMS and time response graphs. This information shall be able to
store in an USB storage device for printing using Microsoft Excel / Access
/ Words. Time response graphs displaying different signals simultaneously
shall be incorporated in the On-Board CCMS.
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vi) The RCCMS operating system and software shall be the same as what is
running under the On-Board CCMS.
vii) The software in the On-Board CCMS shall be made accessible for the
Purchaser to include additional or new monitoring points and to modify
software for presentation, reports for future enhancements.
viii) Original Licensed software shall be used, these includes the operating
system application software. One original licensed copy of the software
package shall be provided for every computer in the Agreement.
5-7.6 On-Board CCMS Hardware Requirements
(1) The On-Board CCMS shall be mounted in an environmental controlled, industrial

type cabinet that can withstand vibration.
(2) The On-Board CCMS shall consist of but not limited to the following items:
i) Computer
The specification of the above computer should be the subject to establish

which will be finalized during design period. The details will be released to
the Contractor.
5-7.7 Condition Monitoring
(1) The status and condition for the electrical systems, sub-systems and all the
essential components, Electrical, Mechanical and Hydraulic which are critical to
the proper functioning of the crane shall be monitored, during all modes of
operation and status of power supplies.
The Contractor shall provide a UPS, suitably rated for at least 10 minutes, to afford
access to all information in the event of power failure relating to the shore power.
(2) The CCMS shall present all information, status, graphics and data in easy to read
window display formats. The Purchasers preferred format for real time data, being
graphical displays rather than numerical presentation of the relevant data.
(3) The main screen shall lead the user to separate screens, divided into major
applications.
(4) Principle functions and components, associated with each application shall be
displayed, in real time mode, on individual screens, such as, but not limited to:
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Motor Feedback Signals, i.e. Speed, Current, Voltage, Frequency, Torque

Revolutions, Directions and Temperature.
Reference signals of Controller, Ramp Generator and Acceleration/ Deceleration

Ramps, Encoders, Pulse Generators.
Performance, Operation, Positioning, Current, Voltage and Speeds of Converters,

Inverters, Brakes, Contactors, Relays and other devices, applicable to the
application.
Hardware status of Limit Switches, Interlocks, Cam Switches, Sensors, Encoders,

Fuses and other Protection devices shall be monitored and displayed in an
approved format.
Data relating to Loads, Component Operational Time and Operational hours of

major devices, i.e. Motors, Converters, Inverters, and Brakes shall be displayed in
an approved format.
Provision shall be made for Status Warning, Alarm Trips and Faults to be
displayed at all times on all screens.
The system shall provide sub-windows, where operational performance of sub-

assemblies can be monitored, such as, but not limited to:
High Voltage, Shore Supply, Hydraulic Motors and Pumps, and Spreader
Functions (including single lift, and twinlift operation).
Performance indicators include but not limited to Operational Hours, Breakdown

Hours and Number of Failures, Net Cycle Times, Twist lock Count, Mean Move
Between Failure (MMBF) and Mean time To Repair (MTTR).
(5) The Contractor shall provide easy to access data of Systems, Parameter Settings of
PLC and/or Drives and Components in easy to read formats. These systems and
components shall include, but not limited to the following:
Performance of the Drives (Inverters and Converters) which includes the AC
Supply, AC Motor Control, DC Motor Control (if any), Operator Control, Motion
Interlocks, Safety Interlocks, Sequence Interlocks.
The temperatures for all AC Motors, DC Motors (if any), Gears, Reducers, Rope
Drums for the Main Hoist, Gantry Travel, Trolley Travel and Boom Hoist.
Monitoring and status of relevant data associated with High Voltage Panel,
Spreader (Single lift and twinlift).
The operating voltages and currents for all the Converters, Invertors, Brakes and
Motors.
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The status of the high voltage switches, low voltage switches, protections relay.
A real time update of all Positioning / Distance sensors.
Threshold values for warning and shutdown shall be incorporated in the CCMS.
Adjustment of the threshold values shall be made accessible to the Purchaser.
Any abnormality in the Crane’s system and components shall be prompted and
immediately displayed on the screen of the On-Board CCMS.
A real time update of all speeds, motions and operations.
All Ramps
Actual Loads
(6) The following, as a minimum, data associated with the Hoist operation shall be
displayed:
i) Controller Position of Forward, Reverse, Hoist, Lower, Left, Right and

Zero, shall be displayed. Actual proportional position of Controller
reference shall be displayed in an approved graphical format and indicates
to the user actual percentage (%).
ii) Hoist motion interlocks, Spreader interlocks, Slack Rope, Load Cell
measuring.
iii) Hoist Inverter status, interlocks, performance and protection devices.
iv) Hoist Brake Function, Operation and Brake Proving shall be displayed
v) Function and Operation of Limit Switches, Cam Switches, Encoders,

Tacho-Generators and Pulse Encoders.
vi) Hoist Speed, Slowdown, Speed Check, Stop and Positioning.
(7) The following, as a minimum, data associated with the Trolley operation shall be
displayed:

Zero, shall be displayed. Actual proportional position of Controller
ii) Trolley motion interlocks, Spreader interlocks,
iii) Trolley Inverter status, interlocks, performance and protection devices.
iv) Trolley Brake Function, Operation and Brake Proving shall be displayed
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vi) Trolley Speed, Slowdown, Speed Check, Stop and Positioning.
(8) The following, as a minimum, data associated with the Gantry operation shall be
displayed:

Zero shall be displayed. Actual proportional position of Controller
ii) Gantry motion interlocks.
iii) Gantry Inverter status, interlocks, performance and protection devices.
iv) Gantry Brake Function, Operation and Brake Proving shall be displayed.

vi) Gantry Speed, Slowdown, Stop and Positioning.
(9) The following, as a minimum, data associated with the Boom operation shall be
displayed:
i) Controller Position of Up, Down shall be displayed. Actual proportional

position of Controller reference shall be displayed in an approved graphical
format and indicated to the user actual percentage (%).
ii) Boom motion interlock, Spreader interlocks.
iii) Boom Hoist inverter status, interlocks, performance and protection devices.
iv) Boom Hoist Brake Function, Operation and Brake Proving shall be
displayed.

vi) Boom Speed, Slowdown, Speed Check, Stop and Positioning.
(10) The following, as a minimum, data associated with the Spreader operation shall be
displayed, which include single lift and twinlift operations:

Zero shall be displayed. Actual proportional position of Controller
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ii) Spreader motion interlocks, Spreader Retract and Expand interlocks,
iii) Spreader Motor and Pump status, interlocks, performance and protection
devices.
iv) Spreader Hydraulics Function, Operation and Proving shall be displayed.

vi) Spreader Stop and Positioning.
vii) Spreader Twistlocks, Lock and Unlock, including indication and By-Pass
status.
viii) Spreader Flippers, Up and Down
ix) Function clock shall display actual operation time of Expand/Retract,

Twistlock Operation and Flipper Operation.
(11) The following, as a minimum, data associated with the General Crane Control
System shall be displayed.
i) Emergency Stop operation where the status of individual stations shall be

displayed.
ii) Shore Power Supply, Auxiliary Power Supply, Shore Power Supply and
UPS function, status and performance.
iii) Function Operation and Status of Circuit Breakers, Fuses, Contactors,

Relays and Protection devices, shall be displayed.
iv) Operator Mode Selection, Function and Status
5-7.8 Fault Diagnosis
(1) The faults and status data including historical data shall be stored in the On-Board
CCMS database. All the data in the database shall be translated and stored in a
suitable text file for a standard editor. All data shall be easily downloaded to an
USB storage device and removable hard-disk. A zip function shall be available in
the software for file compression.
(2) The objective of the fault diagnosis is to assist Purchaser’s engineers to remedy the
fault or confirm the exact nature of a fault within a very short time. All faults shall
be coded with a suitable numerical code and the first fault causing an alarm, trip or
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crane stoppage shall be highlighted as first fault. Provision shall be provided that as
a minimum the system shall display twenty (20) faults that may occur at any one
time.
This first fault shall be displayed clearly to assist the Purchasers engineers on the
CCMS and remote display units. Faults interrupting crane operation shall be
highlighted, either by flashing or appearing in a “Pop-up” window, regardless of
screen selected and fault indication shall be only when crane motion or operation is
selected.
(3) The fault diagnosis shall be able to narrow down the faults to the exact components,
safety interlocks failures, drive faults, PLC controller failures.
There shall be details and information on faulty component locations and possible
remedy actions to be taken. There shall be intermediate fault tracing and
measurements checkpoints and these functions shall be made available to
Purchaser’s qualified personnel to input new parameters for troubleshooting
purposes. The resolution and duration of these measurements are 10ms to 100ms
and 5s to 50s respectively.
(4) Drawings on electrical circuit, PCB layout, schematic drawing, software ladder and
software device listing of crane control, Drives and PLC shall be made available in
the fault diagnostic mode. Access to the information shall be easily obtainable on
any CCMS screen.
The CCMS shall store all faults in appropriate historic files in daily, weekly,
monthly and yearly log folders, easily accessible and selection of data shall be by
selecting a daily, weekly, monthly or yearly option.
5-7.9 Preventive Maintenance
(1) The utilization hours of the consumable parts shall be recorded automatically and
compared with the respective pre-set replacement interval. Adjustment of the
replacement interval shall be made available to the Purchaser. The system shall
prompt the user when a part is due for replacement. The system shall have
sufficient capacity which allows the Purchaser to add new consumable parts. The
consumable parts shall include but not limited to the following:
(i) Brake pads and lining

