SIWZ RMGs Schedule 5 Technical Specification PDF

SCHEDULE 5
Procedure no. EU /03/RMG/ZZ/2011; EU/16/RMG/ZZ/2011 for awarding a contract in the open tender procedure: Supply of RMG Rail Mounted Gantry Cranes 2 units
Technical Specification of a RMG x 2 units /RMG CRANE /
RAIL MOUNTED GANTRY CRANE SPECIFICATION OVERVIEW

PROJECT Supply of the following equipment defined within this Technical Specification: Two Rail Mounted Gantry Cranes with Cantilever Beam on one side for Intermodal Application The gantry cranes have to be designed for travel over curved rails. Two 65 MT Twin Lift hydraulic Spreaders 20/40ft One Piggy Back One 60 MT Cargo Beam CAPACITY Containers in single lift mode 20/40ft Containers in twin lift mode 2x20ft Piggy Back Arms Cargo Beam DIMENSIONS Gantry Rail Span Radius of two curvatures on the gantry rails: - radius of first curvature - radius of second curvature Cantilever (one side) Lift above rails Overall crane width (bumper to bumper) Clearance between legs Gantry Travel SPEEDS Main Hoist Hoisting with rated load Lowering with rated load Hoisting with empty spreader Lowering with empty spreader
51 MT 2x 32,5 MT 51 MT At least 60 MT
28.00 m 900/872 2000/1972 9.10 m (Waterside, Nearside) 12.00 m 24.38 m 17.00 m 685 m
20 20 40 40
m/min m/min m/min m/min
Trolley Trolley with or without rated load Gantry Gantry with or without rated load ACCELERATION TIMES Main Hoist Rated load Empty Spreader Trolley Gantry ELECTRICAL SYSTEMS Main Power Supply Main Power Cable Reel Location Drive Control System Programmable Logic Controllers Crane Monitoring Communication
100/120m/min
150 m/min
1.5 3.6 3.0 7.0
sec sec sec sec
15.0kV, 3-phase, 50 Hz Landside, Farside leg
Local and Remote Fiber Optic embedded in power cable
FEATURES Gantry Articulation. The requirement is for RMG to travel over curved rails. Anti-sway system Trim Functions Skew adjustment Side-shift Gantry Wheel Brakes with high speed release Anti-collision for Crane to Crane Checker Cabin under sill beam at Ground Level Ground Level Control Station
SITE CONDITIONS Ambient Temperature Humidity In Service Wind Stowed Wind DEFECT LIABILITY PERIODS (DLP) Entire Crane & accessories after Taking-over Components repaired during DLP Crane Structure Paint and Galvanizing
Range -25C to +35C Up to 95% Sustained 22m/sec, Gust 25m/sec Sustained 42m/sec
2 Years 1 Year or balance of DLP 10 Years 5 Years
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RMG Technical Specification
Table of Contents
1 GENERAL ............................................................................................................................................... 9 1.1 1.2 1.3 2 PROJECT DESCRIPTION ............................................................................................................................. 9 SITE ......................................................................................................................................................... 9 OVERRIDING REQUIREMENT OF THE PURCHASER ........................................................................................ 9
OVERALL DESIGN CRITERIA ......................................................................................................... 10 2.1 TYPE OF CRANE ...................................................................................................................................... 10 2.2 TYPE OF CARGO ...................................................................................................................................... 10 2.3 OPERATING ENVIRONMENT AND DESIGN AIM ........................................................................................... 10 2.4 MODE OF OPERATION ............................................................................................................................. 10 2.5 STATUTORY REQUIREMENTS AND MINIMUM DESIGN STANDARD ............................................................... 10 2.6 SAFETY OF MACHINERY ........................................................................................................................... 11 2.6.1 Conformity with the EU Machinery Directive ................................................................................ 11 2.7 MINIMUM CLASS OF CRANE ..................................................................................................................... 11 2.8 GENERAL DESIGN CRITERIA .................................................................................................................... 12 2.8.1 Crane Particulars ........................................................................................................................... 12 2.8.2 Dimensional Restrictions ............................................................................................................... 13 2.8.3 Yard Interface ............................................................................................................................... 13 2.8.4 Communication Facility Interface (Radio, RF) ............................................................................... 14 2.8.5 Climatic Conditions ....................................................................................................................... 14 2.8.6 Wind Conditions ............................................................................................................................ 15 2.8.7 Lifting Loads and Stability ............................................................................................................. 15 2.9 NOISE CONTROL ..................................................................................................................................... 16 2.10 OPERATIONALLY CRITICAL COMPONENTS ............................................................................................. 16
CRANE STRUCTURAL SPECIFICATION ....................................................................................... 17 3.1 GENERAL REQUIREMENT.......................................................................................................................... 17 3.2 DESIGN .................................................................................................................................................. 17 3.2.1 Equipment and Materials ............................................................................................................. 17 3.2.2 Fittings .......................................................................................................................................... 18 3.3 MATERIAL ............................................................................................................................................... 18 3.3.1 General ......................................................................................................................................... 18 3.3.2 Steel .............................................................................................................................................. 18 3.3.3 Edge Finish .................................................................................................................................... 18 3.3.4 Surface Finish ................................................................................................................................ 18 3.3.5 Draining and Inspection Manhole ................................................................................................. 18 3.4 CALCULATIONS........................................................................................................................................ 18 3.4.1 Submission to Purchaser ............................................................................................................... 19 3.4.2 Audit.............................................................................................................................................. 19 3.4.3 Calculations................................................................................................................................... 19 3.4.4 Drawings ....................................................................................................................................... 19 3.5 LOADS .................................................................................................................................................... 19 3.5.1 Load Combinations ....................................................................................................................... 19 3.5.2 Engineering Standard ................................................................................................................... 19 3.6 MEMBERS SUBJECT TO BUCKLING............................................................................................................ 20 3.7 FATIGUE DESIGN CRITERIA ..................................................................................................................... 20 3.8 CONNECTION DESIGNS ............................................................................................................................ 20 3.8.1 Pin Joints ....................................................................................................................................... 20 3.9 GANTRY STRUCTURE STIFFNESS .............................................................................................................. 20
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3.10 3.11 3.12 3.13 3.14 3.14.1 3.14.2 4
CAMBER .............................................................................................................................................. 21 TROLLEY RAILS & RAIL FIXING............................................................................................................ 21 WORKMANSHIP ................................................................................................................................... 21 QUALITY CONTROL OF STRUCTURE FABRICATION................................................................................. 22 TEMPORARY STRUCTURES ................................................................................................................... 23 Temporary Structures ................................................................................................................... 23 Sea-Fastening................................................................................................................................ 23
FUNCTIONAL SYSTEMS DEVICES AND EQUIPMENT ............................................................... 24 4.1 MAIN HOIST ........................................................................................................................................... 24 4.1.1 Main Hoist..................................................................................................................................... 24 4.1.2 Sway Control ................................................................................................................................. 25 4.1.3 Trim Control .................................................................................................................................. 25 4.2 TROLLEY ................................................................................................................................................. 25 4.2.1 Trolley Frame ................................................................................................................................ 25 4.2.2 Trolley Drive .................................................................................................................................. 25 4.2.3 Power Feeder ................................................................................................................................ 26 4.3 GANTRY .................................................................................................................................................. 26 4.3.1 Gantry Drive .................................................................................................................................. 26 4.3.2 Stowage Pin .................................................................................................................................. 27 4.3.3 HV Cable Reel ................................................................................................................................ 28 4.3.4 Gantry Anti-collision System ......................................................................................................... 29 4.3.5 Gantry CCTV .................................................................................................................................. 29 4.4 ELECTRICAL CONTROL HOUSE ................................................................................................................. 29 4.4.1 General Construction .................................................................................................................... 29 4.5 OPERATORS CAB .................................................................................................................................... 30 4.5.1 Construction General .................................................................................................................... 30 4.5.2 Cab Access..................................................................................................................................... 31 4.5.3 Window Visibility .......................................................................................................................... 31 4.5.4 Emergency Lighting System .......................................................................................................... 31 4.5.5 Air Conditioning/Heating .............................................................................................................. 31 4.5.6 Fire Protection............................................................................................................................... 32 4.5.7 Cab Dimensions............................................................................................................................. 32 4.5.8 Cab Fittings ................................................................................................................................... 32 4.5.9 Checkers Cab ................................................................................................................................ 33 4.6 PERSONNEL ELEVATOR ............................................................................................................................ 33 4.7 HEAD-BLOCK ........................................................................................................................................... 33 4.7.1 Head-block Fittings ....................................................................................................................... 33 4.7.2 Spreader Cable .............................................................................................................................. 34 4.8 SPREADER............................................................................................................................................... 34 4.8.1 Twin Lift Telescopic Spreader ........................................................................................................ 34
INTER-FUNCTIONAL SYSTEMS & COMPONENTS .................................................................... 37 5.1 MECHANICAL SYSTEM/COMPONENTS ....................................................................................................... 37 5.1.1 Bearing, Seals................................................................................................................................ 37 5.1.2 Gearing ......................................................................................................................................... 37 5.1.3 Gear Reducers ............................................................................................................................... 37 5.1.4 Wire Rope Winch Drums ............................................................................................................... 37 5.1.5 Wire Rope Sheaves........................................................................................................................ 38 5.1.6 Wire Ropes .................................................................................................................................... 39 5.1.7 Shafts, Axles .................................................................................................................................. 39 5.1.8 Couplings....................................................................................................................................... 39
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5.1.9 Steel Wheels.................................................................................................................................. 40 5.1.10 Pins, Pin Brackets .......................................................................................................................... 40 5.1.11 Bolts .............................................................................................................................................. 40 5.1.12 Lubrication .................................................................................................................................... 40 5.1.13 Trolley Buffer................................................................................................................................. 40 5.1.14 Gantry Buffer ................................................................................................................................ 41 5.2 HYDRAULIC SYSTEM / COMPONENTS ........................................................................................................ 41 5.2.1 Standards ...................................................................................................................................... 41 5.2.2 Components Sources ..................................................................................................................... 41 5.2.3 Operating Condition...................................................................................................................... 41 5.2.4 Hydraulic Fluid Reservoir .............................................................................................................. 41 5.2.5 Power Unit .................................................................................................................................... 42 5.2.6 Valve Mounting............................................................................................................................. 42 5.2.7 Relief Valve ................................................................................................................................... 42 5.2.8 Flow Control Valve ........................................................................................................................ 42 5.2.9 Check valves .................................................................................................................................. 42 5.2.10 Servo Valves .................................................................................................................................. 42 5.2.11 Control Valves ............................................................................................................................... 43 5.2.12 Solenoid Valves ............................................................................................................................. 43 5.2.13 Piping ............................................................................................................................................ 43 5.2.14 Hoses ............................................................................................................................................. 43 5.2.15 Assembly Test ............................................................................................................................... 44 5.2.16 ............................................................................................................................................................ 44 5.2.17 Catch Basins .................................................................................................................................. 44 5.2.18 Filters ............................................................................................................................................ 44 5.2.19 Actuator ........................................................................................................................................ 44 5.2.20 Application for Spreader ............................................................................................................... 44 5.2.21 Gauges .......................................................................................................................................... 44 5.2.22 Covers ........................................................................................................................................... 44 5.2.23 Hydraulic Fluid .............................................................................................................................. 44 5.3 ELECTRICAL AND ELECTRONIC SYSTEM / COMPONENTS ............................................................................ 45 5.3.1 General ......................................................................................................................................... 45 5.3.2 Power Supply Specifications.......................................................................................................... 45 5.3.3 Power Factor and Harmonic Voltage Distortion ........................................................................... 45 5.3.4 Protection against Power Surge.................................................................................................... 46 5.3.5 Protection for Power Dip/Power Failure ....................................................................................... 47 5.3.6 Wiring ........................................................................................................................................... 47 5.3.7 Marking and Identification ........................................................................................................... 48 5.3.8 Conduit Cable Tray and Junction Box Panels ................................................................................ 48 5.3.9 Electrical Trunking ........................................................................................................................ 49 5.3.10 Motors .......................................................................................................................................... 49 5.3.11 Brakes ........................................................................................................................................... 50 5.3.12 Transformers ................................................................................................................................. 50 5.3.13 Enclosures ..................................................................................................................................... 50 5.3.14 Meters, Counters........................................................................................................................... 51 5.3.15 Limit Switches ............................................................................................................................... 51 5.3.16 Space Heaters ............................................................................................................................... 52 5.3.17 Name Plates .................................................................................................................................. 52 5.3.18 Encoders........................................................................................................................................ 52 5.3.19 Circuit Breakers ............................................................................................................................. 52 5.4 CRANE MOTION CONTROLS ..................................................................................................................... 52 5.4.1 Control System General ................................................................................................................ 52 5.4.2 Programmable Logical Controllers (PLC) ...................................................................................... 53