(ii) Brake shoes
(iii) Wire ropes
(iv) Bearings
(v) Oil and air filters
5-7.10 Equipment Performance Data and Operation Log
(1) The CCMS shall provide records on equipment performance and operation data.
These data shall include but not limited to the following:
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(i) Frequency of breakdowns

(ii) Twist Lock Count
(iii) Main Hoist, Boom Hoist, Trolley, Gantry Hours and overlapping Main
Hoist / Trolley Hours
(iv) Occupied Time
(v) Mean Move Between Failure
(vi) Mean Time to Repair
(vii) Availability
(viii) Breakdown Percentage
(ix) Average Cycle Time
(x) Handling Capacity
(xi) Number of containers handled according to the size and weight of the
containers.
(2) These data shall be available in trend graphs / charts plotted against time. The
equipment performance and operation report format and the formulas for the
equipment performance parameters shall be discussed and approved by the
Purchaser before implementation. The Purchaser will release the exact details to
the Contractor at design stage. The data shall be stored in the On-Board CCMS
database and accessible by RCCMS. The data shall be able to download or export
data files to other commercially available software such as Microsoft Access /
Excel, Lotus etc. All counters in the CCMS shall be able to be reset by the
Purchaser’s engineering personnel.
5-7.11 Remote Crane Condition Monitoring System (RCCMS)
(iii) IF APPLICABLE
5-7.12 RCCMS Software Requirements
IF APPLICABLE
5-7.13 RCCMS Hardware Requirements

IF APPLICABLE
5-7.14 Server(s)
IF APPLICABLE
5-7.15 CCMS Reporting Format
The CCMS reporting format will be released to the Contractor, and to be agreed by the
Purchaser during design period.
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5-7.16 CCMS Data Communication
(1) The RCCMS shall allow being accessed remotely i.e. multi-users log on from outside
the terminal. The Contractor shall submit the communication protocol for sending
data to these computers and for communication between On-Board CCMS and
RCCMS. The communication protocol shall be submitted for the Purchaser for
approval.
(2) The data communication between the On-Board CCMS, Server(s) and RCCMS shall
be through an optical fibre link data communication media.
(3) The Contractor shall provide and install the following hardwares and cables on the
Crane for communication among the above servers and computers.
- Terminating boxes with ST connectors for fibre-optic cables inside the

Operator’s Cabin and Checker’s Cabin.
Two sets of six cores multi-mode fibre-optic cable from the fibre-optic
termination box in the Electrical House to the terminating boxes inside the
Operator’s and Checker’s Cabins. Size of each core of the fibre-optic cables
shall be 60/125 microns.
6. Common Items
6-1. Walkways, Stairs, Ladders and Platforms
6-1.1 Applicable Code/ Standard
(1) Walkways, stairways and platforms shall be designed to avoid tripping, skidding,
ducking or crawling. Clear headroom of 2.1m shall be maintained throughout the
walkways, stairways and platforms. Special non-skidding treatment and snow
accumulation shall be applied to flat structural surfaces if used as walkways.
(2) The design of walkways, stairs and ladders shall comply with the requirements of
BS4211, BS5395, BSEN13586 and ISO11660.
(3) All components making up the walkways, stairs ladders and platforms system and
supporting brackets and members, shall be hot dipped galvanized after all
fabrication work has been completed.
The design shall be “modular” and shall be assembled with either galvanized
structural bolting or structural pins.
The stairway/ platform system may be used to support conduits carrying cables for
the walkway lighting system.
The requirement for a continuous top handrail member can be achieved by

incorporating in the design, short sections of hot-dipped galvanized pipe, located
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onto spigots and welded into position by small circumferential welds. The
galvanized coating at the in situ welds shall be reinstated with a “Zinc- Spray”
technique.
6-1.2 Stairway Requirements
(1) Landings shall be provided for ladders or stairs at intervals of between 4 meters and 6
meters. The gradient of stair shall not exceed 50 degrees.
(2) Stairway treads shall be expanded metal or open grid metal construction, hot dip
galvanized.
(3) Stairs, platforms and walkways shall be provided to allow ample and safe access to
all sheaves, pins, wheels, carriers, ropes, machineries, switches and control
equipment, etc., where preventive maintenance is necessary. At least 600mm clear
passage around any machinery shall be provided. Application of vertical or near
vertical ladders shall be limited to places where frequency of usage is less than twice
a year.
(4) The main stairway from ground to the Machinery House girder level shall be located
on the land side, left hand side (looking to seaside).
6-1.3 Ladder Requirements
(1) Special ladders shall be installed inside the seaside front legs for their entire length
for inspection of structure, wiring or fittings. Man holes at the top and the bottom of
the legs with hinged doors with seal shall be provided as access ways. The locking
mechanism for manholes shall be such that a person entering an enclosed space shall
be able to lock-open the manhole cover with the lock. The cab access platforms shall
be equipped with pipe frame construction, inward opening and self-closing (by
gravity) hinged gates on trolley side and gantry structure side. Opening of the door
shall prohibit the trolley motion.
(2) Vertical or near vertical ladders of over 2 meter length shall be attached with safety
hoops. The space within the hoop shall be sufficient for a man with tools to climb up
or down the ladder and shall not be smaller than 650mm depth x 600mm width.
Vertical straps for the hoops shall be spaced adequately to prevent a human body to
fall through.
(3) Where a ladder enters a walkway or platform from a lower level, protection against
falling into the opening in the platform shall be provided.
This protection shall preferably be a simple gravity (or spring close) hinged bar, and
be located such that a person can step off the ladder before having to release his hold
on the ladder, to raise or push open the bar.
6-1.4 Platforms Requirements.
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Adequate, permanent and safe access platforms shall be provided in all areas requiring
inspection and maintenance as outlined in 6-1.2 (3). These shall include but not be limited to
the following platforms:-
(1) At the top end of legs, at each connection point of gantry structure and boom/girder
connection point.
(2) Adjacent to the Power or Energy chain.
(3) On the girder/boom to allow safe maintenance of the Catenery trolley (if any).
(4) Around all four sides of the machinery house.
(5) Cabin (maintenance platform at backreach).
(6) Main Structural Pins.
6-1.5 Walkway Handrail Requirements
(1) For a level walkway the height of the top handrails shall be 1100mm with two
intermediate rails at heights of 350mm and 685mm. The height shall be increased as
necessary at the stairway etc., to ensure safety of passage. The handrail shall be
constructed with pipe, all welded joints finished smooth to same diameter as the pipe,
and continuous along walkways, platforms and stairways. Adequate safety straps or
bars shall be installed between the lowest safety hoop of a vertical ladder and
handrail for landing wherever there is a wide clearance which may allow a person to
fall.
(2) The height of kick plate from the walkway tread level shall be 150mm. The kick
plate shall be continuous along walkways, stairways and platforms, and constructed
of steel strip on nominal width of 100mm, of minimum thickness 5.0mm.
6-1.6 Cab Access Platforms
Walkway shall be provided from the landside leg to enable the operator to enter the cabin
from the rear through a hinge door. The walkway shall be level.
The interlock protection for access way please refer to clause 5-5.2.
6-1.7 Cab Window Cleaning Platform
The cab window cleaning platform shall be fitted near backreach end of the girder which
allows the operator to clean lower front, bottom and lower windows safely. Access to the
cleaning platform shall be limited to from the operator's cab or from a stair/ walkway system
leading down from the crane backreach.
Interlock protection for access to the window cleaning platform shall also be provided;
details refer to clause 5-5.2.
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6-2. Illumination and Lighting
6-2.1 Walkways, Stairs, Ladder, Cab Access
(1) The supply voltage for lighting sources shall be as specified in 5-3.2 (4). Special
consideration to be given to minimise phase imbalance.
(2) A lighting system shall provide adequate illumination for all ladders, platforms,
walkways, machinery house and operator's cab. Energy saving lighting appliance
such as LED lighting is preferable.
6-2.2 Work Area Floodlights
(1) A floodlighting system shall provide adequate lighting to all work areas of the crane
including penetration into the ship’s cell. An average illumination of 100 lux at quay
level measured within 10.0m either side of the centreline of the Crane along the
entire trolley travel range shall be achieved. The minimum to maximum level of
illumination shall be greater than 0.7.
(2) To assist the berth operators when working beneath the crane, fixed floodlights shall
be mounted to the topside of the portal beams of the Crane to achieve the required
level of illumination. At least 4 nos. high pressure sodium lamps of 1000 watt shall
be fitted on top of the portal beam to provide sufficient lighting for the landside face
of containers in each lane.
6-2.3 Floodlights on Trolley
(1) Powerful spot lights minimum four (4) nos high pressure sodium lamps of 1000 watt
each shall be mounted near the cab at or below the cab bottom level to provide
excellent viewing of the ship’s cell or a slot at night when the crane trolley is
working over a vessel.
(2) The positioning of all floodlights shall not cause glare for the berth operators or in
the Crane operators cab nor shadows which make it difficult for the operator to safely
operate the crane.
6-2.4 Emergency Lighting for Escape Routes
Emergency torch-lights operated by rechargeable batteries shall be provided in the operator’s

cabin, electrical house and machinery house. Battery chargers to keep the batteries in
continuously charged condition shall also be provided.
6-2.5 Lighting Control Switches
Light switches shall be gathered in several convenient locations to allow centralized control.
Three On-off control switches which control on/off of all the operational lights including
walkway lights shall be located at ground level, machinery house and operator's cab to allow
switching from any of these three locations.
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6-2.6 High Pressure Sodium Lamp and Ballast
The high pressure sodium lamps shall be outdoor type and fitted with spring loaded
anti-vibration bulb socket complete with integral ballasts. These ballasts shall be high power
factor type of not less than 0.85 lagging.
6-2.7 Fluorescent Lamps
The Fluorescent lamps shall be rapid-start type, and equipped with steel either a wire mesh
guard or a toughened plastic weather proof surround.
Lighting fixtures fixed in external locations shall be the “outdoor” type. Externally mounted
lighting fixtures shall have an IP55 class of protection and made of stainless steel material.
6-2.8 Boom Latch Area Illumination
The boom latch shall be well illuminated from beneath for viewing from the operator cabin
and boom control station.
All the light fixtures shall have safe access for replacement of bulbs, socket, glass diffusers,
etc.
6-2.9 Aviation Warning Lights
Aviation warning lights shall be installed at the following locations:-
(1) At the Boom end:
Two (2) FAA approved 100 watt screw on type strobe lights mounted such that the
lights are vertical when the Boom is in the fully raised position.
(2) At the top of the Superstructure (or ‘A’ Frame):
These Warning Lights shall be energised continuously. To provide continuity when

the main supply to these lights is interrupted for any reason then a back-up system
shall be switched in automatically.
The back-up power shall allow for a power outage of not less than two (2) hours.
The bulbs shall be of durable long life construction or LED lighting and shall be able
to be replaced from the normal platforms.
6-2.10 Access for Lights Maintenance
All lights must be safely accessible for maintenance.
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6-3. Painting and Protective Coating
6-3.1 Paint System General

NOT REQUESTED / NOT USED.
6-3.2 Surface Preparation

6-3.3 Abrasive Blast Cleaning

6-3.4 Painting Generally

6-3.5 Paint Systems

6-3.6 Galvanising
6-3.7 Reinstatement of Protective Coatings at Site

6-3.8 Inspection and Sample Panels

6-4. Purchaser’s Logo, Crane Numbers, Signs

6-4.2 Crane Numbers

6-4.3 Crane Capacity Signs (In Polish)
(1) Capacity signs showing the safe working load of the Crane shall be fitted to both
outsides of the portal beam where clearly legible from the ground level.
(2) Capacity sign showing the safe working load of the spreader and spreader number
which will be designated by the Purchaser in the drawing approval process shall be
fitted or painted on both sides of the spreader.
(3) Capacity of each lifting lug on the spreader shall be indicated near each lug.
6-4.4 Manufacturer’s Name Plates
(1) Manufacturer's name plate could be placed on the portal beam only. The size and
location must be approved by the Purchaser.
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(2) A plate showing year and place of manufacturing, manufacturing number, principal
dimensions, speeds and capacity of the Crane shall be fitted in the operator's cab.
(3) Following warning signs shall be fitted to the Crane. All warning signs and
messages shall be approved by the Purchaser.
i) Pedestrian and quay workers warning signs. Total 5 signs.
ii) Warning signs on angled face bracket on the landside upper edge of landside
sill beam "BEWARE OF OVERHEAD LOADS” to be provided in Polish
and English. (Refer to Appendix IV.)
iii) High voltage warning signs for various position where high voltage
connection is made, and each of the 15 KV equipment. (Refer to Appendix
IV)
(4) Each item of machinery shall be properly labelled for its direction of motion or
operation and for any precautions to be taken before operation or maintenance.
(5) The components manufacturer's name plate shall be fitted on each major mechanical
system or component showing type, capacity, serial no., mfg, no., mfg. date, etc., for
future reference.
(6) Labels and caution plates shall be in English and Polish. Size and design shall be
approved by the Purchaser.
6-4.5 Other Signs
NOT USED.
6-5. Alarms, Warning, Signals & P.A. System
6-5.1 Gantry Travel Warning
(1) Four (4) yellow flashing electronic type strobe warning lights shall be installed at
four corners of the crane. These lights shall be automatically activated by gantry
motion. The type must be approved by the Purchaser.
These lights shall be mounted in a position where they can be clearly seen by both
pedestrians and by the operators of the Prime Movers.
(2) One common amplifier for travel warning gong sound and siren sound shall be
installed inside the electrical room, and the warning sound shall be emitted through
four (4) speakers installed at four corners of the Crane. The gantry travel warning
gong sound shall be automatically activated by gantry motion. The siren sound shall
be activated by the operator by pressing down the foot switch on the floor of
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operator's cab, and when pressed during gantry motion, it shall override the travel
warning gong sound. The type of sounds to be approved by the Purchaser.
(3) Alarm speakers shall be located at a maximum height of 2.5m above ground level.
The alarm speakers shall generate signal level of not less than 95dB at 1 kHz at a
point 1m forward (relative to the direction of motion of the Crane) of each of the
speaker measured at a height of 1.5m above ground level. In order to minimise
disturbance to communities around the terminal, the signal must not exceed the
above limit by more than 3dB. The alarm tone shall consist of an intermittent signal,
sounding at 1/sec for duration of 0.5 sec.
(4) The volume of the alarm shall be adjustable at the amplifier.
6-5.2 Wind Speed Warning
(1) The anemometer shall have three independently adjustable pre-setting pointers and
sufficient electrical contacts and terminals to:
i) Activate intermittent audio warning and amber warning lamp in the operator's
cab when the wind speed exceeds the lowest setting of the wind speed
(setting shall be manually adjustable).
ii) Activate continuous audio warning and red warning lamp when the wind
speed exceeds the middle setting of the wind speed (setting shall be manually
adjustable).
iii) Deactivate motion control while keeping status of (ii) when the wind speed
exceeds the highest setting. (Setting shall be manually adjustable).
(2) Once the above pre-set value (i) is exceeded, the anemometer shall only be capable
of being reset manually when wind speed falls below the pre-set alarm value (i).
(3) The wind vane to withstand the storm wind condition as specified in 2-7.7.
6-5.3 Main Hoist Overload Warning
An audible alarm in the operator's cab to be activated and a red warning light for indicating
'Hoist Overload' must be lit when overload is detected on hoist system. With 10% overload
for the specified load cases, detected for more than 3 sec. the hoisting motion shall be cut off
automatically. After hoisting motion is disallowed, only lowering motion shall be allowed.
6-5.4 Premature Twistlock Operation Warning
(1) The ‘premature locking’ movement before the spreader is landed on the container or
hatch cover shall be prohibited by means of electrical interlock on the logic control
circuitry. There shall be no physical movement of the twist locks on the spreader
even though the switch is turned to ‘Lock’ position. Audible and visual alarms
noticeable at ground level and at inside the operator’s cab shall be activated by this
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premature turning of the lever type twist lock limit switch and all motions of the
crane shall be deactivated. Both audible and visual alarms shall cease when the twist
lock switch is returned to its original position.
(2) The ‘premature unlocking’ movement while suspending the load with twist locks
shall be prohibited by means of electrical interlock on the logic control circuitry.
There shall be no physical movement of the twist locks on the spreader even though
the switch is turned to ‘Unlock’ position. Audible and visual alarms noticeable at
ground level and at inside the operator’s cab shall be activated by this premature
turning of the lever type twist lock limit switch and all motions of the crane shall be
deactivated. Both audible and visual alarms shall cease when the twist lock switch is
returned to its original position.
6-5.5 By-pass Switch Abuse Warning
(1) Twist lock interlock bypass push button
When this push button is depressed to handle a difficult situation in order to carry out
hoisting or lowering function, an alarm sound shall be broadcast by an independent
amplifier through a speaker located outside the operator’s cab and face downward.
The hoisting speed and the trolley speed shall be slow down mode since this is a
difficult condition and safety is required.
(2) Landing bypass push button
When this push button is depressed to allow the twist locks to turn in case of difficult
condition such as deformed containers, an alarm sound shall be broadcast by an
independent amplifier (same as the one for twist lock interlock bypass push button)
through a speaker located outside the operator's cab and face downward. The hoisting
speed and trolley speed shall be at slow down mode since it is a difficult condition
and safety is required.
(3) Labels shall be provided for each switch and indicator in both English and Polish, to
be approved by the Purchaser.
6-5.6 H.T. Slip Ring Space Heater Indicator
Two LED indicator lights indicating functioning or malfunction of the space heater shall be
installed near the cable reel machinery where clearly visible from ground level. ‘White’ lamp
is turned ‘on’ when space heater is in working condition and ‘red’ lamp is turned ‘on’ when
space heater is defective.
6-5.7 Electrical Control House A/C Warning
Visual and audible warning shall be provided if the temperature of the control panel room
rises above 40 degrees C. The air conditioning system failure shall be indicated by a warning
lamp in a location outside of the room in the machinery house, and in addition a warning
buzzer within the operator's cab.
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6-5.8. Public Address/ Warning
One loudspeaker pointing down shall be mounted on the trolley or near the operator’s cab to
broadcast the following warning sound:
(1) Twist lock interlock bypass push button.