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5.4.3 Power Supply ................................................................................................................................ 54 5.4.4 Discrete I/O Modules .................................................................................................................... 54 5.4.5 Motion Control Switches in Operators Cab .................................................................................. 54 5.4.6 Remote Motion Control ................................................................................................................ 55 5.5 OPERATIONAL SAFETY INTERLOCKS ......................................................................................................... 56 5.5.1 Main Motions Interlocks ............................................................................................................... 56 5.5.2 For Trolley Operation .................................................................................................................... 57 5.5.3 For Gantry Travel Operation ......................................................................................................... 57 5.5.4 Spreader Functional Interlock ....................................................................................................... 58 5.5.5 Cab Entrance Door Interlock. ........................................................................................................ 58 5.6 COMMUNICATIONS .................................................................................................................................. 59 5.6.1 Intercom System ........................................................................................................................... 59 5.6.2 Radio Communication System ...................................................................................................... 59 5.6.3 Data Communication System........................................................................................................ 59 5.6.4 Public Address System................................................................................................................... 59 5.6.5 Operation Centre / Maintenance Office Station ........................................................................... 59 5.7 CRANE CONDITION MONITORING SYSTEM (CCMS) ................................................................................. 59 5.7.1 General ......................................................................................................................................... 59 5.7.2 CCMS Description .......................................................................................................................... 60 5.7.3 On-Board Crane Condition Monitoring System (On-Board CCMS) ................................................ 60 5.7.4 On-Board CCMS Software Requirements ...................................................................................... 60 5.7.5 On-Board CCMS Hardware Requirements .................................................................................... 61 5.7.6 Condition Monitoring .................................................................................................................... 62 5.7.7 Fault Diagnosis.............................................................................................................................. 64 5.7.8 Equipment Performance Data and Operation Log........................................................................ 65 5.7.9 Remote Crane Condition Monitoring System (RCCMS) ................................................................. 65 5.7.10 RCCMS Software Requirements .................................................................................................... 66 5.7.11 RCCMS Hardware Requirements................................................................................................... 66 5.7.12 Server(s) ........................................................................................................................................ 67 5.7.13 CCMS Reporting Format ............................................................................................................... 67 6 COMMON ITEMS ............................................................................................................................... 68 6.1 WALKWAYS, STAIRS, LADDERS AND PLATFORMS ...................................................................................... 68 6.1.1 Applicable Code or Engineering Standard..................................................................................... 68 6.1.2 Stairway Requirements ................................................................................................................. 68 6.1.3 Ladder Requirements .................................................................................................................... 68 6.1.4 Platforms Requirements ............................................................................................................... 68 6.1.5 Walkway Handrail Requirements ................................................................................................. 69 6.1.6 Cab Access Platforms .................................................................................................................... 69 6.1.7 Walkway Requirements ................................................................................................................ 69 6.2 ILLUMINATION AND LIGHTING ................................................................................................................. 69 6.2.1 Walkways, Stairs, Ladders, Cab Access ......................................................................................... 69 6.2.2 Work Area Floodlights .................................................................................................................. 69 6.2.3 Floodlights on Trolley .................................................................................................................... 70 6.2.4 Emergency Lighting for Escape Routes ......................................................................................... 70 6.2.5 Lighting Control Switches.............................................................................................................. 70 6.2.6 High Pressure Sodium Lamp and Ballast....................................................................................... 70 6.2.7 Fluorescent Lamps ........................................................................................................................ 70 6.2.8 Access for Lights Maintenance ..................................................................................................... 70 6.3 PAINTING AND PROTECTIVE COATING ...................................................................................................... 70 6.3.1 Paint System General .................................................................................................................... 70 6.3.2 Surface Preparation ...................................................................................................................... 71
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6.3.3 Abrasive Blast Cleaning................................................................................................................. 72 6.3.4 Painting General ........................................................................................................................... 73 6.3.5 Paint Systems ................................................................................................................................ 74 6.3.6 Galvanizing ................................................................................................................................... 76 6.3.7 Reinstatement of Protective Coatings at Site ............................................................................... 76 6.3.8 Inspection and Sample Panels....................................................................................................... 77 6.4 PURCHASERS LOGO, CRANE NUMBERS, SIGNS ......................................................................................... 78 6.4.1 Purchasers Logo ........................................................................................................................... 78 6.4.2 Crane Numbers ............................................................................................................................. 78 6.4.3 Crane Capacity Signs ..................................................................................................................... 78 6.4.4 Manufacturers Name Plates ........................................................................................................ 78 6.4.5 Other Signs .................................................................................................................................... 78 6.5 ALARM, WARNING SIGNALS ..................................................................................................................... 78 6.5.1 Gantry Travel Warning ................................................................................................................. 78 6.5.2 Main Hoist Overload Warning ...................................................................................................... 79 6.5.3 Premature Twistlock Operation Warning ..................................................................................... 79 6.5.4 By-Pass Switch Abuse Warning ..................................................................................................... 80 6.5.5 Electrical Control House A/C Warning .......................................................................................... 80 6.5.6 Public Address/Warning ............................................................................................................... 80 6.6 EMERGENCY STOP PUSH BUTTONS & DRIVE LOCK OUT............................................................................ 80 6.6.1 Locations ....................................................................................................................................... 80 6.6.2 Type .............................................................................................................................................. 81 6.6.3 Emergency Stop Signs ................................................................................................................... 81 6.7 SERVICE OUTLETS................................................................................................................................... 81 6.7.1 Location ........................................................................................................................................ 81 6.7.2 Type Model ................................................................................................................................... 81 6.8 FIRE EXTINGUISHERS .............................................................................................................................. 81 6.8.1 Locations ....................................................................................................................................... 81 6.8.2 Type-Model ................................................................................................................................... 81 6.9 MAINTENANCE TOOLS AND EQUIPMENT ................................................................................................... 81 6.9.1 Mechanical Maintenance Tools .................................................................................................... 81 6.9.2 Electrical/Electronic Maintenance Tools ....................................................................................... 82 6.9.3 Hydraulic Maintenance Tools ....................................................................................................... 82 6.9.4 Special Tools and Equipment ........................................................................................................ 82 6.9.5 Wear Gauges ................................................................................................................................ 82 7 PROJECT QA & ADMINISTRATIVE REQUIREMENTS ............................................................... 83 7.1 DOCUMENT SUBMISSION (PROJECT) ........................................................................................................ 83 7.1.1 Project Organization Chart (Shop & Site)...................................................................................... 83 7.1.2 Project Schedule (Shop & Site) (Program) ..................................................................................... 83 7.1.3 Project Progress Report ................................................................................................................ 83 7.1.4 Quality Assurance Program/ Manuals .......................................................................................... 83 7.1.5 Daily Plan and Report (Site Work)................................................................................................. 84 7.2 DOCUMENT SUBMISSION (TECHNICAL) .................................................................................................... 84 7.2.1 Submission Schedule ..................................................................................................................... 84 7.2.2 Conceptual Design ........................................................................................................................ 84 7.2.3 Drawings and Calculations for the Purchaser's Review ................................................................ 84 7.2.4 Lubricant List ................................................................................................................................. 85 7.2.5 Sea Fastening ................................................................................................................................ 85 7.2.6 Crane Delivery Method Statement................................................................................................ 85 7.2.7 Site Work Method Statement ....................................................................................................... 86 7.2.8 Tests on Completion...................................................................................................................... 86 7.2.9 Up-Dated Drawings ...................................................................................................................... 86
RMG Specification
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7.2.10 Training Program .......................................................................................................................... 87 7.2.11 Structural Maintenance Program ................................................................................................. 87 7.2.12 Operation Manuals ....................................................................................................................... 88 7.2.13 Maintenance Manuals .................................................................................................................. 89 7.2.14 As-Built Drawings .......................................................................................................................... 89 7.3 SHOP INSPECTION AND TESTS ................................................................................................................. 90 7.3.1 Shop Inspection and Verification .................................................................................................. 90 7.3.2 Pre-Shipment Inspection and Test ................................................................................................ 91 7.4 SHIPMENT, DELIVERY AND SITE WORK .................................................................................................... 92 7.4.1 Clearance for Shipment................................................................................................................. 92 7.4.2 Notification of ETA Site ................................................................................................................. 92 7.4.3 Navigation Requirement ............................................................................................................... 92 7.4.4 Berthing and Roll-off Requirements.............................................................................................. 92 7.4.5 Customs Clearance........................................................................................................................ 93 7.4.6 Work Permits ................................................................................................................................ 93 7.4.7 Site Safety and Security................................................................................................................. 93 7.4.8 Site Erection Area and Access ....................................................................................................... 93 7.4.9 Site Office Communication............................................................................................................ 93 7.4.10 Test Weight ................................................................................................................................... 93 7.4.11 Water, Electricity Supply ............................................................................................................... 93 7.4.12 Contractors Representatives ........................................................................................................ 93 7.5 SITE INSPECTION AND TESTS, CERTIFICATION ......................................................................................... 94 7.5.1 Tests on Completion...................................................................................................................... 94 7.5.2 Defects List .................................................................................................................................... 94 7.5.3 Rectification Report ...................................................................................................................... 94 7.5.4 Endurance Test ............................................................................................................................. 94 7.5.5 Taking-over Certificate.................................................................................................................. 95 7.5.6 Access for Remedial Work............................................................................................................. 95 7.6 TRAINING & SUPPORT............................................................................................................................. 95 7.6.1 Training Off-Site ............................................................................................................................ 95 7.6.2 Training On-Site (Operators) ......................................................................................................... 95 7.6.3 Training On-Site (Maintenance).................................................................................................... 96 7.6.4 Training for Critical Components (On Site) ................................................................................... 96 7.6.5 Training & Service Visits following Taking Over (On Site) ............................................................. 97 7.7 SPARE PARTS .......................................................................................................................................... 97 7.7.1 Ordered Spare Parts ...................................................................................................................... 97 7.7.2 Spare parts for Commissioning Work ........................................................................................... 97 8 APPENDICES ...................................................................................................................................... 98 8.1 8.2 8.3 APPENDIX 1 DOCUMENT SUBMITTALS ................................................................................................... 98 APPENDIX 2 INSPECTION / TEST CONTROL SHEETS ............................................................................ 100 APPENDIX 3 CORPORATE COLORS AND DECALS ................................................................................... 107
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TECHNICAL SPECIFICATION Functional Requirement for the Crane 1 1.1 GENERAL Project Description To carry out the design, construction, delivery, installation, testing and completion of Two (2) units of Rail Mounted Gantry Cranes having a rated load of 2x32,5 Metric Tons in twin lift mode. The cranes shall be delivered in a fully assembled and tested condition. 1.2 Site The Cranes shall be delivered and completed at the Purchasers site which is referenced in the Special Conditions. 1.3 Overriding Requirement of the Purchaser The Purchasers overriding requirement is for the Works to be suitable in all respects for safe, efficient and continuous use under actual operational conditions in a modern, large capacity, international container handling facility for a period of not less than twenty (20) years subject to fair wear and tear (excluding categorically any fatigue failure), and routine maintenance. For the purposes of this Contract acceptable routine maintenance shall be within the following general parameters. (1) 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. For the paint system acceptable routine maintenance shall be: Preparing and over coating the existing paint system at year 10 after the issuance of the Taking-over Certificate. Removing defective parts of the paint system back to clean steel and repainting in isolated areas but not exceeding in aggregate more than 1% and 2% of the total surface area at years 5 and 10. The removal of the paint system back to steel and replacement of the paint system in areas aggregating more than the above percentages of the total surface area of the painted part of the Crane shall be Defects remedial works and not maintenance.
(2)
(3)
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. 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.
(4)
RMG Specification
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2 2.1
OVERALL DESIGN CRITERIA Type of Crane The Crane shall be a, electrically driven, rail mounted gantry crane with a self-driven trolley and cab. The Crane drive and control shall be full AC inverter drive, with fully digitalized controls 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 2 ISO 20ft and 40 ft containers including high-cube, half height, flat rack containers. Other types of container with ISO corner fittings at 20ft or 40 ft positions such as 45ft, 48ft and 53ft containers. Containers with over-height cargoes through an existing over-height cargo container-lifting frame owned by the Purchaser. Damaged container with slings and shackles attached to lifting lugs of the spreader. General cargo by Cargo Beam (ramshorn hook) Trailers by Piggy Back Arms
4 5 6
Note: Exclusive accessories for handling high cube, half height and flat rack containers are not included. 2.3 Operating Environment and Design Aim 1 The Crane shall be operated and maintained on 24 hours per day basis in all weather conditions. All electrical, electronic, and mechanical equipment shall be non-hygroscopic, non-corroding and tropicalized for use in conditions stated elsewhere in this Specification. The Cranes shall conform to the noise requirements in this Specification. Special considerations shall be given in all aspects of the design for achieving accurate load spotting ability with quick sway damping, and ensuring full operational capability and safety for round the clock operations, including operation in heavy rain conditions. The Crane shall be exposed to non-technical personnel specifically at the ground level and during access to trolley/operators cab. The Contractor shall provide safe protection in and around all equipment and fittings in these areas of the Crane. Ease of maintenance and safety of the maintenance staff shall be considered throughout the design to minimize downtime of the Crane.
2 3
2.4
Mode of Operation The Crane shall be semi-automatic and manually controlled. All functions on the Crane shall be controlled by the operator.
2.5
Statutory Requirements and Minimum Design Standard 1. The Crane electrical, electronic equipment and its mechanism shall be designed and manufactured to comply in all aspects with the requirements of all latest, laws, ordinances, rules, orders, or other legal or regulatory institutes applicable in the country of operation.
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2.
Where items are not covered by local statutory requirements, the Crane and other Goods shall be designed and manufactured to at least the standards as specified in this Specification. For items which are not specified above, then to at least to the current applicable recommendations of the following organizations: AWS BSI DIN FEM OSHA IEC IEEE ISO JIS UL American Welding Society Bridges and Dynamically Loaded Structures British Standards Institute Deutsche Industrie Normen Federation Europeane de la Manutention Occupational Safety & Health Administration International Electrotechnical Commission Institute of Electrical and Electronic Engineers International Standards Organization Japanese Industrial Standards Underwriters Laboratory
The Contractor shall define all standards used in the design of the Crane.
2.6 2.6.1
Safety of Machinery Conformity with the EU Machinery Directive (1) The crane shall comply with the requirements of the European Machine Guidelines, particularly Machinery Directive 2006/42/EC. The cranes shall be provided with a declaration of conformity and the CE marking and symbol according to the relevant Appendixes of the Machinery Directive. The Supplier/ Contractor are solely and entirely responsible for all aspects of this conformity declaration and CE marking. A single electric power, control or hydraulic component failure or malfunction shall not damage the crane or injure personnel. If possible, component failure or malfunction shall safely stop the crane operation. If this is not possible, a redundant system shall be supplied. The redundant system shall both safely stop the crane and prevent operation until maintenance personnel make corrections. A means shall be provided so the maintenance personnel may routinely check each redundant or backup system. The check procedure shall be included in the maintenance manual. No crane component shall change state as a result of a power failure. Powering or repowering the crane or any system within the crane shall not result in an unanticipated or potentially unsafe motion or condition.
2.7
Minimum Class of Crane Unless otherwise stated, F.E.M. 1.001, 3rd Edition Revised 1998.10.01, and relevant other design standards noted in these Specifications, shall be used in the design of the Crane and its mechanisms.
Structures: Class of Utilization State of Loading Group Classification U8 Q3 A8
RMG Specification
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Mechanisms Mechanisms Hoist Trolley Travel Gantry Travel Class of Operation T8 T8 T8 State of Loading L3 L3 L3 Group Classification M8 M8 M8 Service Life 50,000 Hrs. 50,000 Hrs. 50,000 Hrs.
2.8 2.8.1
General Design Criteria Crane Particulars Major dimensions, clearances and performance requirements: (1) Rated Load Under Spreader 65 Metric Tonnes (MT) One container 51 MT 10% eccentric loading Twinlift of two 20 containers 2 x 32.5 MT evenly loaded Lifting lugs 4 x 10 MT in the main frame and end beams 81.25 MT under spreader. ISO 20, 40 and up to 53 containers with ISO corner fittings at 20 or 40 position. 20/40 twin-lift telescopic hydraulic type. 28,000 mm centers of wheels 9,100 mm (waterside) 12,000 mm (One over 3 high Containers to provide minimum clearance of 625 mm to the lowest point of spreader (gather guides). 12,400 mm to Emergency hoist limit at the lowest point of spreader. For lowering, the head-block (spreader removed condition) shall be able to be lowered onto the ground. (8) (9) Overall Crane Length Speeds - Main Hoist 24,380mm bumper to bumper overall.