(2) Landing interlock bypass push button.
(3) Premature ‘ Locking’ switching
(4) Premature ‘unlocking’ switching
6-6. Emergency Stop Push Buttons
6-6.1 Location
A total 17 nos. of emergency stop push buttons (excluding the emergency stop buttons for
manlift) shall be installed on the Crane in the following locations:-
2 in Operator's Cab
5 in Machinery House (1-Near Main Hoist motor)
(1-Near Trolley motor)
(1-Near Boom Hoist motor)
(1-Near Front door)
(1-Near Rear door)
1 in Boom Control Station
1 in Gantry Control Station
6 one near each corner of the Crane (near gantry buffer) and near the centre of landside and
seaside sill beams, at ground level facing inside of the Crane to be readily reached by
ground operation personnel
1 - in the Control Panel Room
1 - in the Headblock Man cage
1 in backreach girder end
1 in boom front end
All emergency stop buttons shall be connected to individual I/Os and the status shall be
displayed on the CCMS and fault display.
6-6.2 Type
Mushroom head emergency stop pushbutton (self latch) switches shall be provided. All
emergency stop buttons shall be recessed to prevent it from being actuated accidentally.
6-6.3 Emergency Stop Signs
Refer to Appendix IV.
6-7. Service Outlets/ General Purpose Outlets (GPO’s)
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6-7.1 Location
(1) Service outlets shall meet GCT standard, with ground, 230V, 1-phase, 16 Amp.
capacity (11 units), and 400V, 3-phase, 30 Amp capacity (3 units) shall be provided
at following locations:
i) Operator's cab and checkers cabin.

ii) Work bench in machinery house.
iii) Machinery house on the wall.
iv) The boom.
v) The girder (near back reach end).
vi) Ground level, one each under seaside and landside sill-beam, facing inside of
the Crane.
vii) At the top of the A-Frame.
viii) Adjacent to the cable reeling drum.
ix) Control desk in E-Room.
6-7.2 Type Model - General Purpose Outlets (GPO’s)
230V 16 Amp outlets shall conform to BS1363. Matching plug of industrial type for each
outlet (one plug per outlet) shall be supplied by the Contractor, if other types are installed.
6-8. Welding Outlets
6-8.1Locations
Welding outlets shall be provided at the following locations: -
(1) One on work bench in machinery house.

(2) One on the Backreach end of girder.
(3) Two at ground level, one each under seaside and landside sill-beam, facing inside of
the Crane.
(4) One on the mid outreach point on the boom.
(5) At the top of the mast.
Matching plugs of industrial type for all outlets (one plug per outlet) shall be supplied by the
Contractor.
6-8.2 Make-Model
Three pole, grounded type, 15 kW welding outlet for 400 V, 3-phase, 50 Hz 63 Amp service
shall be provided with twin welding cable. All welding outlets installed outdoor shall be
weatherproofed to IP55.
6-8.3 Welding Machine
One unit of welding machine shall be provided in the machinery house.
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6-9. Fire Extinguishers
6-9.1 Locations
Each crane as a minimum shall be provided with fire extinguishers in the following locations:
(1) Machinery House - two (2) of 5kg capacity.

(2) Electrical Room - one (1) of 5kg capacity.
(3) Operators Cabin - one (1) of 3 kg. Capacity.
(4) Quay level near at the access ladder – one (1) of 5kg capacity.
6-9.2 Type-Model
All the portable fire extinguishers shall be CO2 type of Local Government approved model,
and shall be locally refillable by an approved contractor.
6-10. Maintenance Tools and Equipment
6-10.1 Mechanical Maintenance Tools

6-10.2 Electrical / Electronic Maintenance Tools
A notebook computer shall be provided for each crane supplied under this contract. The
computer shall have the same design specification and capacity as the Personal Computer
specified in Clause 5-7.6 (2) i) with individual license software, detail shall be finalized
during design period. Connection cable shall also be provided for connecting to the CMS
computer.
6-10.3 Hydraulic Maintenance Tools
NOT USED.
6-10.4 Special Tools and Equipment/ Jigs
(1) One unit of portable control panel for operating and testing spreaders in the
workshop and at site. The panel shall incorporate push button switches, selector
switches, indicator lamps, PLC, input / output devices, spreader multi-pin connector,
cables and all parts and software necessary for operating and confirming all the
functions and safety features of the spreader. Power supply cable and plug shall be
provided.
7. Project Q.A. and Administrative Requirement
7-1. Document Submission (Project)
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7-1.1 Project Organisation Chart (Shop & Site)
(1) The Contractor shall submit to the Purchaser a project organisation chart within one
(1) month after the date of the Agreement.
(2) The schedule shall show the organisation of the Contractor’s resources, which he
intends to employ in the total project from shop manufacturing through to the site
commissioning phases. This will clearly identify the departments involved, the
people responsible for each and the number of personnel directly involved in
administering the project.
7-1.2 Project Schedule (Shop & Site)
(1) The Contractor shall submit to the Purchaser a project schedule within one (1) month
after the date of the Agreement.
(2) The project schedule shall be presented in the form of a timed schedule covering all
activities appertaining to the manufacture of the Crane(s). The contents shall include
but not be limited to the following: -
i) Contract start date.

ii) Engineering Design Period.
iii) Submission of Drawing/Design Calculations including the period allowed for
the design audit.
iv) Procurement of Materials and Components.
v) Manufacturing Periods for the main Structural Sections.
vi) Erection in the Contractors Facility.
vii) Shop Test and Commissioning.
viii) Transportation Period.
ix) Site Commissioning.
x) Completion Date(s)
(3) The project schedule will be provided in a format approved by the Purchaser and
shall be presented in a way that clearly shows each activity and interrelationships
connected in a logical programme sequence. Each activity shall show the duration,
early start and early finish and shall identify the critical path of the project.
7-1.3 Project Progress Report
(1) The project schedule shall subsequently be updated and submitted to the Purchaser at
intervals of no more than one month throughout the course of the project.
(2) The monthly update will show actual progress against the original baseline so that
effect of any slip or improvement in progress can be easily identified.
7-1.4 Quality Assurance Programme/ Manuals
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(1) Contractor shall submit to the Purchaser a Quality Assurance Programme for review
within one (1) month after the date of the Agreement. (This QAP shall not differ to
any significant degree from the typical QAP submitted as part of the tender
submissions.)
(2) The programme shall consist of General Quality Assurance Program, which states
Contractor's general practice and organisation to assure quality during design,
procurement, fabrication and erection periods, and a Specific Quality Assurance
Programme.
(3) The Specific Quality Assurance Programme is particularly for the Cranes and
Related Equipment in this Contract, which shall include drawings / data submittal
schedule for review of drawings by the Purchaser and key inspection and test items
during fabrication and delivery up to hand over of the Crane to the Purchaser with
proposed timing and locations of conducting such inspection and test.
This Programme must cover all the inspection and review items as set out in
Appendix II "Inspection Control Sheet" and Appendix V "Minimum Requirement for
Drawings / Calculations / Data Submission".
An organisation chart with names of the quality assurance team personnel proposed
for this Contract for each major stage of fabrication, delivery, commissioning and
Defects Liability Period shall be included in this Programme.
The Purchaser reserves the right to review the nominated personnel and require
substitutions if considered necessary and in the best interests of the Project.
7-1.5 Daily Plan and Report (Site Work)
For the duration of the period of site work at the Purchaser’s premises, the Contractor shall
submit, at daily intervals in a form approved by the Purchaser, his progress of activities and
tests carried out. This daily plan shall also indicate weather conditions, number of
Contractors personnel and sub-contractors engaged at site together with the activities planned
for the next day.
To facilitate inspection of on-going works, the contractor shall supply, by 0900 Hours on
each Monday morning, a plan of the facilities where work on cranes, being supplied under
this contract, is being carried out, marked-up with the locations of major components and
materials, as at 2400 hours on the previous Sunday.
This plan shall be updated during the week if components are relocated in the period.
The plan does not need to be a “drawing-office” quality drawing. It can simply be a base map
of each facility neatly marked-up by hand, sufficient to allow the purchaser’s representative
to locate the relevant components, without the need for continual recourse to the Contractor’s
personnel.
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7-1.6 Third Party structural design review
Employer shall employ a Third Party Auditor (TPA) to carry out the crane structure review
prior to crane fabrication process. Contractor shall submit the relevant information to the
Third party Auditor and attend the associated meetings to ensure the entire design review
process can be completed within 6 weeks from the date of TPA has received all the
required structural drawings. Scope of structural design review should be included but not
limited to the following items:
a) Stability and Wheel Load Study
b) Structural Analysis and Design Review
c) Structural Drawing Review
d) Gantry Equalizer Structure Review
e) Sea fastening Review for Sea Voyage
f) Design review meeting
g) Trolley structure review (option)
7-2. Document Submission (Technical)
7-2.1 Submission Schedule
The Contractor shall submit technical information at the times outlined below for the
purchasers review.
7-2.2 Conceptual Design
The Contractor shall, submit to the Purchaser a conceptual design, within one month from
the date of the Agreement which outlines his proposal for the Crane. The design shall show
clearly by drawings and description the following details: -
- General arrangement of the Crane