(2) (3)
Test load for overload test Lifted Load
(4) (5) (6) (7)
Spreader Gantry Span Cantilever (one end) Lift above gantry rail
20m/min. minimum with 51 MT or 2x32.5 MT load under spreader. 40m/min. minimum with empty spreader. The Load-Speed relationship shall be on a power constant curve. Accelerations shall be: 40m/min. with 0 MT under spreader. Acc./Dec = 3.6s 20m/min. with 51 MT under spreader. Acc./Dec = 1.5s
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- Trolley
120 m/min. minimum. Acceleration time max. 3.0 s. Deceleration time max. 3.0 s. 150 m/min. with Rated load under spreader. Acceleration/Deceleration time max. 7.0 s. 150 m/min with No Load under spreader
- Gantry
The above speeds must be achieved for crane operation under a sustained 22 meter/sec. wind condition. (11) Trim Adjustment 3.0 degrees Speed: 0.5 degree/second minimum Trim adjustment system shall be capable of changing attitude of a 51 MT container (40) with 1.2 meter eccentricity Side Shift the spreader +200mm minimum from either side of center Skew adjustment the spreader 5 degrees with rated load The Crane shall be provided with electric anti-sway dampening. The anti-sway system shall be capable of damping the spreader after the trolley has stopped with full deceleration at any operational speed with any operational load, to within 150mm of lateral displacement after 2.5 cycles of sway. The same criteria will apply to the yawing motion following the trolley stopping from any operational speed with full deceleration, or after the end of the skew motion command. The system shall meet the above criteria measured at the spreader in the 40 position between 3.5 meters above the ground level. (15) 2.8.2 Number of gantry wheels Four (4) Wheels per corner (Min)
(12) (13) (14)
Side Shift Skew adjustment Anti-sway
Dimensional Restrictions (1) The total length of the Crane shall not exceed 24,380mm. Possible Interference between Electrical Control House located on outside of main girder on main power cable reel side of crane and adjoining crane on same runway. Purchaser (2) The crane manufacturer shall submit his preferred design drawing to show operational clearances
2.8.3
Yard Interface (1) Power Supply (i) The power supply to the crane shall be 15.0 kV +10% 3 phase, 50Hz+ 2%. (ii) The high voltage trailing cable connection at the power feeding pit in the yard shall be proprietary HV cable joint. The Contractor shall undertake termination of the cable conductors and fiber waveguide at the feeding pit. The high voltage cable shall be supplied by the Contractor along with the suitable cable reeling device and cable connection joint. A sufficient length of cable to cover 350 meters gantry travel range either side of the central feeding point shall be provided by the Contractor. 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 cable joints made at site and high voltage wiring shall pass the inspection requirements of the local supply company and hi-pot test results shall be provided.
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(iii)
The high voltage trailing cable shall be round type HV flexible power cable with integrated fiber optic data cables.
(2) Gantry Rail and Wheel Loading (i) (ii) Up-lift load shall not be applied to the gantry rails. The Contractor shall submit in its Tender for the Purchasers review, the declared wheel loads as defined in the form of tenderer to clarify vertical and horizontal loads under operational and stowed conditions. The maximum wheel loads shall be calculated with the Trolley in the most severe position with the wind acting in the most severe horizontal direction. Wheel loads shall under no circumstances exceed the Maximum Allowed Crane Loads figures as tabulated in the Form of Tender, DECLARED WHEEL LOADS AND OTHER LOADS OF THE CRANE. Should any or all of such loads exceed such Maximum Allowed Crane Loads figures, this shall constitute a Detect and the Contractor shall not be entitled to despite this on any grounds or in any circumstances. The gantry rails are level. A vertical tolerance of 50 mm measured at the rail head surface from the mean position throughout the gantry rail length shall be permitted. Gantry Rail The gantry rail is A100 type
(iii) (iv)
(v) (vi)
(3) Stowage Pins
The Contractor shall submit for the Purchasers review a design of adequate stowage pins to resist horizontal component of the forces applied to the Crane under its stowed condition. The stowage sockets in the yard shall be installed by Purchaser in accordance with the dimension and load characteristics provided by the Contractor.
2.8.4
Communication Facility Interface (Radio, RF) (1) Permanent mounting shall be provided inside the drivers cabin with necessary installation. (2) A regulated Power Supply within the range 12 to 13.6 Volts DC (Negative Ground) shall be installed and protected through an appropriately sized circuit breaker. A cable shall be routed from the circuit breaker to the radio enclosure. Current drain characteristics for this type of radio equipment shall not exceed 20 Amps. (3) An aperture shall be provided at or near the radio location for installation of a coaxial R58 cable connecting to an externally mounted aerial. The aperture shall be fitted with a waterproof fitting ready for acceptance of coaxial cable. (4) A minimum of 6 similar Circuit Breakers rated for the appropriate DC Voltage and current, connected to screw type terminal connectors plus negative and earth terminations shall be provided.
2.8.5
Climatic Conditions The Crane and other Goods shall be designed and constructed to be fully capable of operating safely and withstanding the following climatic conditions. (1) (2) (3) (4) (5) Ambient temperature -25oC to +35oC Relative humidity Max. 95% Dew point Max. 30oC Wind up to 25m/sec. without special warning during operation. Storm Containing Lighting.
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More stringent and specific requirements shall apply for individual crane subsystems and components, which are separately specified in each relevant clause of this Specification. 2.8.6 Wind Conditions The entire Crane structure with all of its machineries, components, fittings, or accessories shall be designed and constructed to withstand following wind loading conditions. (1) For Operation: Allow for wind loading of sustained wind speed of 22m/sec. for safe load handling operation of the Crane. For the stowed condition of the Crane: A wind loading of wind speed up to 42m/sec shall be allowed for the condition that the Crane is out of service and stationary without any tie downs and wheels chocked. The Stability Safety Factor under this condition shall be at least 1.4 (Stabilizing Moment divided by Overturning Moment)
(2)
2.8.7
Lifting Loads and Stability (1) One side landing i) A normal operating condition shall include the case of one side landing of a 45ft concentric 51 MT weight container whereby the main hoist wire ropes on the landed side are assumed slack and not carrying load. ii) The calculations of the structural and mechanical components shall include calculation for this criterion.
(2)
Eccentric container handling i) All structural, mechanical and electrical systems or system components shall be designed to be capable of handling continuously 51 MT gross weight containers with eccentricity of 1.2m in longitudinal (gantry) direction and 0.25m in transverse (trolley) direction. The eccentricity of the container shall not cause any horizontal drift of the container during hoisting/lowering motion. The Contractor shall submit for the Purchasers review, a design method to completely eliminate the possibility of lifting one end of a container by two twistlocks. The design shall incorporate a system to immediately detect this condition and to render the hoist motion inoperable. The spreader, which stops with one end locked inside a container, shall allow lowering only with attendance of maintenance personnel.
ii)
(3)
Fatigue condition The structural fatigue calculations must meet the requirements of F.E.M. 1.001, 3rd Edition Revised 1998.10.01.
(4)
Stability i. The Crane shall remain stable with a safety factor of at least as per the F.E.M. requirements (Righting moments compared with overturning moments) in the most extreme adverse operating and stowed conditions No damage shall be sustained when a dynamic snag load is applied in any trolley and hoisting position. The Crane shall remain stable and not sustain any damage in the case when an emergency push button is pressed during gantry travel with a rated speed with 2x32.5 MT rated load
ii.
iii.
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suspended at any lifting position in an operational gantry gradient of not more than two percent. (5) All other loading conditions forming the design criteria other than specified in this Specification shall be submitted to the Purchaser for review.
2.9
Noise Control The Cranes noise level shall conform to the following requirements: (1) The noise level inside the operators cab shall be below 75dB during operation, with air conditioner on, and doors and windows closed condition. The noise level measured at a distance of 1 meter from the main motion motors (main hoist, trolley and gantry) shall be below 75 dB with motors running at full speed.
(2)
*CLARIFICATION, Private residences are located within 200m of terminal whereby noise limits of 65dB during day time and 50dB during night time are strictly applied. No relaxation of these values will be accepted. (3) The noise level inside the Electrical Control House shall be below 85 dB during operation with heater/air conditioner on, and doors and windows in the closed condition. The Contractor shall include test results of actual noise levels within the Tests on Completion document.
(4)
2.10
Operationally Critical Components (1) The Contractor shall submit the inspection and replacement schedule for operationally critical components to the Purchaser. Inspection schedules shall contain detailed instructions about the components to be inspected along with the method and rejection criteria for inspection. The objective is to assist the Purchaser to establish a standard for maintenance and inspection of operationally critical components (ie. those components and structural joints where failure could have catastrophic consequences such as load fall or structure collapse).
(2)
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3 3.1
CRANE STRUCTURAL SPECIFICATION General Requirement (1) Deflection or oscillation of the structure shall not affect the Crane capacity and operating efficiency (particularly spreader positioning ability).
(2)
Girders shall be designed to allow the operator to escape from the operators cabin to the walkway of the girder at any point of trolley travel range, in the event of an emergency.
3.2
Design (1) (2) The structure shall consist of sections, box members forming the gantry frame and girder. The sill beams, legs and girder and cantilever 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. If the Contractor proposes to use flanged, bolted joints, they shall be made using ASTM A325 or A490 bolts. Fracture critical members or member components, FCMs, 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. The Contractor shall determine which member or member component is in the FCM category. All FCMs shall be identified on the drawings. FCMs shall be accessible for periodic structural inspections. Non-fracture critical members shall be accessible where practical for periodic structural inspections. 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. Material used for longitudinal structural stiffeners shall be the same material (or have the same material yield strength) as the plate to which it is attached. The use of different grade steels in the cross section of main structural components must be approved by the Purchaser.
(3)
(4)
(5)
(6)
(7)
(8)
3.2.1
Equipment and Materials The following equipment/machinery shall be fitted to the main structure. (1) (2) (3) (4) (5) (6) (7) Gantry drive machinery. Gantry buffers. Gantry wheel brakes with limit switches. Cable reel with cable guide and limit switches. Main hoist sheaves. Stowage pins with limit switches. Gantry travel operating station at ground level .
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3.2.2
Fittings The following fittings shall be fitted to the main structure. (1) Walkways, stairs, ladders and platforms. (2) Lighting for operation and for walkway, stairs ladders and platforms. (3) Wind vane for anemometer at a high level where least affected by turbulence caused by own crane structure during operation. (4) Intercom system. (5) Travel warning device. (6) Two speakers fitted at yard level on each sill beam facing inside of the crane. (7) Service outlets. (8) Emergency stop buttons. (9) Drive Lock-Out Switches. (10) Fire extinguishers. (11) Checkers cab.
3.3 3.3.1
Material General All materials used in the Crane shall be new, of good 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 manufacture. The steel materials for all the stressed members shall be selected from the materials which specification includes notch toughness for service in an environment with temperature in the range -25 to +35C.
3.3.2
Steel The steel used for the manufacture of the Crane shall comply with an internationally recognized engineering standard such as: British Standards (BS) Deutsche Industrie Norman (DIN) Japanese Industry Standards (JIS) Alternative codes will be accepted depending upon specifications and certification offered by the Contractor and approved by the Purchaser.
3.3.3
Edge Finish All edges of structures shall be free from sharp edges or burrs.
3.3.4
Surface Finish (1) (2) All welding spatter shall be removed from structure surfaces. The metal surfaces shall be cleaned and treated as defined in 6.3 (Painting and Protective Coating).
3.3.5
Draining and Inspection Manhole (1) The steel structure and mechanisms shall be designed to drain water effectively. Any draining water shall not affect safety of operations or maintenance work under heavy rain conditions. No water trap shall be permitted in any part of the crane structure.
3.4
Calculations
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3.4.1
Submission to Purchaser (1) Wheel load, stability, braking capacity and drive power calculations for all motions, and peak power consumption calculations shall be submitted for Purchaser's review prior to commencement of detailed design. Refer to Appendix 1 for detailed list of submissions 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.
(2)
3.4.2
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. Calculations to justify the selection of proprietary items such as hoist, trolley, gantry and components e.g. motors, couplings reducers brakes etc.
3.4.3
Calculations The design for the structure shall be calculated using the methods and procedures defined by internationally recognized design standards. The calculations shall be prepared and presented in a clear and precise format and shall demonstrate all methods and assumptions used in each element of the 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.
3.4.4
Drawings The Contractor shall provide 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 pdf format at least A1 size 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.]
3.5 3.5.1
Loads Load Combinations 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.
3.5.2
Engineering Standard The Contractor shall comply with FEM 1.001, 3rd Edition Revised 1998.10.01, Rules for the Design of Hoisting Appliances for calculation of stresses in structural components. Alternative standards such as BS are accepted providing the Contractor provides adequate justification and detailed reference.
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3.6
Members Subject To Buckling The design of columns, beam columns, frames and beams subject to buckling shall be in accordance with the FEM specification.
3.7
Fatigue Design Criteria (1) Fatigue design shall generally conform to the requirements of F.E.M. 1.001, 3rd Edition Revised 1998.10.01. Cumulative damage shall be evaluated for the normal operating conditions. The load spectra for development of the stress cycle spectra shall be presented by the Contactor for approval by the Purchaser. The specified loads and cycles shall represent the effects of the actual anticipated operating conditions.
(2) (3)
3.8
Connection Designs (1) 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. 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 AWS D1.1 latest edition. Bolted joint design shall conform to the AISC Specification using 0.9 times AISC allowable values. Prying action due to distortion of the connection details shall be considered. Bolts governed by fatigue strength shall comply with ASTM A325.
(2)
(3) (4)
3.8.1
Pin Joints (1) All pins shall have angled lubrication drillings to avoid any change in direction that will hinder flow of grease nipple to the bearing surface. Eyebars 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.
(2)
3.9
Gantry Structure Stiffness (1) Deflection or oscillation of the structure shall not affect the Crane capacity and operating efficiency (particularly spreader positioning ability). The horizontal displacement at the girder level due to full acceleration or deceleration of trolley with a rated load, or full acceleration or deceleration of trolley while suspending a rated load at the maximum upper limit position, shall not exceed 80mm. The main structure shall be designed so as not to sustain damage in the event of puncture of any one.
(2)
(3)
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3.10
Camber The two main girders shall be designed with an appropriate camber so that under loaded conditions the main girders are level.
3.11
Trolley Rails & Rail Fixing Trolley rails may comprise standard rail and clips or welded square bar. In the event that the rail is manufactured from square bar, the material specification for the bar and welding procedures, inclusive of pre-heat, post heat and electrode specification shall be provided within the maintenance manuals.
3.12
Workmanship (1) The whole of the structural fabrication and assembly shall be performed in a thorough, workmanlike manner and shall follow the best modern practices in the manufacture of highgrade structures. Welders, welding operators and tackers shall be certified, for the material, processes and type of welding being performed. 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. The Contractors 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. The Contractors 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 Purchasers representative on site. The Contractors 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 rod hot boxes is essential and will be closely monitored by the Purchasers Representative. A325 and A490 bolts (or their equivalent specification such as ISO/EN/DIN) that are 7/8 (22m) 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) (ii) Hardened washers shall be placed under the both the head and the nut. The Contractor shall notify the Engineer if the highest and lowest torques measured during wrench calibration varies by more than 10 percent of the lowest torque, so they may develop the appropriate solution. If the range exceeds this tolerance, filed tightening may be erratic. The snug tight tension shall be approximately 15 percent of the specified tension and shall be achieved using a calibrated wrench. The sequence of bolt tensioning shall be shown on the drawings.