- Trolley and operators cab
- Girder and boom configuration
- A-frame, forestay and backstay arrangement
- Rope reeving arrangement
- Machinery house
- Lower Crane structure
- Gantry equalisers, bogies and wheel arrangement.
7-2.3 Drawings and Calculations for the Purchaser's Review
Following review and acceptance of the conceptual design and prior to the fabrication or
ordering of components, the Contractor shall submit detailed drawings and calculations for
review to the Purchaser. This information shall include but not be limited to the following: -
(clause 3-2.2 also refers)
(1) Three (2) sets of structural, mechanical and electrical calculations on all aspects of
the crane design, for example
- Stability and wheel load calculations
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- Crane structure stress calculations

- Fatigue analysis for all stress carrying structural members.
- Load combinations for various design criteria.
- Design calculations for the hoist, trolley, gantry, and boom hoist main motion
component parts.
- Crane electrical load calculations.
- Transformer sizing calculations.
- Lighting calculations.
- Trim list and skew and anti-sway system
(2) Three (2) sets of general arrangement and design drawings showing all elements, sub
elements, component parts, layouts, structure details, connections of the Crane.
The drawings shall include but not be limited to those items listed in the List
contained in Appendix V.
(3) General arrangement drawings, calculations and drawings other than listed in above
list, which clarifies further details, shall be submitted from time to time at the request
of the Purchaser for review.
(4) 2-copies each shall be submitted for the review.
(5) Contractor shall submit any other documents as requested from time to time by the
Purchaser.
(6) The Purchaser's comments on the drawings or submittals shall not waive Contractor's
duties or obligations to achieve satisfactory performance of the crane as set out in the
Conditions of Contract, specifically Clause 3. The Purchaser undertakes neither duty
to the Contractor to identify nor notify to the Contractor any errors or omissions in
the Contractor's design.
(7) One month before the shipment of the first Crane(s), the Contractor shall submit to
the Purchaser four (2) sets of all drawings reviewed and if necessary revised
according to the Purchaser comments or for other agreed reasons
7-2.4 Lubricant List
(1) The Contractor shall supply a complete list of oil and lubricants to be used on the
Crane three (3) months prior to the test of the Crane in Contractor's shop for the
Purchaser's approval.
(2) All the oil and lubricant used for the crane shall be selected from those available
locally in Poland and used by the Purchaser.
7-2.5 Ordered Spare Parts List
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7-2.6 Crane Delivery Method Statement
(1) No later than three (3) months before the arrival of the first Crane(s), the Contractor
shall submit a method statement for the Purchasers approval for the roll-off or lift-off
of the crane(s) to the Purchasers quaydeck. The method statement shall include: -
(i) The total area required for the roll-off operation.

(ii) Full details of the transportation vessel and the stowage of the crane(s)
(iii) Orientation of the vessel when offloading
(iv) Number and position of bollards and moor lines,
(v) Length and position of sea anchors. (if applicable)
(vi) System of transferring the crane to the quaydeck
(vii) All skid beams and skid beam centres. (If applicable)
(viii) All positions and magnitude of loadings applied to the quaydeck during the
offloading operation.
(2) The proposal shall also show a period of occupancy and the length of the Purchaser's
berth required for roll-off or lift-off operation
7-2.7 Site Work Method Statement
(1) No later than three (3) months before the arrival of the first Crane(s), The Contractor
shall submit to the Purchaser a site work method statement for the Purchasers
approval showing all activities from arrival of the crane(s) through to acceptance.
The method statement shall include: -
i) The total area required to commission the crane(s) and to store the loose
items and spare parts. (This will be strictly subject to the Purchasers approval)
ii) Roll-off or Lift-off scheme and date of performance.
iii) Key activities of the commissioning and duration.
iv) Number of days required from the date the crane is ready for starting up and
load testing.
v) Date the Crane will be Test Commissioned and handed over to the Purchaser.
vi) Date the Crane will be finally handed over to the Purchaser.
vii) Other key dates of significance.
7-2.8 Commissioning Test Procedure
(1) No later than six (6) months after the award of the contract, the Contractor shall
submit to the Purchaser for his approval a Commissioning Test Procedure.
(2) The Commissioning Test Procedure shall be in a form of a document and shall
contain detailed field and function check procedure to fully demonstrate the specified
requirements and the suitability of the crane for container handling operations. The
procedure shall describe the tests to be performed, the indications to be measured and
the method by which they are measured. It shall contain the design or acceptable
values of each measurement along with blanks in which the tester can enter the
measured values.
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(3) Provision shall be made within the procedure for the tester and the Purchaser’s
Representative to initial and date each separate test.
(4) The Commissioning Test Procedure shall be duly completed by the Contractor
following each individual test or each series of tests conducted at the Contractor’s
facility and at site. Where necessary the Purchaser’s Representative shall verify the
results.
(5) The Contractor shall submit the completed Commissioning Test Procedure no later
than one (1) month after the notification of successful completion of the
Commissioning Test.
7-2.9 Up-Dated Drawings
(1) No later than one (1) month after the date of the Agreement, the Contractor shall
submit to the Purchaser full details of the Contractors system of drawing
management, which shall be maintained throughout the project.
(2) The Contractor shall demonstrate that a logical system of drawing administration
exists, and shall clearly establish to the Purchaser, the procedures and current
practices in place which deal with alterations, modifications and re-issue of drawings
from the design stage through to the “as built” drawings.
(3) The tenderer shall submit summaries of the material to be provided subsequently,
should they be awarded the contract, as part of their tender documentation.
These summaries shall be reviewed as part of the tender assessment.
7-2.10 Training Programme
(1) No later than three (3) months before the arrival of the cranes, the Contractor shall
provide a comprehensive training programme to cover the theoretical and practical
training requirements for the Terminal’s Crane operators, electrical and mechanical
tradesmen and electronic technicians. The programme shall be aimed at all aspects of
the crane in the respective disciplines in order to provide the trainees with a sound
basic knowledge of the crane(s) systems
(2) The Contractor shall use the training personnel from the sub-contracted suppliers
where possible and shall not rely upon untrained trainers or site commissioning
personnel.
The contractor shall allow for and ensure that suitably qualified and empowered
representatives of electrical control/ equipment supplier are in attendance during the
Testing and Commissioning activities to attend to and rectify any minor faults
deficiencies or discrepancies discovered during the process.
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(3) The scope of training to be conducted for the disciplines shall be generally as
outlined in 7-6.
(4) The language used for the training shall be English/ Polish.
Structural Maintenance Program
(1) The Contractor shall submit a Structural Maintenance Program for review. The program
shall be based on the principles of fracture mechanics. This program shall include:
(i) Inspection intervals

(ii) Locations to be inspected
(iii) NDT procedures to be used
(iv) Reporting procedures
(v) Repair procedures
(vi) Documentation showing the parameters used to determine the inspection intervals in
accordance with the criteria specified below
(2) The first structural inspection will be made during the defect liability period, but later than
after 200,000 moves, in accordance with the Structural Maintenance Program. The
inspection results will be given to the Contractor. Within 30 days, the Contractor shall
submit a plan to repair any defects found. Upon Purchaser’s approval of the Contractor’s
plan, the Contractor shall repair the defects at his expense.
(3) Later inspections will be made according to the recommended inspection interval, which
shall be included in the Structural Maintenance Program, The inspection interval shall be
determined according to the following table “ Inspection Interval Criteria”. Locations where
the cumulative damage ratio is less than the minimum 24 year values do not need to be
included in the Structural Maintenance Program. The first inspection period will begin after
completion of the first inspection during Defect Liability Period.
(4) The inspection method shall be selected to detect fatigue cracks. Only the critical locations
need to be inspected by NDT. The critical locations on all members are those locations
where fatigue cracks, if any, would be expected to initiate. The inspected region shall extend
a reasonable distance beyond the critical point. MT shall be used at the critical locations of
filet welds and UT shall be used at the critical locations of butt welds. VT shall be used at all
locations of potential fatigue cracks.
(5) The Contractor shall provide permanent access ladders and platforms at all inspection
locations, with inspection intervals of 12 years or less. Access shall meet applicable safety
laws and regulations.
INSPECTION INTERVAL VS. CUMULATIVE DAMAGE RATIO D = L/K1 OR 2
DETAIL 24 YEARS 12 YEARS 6 YEARS

NFCM FCM NFCM FCM NFCM FCM
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B 0.21-0.41 0.19-0.38 0.42-0.69 0.39-0.64 0.70-1.00 0.65-1.00