(2)
(3)
(4)
(5)
(6)
(7)
(iii)
(iv)
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(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. 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. 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. Bolt tension may be verified at locations selected by the Purchasers Representative. Bolt tension verification shall be performed by the Contractor in the presence of the Purchasers Representative and in such a manner that the torque can be wrench gage read during verification.
(vi)
(vii)
(viii)
(8)
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 D1.1-2006. 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:-
Weld All Welds Full Penetration Butt Welds (Compression) Full Penetration Butt Welds (Tension as determined by stress levels due to operating load combinations. Full Penetration Butt Welds in Tension Bars (if applicable) Fillet Welds or Partial Penetration Welds On FCM On Non- FCM
Type of Testing/ Inspection 100% Visual 25% UT
Acceptance Criteria AWS 1.1 2006 AWS 1.1 2006
100% UT
AWS 1.1 2006
100% UT
AWS 1.1 2006
100% of length MT 10% of length MT (as nominated by the Purchasers Representative)
AWS 1.1 2006
Rejection of any portion of a weld inspected on a less than 100% basis shall require inspection of 100% of that weld. Ultrasonic testing of tension welds shall be done by or under the direct supervision of an ASNT Certified LEVEL III *or equivalent qualified person. 3.13 Quality Control of Structure Fabrication
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(1)
Quality Control shall be the responsibility of the Contractor. The Contractor must implement a written quality control program and shall be part of the Contractors Quality Assurance Manual that shall be submitted to the Purchaser for review within 1 month of the date of the Agreement. The Quality Assurance Manual shall also contain the Contractors Inspection and Testing Specification. The quality control program 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. 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 3.12). Welding, machining, measuring and inspection equipment maintenance and calibration. Machining finishes surfaces, bolt tensioning procedures. Procedures for non-conformance (NCR) and Punch List (PL) reporting and rectification of defects. Design and manufacturing drawing control and procedures for revisions, updates and reissue of drawings Procedures for material cleaning, preparation blasting and painting.
(2)
3.14 3.14.1
Temporary Structures Temporary Structures Connections details of temporary structures (such as lifting lugs, etc) fitted onto Operationally Critical Components must be reviewed by the Purchaser.
3.14.2
Sea-Fastening At least three months before the intended shipment, the Contractor shall submit sea-fastening structure connection details to crane structures for the Purchasers 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 minimizes any Hot Work at the site to minimize the risk of damage to paintwork and the need for extensive paint system repairs.
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FUNCTIONAL SYSTEMS DEVICES AND EQUIPMENT Lifting lugs shall be provided for all sub-assemblies such as reducers, gantry / trolley / hoist/ hydraulic tanks etc. These should be installed on each assembly, clearly identified and marked (stamped) with SWL.
4.1 4.1.1
Main Hoist Main Hoist (1) The Main Hoist system shall consist of one (1) AC Motor, two (2) AC servo operated brakes, Reduction Gear and one (1) wire rope drum. The main hoist drive reduction gearbox shall be totally enclosed, oil bath lubricated type. Couplings which connect the hoist gearbox to the hoist drum shall be manufactured by an internationally recognized manufacturer of this type of component. Wear indication marks shall be provided in a convenient place for viewing without dismantling of any components. Two (2), AC servo operated disc brakes shall be fitted on the high-speed pinion shaft. Each brake shall be rated at 150% rated motor torque and shall be capable of stopping and holding the maximum rated load from full rated speed. The calculated setting torque of each brake shall be at least 10% less than the full capacity of the brake. A calculation of brake compliance for the defined duty shall be provided from the brake manufacturer. Over-speed switch shall be fitted to the main hoist motor to shut down the drive and set the brakes if the load exceeds 115% of rated speed. Heavy duty, pulse encoder, of IP55, shall be installed on the main hoist motor for closed loop speed feedback and control and a cam limit switch shall be installed at the hoist rope drum shaft for hoist limit switches and slow down checks. The encoder shall be mounted externally from the motor/fan casing. Acceleration from zero speed to a maximum speed or deceleration to zero speed shall be smooth and stepless for all load combinations. There shall be two (2) stages of upper hoist slowdown to cater for an empty spreader and a loaded spreader in order to enhance performance of container handling. For this function a software limit switch system track limit switch shall be provided using an absolute encoder on the hoist drum to calculate exact hoist position at all times. In the condition of empty spreader, the hoist shall incorporate a lower slow down whilst the loaded spreader condition shall incorporate a higher slow down position using position from absolute encoder and lock/unlock signals Under each condition the emergency upper hoist limit shall not be tripped. The Contractor shall propose a method statement with calculations for the Purchasers review. (10) (11) Frequent inching operation and plugging operation shall be catered for in the design. The hoist brakes, pads and disc shall be protected from the weather with an easily removable or accessible enclosure, so designed to allow access to all components for maintenance.
(2) (3)
(4)
(5)
(6)
(7)
(8)
(9)
(12)
Outboard wire ropes shall be stationary during the hoisting and lowering motions and all dead-end wire ropes shall be terminated with Wedge Sockets.
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4.1.2
Sway Control (1) The Anti-sway/yaw device or sway/yaw damping system shall work effectively for a short distance travel as well as for a stop after full deceleration. The operation of the system shall not alter the elevation of the spreader with or without load at any height. A simple anti-sway system which is of proven design shall be provided. The sway control shall bring the spreader to a stop following full deceleration of the trolley from full speed with any operational load to within 150mm 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 2.5 cycles of sway.
(2) (3)
4.1.3
Trim Control (1) The Spreader trim motion to be controllable up to its maximum angle of 3 at a speed 0.5 per sec minimum One push button switch on the control console shall automatically correct the spreader position to a Zero List position. Zero List position shall be indicated with a lamp on the panel in cab. The system shall be electrically operated.
(2)
(3) (4) 4.2 4.2.1 Trolley
Trolley Frame (1) The trolley frame shall be fitted with the main hoist machinery, trolley drive machinery, trim device, operators cab, and buffers (or buffer reaction stoppers) for forward motion and backward motion collision impact. The buffers shall be capable of absorbing and dissipating the impact of collision at full speed with rated load. The trolley frame shall be fitted with safety drop-stop lugs which shall support the trolley in case of wheel or axle failure. The trolley frame shall have jacking points for trolley wheel replacement work and wheelbearing housings shall be split to permit wheels and axles to be dismantled easily. The trolley frame shall provide a safe emergency access from the operators cab to the walkways of the girder at any point of trolley travel range. The trolley frame shall be provided within safe maintenance platform and access to all of its components and machineries for maintenance. A mirror of break resistant material shall be provided to assist viewing the far side of lifted container in a slot underside of the trolley frame. The mirror position shall be easy for the operator to adjust. Two pairs of heavy duty side guide rollers shall be fitted on one side of the trolley frame at fore and aft to guide the trolley movement. The cam following roller bearings of the rail guide shall be heavy duty and strong enough to resist damages by horizontal force. An electrically operated maintenance hoist for carrying tools and components up to 500kg capacity shall be installed on the trolley platform. Total time to raise rated load from ground to trolley shall be less than 1 minute. The hoist motor shall be provided with overload protection.
(2)
(3)
(4)
(5)
(6)
(7)
(8)
4.2.2
Trolley Drive
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(1)
The Trolley shall be driven by one (1) or two (2) trolley motors, dependent upon the Contractors design. The trolley brake(s) shall be rated at 160% of rated motor torque. The reduction gears shall be totally enclosed, oil bath lubricated type. Geared limit switch drive shall be by a proper gear reducer and a flexible coupling. Chain drive is not permitted. The design of the coupling shall be such that when the coupling is required to be dismantled, it is not required to shift the gearbox or trolley motor. The trolley drive system, and wheel, shaft and bearing system shall be designed to facilitate fast replacement of components at any point on the girder. The replacement of a trolley wheel shall not take longer than 1 hour with 2 people. Frequent inching operation and plugging operation shall be catered for in the design.
(2) (3) (4)
(5)
(6)
4.2.3
Power Feeder (1) Power and control cables shall be routed to and from the trolley by a proprietary cable chain system. The Contractor shall submit design calculations which are approved by the cable chain manufacturer to demonstrate appropriate considerations in respect of the following parameters: (1) Cable clearance and bend radius within each carrier link, inclusive of manufacturers recommended allowances. Adequate allowance for cavity fill including manufacturers recommended safety factors. In any case less than 60% of the total cavity cross sectional area. Even and symmetric weight distribution within each carrier cavity. Appropriate consideration for separation of dissimilar cables and regard for cable replacement.
(2)
(2)
(3) (4)
(3) (4)
Cable carriers shall have extra slots for extra cables (in addition to the specified spare wires). The cable system shall include 20% spare control wires of each type/size and 6 cores fiber optic cables. All cables shall be purchased from the cable carrier supplier and confirmed suitable for the application. Access to the energy chain system shall be by a permanent walkway and platform. Manufacturers recommendations shall be adhered to strictly for installation detail and tolerances. A platform on the trolley may be used for access to the energy chain providing it provides safe access and hand rails are fitted. The system design shall not generate water traps internally, between cables and chain material or externally between chain material or crane structure.
(5)
(6)
(7)
4.3 4.3.1
Gantry Gantry Drive (1) The gantry drive motors and brake system shall provide sufficient thermal capacity, torque and traction for all operating conditions.
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(2)
Acceleration and Deceleration forces shall not result in wheel loads which exceed the allowable values defined earlier. The gantry drive and motors shall be capable of accelerating, driving a distance of 300m and decelerating with and against the operating wind load without adverse heating of any component. The gantry service brakes shall comprise electromagnetic, spring applied double disk brakes mounted to each gantry motor. The dynamic rating shall be greater than 100% of maximum motor torque but not greater than 150% of the maximum motor torque. The brake thermal capacity must be sufficient to stop the crane from rated speed with a following maximum operating wind whilst not sustaining damage in the event that an emergency stop button is pressed without any aid of wheel or rail brakes. Each brake shall be supplied with a strong, lightweight, latching rain proof enclosure. Brakes shall set after an adjustable time delay of no gantry operation. The brake rating and design calculation shall be submitted or formally approved by the brake manufacture and submitted to the Engineer for review. Storm wheel brakes shall be provided on sufficient number of idler wheels and be capable of holding the crane under sustained storm wind of 40m/sec in combination with gantry brakes and with stowage pins in the disengaged condition. The braking calculation shall assume coefficient of friction between wheel and gantry rail to be 0.12. The brake spring life shall be greater than 1,000,000 cycles and the brakes shall provide for 10mm float with cleaning pads. Wheel brakes shall be spring applied and hydraulically released acting upon idler wheel flanges which are designed for brake installation. The hydraulic power units shall be manufactured and supplied by the wheel brake manufacturer. Hand pumps for manually releasing the rail brakes shall be provided. The gantry drive shall be self-contained within its drive truck, motors shall drive through a totally enclosed, oil lubricated, helical and/or spiral bevel gearbox with one motor and one motor driving one wheel. The motor shall be flange mounted to the reducer. Drive components shall be protected by their location or by substantial fenders against damage by vehicular traffic. The gantry trucks shall be equipped with safety lugs to support the truck in case of wheel or ` wheel shaft failure. Each truck and equalizer beam shall have proper jacking points to facilitate jacking for simple removal of any wheel without dismantling trucks or equalizer beams. Jacking load and position shall be approved by the Purchaser to prevent overloading of quay structure. Wheels and gearboxes shall be fitted with robust safety guards. Rail scraper shall be provided in front of the outer and inner wheels at each corner. 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 traveling speed. Limit switches to prohibit gantry travel motion when the stowage pins are inserted into the ground socket shall be provided. Gantry motion shall be prohibited whenever the hoist motion is activated.
(3)
(3)
(4)
(5)
(6)
(7)
(8)
(9) (10) (11)
(12)
(13) 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 defined. The design to size the pin and its supporting structure shall not consider the clamping force of the rail brakes or the force of the motor brakes.
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(2)
The arrangement of the stowage pins shall suit the stowage pin recess in the yard, drawings and relevant details will be supplied by the purchaser. A suitable latching device shall be provided for securing the pins in their raised and lowered position. 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 engagement or disengagement of the pin. Limit switches shall disable the gantry drive unless all stowage pins are in the raised position.
(3)
(4)
(5)
4.3.3
HV Cable Reel (1) Cable reel (i) The cable reel shall be installed on one of the legs, or as agreed. The drive control system of the cable reel shall be designed to minimize abrupt starting; braking and excessive slack / tension in the cable when the Crane passes the cable feed point. Sensors/switches to detect the above conditions shall be provided. The mono spiral cable reel shall be manufactured entirely from stainless steel or be hot dip galvanized after all fabrication and machining work is completed. Cable guide wheels shall be installed near the gantry trucks to keep the high voltage cable close to the ground level. The cable shall be laid inside the cable slot within the wheelbase of the gantry trucks in one corner. The system shall be well protected from weather especially in the vicinity of the high voltage slip ring components and the slip ring enclosure shall be stainless steel. The cable reel drive machinery and slip ring area shall be fenced off to allow access of authorized persons only. A high voltage warning sign shall be provided and fitted to the entrance of the fenced area. A suitably sized space heater shall be provided for the slip ring. Limit switches to control gantry motion near the traveling limit (limited by cable length) shall be provided. A manual operating station 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 and shall provide controls for forward, reverse and slack cable bypass.
(ii)
(iii)
(iv)
(v)
(vi) (vii)
(viii)
(2) High Voltage (HV) Trailing Cable (i) The cable shall be round type with three conductors, with ground and embedded fiber optic cables for data transmission. Sufficient length of cable shall be installed to provide for the full length of 685m crane travel, three dead wraps on the reel plus one safety wrap when full, fairlead from the ground and three turns on the stress relieving drum in the cable pit. A distance of 10m should be allowed from the stress relief drum to the point of termination to the service cable. The composite cable shall incorporate minimum 6 numbers of low loss silica glass optical fiber waveguide. The cable reel mechanisms shall incorporate low loss connecting devices that allow the use of all waveguide simultaneously linking the
(ii)
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equipment on the crane to external devices. The standard for the waveguide shall be 62.5/125 micron. (iii) The high voltage trailing cable connection at the power feeding pit in the yard shall be a proprietary type of HV cable joint. The Contractor shall undertake termination of the HV cable conductors and fiber waveguide at the feeding pit into a special connector box provided by the Purchaser for this purpose. 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 cable joints made at Site and high voltage wiring shall pass the inspection requirements of the local power supply company and Hi-Potential test results shall be provided.