C 0.18-0.36 0.17-0.33 0.37-0.62 0.34-0.57 0.63-1.00 0.58-1.00
D 0.18-0.35 0.16-0.33 0.36-0.61 0.34-0.56 0.62-1.00 0.57-1.00
E 0.15-0.29 0.13-0.26 0.30-0.50 0.27-0.45 0.51-1.00 0.46-1.00
G 0.17-0.34 0.16-0.31 0.35-0.58 0.32-0.53 0.59-1.00 0.54-1.00
F2 0.16-0.32 0.15-0.29 0.33-0.56 0.30-0.51 0.57-1.00 0.52-1.00
G 0.21-0.41 Not allowed 0.42-0.70 Not allowed 0.71-1.00 Not allowed
W 0.20-0.40 0.19-0.37 0.41-0.69 0.38-0.64 0.70-1.00 0.65-1.00
TUBULAR 0.20-0.35 0.15-0.30 0.36-0.64 0.31-0.50 0.65-1.00 0.51-1.00
Inspection Interval Criteria
7-2.11 Operation Manuals
(1) The Contractor shall provide 5-sets each of operating instruction books to the
Purchaser two (2) months before the date of the first crane departure from the
Contractor's assembly yard, the manuals shall be in both English and Polish language.
(2) The operating instruction manual shall clearly state the start up procedure of every
device on the Crane including all bought-in equipment, and all the points to be
observed or checked during the start up.
(3) Corrections shall be made for any changes made in the instructions during the
commissioning period, and the revised instruction books shall be submitted one (1)
month after the notification of successful completion of the Commissioning Test of
the first Crane(s)
(4) Two sets of above instructions shall be submitted in a CD ROM format.
7-2.12 Maintenance Manuals
(1) The Contractor shall provide 2-sets each of maintenance manuals to the Purchaser
two (2) months before the date of the first crane departure from the Contractor's
assembly yard, the manuals shall be in both English and Polish language.
(2) The maintenance manual shall include a complete list of wearing parts showing the
allowable limit of wear for each parts.
(3) The manual shall include maintenance intervals and procedures for all the bought-in
equipment, and also calibration instructions and standards for meters, gauges and any
components which require periodical calibration to allow calibration by the
Purchaser's maintenance staff.
(4) The relevant parts of manual shall be revised and resubmitted as soon as practicable
by the Contractor for any changes in system or component design.
(5) Two sets of manuals in CD ROM shall be submitted.
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7-2.13 As-Built Drawings
The Contractor shall submit to the Purchaser 2-full size copies and two sets in CD ROM
(English version, Acrobat [.pdf]) the following as-built drawings within 30 days after the
date of Commissioning Certificate for the first Crane(s).
(1) All drawings that were previously submitted for the Purchaser's review and revised as
built as at the shipment date.
(2) Detailed drawings for wearing parts showing machining tolerances, wherever
applicable, and wear limits
(3) Detailed electrical control circuit drawings, control logic programs, and wiring
diagrams.
(4) Full details of all bought-in equipment, drawings instructions, etc.
(5) List of structural connection bolts and machinery fitting bolts with tightening torque
value for each location/size.
The Contractor shall revise and resubmit drawings for replacement in case any modification
or revision is made on the Works (as defined in the Agreement) after the initial submission.
7-2.14 Certification
The following certificates shall be provided by the Contractor to confirm the suitability of
the relevant components for incorporation into the crane construction.
- Steel Plate Materials

- Mechanical and Physical Properties
- Notch Toughness Properties
- Wire Rope Certificates

- For all ropes
- Rope Anchors or Sockets
- Load Cells
- Certificates of conformity for major components of sub-contract supply detailing

testing carried out by suppliers such as, but no limited to,
- Electric motors
- Brakes
- Reducers
- Couplings
- Transformers
- Personnel Lift (if applicable)
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- Buffers
- Rails
- Maintenance Crane
- Twistlocks
- Pressure vessel
- Spreader
The certificates shall show

- Testing carried out by the manufacturer
- Results of such testing
- Place and date of manufacture
- Serial Numbers (if relevant)
These certificates shall be handed to the Purchaser Representative prior the

commencement of the Testing and Commissioning activities.
7-3. Shop Inspection & Tests
7-3.1 Shop Inspection and Verification
(1) Inspection and testing of the Crane shall be performed to verify or demonstrate the
Crane's conformance to this Specification and the Purchaser's Requirement as set out
in Clause 3 of the Conditions of Contract, following the approved Specific Quality
Assurance Programme as stated in 7-1.4.(3).
(2) Without limitation to the Purchaser's rights under the Agreement, the Contractor and
the Purchaser shall agree to the content, nature and extent of the review, inspection
and tests to be carried out to any of the Goods at each of the following stages:
i) Design.
ii) Fabrication and assembly; test & commissioning
iii) Pre-shipment;
iv) Upon Delivery;
v) Tests pursuant to Clause 13 of the Conditions of Contract, which, if
successful will lead to the issue of a Commissioning Certificate.
vi) Such further tests as otherwise may be required that in the opinion of the
Purchaser is pursuant to Clause 9 of the Conditions of Contract.
(3) The Contractor shall notify the Purchaser of the date and place of each key inspection
or test, at least three (3) weeks prior to the date when the key inspection or test is to
be made.
(4) Inspection and test items shall generally include (but not limited to) the following
fundamental items.
i) Materials and components sources and identification of standards applied.

ii) Workmanship overall.
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iii) Inspection of Operational and Maintenance Safety, Test of all safety

equipment and safety devices.
iv) Inspection of Operational Efficiency, Functional Test of all components
equipped for operation.
v) Inspection of Maintenance Efficiency, Functional Test and inspection of all
equipment for maintainability.
vi) Rated Load Tests, 1/2 Loads Tests, 1/4 Load Tests and No Load Tests
including Anti-sway Function Test and Measurement of Speeds and
accelerations.
vii) Overload Tests including Stability Test and Measurement of Structural
Deflection.
viii) Accessories and Spare Parts Inventory.
ix) Operating Instruction and Maintenance Manual Review.
x) Weight verification as necessary.
xi) Statutory inspection and tests.
(5) The Purchaser reserves the right for itself or any party authorised by the Purchaser to
inspect the Crane at any time during fabrication and delivery.
(6) Any inspection or test results verified by the Purchaser shall not waive Contractor's
duties or obligations to achieve satisfactory performance of the Crane in actual
operation as set out in Clause 3 of the Conditions of Contract.
(7) The Contractor shall submit to the Purchaser a list of designed weights of the moving
loads, namely, the trolley, head block and spreader, and any other moving loads,
when the design of these components are completed.
(8) At the same time, Contractor shall submit a list of calculated maximum structural
stresses at critical points of the Crane structure.
(9) The Contractor shall verify the calculated stress level by actually weighing these
moving weights after the fabrication and assembly are completed.
(10) The weight of trolley assembly, head block assembly and spreader assembly shall be
weighed by a third party, who will issue an authorised certificate. The Certificate
shall be submitted to the Purchaser.
(11) The Contractor shall be responsible for maintaining the calculated stress level within
allowable limits. If there are differences between the designed weights and the actual
measured weights, the Contractor shall re-submit calculations of all stress levels
based on the true weights to show that the levels are maintained within requirements.
Any stress levels over the allowable limit will require a redesign to be carried out by
the Contractor.
(12) The recalculation and if necessary the redesign plan shall be submitted to the
Purchaser for review no later than commencement of the pre-shipment Crane
assembly load test.
134
7-3.2 Pre-Shipment Inspection and Test
(1) The Crane shall preferably be fully erected in the Contractor’s facility and tested
prior to shipment.
(2) The Contractor shall prepare a shop assembly and Crane erection programme
including all tests and dimensions to verify the proper installation and assembly of
the cranes components. The drawings shall include assembly procedures, drawings,
dimensional acceptance criteria, structural member dimensional checks, structural
frame alignment dimensions, structural pin and bore fits, structural bolt torques and
machinery alignments.
(3) The Contractor shall inspect the assembly of components and Crane erection
throughout the process to verify and to be satisfied that the requirements of the
Specification are being fully complied with in all respects.
(4) The Crane shall be fully lubricated in accordance with the manufacturer’s
recommendation prior to any shop testing. A lubrication checklist shall be included
in the test documentation.
(5) The assembled crane shall be inspected and tested at the Contractor’s assembly
facility. All installations and functions shall be verified for compliance to the
Specification. The Crane testing shall as a minimum include the following: -
(i) Verify trolley speed, acceleration according to Specification (See 2-7.1 (14))
(ii) Verify hoist speeds, accelerations according to Specification (See 2.7.1 (14))
(iii) The sway control and anti-sway system shall be set up and tuned under a
range of load conditions. Verify the sway control and the effectiveness of the
electronic anti-sway.
(iv) Boom travel sufficient to verify the hinge geometry. Boom hoist under crane
power from operating to the stowage position and from stowage position
back to operating position using automatic controls for slowdowns and stops.
The boom shall hang on the disc brake at highest load position as a
verification of disc brake operation.
(v) Snag system release under reduced load. Snag load trip of hoist utilizing a
lower than normal snag setting.
(vi) Trim, list and skew motions.
(vii) Interlocks and limit switch settings, and software.
(viii) Brake dynamic torque values shall be verified for each drive by driving
through each brake and calculating the braking torque from the current draw.
Thermal capacity of the brakes shall be verified in the same manner with
135
torque, time and brake revolutions recorded. All brakes shall have their
linings properly burnished or seated to the manufacturer's recommendations
prior to conducting these tests.
(ix) Check structural alignment and integrity.
(x) Inspect and demonstrate that all electrical wiring and wiring components are
installed and properly marked.
7-4. Shipment, Delivery and Site Work
7-4.1 Clearance for Shipment
The purchaser’s preference is that the Crane(s) shall be totally assembled in the Contractor's
yard and tested for functions of all the devices before shipment. Full-load heat run tests,
operational check of interlocks and safety devices and preliminary deflection tests and
coupling alignment checks shall be performed, through the permanent control gear and
components installed on the crane, in the Contractor's yard.
The Purchaser prefers that the cranes supplied under this contract shall be fully tested and
commissioned at the Contractors site, prior to dispatch, where all the necessary resources
are readily available. Compliance with a “Shipping Delivery Schedule” will not be
sufficient cause to depart from this requirement.
THE PURCHASER VIEWS THIS REQUIREMENT MOST SERIOUSLY AND

CONSEQUENTLY THE PURCHASER RESERVES THE RIGHT TO DENY
BERTHING ACCESS AT THE TERMINAL TO ANY VESSEL DELIVERING AN
ASSEMBLED CRANE(S) THAT HAS/ HAVE NOT BE FULLY TESTED AND
COMMISSIONED AT THE CONSTRUCTION SITE.
NOTWITHSTANDING, A TENDER BASED ON ERECTION AT SITE, EMPLOYING

A “PRE-ASSEMBLED” TECHNIQUE WILL BE GIVEN FULL CONSIDERATION
PROVIDED THE TENDERER PROVIDES FULL DETAILS OF HIS “ON-SITE”
REQUIREMENTS, DELIVERY AND ERECTION PLANS SO THAT THE
INTERRUPTION TO TERMINAL OPERATIONS CAN BE FULLY ASSESSED BY
THE PURCHASER.
7-4.2 Notification of ETA Site.
(1) The Crane shall be in fully assembled condition when delivered to the quayside of
the Purchaser's terminal.
(2) The Contractor shall notify the Purchaser of the estimated time of arrival of the
marine transport vessel ("ETA") which is carrying the Goods (or any part of the
Goods) at least 14 days prior to such ETA. Upon receiving such notice, the
Purchaser shall tentatively allocate a berth at Site for delivery and unloading of the
Goods. The Contractor shall confirm to the Purchaser the date of actual departure of
the vessel from the loading port and thereafter the daily Noon position of the vessel
136
together with an up-dated ETA by daily facsimile transmission to the Purchaser. The
exact berthing time and berthing position for the vessel shall be agreed and fixed at
least one day prior to the ETA between the Purchaser and the Contractor based on the
Contractor's daily position and ETA report.
Full load tests, deflection tests and coupling and wheel alignment tests may be
repeated at the terminal site at the purchaser’s representative’s discretion.
(3) The Crane shall be rolled off or lifted off from a vessel onto the designated position
of the quay, then shifted to a designated test position by the Contractor. Such
operations shall in no way over-stress any part of the piled quay deck and the yard.
Specifically any loads on the quay apron waterside of the waterside crane rail beam
(overhung slab) is prohibited.
7-4.3 Navigation Requirement
(1) The Contractor shall be responsible for following all necessary procedures to ensure
the safe passages of vessels whilst navigating in the Port. The Contractor shall
maintain close contacts with the relevant Maritime Authorities.
(2) The Cranes aviation warning lights shall be kept lit continually from the time the
vessel carrying the crane approaches the Harbour. The temporary power source for
the warning lights shall be prepared by the Contractor.
7-4.4 Berthing and Roll-off Requirements
(1) The time allowed for the vessel to stay at the Purchaser's berth for the delivery and
unloading of the Goods shall be as defined in the Conditions of Contract from the
agreed time of berthing as set out in 7-4.2 above notwithstanding the actual time of
the berthing of the vessel.
(2) The vessel must leave the berth as soon as practicable after completion of the
unloading regardless of the above time limit. The Contractor shall inform to the
Purchaser the estimated time of departure ("ETD") of the vessel at least four (4)
hours before such ETD.
(3) All the necessary calculations, design, engineering, preparation works and clean up
works for the roll-off and shifting the Crane to a designated test position and testing
at the site shall be the responsibility of the Contractor. The preparation works shall
include obtaining necessary technical information of the quay from outside
consulting engineers, and obtaining necessary clearance or permit for the works from
government offices concerned.
(4) The Contractor shall have obtained all necessary approval, clearance, permits etc
required for the site works prior to the vessel departing from the Contractors facility
7-4.5 Customs Clearance
137
The consignee for shipment of all the Goods in this Contract shall be the Contractor. Import
declaration and cost thereof shall be the responsibility of the Contractor.
7-4.6 Work Permits
All engineer/supervisors dispatched for start-up, testing and training shall obtain proper
working visas for Poland which must be valid for entire estimated period of stay.
7-4.7 Site Safety and Security
(1) The Contractor shall comply with the Purchaser's security requirements for making
entry or exit to and from the Terminal, and inside the Terminal.
(2) The Contractor and its subcontractors shall be responsible for protecting their own
plants, tools, temporary site offices and other belongings from weather, fire or theft.
The Crane shall be protected by the Contractor from typhoon, fire, collision and any
other possible risks until the Crane is commissioned to the Purchaser. Erection All
Risk insurance, Third Party Liability insurance, Workmen's Compensation insurance
and other necessary insurances shall be secured and maintained by the Contractor.
(3) The Contractor shall be totally responsible for the safety of their personnel. The
Purchaser’s Site staff will be required to comply with any site safety requirements
issued by the contractor within the working area.
7-4.8 Site Erection Area and Access (NOT USED)
NOT APPLICABLE
7-4.9 Site Office Communication
The Contractor shall at his own cost provide for the installation of a telephone line for
outside call and facsimile or other purposes.
7-4.10 Test Weight
The load test weights shall be provided by the Purchaser for the load testing and adjustment
of the Crane.
7-4.11 Water, Electricity Supply
The Contractor shall at his own cost provide for the installation of suitable metering
equipment, supply fix and dismantle after use all pipework, valves, meters, cables,
switchgear etc and shall pay for the cost of supply of water and electricity that he may require
for the contract.
7-4.12 Contractor’s Representatives.
138
(1) One English / Polish speaking principal site engineer shall be dispatched prior to
arrival of the Crane(s) to plan and coordinate the work and to communicate with and
report to the Purchaser. He/She shall stay in the Purchasers locality for the entire
period from delivery to handover of the Crane to the Purchaser.
(2) A sufficient number of qualified start-up engineers and training engineers shall be
dispatched to the Purchasers Terminal to handover the Cranes in an expeditious
manner. For handover (Acceptance) and training, refer to Handover (Acceptance)
Certificate in the Conditions of Contract.
7-5. Site Inspection and Tests, Certification
7-5.1 Commissioning Tests Application
(1) The Crane shall be verified at Site as operational and safe under any load conditions
prior to the Commissioning Tests. Only minor items pertaining to maintainability
which do not affect the safety of operations or maintenance work may be allowed by
the Purchaser as a pending item for correction at the time of the Commissioning
Certificate. These items shall form part of the Defects List. Refer to 7-5.2.
(2) The Commissioning Tests which will be as defined in the approved Commissioning
Test Procedure. (See Clause 7-2.8) The Contractor shall show the Purchaser by
documentation or by physical demonstration (in either case as determined by the
Purchaser) that all functions of the Crane are safe and conforms to the Purchaser's
Requirements. The Contractor shall correct or modify whatever aspect is found
unsafe. The Crane(s) shall be required to pass all Statutory tests, which will be
carried out and witnessed by the Purchasers Representative.
(3) Application of inspection for the Commissioning Tests must be submitted to the
Purchaser's in writing at least 2 days prior to the intended inspection date.
7-5.2 Defects List
(1) The Purchaser or his representative shall be allowed to gain access to any part of the
Crane(s) during their assembly at the Contractors facility and during the site
commissioning period for the purposes of inspecting part or completed works. If in
their opinion certain parts of the works does not meet with the requirements of the
Specification, or is deemed as bad practice or poor workmanship, then these shall be
noted as a defect and informed to the Contractor in a list.
(2) The compilation and provision of this list by the Purchaser or his representative will
in no way relieve the Contractor from his obligation to provide defect free crane(s).
7-5.3 Rectification Report
(1) The Contractor will be obliged to correct these defects and any other defects before
the Commissioning Tests or within an appropriate timeframe approved by the
Purchaser.
139
(2) The rectification of defects in the defects list shall be carried out in a thorough and
workmanlike manner. The Contractor shall prepare and submit to the Purchaser a
rectification report that confirms defect completion together with a description of the
action taken.
(3) Prior to the commencement of the on-site testing and commissioning and acceptance
test, all the lubrication points shall be greased and fluid levels checked and topped up
as required.
7-5.4 Commissioning Test
The Contractor shall carry out a series of tests as outlined and defined the Commissioning
Test Procedure in order to prove that all requirements and functions of the Crane meets with
the Specification. The Crane(s) will be required to undergo inspection and test and
performance trials in order to achieve a Commissioning Certificate and a Final Acceptance
Certificate.
Within six months at awarding a contract the Purchaser will provide to the Contractor a
draft of the proposed Testing and Commissioning Programme Requirements.
In the interests of an efficient Testing and Commissioning programme, prior tot he

commencement of the final testing and commissioning programme the Contractor shall
have carried out a trial testing and commissioning procedure to prove that, in fact, the
crane(s) is/are ready for the contractual testing and commissioning to proceed.
It is not acceptable for the contractual Testing and Commissioning programme to be used
for “fault finding” which may lead to the Purchaser suspending any witnessing of Testing
and Commissioning activities until the crane is ready for such Testing and Commissioning.
7-5.5 Endurance Test
(1) The Endurance Test forms part of the Commissioning Test. The Crane shall be
required to undergo a test to demonstrate the combined operation of all crane systems
and the reliability of the components. The endurance test shall consist of repetitive
cycling, as follows, whilst handling the crane’s rated load, at a rate equivalent to not
less than 20 moves per hour.
i) Pick up the container in the backreach of the crane.