4.3.4
A maximum of two high voltage trailing cables shall occupy the same trench at any one time. Gantry Anti-collision System (1) The crane shall be equipped with proprietary anti-collision systems to prevent collision between the crane and vehicle and crane to crane. It is preferred that the crane to crane system be based upon a long range ultrasonic sensor positioned to detect RMG cranes travelling along gantry rails. The system shall be capable of detecting any RMG in configurations from one over three high and the sensor shall be positioned in a location where it may be accessed for maintenance from the fixed ladders or platforms. An audible warning of crane approach shall be provided in the operators cabin and motion slowdown/stop features shall be provided in a logical sequence in the direction of travel.
(iv)
(2)
4.3.5
Gantry CCTV (1) The crane shall be equipped with CCTV cameras on the far side which provide high resolution views in both directions of gantry travel of the gantry runways. The purpose of the system is to provide additional vision for the operator to detect personnel or obstacles which may be positioned out of his field of view. Flat screen panels shall be positioned either side of the operator towards the front lower corners of the cabin in a convenient position so that the relationship between the panels and the cameras is logically perceived. The screens shall be shaded as necessary to ensure clear view in all cabin ambient lighting levels Panel brightness shall be adjustable for day and nighttime operation and the sensitivity of the cameras shall be suitable for operating efficiently during nighttime operation to provide good definition down to 10lux lighting level. Cameras shall be positioned in a convenient location so that maintenance can be performed without additional access equipment. The cameras shall be adjustable for position, enclosed within a weatherproof, security housing and having an automatic thermostatically controlled condensation heater.
(2)
(3)
(4)
4.4 4.4.1
Electrical Control House General Construction (1) The Electrical Control House shall be a walk-in type, weatherproof, insulated, and air conditioned. The Control House shall be located on the outside of the main girder on the main power cable reel side of the crane.
(2)
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(3)
The floor of the Control House shall be completely fitted 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. All electrical cables installed underneath the floor shall be accessible. The access doors shall be metal sliding type with non-corrosive heavy-duty hardware locks and safety glass windows in upper panels. The doors shall be located at each end of the Control House and shall be self-closing. A drip shield shall be provided over the doors. A steel locker with door lock shall be provided inside the Control House minimum dimensions 1500H x 900W x 400D. A working table (table top size minimum 750mm x 1200mm) and a chair shall be provided in the Control House.
(4) (5)
(6)
(7)
4.4.2
Fittings, Facilities Located in the Electrical Control House (1) Push button switches for the main control circuit, the main motion power source, and the lighting control switches. (2) Main high tension power supply source switch panels and their remote control switches. (3) Main hoist, trolley, gantry motion drive control panels, cubicles, etc. (4) Transformers. (5) Auxiliary power source panels. (6) Auxiliary motor starter and control panels. (7) Fluorescent lighting arranged to provide uniform illumination in all areas of not less than 300 lux throughout. (8) Intercom unit (9) Specific meters and counters. (10) Fire extinguisher. (11) Service outlets (12) Ballast bank for all the high-pressure sodium lamps, or similar type lamps on the Crane (13) Central switch panel for Crane lighting. (14) Harmonics Suppressor. (15) Power factor corrector. (16) Two (2) heater/air conditioners
4.5 4.5.1
Operators Cab Construction General
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(1)
Operators cab shall be constructed of sheet steel, double bottom, double ceiling and double wall, fire proof, fully air-conditioned. The cab shall be water tight as operated in the conditions as specified in previous clauses. The design of the cab shall allow the operator to clean the outside of all windows safely. The cab connection to the trolley shall include anti-vibration mounts to reduce impact and vibration to the operator. A shield shall be fitted above the windscreen to prevent wire rope lubricants from splashing onto the glass. 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 supporting failure. Secondary, redundant fixings shall be provided; each designed to carry the full mass of cabin and operator.
(2) (3)
(4)
(5)
4.5.2
Cab Access (1) Operator Cab access shall be from a hinged door on one side of the cab. The door shall be selfclosing, with a latch to keep the door in the open position. It shall be possible to access the cabin without passing over the trolley. A secondary escape ladder shall be provided to enable the operator to climb up to the trolley
(2) 4.5.3
Window Visibility (1) Cab windows shall provide as much view as possible including lower rear view. The rear side of the cab shall have half windows. It shall protect the operator from the glare of the sun with fine screen type roll up sun shade on upper front, side and rear windows which have characteristics to allow vision through it. Window glass shall be scratch resistant meeting the requirements of BS6206 class A safety glass with both surfaces being flat, parallel and fine polished, giving clear undistorted vision. Full direct vision of a ground slot between two - 5 high stacks immediately below the front bottom window shall be ensured without supplemental devices, from the normal seating position of the operator. The front and bottom window shall be laid out symmetrically about the Crane centerline in left and right direction.
4.5.4
Emergency Lighting System (1) Emergency lighting operated by individual rechargeable batteries shall be provided in the control house. 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.
4.5.5
Air Conditioning/Heating (1) The Electrical Control House shall be well insulated to keep the inside temperature at 25 deg. C at all times. Warning of failure of the system shall be indicated as shown in 6.5.6 (Electrical Control House Heating/Air Condition Warning). 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 heating/air conditioners. The heating/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 heating/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. There shall be (n>=2) sets of Cassette Type Heating/Air Conditioner installed in the electrical room which are sufficiently rated to maintain Electrical room temperature at 25deg.C or below.
(2)
(3)
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An additional one (1) unit shall be pre-mounted as a spare in case any of the in-service units fails. Total n+1 air conditioner units shall be provided in the E-room on the crane. (4) It is acceptable to allow heating/air conditioning units to run continuously but in this case, they shall not have a detrimental effect on the power factor whereby consumption of reactive power increases when the cranes are idle.
4.5.6
Fire Protection (1) (2) An automatic system to detect a fire in the Electrical Control House shall be installed. The system shall include a smoke detector in each individual electrical panel of the control house near to sensitive equipment such as transformers and switchgear. Fire warning messages shall be transmitted through CCMS, RCCMS and to the operator message panel according to a predefined escalation procedure which will ultimately shut down the crane automatically and safely when critical conditions are reached.
(3)
4.5.7
Cab Dimensions Minimum inside floor width of the cab shall to be 2,000mm and length (fore and aft including bottom glass frame) 2,400mm.
4.5.8
Cab Fittings The operators cab shall be fitted with the following fittings and shall not in any way obstruct operators view required for Crane Operation. (1) One right-hand and one left-hand control console. The consoles together with the chair shall be ergonomically laid out to minimize fatigue of the operator. (These may be combined with the operators chair). For detailed requirements refer to 5.4.6 (Main Control Switches in Operators Cab). One upholstered operators seat having contoured swab for thru legs vision with seat belt. The seat height and position forward and backward shall be adjustable to best suit each operator. Spreader Landing (Yellow) and Lock (Red), Unlock (Green), Wind Speed Warning (Amber) and Wind Speed Alarm (Red) indicating lamps in a box fitted at lower (middle) front part of the cab. Window wipers and washers Wipers and washers to ensure the view angle required for operation. Wipers and washers shall be fitted to front and side windows. (5) (6) Communication equipment. Heater and Air conditioning unit shall be Split Type to maintain 20C in all ambient temperatures. Service outlet (four 16 amp, Sockets) configuration as used in country of operation. Lights and light switches. Foot rests for the operator (position to be adjustable for each operator). D. C. outlet for radio communication equipment See Section 5.3.2 (7), (8) for details of this power supply complete with a battery relay to cut off battery supply after 30 minutes when the engine is down.
(2)
(3)
(4)
(7) (8) (9) (10)
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(11) (12)
Safety bars wherever necessary to prevent accidental fall of the operator or maintenance staff. Siren switch (or call for emergency warning sound) incorporated into RH Master Controller Joystick. For details see 6.5.1(2) (Gantry Travel Warning) for full description on the common amplifier. 6 Spare MCBs, 16 Amp capacity. Coat hook. A foldable chair fixed to the wall at suitable level for use by operator trainer or a second operator inside the cab. The foldable chair shall be able to swing back to the wall with a latch when not in use and shall mount flush on the wall surface. Container load indicator. Fault code and message panel. Wind Speed Indicator analogue type CCTV flat panels and controls for Gantry travel
(13) (14) (15)
(16) (17) (18) (19) 4.5.9
Checkers Cab (1) A checker's cab fabricated in mild steel shall be provided under the sill beam or other safe location agreeable by the Purchaser. The checkers cab shall be bolt mounted to the sill beam The following shall be provided: a. b. Service outlets (2 Units) Heating and Air conditioning system to maintain interior temperature at 20C under the lowest or highest ambient condition Ventilation fan Fluorescent lighting Stabilized DC power supply 24V (10Amp) and 12V (20 Amp.) power supply for communication equipment. Hand set for communication with other areas within the Crane as specified in 5.6.1 (Intercom System). Fixed working height desk and swivel chair
(2)
c. d. e.
f.
g.
4.6
Personnel Elevator This clause is not used no personnel elevator is required.
4.7 4.7.1
Head-block Head-block Fittings (1) Fittings The major fittings on the head block are listed below. All components on the head-block shall be laid out to maximize operators forward view.
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(i) (ii) (iii)
Main hoist sheave blocks. Arrangement to minimize the spreader rocking motion. Spreader cable with cable reel Platform with handrails with access openings. Necessary access ladders to align with the ladders on the spreader shall be fitted. Head-block shall be designed with a twistlock connection according to the manufacturers standard. An electrical connector for the feeder cable for the spreader. Anti-sway wire rope connections. Limit switches, junction boxes, etc. System required for side shifting of containers
(iv)
(v) (vi) (vii) (viii) (2)
All the fittings shall be securely fitted to the head block to withstand frequent impact during landing. Head-block design to allow full access to the spreader terminal boxes.
(3) 4.7.2
Spreader Cable (1) The Spreader cable shall have at least 6 nos. spare 2.5 sq. mm spare wires and each shall be terminated in plugs/sockets at both ends. All the electrical wire connections shall be designed to withstand frequent impact of landing.
(2) 4.8 Spreader
One twin telescopic spreader shall be provided with each crane. The spreader shall have the following general requirements: 4.8.1 Twin Lift Telescopic Spreader (1) Spreader Frame (i) The structural frame shall be designed and constructed to have adequate safety factors to prevent premature fatigue failure within 2 million load cycles. Flared guides shall be provided at 4 corners of upper surface of the frame. Access ladders to the platform on top of the head block shall be fitted to the main frame on both sides and shall be positioned 1200mm either side of the spreader center line to permit interchangeability with existing equipment. The spreader frame design to allow at least 100mm clearance between the lowest point of spreader frame and top of container when the spreader is landed on a container.
(ii)
(iii)
(2)
Spreader Power Unit The spreader shall be hydraulic type. The main electrical panel shall be stainless steel, NEMA 4X standard easily accessible and provided with hinged door and robust stay.
(3)
Spreader Twist Locks (i) Twist-lock shape to fit ISO corner fitting.
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(ii)
Twist locks shall be floating type and fitted with sleeve type twist lock guides. Greasing nipples shall be fitted suitable positions on the sleeve guide so that grease can be injected into the sleeve for lubrication between the sleeve and twist lock shank. Twist lock movement from Unlock position to Lock position shall be prohibited by a mechanical and electrical interlocks unless four twist locks are confirmed to be fully inserted into corner fittings and the spreader is landed onto a container. Twist lock movement from Lock position to Unlock position shall be prohibited by a mechanical and electrical interlocks unless complete landing of the spreader is confirmed. 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 twist lock sensing is preferred. The hoisting motion shall stop immediately if only one side (2 twist locks) is locked inside two corner castings and the other side (2 twist locks) is locked outside the corner casting.
(iii)
(iv)
(v)
(4)
Spreader Flipper, Side Guides Two (2) fixed but manually retractable flippers shall be provided.
(5)
Spreader Telescoping (i) Telescoping guide shoes or rollers shall be designed to allow easy and quick access and simple adjustment. Replacement of guide shoes shall be able to be performed without dismantling main frames. Mechanical stoppers shall be fitted for 20 and 40 positions. Such stoppers shall be automatically engaged following operators command for desired spreader length. Operating time for extension or retraction shall be less than 30 sec between 20-40 positions. The telescopic motion shall allow for approx. The 3 seconds slow motion period after start and before stop of telescopic motion to minimize impact of start/stop on the driving system is not required Telescoping mechanism shall be fitted at middle of the 20'-40' spreader complete with telescoping motor and controls. All this equipment shall be easily accessible for minimum down time. Separating capacity 01600 mm with full load
(ii)
(iii)
(iv)
(v) (6)
Spreader Landing Probe The landing probes shall positively detect the landing of the spreader on the container and monitored individually by the PLC.
(7)
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 spreader).
(8)
Spreader Protection (i) All mechanical, and electrical components fitted on the spreader shall be protected from frequent impact and vibration of operation. All related fasteners shall be anti-loosening type.
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(ii)
All electrical cables connected to the moving parts of the spreader shall be properly protected from damages due to interferences with stationary parts. All the electrical parts shall be protected from the weather. Twistlock counter and spreader operating (extend/retract) hour meters shall be fitted in the spreader junction box. Each individual position sensing proximity switch for twist lock Locked and Unlocked, with LED indicator positioning shall be connected individually to the I/O unit in order to prevent any incorrect indication and unsafe movement of twist locks caused by short circuit of any proximity switches failed during operation. Such short circuit status of a failed proximity switch shall immediately prohibit the main hoist or lower function until a new replacement proximity switch is in place. Spreader E. Stop pushbutton switches shall be fitted on the side of the electrical panel and at each end of the telescoping booms. A padlocked spreader isolating switch for maintenance lock-out shall be installed on the side of the electrical panel enclosure.
(iii) (iv)
(v)
(vi)
(vii)
(9)
Visibility for Spotting The inner lower edge lines of twist lock boxes of the spreader to be clearly visible by the operator for spotting the spreader onto the 40 container.
(10)
Spreader Meters and Indication. (i) A non-resettable, vibration damped twistlock counter shall be fitted inside the spreader electrical panel. The counter is required to record actual number of containers loaded and unloaded by the spreader. As such the counter shall be designed to register one count when the following combinations of motion is detected spreader not landed, spreader landed, twistlocks locked, spreader not landed, spreader landed, twistlocks unlocked, spreader not landed. A spreader operating hour meter shall be fitted on the spreader (extend/retract motor running hour). LED indicating lights shall be fitted to the upper section of the main frame or on the head-block. The lights shall be clearly visible in all lighting conditions and shall be unobstructed from the operators field of vision. The lights shall follow the color code: Yellow Red Green Spreader Landed Twistlock LOCKED Twistlock UNLOCKED
(ii)
(iii)
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5
5.1 5.1.1
INTER-FUNCTIONAL SYSTEMS & COMPONENTS

Mechanical System/Components Bearing, Seals All the bearing shall be anti-friction bearings 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, effective means of lubrication and seal shall be provided. Oil less bearing or oil less bushes are not permitted. (1) The bearing design shall be based on full rated speed and maximum load with the following life as a minimum requirement in accordance with noted service life For main hoist system: For trolley travel system: For gantry travel system: (2) 50,000 hours 50,000 hours 50,000 hours
Bearing housing or retainer shall be a split type or bolt-down type to facilitate fast inspection and replacement work.