ii) Hoist 15 metres.
iii) Trolley forward 30 metres.
iv) Lower 14 metres. (1 metre from quay)
v) Wait 30 seconds.
vi) Hoist 14 metres.
vii) Trolley forward 30 metres.
viii) Lower 15 metres.
ix) Wait 30 seconds.
x) Hoist 15 metres.
140
xi) Trolley back 30 metres

xii) Lower 15 metres.
xiii) Unlatch the container.
xiv) Wait 30 seconds.
xv) Repeat.
xvi) After each 30 minutes operation the crane(s) shall be gantried for a minimum
of 30 metres to a new position and the cycle repeated. The crane shall then be
gantried back to the original test position.
This cycle is a preliminary proposal and the final test cycle shall be determined by the
crane configuration and in agreement with the Purchaser.
(2) The cycling test shall be continued for a period of 24 hours and in the event of a
malfunction shall be continued until 24 hours of trouble free operation has been
logged.
(3) Throughout the period of testing the current, voltage, speed, main drive mechanism
temperature, noise and vibration shall be recorded at regular intervals relevant to the
specific function but not less than 30 minutes. Any malfunctions or problems and any
remedial action taken during the test shall be recorded.
(4) For the avoidance of doubt, a “reset” fault will not be considered as sufficient
grounds for a discontinuance of the Endurance Test.
However, a series of resets on the same function, which is evidence or indication of

a more serious condition, may be considered as grounds for suspending the tests, at
the discretion of the Purchasers Representative.
Any condition which requires the intervention of a Technician, the use of hand
tools for adjustments or resetting of variables by way of modification or
amendments, to the programme, by the Programming units, shall be grounds for
suspending a test and recommencing a further Endurance Test.
7-5.6 Acceptance Certification
(1) The Commissioning Certificate will be issued on successful completion of the

Commissioning Test (including the Endurance Test) and the Training, as defined in
Clause 7-6.
(2) The Final Acceptance Certificate will be issued on successful completion of the
Initial Trial Period as defined in Clause 2-4
7-5.7 Access for Remedial Work
Following the issue of the Commissioning Certificate, the Contractor shall be allowed access
to the Crane(s) for remedial work only with the approval of the Purchaser.
141
7-6. Training
7-6.1 Training Off-Site
7-6.2 Training On-Site (Operators)
The Contractor shall carry out the operator introduction or orientation training of the
Purchaser's staff during the on-site commissioning period and for a period of seven (7) days
following the Commissioning Test of the Crane. The training shall be conducted by suitable
Contractor trainers. The training shall cater for approximately eight (8) groups of operators
and the content shall include but not be limited to the following: -
(1) Instruction and hands-on training of the cranes start-up procedure.
(2) Instruction on lighting control.
(3) Instruction and hands-on training of normal container handling operation in the cab.
(4) Instruction and hands-on training of normal shutdown procedure.
(5) Instruction on the use of equipment for emergency.
Emergency stop buttons

Escape route
Fire fighting equipment
Communication
7-6.3 Training On-Site (Maintenance)
The Contractor shall carry out the maintenance training of the Purchaser's staff during the
commissioning period and for a period of seven (7) days following the Commissioning Test
of the Crane. The training shall be conducted by suitably qualified Contractor and Crane
component supplier trainers. The training shall cater for approximately five (5) groups of
electrical maintenance staff, and five (5) groups of mechanical maintenance staff and the
content of the training shall include but not be limited to the following: -
(1) Instruction and hands-on training of starting and shutdown procedure.
(2) Instruction and explanation of all the devices on the Crane (separately for electrical
and mechanical staff).
(3) Instruction of Start-stop procedure and checking points of all the devices or systems
on the Crane.
(4) Lectures on electrical/electronic control systems of the Crane and adjustment

method/standards both in a classroom and on the Crane.
142
(5) Lectures on mechanical/hydraulic systems of the Crane and adjustment

method/standard both in a classroom and on the Crane.
(6) Lectures on Condition Monitoring System on the Crane and in a classroom.
(7) Inspection and Maintenance of Operationally Critical Components.
(8) Instruction on trouble shooting and repair.
(9) Instruction on emergency equipment.
Emergency stop buttons

Escape route
Fire fighting equipment
Communication
(10) Instruction on routine maintenance of devices and preventive maintenance plan,

including explanation of special tools, gauges or jigs.
Special training on the Operationally Critical Components Maintenance.
7-6.4 The operationally critical components (see 2-10) shall be presented and the Contractor shall
therefore prepare and present the training this subject separately.
7-7. Spare Parts
7-7.1 Ordered Spare Parts
(1) The Ordered Spare Parts List is attached hereto in the Form of Tender. For definition
and the requirements, refer to the Conditions of Contract.
7-7.2 Spare Parts for Commissioning Work
(1) The spare parts for the commissioning work shall be provided by the Contractor in
addition to the Ordered Spare Parts.
- END --
143

Container Crane 2DT2014 Część-3 STS Technical Specification

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Container Crane 2DT2014 Część-3 STS Technical Specification

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GDYNIA CONTAINER TERMINAL S.A.

QUAYSIDE CONTAINER CRANES

TENDER REFERENCE: 2/DT/2014/2 (GCT)

3-13.1 Temporary Structures............................................................................................................................ 39

5-1.12 Lubrication ............................................................................................................................................ 70

5-4.4 Discrete I/O Modules ............................................................................................................................ 90

6-3.6 Galvanising ......................................................................................................................................... 117

7-2.14 Certification ........................................................................................................................................ 132

I. Structural Limit of the Crane – Light Tower

II. Inspection Control Sheets

III. Miscellaneous Detail Drawings

IV. Reference Drawings and Date

V. List of Drawings/ Calculations to be reviewed by the Purchaser (Minimum Requirements)

Section C. TECHNICAL SPECIFICATION

C (I) Functional Requirement for the Crane

1-1. Project Description

THIS TECHNICAL SPECIFICATION INCLUDES BOTH OF TYPES OF THE EQUIPMENT:

IN SOME CASES THE TECHNICAL SPECIFICATION APPLIES ONLY TO A NEW CRANE.

IS PERMISSIBLE TO USE EQUIVALENT TECHNOLOGICAL SOLUTIONS TO THOSE

1-2. Terminal Site

The crane shall be delivered and installed at Gdynia Container Terminal at

1-3. Overriding Requirement of the Purchaser

ii) For items of electrical and mechanical equipment, controls, systems,

iii) The foregoing shall apply notwithstanding any inconsistent requirement or

1-4. Project Management

2. Overall Design Criteria

2-1. Type of Crane

2-2. Type of Cargo

The type of Cargo to be handled by the Crane shall be

(3) Not used.

2-3. Operating Environment and Design Aim

The MMBF is defined as:

MMBF = Twist Lock Count (TLC) for one week

2-5. Statutory Requirements and Applicable Standards

- Wiring Regulations to Polish Standards for electrical installations (PN.60204-

- Local Ordinances and Regulations. (Including safety inspection of Cranes and

AWS American Welding Society – Dynamically Loaded Structures

ASTM American Society for Testing and Materials

BSI British Standards Institute

DIN Deutsche Industrie Normen

FEM Federation Europeene de la Manutention

GB Chinese Standard Institute

IEC International Electrotechnical Commission

IEEE Institute of Electrical and Electronic Engineers

ISO International Standards Organisation

JIS Japanese Industrial Standards

2-6. Minimum Class of Crane

2-7. General Design Criteria

2-7.1 Crane Particulars

(4) Spreader 20'/30’40'/45' twin-lift spreader. For twin lift spreader

(5) Span (Gantry) 30,480 mm.

(10) Usable inside Not less than 16.9m

(11) Clearance height Not less than 15,000 mm

(13) Boom width, or Not more than 16,000 mm

(14) Speed: Main Hoist:

(19) Gantry buffer level. 1,500mm above top of rail.

(20) Trailing cable type Round type

(21) Cable Slot Details Quay Structure.

2-7.2. Dimensional Restriction of the Crane

(5) Trolley rail gauge shall be not less than 6 meters.

2-7.3. Quay/Yard Interface

(1) Power Supply

The conductor shall be stranded flexible conductor consisting of tinned

(2) Gantry Rail