5.1.2
Gearing (1) (2) Open gears are not permitted. Gears shall be of helical or herringbone type and designed in accordance with the relevant BS, AGMA or DIN standards. The durability rating for the main hoist, trolley and gantry drives shall be based on a minimum service factor of 1.3 for rated load and rated speed and a wear factor of 0.7. All other gearing shall be selected or designed for a minimum service factor of 1.0. The gearing for all main drives shall be totally enclosed in a split, oil tight steel box with oil bath lubrication
(3)
(4) (5)
5.1.3
Gear Reducers (1) All main motion gearboxes shall be fitted with gear inspection windows, weatherproof breathers and oil and temperature level gauges. The gearboxes shall be free from oil leakage. Dipstick type oil level gauge is specifically not allowed. The gearboxes shall be designed to allow easy replacement of gear or gear shafts without removing the whole gearbox assembly from its mounting base. Drain pipes with shut off valves and end plugs shall be fitted to each gear box. An appropriate drain receiving space for each drain outlet shall be provided. Particular care shall be taken during the overall design phase to ensure that adequate space and facilities are provided for the changing of oil seals, draining of oil into adjacent receptacles, checking of mounts and bolt on type covers for internal inspection of all gear teeth. All gearboxes shall be mounted with shims and adjusting blocks.
(2)
(3)
(4)
5.1.4
Wire Rope Winch Drums (1) The main hoist drums shall be of rolled welded steel construction, stress relieved, 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 neighboring 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 throughout the whole range of operation. 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 not be less than 5% nor more than 7% larger than the nominal radius of the rope. The diameter of the drum at the bottom of the groove shall not be less than 29.6 times the nominal rope diameter. The maximum angle of fleet between the rope and a plane perpendicular to the longitudinal axis of the drum shall not exceed 3.5 degrees. The drum shall be flanged at both ends. The wire ropes shall be secured to the drum by a suitable clamping device. The length of the hoist drum and wire ropes shall be such that when the head-block is at its lowest specified point at least three full turns of rope shall remain on the drum, and when the load is at its highest possible point at least one empty groove shall separate two adjacent ropes, depending on the drum configuration. Wire rope winch drum shall have machined grooves sufficient to lay wire ropes in single layer. One extra turn for service and appropriate number of dead turns for each wire rope end shall be allowed for on the drum. Rope grooves shall be surface hardened to HB321 minimum. 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. Prevention against overflow of oily water out of trays during rainy operational condition shall be taken into consideration. Tubular Steel wire rope guards shall be fitted behind the wire rope drum to prevent rope jumping the grooves. The clearance between main host wire rope and the surface of the guards shall be equal to half of the wire rope diameter.
(3)
(4)
(5)
(6) (7) (8)
(9)
(10)
(11)
5.1.5
Wire Rope Sheaves (1) All wire rope sheaves shall be centrifugally cast or forged or machined steel construction with smoothly machined grooves. Fabricated or gravity cast sheaves are not acceptable. The bottom of the grooves shall 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 7% nor more than 15% larger than the nominal radius of the rope with 11% being the optimum. Wire rope sheaves shall have pitch diameter of 29.4 times the nominal rope diameter. Guide rollers (fairleads) shall have a minimum diameter of 5 times the rope diameter and the diameter of equalizing shaves shall not be less than 18 rope diameters. The maximum angle of fleet between the rope and a plane perpendicular to the axis of the sheave shall not exceed 2.5 degrees. The surface of the groove of the sheave shall have a hardness value of minimum 280-320 on the Brinell Scale. The depth of the material hardened to this level shall be at least 5mm. Certification of Hardness is required. Rope Sheaves shall include requirement for 100% MT in the rope grooves and provision for one spare sheave of each type so that depth of hardness may be checked by destructive testing
(2)
(3)
(4)
(5)
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(6)
All running sheaves shall be fitted with anti-friction roller bearings with grease fittings for pressure lubrication.
(7)
Minimum designed life of the sheave, specifically the groove and bearing retainer, shall match the bearing life of 25,000 hoist operating hours. The pitch diameter shall be at least 30 times the wire rope diameter. An equalizer sheaves may have smaller diameter provided that the small radius will not reduce the safety factor of wire rope below specified value. Application of hanger sheave (sheave mounted on swinging hanger) is categorically rejected. All sheaves shall be mounted by shaft and supported at both sides. Single side support with retainer ring is not allowed. All sheaves shall be designed with easy access and with ample space for maintenance and repair. The clamp and retainer shall be fitted opposite to the wire rope pulling force direction. Clamp and retainer bracket shall easily be removed for sheave replacement.
(8)
(9) (10)
(11)
5.1.6
Wire Ropes (1) (2) (3) (5) The factor of safety shall not be less than 6 for all ropes under concentric lifting conditions. All the wire ropes shall be right regular lay (Z-lay) wire rope 1770 N/mm2 unless agreed otherwise. Wire rope lubricant shall be carefully selected to minimize dripping problems. Wire rope dead end splice shall be a mechanical splice (wire rope clips and cotter socket are specifically not allowed), and the dead end fitting shall be articulated to allow rope end to move freely in long travel and cross travel directions.
5.1.7
Shafts, Axles (1) Axles and Shafts shall be designed with due consideration and within acceptable allowances and finishes for stress concentration at keyway, fillets, necks, lubrication holes or other notches. All splines, gear teeth, or threads shall run out smoothly or shall be undercut and the surface finish shall be uniformly smooth and free from defects. Grooves in shafting and axles shall not be located in areas subject to bending loads, unless oversized stock is provided in compensation. Gearing axle brackets shall be a split type or a bolted type for simple removal of axle and bearing. Shafts shall be properly covered or guarded for safety. Particular attention shall be made during design to ensure that the removal of the axles and shafts is facilitated by means of drawing holes.
(2)
(3) (4) (5)
5.1.8
Couplings (1) All main drive couplings shall be supplied by an internationally recognized manufacturer of couplings. Main driving shafts shall be fitted with flexible couplings. All coupling bolts shall be locked with a proper anti-loosening system such as lock wires. Grease nipples shall be fitted at OEMs greasing locations. Rotating Couplings shall be lubricated with special grease to prevent oil separation and leakage under the effects of centrifugal force.
(2)
(3)
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(4)
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. All spline couplings shall be fitted with a maximum allowable wear indicator visible without dismantling the coupling. The grease nipple for the spline coupling shall be extended to the edge of the main hoist winch drum to facilitate easy maintenance.
(5)
5.1.9
Steel Wheels (1) Trolley wheels shall be flangeless type, forged steel wheel with hardened tread. Certification of hardness depth and standard followed will be required by the purchaser. Minimum designed life shall be 50,000 trolley operating hours. If guide rollers are required, the guide rollers shall be designed to have a minimum operating life of 50,000 trolley-operating hours. Prevention of falling of guide rollers when failed shall be taken into design consideration. In normal operating condition, the guide rollers shall not cause any damage to the rail or associated fixtures. Gantry wheels shall be flanged type, forged steel wheel with hardened tread. Certification of hardness depth and standard followed will be required by the purchaser. Minimum designed life shall be 50,000 gantry operating hours. Trolley and gantry wheels shall include requirement for 100% MT on the wheel tread.
(2)
(3)
(4) 5.1.10
Pins, Pin Brackets (1) For pins which require jacking or pulling for dismantling, adequate space for a jack or a puller shall be provided.
5.1.11
Bolts (1) (2) All bolts are to be manufactured in compliance with the ISO-metric standard. Tightening torque for all fitting bolts shall be clarified by the Contractor in a form of a bolt list clearly indicating bolt location, size, materials and quantities.
5.1.12
Lubrication (1) (2) All the moving parts shall be effectively lubricated. All the lubricants specified by the Contractor shall be locally available in the country of operation and manufactured to the latest appropriate API service classifications. The lubricants initially filled in manufacturers shops shall be pre-approved by the Purchaser for their compatibilities with those lubricants used by the Purchaser. Any excess lubricant shall be trapped in removable trays or receivers. Mechanical operating parts shall be lubricated by high pressure grease gun using corrosion, resistant grease nipples of the hydraulic type to B.S. 1486: Part 1 with nipple grease straight form heads. All points on the crane requiring lubrication shall be easily accessible from permanent service platforms or walkways. All grease points shall be clearly indicated and color coded in order that all grease points requiring the same lubricant can be readily identifiable.
(3) (4)
(5)
(6)
5.1.13
Trolley Buffer
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Trolley buffers shall be installed above the trolley platform at the four corners of the trolley frame. The buffers shall be capable of absorbing and dissipating the impact of collision at full speed with rated load. The buffer shall be of sufficient stroke so as to decelerate the trolley at no more than, 4.90m/sec (0.5G) at 50% rated trolley speed. 5.1.14 Gantry Buffer Gantry buffers shall be installed on the outer most gantry trucks at the four corners of the gantry. The buffers shall be capable of absorbing and dissipating the impact of collision at full speed with rated load. The buffer shall be of sufficient stroke so as to decelerate the gantry at no more than, 4.90m/sec (0.5G) at 50% rated gantry speed. 5.2 5.2.1 Hydraulic System / Components 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. Due to the corrosive condition of the environment, cold drawn, carbon steel seamless tube, to DIN 239 Part 1 to be used and painted to specification. All couplings shall be ZINC plated passivated type for corrosion protection to DIN 2353 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 the country of operation. 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 C to 40 C. The system shall incorporate fluid over temperature protection, which shall operate to indicate the fault and stop the operation of the pump. 5.2.4 Hydraulic Fluid Reservoir (1) 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. Hydraulic reservoirs shall be fitted with level switches which are designed to switch off the associated pump when level falls below a pre-determined level. The purpose of this feature is to prevent continuous pumping of hydraulic oil in the event of hose or fitting failure. 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 cavitation in the pump during the operating cycle. 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. Reservoirs shall be constructed to prevent entry of foreign matter, including fluid contamination and moisture.
(2)
(3)
(4)
(5)
(6)
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(7)
Both fluid intake and return points shall terminate sufficiently below the minimum fluid level to prevent aeration. All hydraulic reservoirs shall have an access suitable for cleaning purposes.
(8) 5.2.5
Power Unit (1) (2) (3) Positive displacement pumps and motors are preferred. Submerged pumps are not permitted Means and good access shall be provided for filling and draining pump and motor casings in accordance with the manufacturers 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 (1) 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 backpressure shall be externally drained. Wherever possible, relief valves 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 1,000 psi 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.
(2)
5.2.8
Flow Control Valve (1) 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.
(2)
5.2.9
Check valves 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 Valves Servo valves shall be rated for maximum operating flow with a maximum pressure drop of 400 psi across both ports combined. Servo valves shall have non-bypass type 3 micron absolute full flow filters on their supply lines. Each servo valve shall have externally adjustable null.
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5.2.11
Control Valves All control valves shall be sub plate 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 manufacturers rated flow and pressure.
5.2.12
Solenoid Valves (1) All solenoid valves shall be replaceable without disassembling the valve or removing it from the sub-plate or manifold. All solenoid valves shall be protected from weather. Valves including specifically solenoid valves shall be readily accessible to allow for any adjustment, operational check, or manual operation in an emergency. Solenoids shall have continuous rating and be equipped with an LED indicator for indicating fault. 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. Solenoid valves shall be equipped to provide remote signals to operators cab / computer control and to central data collecting point. Limit switches on hydraulic cylinders shall provide position feedback to PLC and CCMS instead of solenoid valves.
(2) (3)
(4)
(5)
(6)
(7)
5.2.13
Piping (1) (2) Welded joints in hydraulic pipe work shall not be permitted. 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. All the piping shall be securely fixed and located to the structure and shall withstand internal and external vibration and be protected so as to prevent damage from external forces. Piping between actuating and control devices shall be as short as possible and pipes must be removable without dismantling equipment, components or adjacent piping. Piping shall not be used to support valves or other equipment. Where pressure-testing points are necessary, they shall be provided in accessible positions. The bores of all pipes and fittings shall be thoroughly cleaned to ensure that all scale and foreign matter is removed prior to final assembly.
(3)
(4)
(5) (6) (7)
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. Flexible hose shall be protected from mechanical damages due to interference with structure, equipment, or any moving parts.
(2)
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(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. Hoses shall be designed for burst pressures of 10,000 psig and shall be tested at 5,000 psig.
(4) 5.2.15
Assembly Test Components of the hydraulic system shall be hydrostatically tested to 150% of the safe working pressure. All hydraulic pipes shall be flushed and capped to prevent contamination before installation.
5.2.16 5.2.17
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 reservoirs volume. 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.
(2)
5.2.18
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 (125 mesh or finer). The filter shall be easily accessible for element replacement purposes without having to drain the reservoir and/or system. A magnet shall 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.
(2)
(3)
5.2.19
Actuator All actuators shall be laid out to allow easy removal and reinstallation.
5.2.20
Application for Spreader Spreader shall be hydraulic
5.2.21
Gauges (1) A high quality delivery pressure gauge shall be provided. The gauge shall be connected via a fail to-safe valve and damping loops, and rigidly mounted on a structure. It can only be read by operation of a fail-safe valve. An oil level gauge on the reservoir shall be provided at a location convenient for inspection by direct eyesight.
(2)
5.2.22
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.
5.2.23
Hydraulic Fluid
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The type of hydraulic oil for the initial fill by the Contractor shall be pre-approved by the Purchaser. Hydraulic oil of appropriate grade for the ambient conditions experienced at the site of operation shall be installed in the hydraulic system by the manufacturer prior to shipment for factory testing purposes and shall remain in the system during transport to site. Prior to filling with hydraulic oil, the entire system shall be flushed to remove foreign materials such as swarf or other contamination. Oil cleanliness shall conform to ISO 4406 Code 16/13 or better. 5.3 5.3.1 Electrical and Electronic System / Components 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) The drive system vendor shall undertake a complete power system analysis at the crane operating site that includes existing or future terminal power distribution systems. The study shall include power flow, voltage drop and short circuit calculations to be used in the selection of the crane power distribution equipment and coordination with the terminal power distribution system contractor or utility company. The results shall be submitted to the Engineer within 90 days of issue of the Letter of Acceptance. (3) The drive controls for the Main Hoist, Gantry and Trolley drives shall be AC variable frequency type using Insulated Gate Bipolar Transistor (IGBT) technology. The general requirement for the electrical drive controls is to provide reliable power for the rapid and precise handling of containers through the use of power conversion assemblies controlling AC motors for the Main Hoist, Trolley and Gantry motions. (4) Drive controllers for the Main Hoist, Trolley and Gantry motions shall be independent. (5) 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. 5.3.2 Power Supply Specifications (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) 5.3.3 Supply Voltage from Crane Service Pit AC 15.0 kV 10% 50 Hz5%, 3-phase Main drives AC Motor voltage and control power voltage to be proposed by the Contractor. Control Voltage shall be 24V or 230V 1-phase 50Hz. AC Motors AC 400 V 3-phase 50 Hz Access Lighting AC 230 V 1-phase 50 Hz Floodlighting AC 230 V 1-phase 50 Hz Receptacle Outlets AC 230V 1-phase 50Hz Alarm, intercom, and other accessories AC 230 V 1-phase 50 Hz Heating and Air-conditioning systems AC400V 3-phase 50Hz Window wiper and washer. DC 24 V Radio communication equipment, stabilized DC 24 V, 10 amp and DC 12 V, 20 amp
Power Factor and Harmonic Voltage Distortion
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(1)
Power Factor correction equipment shall be installed on each crane to actively and dynamically regulate the power factor according to the following criteria: Minimum 0.95 lagging average power factor over 15 minute demand period Minimum 0.90 lagging power factor maintained when operating the main hoist and trolley with rated load at maximum speed. Average 0.88 lagging power factor during acceleration and deceleration phase with main hoist and trolley operating simultaneously with rated load in all master controller command positions. Maintain a 0.95 lagging power factor when all drives are idle or the crane is stowed. Minimum instantaneous power factor shall not be less than 0.45 lagging
(2)
Power factor regulation shall be stepless and shall not introduce voltage transients, line notch transients or line notch ringing into the system. The power factor regulation device shall be capable of dynamically tracking the transient loading of the drive systems. Harmonics injected into the system shall be appropriately mitigated on board each crane to prevent undesirable harmonic current injection into the power system. As a minimum, total harmonic voltage distortion at the Point of Common Coupling (PCC) shall meet the guidelines defined in IEEE 519-1992 (IEE Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems) Table 11.1 (Voltage Distortion Limits). The PCC is defined as the feeder cable connecting to the container yard switchgear. Power factor regulation and harmonic voltage distortion shall be verified by monitoring at the PCC of the test crane while all other cranes are idle. Power factor and harmonic voltage distortion shall be recorded with the main hoist and trolley operating and accelerating with rated load and maximum speed and with the main hoist and trolley operating with empty spreader to top speed. Power factor recordings and tests shall be performed on each individual crane with the power quality meter on board the crane. Harmonic distortion measurements shall be performed with an analyzer located at the PCC. The Contractor shall monitor the incoming bus within 2 meters of the PCC, of each crane over the duration of endurance testing and submit a detailed report of the measurements
(3)
(4)
5.3.4
Protection against Power Surge All electrical and electronic equipment shall be protected by transient surge suppressor installed as close as possible to each component 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 the control circuit and in turn may create erroneous signals to trip off the main drives operating circuitry. All rectifiers from AC to DC shall be protected by surge absorber on the AC side as well as the DC side to have a clean DC output and with a suitable diode to maintain the voltage at optimum level. All AC contactors, DC 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.
(2)
(3)
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(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. Any other items considered vulnerable to any transient surge must be properly protected from transient surge to minimize interruption of Crane operation.
(5)
5.3.5
Protection for Power Dip/Power Failure (1) The high voltage power supply electrical circuit of the crane shall be properly designed to minimize 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 The AC Inverter Drive for the Crane shall be designed so that in case of power supply voltage dip or a complete power failure 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. The AC line low voltage power supply to the converter shall be connected in series with AC current limiting reactors to limit the short circuit current if there is any such condition when 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 minimize damages. The Contractor shall demonstrate to the Purchaser by switching off the high voltage power supply when main hoist is lowering at full speed with empty spreader or full load under spreader. Nothing shall burn out except trip of the under-voltage relay as fitted at the AC Inverter.
(2)
(3)
(4)
5.3.6
Wiring (1) *The minimum wire size shall be 1.5 mm except for factory wired panels which may include smaller size wires and communication cables. In general, minimum 2.5 mm is used (power), 1.5 mm will be used on equipment which does not have sufficient space to allow the use of 2.5 mm such as I/O modules, small limit switches, solenoid valves, encoders etc. The wiring size will be based on IEC regulations The Contractor shall ensure that all heavy current low voltage power cables are sized to include suitable de-rating for the temperature and space factor. The mixing of control wires and power wires shall not be acceptable. The Contractor shall submit all calculations on sizing of cables for review by the Purchaser. (2) Wire shall be connected only at the terminal blocks in panels, control box, joint box, or at the terminal for electrical equipment. Wire shall not be joined other than at proper terminals. All conductor wires of 4 sq. mm or smaller shall be terminated at terminal strips and at components having screw type terminals with spade or ring tongue crimped solderless lugs. All wire end terminations shall be checked and where necessary retightened prior to the Commissioning Test. (3) *All the wires shall be run in trunking, conduit or stainless steel cable trays with cover except those wires used in moving application. It is preferable that all the wires are so designed and installed inside the interior of the Structural System. Excess / slack cables shall be provided at all bend points of the cable installation to allow for expansion / contraction of the cable trays. All the wire run through holes and openings of structure shall be protected from insulation damages due to
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mechanical contact with structures. Control and signal wires (including encoder cables) shall be separated from power wires and routed through flexible conduit to avoid any interference causing false signals. Mufti-core cables may be run on cable trays or raceways with adequate cable clamps, and covered with sun-shield and mechanical protection covers. (4) (5) All cable ties shall be heavy duty and UV tolerant without degrading over time. At least 10% of control wires as spare wires shall be installed on all routes and specifically labeled as such. Vertical long distance wiring shall be designed to prevent wire breakage due to suspension of selfweight of wires or cables. Crane structure shall be electrically continuous with flexible wire links over bolted joints, pins and bearings. Wiring on the trolley, head-block and spreader shall be designed to withstand continuous vibration and impact. Each wire shall be fitted with terminal lugs and marked at both ends with ferrule with number corresponding to the number in schematic diagram.
(6)
(7)
(8)
(9)
5.3.7
Marking and Identification (1) All conductors (internal and external to panels), contactors, breakers, fuses etc shall be suitably labeled with their function name 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. On all remote I/Os, every signal shall be labeled with its function name and address code. Color or alphanumeric coding shall comply with IEC 60446 (Basic And Safety Principles For Man-Machine Interface, Marking And Identification) All terminal blocks shall be properly marked with the block number and terminal number as shown on the drawings. Groups of cables entering junction boxes, cabinets, panels and pull boxes shall be tagged as to location of the other end. All panels, junction 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. Detailed wire schedules shall be provided in every panel and junction box. Individual control devices in cabinets shall be labeled 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. Major control cabinets shall be labeled with engraved plastic description tags fastened with stainless steel screws. The method securing cables within the control panels shall utilize 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. If sticks on labels are used as an alternative to identify power and control items/devices in electrical panels, the labels shall be resistant to high temperatures and be good quality 3M type as a minimum.
(2)
(3)
(4)
(5)
(6)
(7)
(8)
5.3.8
Conduit Cable Tray and Junction Box Panels
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(1)
Conduit (rigid and flexible), 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. Flexible conduit with proper fittings shall be used between rigid conduit and pull boxes or terminal boxes 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. Rigid conduits shall be rigidly fastened to the crane structures. All conduits shall be contained within the protection of the crane structures. No conduit is to be installed across walkways or working platforms or in any way that could be considered to impede access, safety operation, etc. For conduit runs of more than 6 meters a pull wire shall be left in place. *Top entry in to terminal/junction boxes shall be avoided A drain hole(s) shall be provided at the lowest point in each junction box. Ladder type, open electrical cable tray shall be stainless steel (T304 Grade) and fixed to the structure using stainless steel bolts and nuts. The type and fixing of cable tray shall be reviewed by the Purchaser and a procedure for repairing damage or cut section edges shall be presented for approval. All exterior electrical panels and junction boxes shall be constructed from stainless steel (T304 Grade) NEMA 4X enclosure of a quality grade which will not display corrosion throughout the lifetime of the crane. Vertically hinged doors shall be provided, having a facility to secure in the open position during maintenance activities. Panels which have doors secured by means of stainless steel clips and bolt are preferred. Environmental Protection shall be IP65 minimum and no fixing bolts shall be permitted to pass through the walls of the enclosure. It shall be possible to remove and replace all internal components without removing the back panel. Small electrical termination/junction boxes for lighting may be manufactured from plastic material.
(2)
(3) (4) (5)
(6) (7) (8) (9)
(10)
(11)
5.3.9
Electrical Trunking (1) Electrical trunking and trunking covers shall be stainless steel (T304 Grade) and free from sharp edges or sharp corners to protect the wires. Trunking shall have appropriate partitions to separate power and control wires, and clamps to prevent excessive wire movement in the duct. Trunking shall be designed to prevent water ingress. Nevertheless the trunking shall not trap any water in case of water ingress.
(2)
(3)
5.3.10
Motors (1) Motors shall be sized according to FEM 3rd edition, booklet 5 Electrical Equipment. The minimum rating and duty of the motors, designated according to IEC 34-1 standard, shall be as follows: Motors Main Hoist motors Trolley travel motors Gantry travel motors Minimum Duty Ratings required S1 Continuous duty S1 Continuous duty S1 Continuous duty
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(2) (3) (4) (5) (6)
Motor terminal box shall be fitted facing an open space for maintenance. All the main motors shall be fitted with space heaters. Cables fitted to motor terminal boxes shall be glanded. Ample space shall be provided for inspection of AC Induction motor itself. All motors shall be connected with an earthing wire from the motor body to the nearest support metal structure to provide a proper earthing connection. Motor cables shall be braided screened to eliminate interference. Outdoor motors shall be specified to provide a minimum of IP55 protection
(7) (8) 5.3.11 Brakes (1) (2) (3) (4)
Ample space shall be provided around brakes for inspection and maintenance works. Brake discs shall be dynamically balanced. Brakes disc shall not sustain damages due to an emergency stop operation. Main hoist and trolley brakes shall be approved by the Purchaser. The deceleration shall be accompanied electrically and regeneratively with the brakes applied only when the motion has slowed down to essentially stopped condition Brake linings to be of non-asbestos material. The main hoist brakes shall be protected from ingress of grease from external rotating machinery. The main hoist brakes shall be fitted inside an enclosure. The enclosure shall be designed to provide for ease of brake maintenance with suitable removable doors.
(5) (6)
(7)
5.3.12
Transformers (1) (2) (3) Transformers shall be dry type. The location of transformers shall be selected not to raise panel temperature. All transformers shall be connected with an earthing wire from the transformer body to the nearest support metal structure to provide a proper earthing connection. Short circuit protection shall be provided on the load side / output of the transformers.
(4)
5.3.13
Enclosures (1) All external components mounted within outdoor enclosures must be designed to allow for wind driven rain and conform to minimum class of IP55. Control boxes and junction boxes exposed to the weather shall be manufactured from stainless steel (T304 Grade). Other outdoor boxes such as enclosures for lights, switches and small terminal boxes, which are commercial products, shall be provided in IP55 rated cast iron, painted steel or in plastic material.
(2)
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5.3.14
Meters, Counters (1) All meters shown in (2) below shall be enclosed in a purpose built single cabinet mounted inside the electrical 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. The following individual meters and counters shall be installed in the electrical house in addition to ordinary meters on the control panels. The display for all meters shall be mechanical digit type i) ii) iii) iv) v) vi) vii) viii) (3) Main Hoist Drive Hour meter Trolley Drive Hour meter Gantry Drive Hour meter Control On or Occupied Hour meter Twist lock counter (For function refer to 4.9.1 (10)) Spreader meters and Indication). Hoist Brake counter Trolley Brake counter Overlapping Main Hoist & Trolley Hours
(2)
In the operator's cab the following meters shall be provided, i) ii) Trim, & Skew meters. Load Indicator in MT.
(4)
On the spreader mechanical type meters shall be provided (unless otherwise specified) as follows i) ii) Non resettable mechanical digit Twist lock counter (For function refer to 4.9.1(10) Spreader Meter Indication) Non resettable operating hour meter (hydraulic pump motor operating hours)
5.3.15
Limit Switches (1) Mechanical lever type limit switches shall be utilized for safety over-travel applications and shall be easily and quickly accessible for adjustment and maintenance. All limit switches shall be mounted on a uni-strut (C-rail) non-corrosive material. Trolley Travel i) ii) Over travel limit switches shall be mechanical lever type. There shall be three (3) proximity limit switches with magnet actuators for speed slow down, speed check and stop. Mechanical lever arm switches shall be used for normal stop and over-travel whilst proximity switches shall be used for slow down.
iii)
Hoist i) ii) Over travel limit switches for hoist shall be weight pull cantilever type. There shall be three (3) cam switches installed on the hoist drum for speed slow down, speed check and stop.
(2)
Application of proximity switches shall be fail-to-safe application. Short circuit status created within the switch at the time of its failure must prevent further motion which is controlled by the switch, and such short circuit fault must be registered for tracing.
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(3)
Special attention is drawn to the twist lock Locked and Unlocked signals from the proximity switches, which shall be fail-to-safe. In order to avoid damage to the spreader and the container by lifting one end only, the proximity switches for Locked and Unlocked signal shall be individually connected to the PLC through an I/O module. When the PLC detects a shortcircuited proximity switch on Locked or Unlocked the hoisting motion shall be immediately stopped. Further motion will be restricted to lowering only.
5.3.16
Space Heaters (1) Space heaters shall be fitted to the following locations i) ii) All AC and DC motors above 7.5kW All control panels.
5.3.17
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. The use of adhesive labels as identification shall not be acceptable.
5.3.18
Encoders Electronic pulse encoders shall be used for position feedback for main hoist, trolley and gantry travel motors. For trolley and hoist position, absolute encoders shall be used.
5.3.19
Circuit Breakers (1) (2) All electrical circuit breakers shall be molded type circuit breaker, except otherwise specified. Circuit breakers shall be designed to isolate defective circuits such as over current or short circuit conditions. When the molded type circuit breakers are tripped, the lever shall stay at mid position to show that it is tripped. The lever shall be pushed down once before it can be switched on again. Mid position of the lever is to show that the outgoing circuit is faulty. Earth Leakage Circuit Breakers (ELCB) shall be used to protect the flood light system in individual branch so that only the affected area will lose the lighting and not the other healthy circuits. Circuit breakers shall be fitted indoors only. If fitted outside, it shall be enclosed inside a waterproof stainless steel box.
(3)
(4)
(5)
5.4 5.4.1
Crane Motion Controls 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 Electrical Control House and operators cab which are operated in the 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
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also be treated so as to resist attacks and entry of bugs and mites such as termites, beetles, fly, etc.
(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 equipped according to the latest industrial standards. This clause does not apply to E.House panels which are accepted to be open type. Ambient Temperature - the system shall be designed and operated in an ambient temperature between -250C to +400C. It shall also withstand a storage temperature range between -250C to +500C. Relative Humidity - The operating and storage humidity of this system shall have a range from 8% to 100% (non-condensing). 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. Control Voltage - the system shall be designed and operated with a power supply as specified elsewhere. 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. 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 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. 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) (ii) (iii) (iv) (v) PLC and discrete I/O modules. Public address system Intercom system Crane computer system and on-board CCMS. Trunk radio
(3)
(4) (5)
(6)
(7)
(8)
5.4.2
Programmable Logical 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. A standard approved bus system shall be provided. If Profibus is selected, the installation shall conform to the Profibus guidelines. The PLCs shall be able to intercommunicate with each other through a network following the Open System Interconnection communication architecture. 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
(2)
(3)
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cartridge-insert space for at least 8 modules excluding 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. 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. 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 memory for future developments.
(5)
(6)
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. LED shall be provided to show the healthy status of the incoming supply and the outgoing supply. This shall be a standard feature of this power supply unit. 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.
(2)
(3)
5.4.4
Discrete I/O Modules (1) The discrete I/O modules shall be the same manufacturer as the PLC and 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 2.6.6 (Climatic Condition). 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 terminals. Individual, fused power supplies shall be provided for each module. Common fuse protection system shall not be acceptable. All solid state output points shall be protected with the installation of switchable relays where the output energizes or de-energizes relay coils, mounted as near to the output module so as to reduce cable runs to a minimum. All solid-state output points shall be protected with fast blow fuses for system protection if this protection is not incorporated into the Output module. Replacement of the fast blow 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. The discrete I/O modules shall be equipped with a removable tab that indicates I/O address code and Function. The Contractor shall label all I/Os as per wiring schematics. There shall be at least 10% spare Input and 10% spare Output ports for each voltage level. Space in the cubicles or junction boxes for adding I/O modules shall be provided. Power supply failure to all I/O modules shall be monitored and stop crane functions. Input and Output signals shall be monitored and stop crane functions in the event of open circuit failure.
(2)
(4)
(5)
(6)
5.4.5
Motion Control Switches in Operators Cab (1) Main hoist and gantry motion control (right console)
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A right-hand control console shall control main hoist and gantry motion with one joystick controller. The controller shall be spring returned and lockable at zero notch and released by push button switch incorporated into the controller joysticks. Fore and aft movement for main hoist, lowering and hoisting left and right movement for gantry travel. Selection of motions shall be on a first-come-first-served basis. (2) Trolley motion control (Left console)
A left-hand control console shall control trolley motion with one joystick controller. The controller shall be spring returned and lockable at zero notch and released by push button switch incorporated into the controller joysticks. (3) Following motion control switches shall be laid out on both consoles. i) Twist lock Lock/Unlock changeover switch. A heavy duty, oversize lever switch on Right Hand Console positioned far enough away from the Master Controller that the operator is required to remove his hand from the Master Controller to operate. Spreader Extend/Retract control switches. One push button switch to automatically correct spreader position to Zero Skew position. Window wiper On/Off switches. Window washer On/Off switches. Warning siren push button switch. This warning siren push button switch shall activate the same amplifier speaker as the landing by-pass, twist lock by-pass alarm sound. Other control switches necessary for normal operation. Emergency stop push buttons. to cut out main hoist, trolley and gantry power. to stop diesel engine and labeled Engine Stop. The button shall be a mushroom type with raised guard to prevent accidental tripping. If operator hits this button switch to stop the diesel engine, the battery relay fitted with a timer of 300 500 sec. shall be activated. After time is elapsed, the battery relay shall drop out and cut off battery power to avoid a flat battery as described above. (4) Following equipment start-stop switches and selectors are less frequently operated switches shall be installed either on the control consoles, or an independent panel within operators reach from his seating position. i) ii) (5) Spreader Electrical Power On/Off push button switch. Lighting switch.
ii) iii) iv) v) vi) vii) viii)
Indicating lamps on the console i) ii) iii) iv) V) Auxiliary power source On indicator. Spreader position indicator (20 or 40). Spreader Zero Skew position indicator. Other indicating lamps as necessary to indicate operable condition with the lamp On. Double 20
(6)
Interlock override spring return key switches Labels shall be provided for each switch and indicator in English language, approved by the Purchaser.
5.4.6
Remote Motion Control (1) The Contractor shall provide Hoist, Spreader and Gantry Wheel Turning remote control station, at ground level on the Nearside of the crane facing the inboard side of the crane in order that the
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Purchaser can carry out operational checks, maintenance and service functions on the Hoist, Spreader and Gantry Wheel turning. (2) The following switches shall be included in the Remote Motion Panel, indicator lights shall also be fitted to indicate correct function: i.) ii.) iii.) iv.) v.) vi.) vii.) viii.) ix.) x.) xi.) xii.) xiii.) xiv.) xv.) 5.5 Hoist Raise Hoist Lower Trolley Forward Trolley Reverse Trim Left Trim Right Spreader Extend Spreader Retract Twistlocks LOCK Twistlocks UNLOCK Emergency Stop Pushbutton Key Switch for Authorized Person to operate Control ON Pushbutton Landed Bypass Twistlock Bypass
Operational Safety Interlocks (1) The Contractor shall provide hardware/software status and an operational verification on all motion protection devices, such as, but not limited to; limit switches, proximity switches, cam switches, speed sensors, encoders, brakes, couplings, solenoid coils and solenoid valves. The Contractor shall display the safety Interlock verification status on the CCMS. Failure of any safety interlock shall inhibit all motions. In addition to all the necessary protection of structural, mechanical and electrical/electronic system and system components, following interlocks are required.
(2)
(3)
5.5.1
Main Motions Interlocks (1) Main hoist (hoisting or lowering) motion to stop: i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) At upper and lower hoist limits. With brake malfunction or not activated or not in correct position. With wire rope slack either with or without spreader. With over-speed. With motor over-heat. Hoisting with an incomplete lock position of twist lock after the spreader is landed on a load fitted with corner fittings. Hoisting with an incomplete unlock position of twist lock. When the actual position of any of the twistlocks is different from Lock/Unlock command switch command. With the activation of an E Stop command. With a position check fault. With loss of lubrication oil pressure if forced lubrication is applied. With the spreader interlock incorrect spreader size, unlock & lock signal interlock, twistlock selector interlock. With the master controller interlock or check fault. PLC / bus transmission error or fault. Landing limit switch detected as not at its intermediate position (spreader attached with a container). When the operator turns the twist lock switch from unlocked to lock or from locked to unlock while the spreader is not sat properly on top of a container. Operator must
xii) xiii) xiv) xv)
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xvi) xvii) xviii) xix) xx) (2)
turn the twist lock switch back to original position to continue hoisting operation. While the gantry brake is energized. Torque verification fault. Drive unit protection on Over-Voltage (OV), Over-Load (OL), Under-Voltage (UV) and Over-Current (OC). Motor side protection on Over-speed (OS), OC, and OV. Speed deviation / control check fault.
Main hoist (hoisting or lowering) motion to slow down, or in slow speed (20%): i) Two main hoist slowdowns shall be provided to cater for empty spreader and loaded with a container condition on hoisting. Both empty spreader slow down and spreader attached with a container slow down shall be submitted to the Purchaser for approval. Both cases shall not hit the emergency stop limit switch striker with sufficient height to clear the combination of 9-6 high containers. Lowering near the lower hoist limit. Hoisting until slack wire rope is taken up. When Twist-lock or Landing by-pass is being depressed by the operator to alert people underneath the crane by an audible alarm that it is dangerous and by-pass of interlock is being used by the operator. When Limit Switch or Bypass Key is activated Hoisting shall be inhibited when the load cell measuring system detects 110% overload. Lowering shall be permitted, but at a reduced speed, 10% of normal lowering speed.
ii) iii) iv)
v) vi)
5.5.2
For Trolley Operation (1) Trolley motion to stop: i) ii) iii) iv) v) At travel end limits. With brake malfunction. With motor overheat. With the cab access swing door in unlocked condition. When the operator turns the twist lock switch from unlocked to lock or from locked to unlock while the spreader is not sat properly on top of a container. Operator must turn the twist lock switch back to original position to continue trolley operation. Motor Over-speed. Torque detection fault. Converter and or inverter fault. Speed Supervision fault. Motor differential fault. (Two motor system, if applicable, shall have individual motor protection devices). Trolley positioning fault. With the Master Controller interlock or check fault. With the activation of an E Stop command.
vi) vii) viii) ix) x) xi) xii) xiii) (2)
Trolley motion to slow down, or in slow speed: i) ii) Near the travel limits forwards and backwards with a safety margin for full deceleration distance before hitting the end stopper. When Twist lock or Landing by-pass is being depressed by the operator to alert people underneath the crane by an audible alarm that it is dangerous and by-pass of interlock is being used by the operator. When Limit Switch or Bypass Key is activated
iii) 5.5.3
For Gantry Travel Operation (1) Gantry motion to stop: i) ii) With brake malfunction. With motor overheat.
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iii) iv) v) vi) vii) viii) ix) (2)
While the main hoist brake is energized. Converter and or inverter fault. Over-speed fault. Torque detection fault. With the Master Controller interlock of check fault. Motor overload. With the activation of an E.Stop command.
Gantry travel warning sound and warning lights shall be kept activated while the gantry control lever is moved to either direction. Gantry travel anti-collision device shall be installed to detect the close proximity of another Crane or container stack, which is likely to cause collision. The device shall: i) ii) iii) Operate audio warning signal in Operators Cabin and via a remote device to warning personnel at ground level. Operate motion Fast Stop. Prevent wheel turn or stop a wheel turn if already in progress
(3)
5.5.4
Spreader Functional Interlock i) Twistlock function a) b) c) d) e) f) ii) Interlock permit on the zero notch of all master controllers. Interlock permit on landing delay on signal. Load cell interlock for unlock function. Signal interlock on unlock and lock sensors. Interlock on Twistlock selector and Twistlock signal. Interlock on holding signal.
The Spreader twist lock movement shall be mechanically and electrically interlocked with the spreader landing detection so that lock movement is prohibited unless all the twist locks are confirmed as inserted into the container corner fittings. The landing signal shall allow for a one (1) second time lag to indicate the completion of landing to the operator and to activate the interlock The premature unlocking movement with a suspended load shall be prohibited by means of an electrical interlock. There shall be no physical movement of the twist locks on the spreader even though the twistlock switch may be turned to Unlock position. Audible and visual alarms detectable at ground level and at the inside of the operators cab shall be activated by this premature movement of switches to unlock. Any such premature movement of switches shall deactivate all crane motions. Both audible and visual alarms shall cease when the twist lock switch is returned to its original position. Alarm tone to be approved by the purchaser. Telescopic function a. b. c. Interlock on the landing or lock signal. Spreader size selector interlock When telescoping, hoist shall still be enabled unless position fault occurs for 40 seconds
iii)
iv)
v)
The twistlock shall remain in their last position after power interruption. i.e. when power is resumed.
5.5.5
Cab Entrance Door Interlock. Refer to 5.5.2
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5.6 5.6.1
Communications Intercom System (1) A communication system which allows selective and partly (simultaneous) communication among the following locations shall be installed: Electrical Control House Two central locations at ground level, each side of the crane Trolley platform Operators cab Handsets shall be provided. The intercom system shall be functional for at least 30 minutes after the engine has been shut down. (2) Speakers Two talkback speakers with volume control in a lockable cabinet shall be fitted inside the checkers cab under sill beam and in the operators cab facing inside to allow communication between operator in the operators cab and ground staff. An amplifier and a microphone shall be installed in the operators cab.
5.6.2
Radio Communication System The radio and UHF set shall be provided by the Purchaser. The Contractor shall supply DC outlet for radio communication equipment.
5.6.3
Data Communication System The Contractor shall supply DC outlet and bracket for terminal
5.6.4
Public Address System A public address system consists of an amplifier with a hand free microphone (goose neck type) shall be installed in the drivers cab. Loud speakers of waterproof construction shall be installed at the following locations: On one leg on each side of the crane at diagonal corners
5.6.5
Operation Centre / Maintenance Office Station This Clause is not used.
5.7 5.7.1
Crane Condition Monitoring System (CCMS) 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 and PLCs. The Crane Condition Monitoring System shall be installed in the following locations: (1) In the Electrical Control House of each Crane (hereinafter referred to as the On-Board Crane Condition Monitoring System, On-Board CCMS.
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5.7.2
CCMS Description The On-Board CCMS 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, keyboards 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. Provision shall be provided at 2 locations, inside Electrical Control House for main computer and screen and Operators Cabin for display. The Contractor shall provide a fault display unit in the Operators Cabin which shall display Alarm Trips and Faults. All text messages, graphics, displays, monitoring, data and status shall be accessible in both English and Polish languages. The Contractor shall provide technical training for the engineering staff of the purchaser. The training shall be conducted in language specified by a competent person representing the Contractor. The Contractor shall provide 6 sets, reproducible maintenance manuals, and operator manuals in both English and Polish languages, recommended spare part list and spare part manual in English to the Purchaser. The CCMS shall have proper documentation of circuit diagrams, source codes, hardware and software and associated peripherals.
(2)
(3) (4)
(5)
(6)
The Contractor shall submit within three (3) months after the date of award of contract, the CCMS system architecture for review by the Purchaser. 5.7.3 On-Board Crane Condition Monitoring System (On-Board CCMS) (1) General Specification The On-Board CCMS is located in the Electrical Control House 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 with in conjunction with the PLCs to provide continuous monitoring, diagnostics, data collection on the cranes operating systems, in all modes of operation and supply status. i.e. Crane Power or Shore Power. The Contractor shall provide a UPS, suitably rated to allow as a minimum, 30 minutes of full access to the CCMS in the event of power failure. The system shall also provide Crane operational data that is used to determine Crane performance, maintenance scheduling, spare part details and daily/shift reports. 5.7.4 On-Board CCMS Software Requirements
(1)
The On-Board CCMS operating system shall be a 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 access any software, PLC, remote PLC, remote I/O and Drives without affecting the real time condition monitoring of the crane control system. The Contractor shall develop a user interface software to meet the following requirements:
(2)
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i)
The software shall be able to run on new operating platform. The operating platform and user interface software has to be approved by the Purchaser. The Contractor shall supply a complete back-up system that shall include the operating system and application software. The back-up system shall be supplied as follows: a) Spare Hard Disk containing operating system and application software, with all parameters and settings set as required for the crane. Stored in DVD-ROM.
b)
The Contractor shall confirm that in the event of a system failure, reloading of the system shall be completed in an acceptable time frame, approved by the Purchaser. The operating system shall be an English version with loading instructions in English. ii) The software shall be commercially available 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 1000 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. The export data files shall include but not be limited to txt, csr, out format.
iii) The proposed structure of the database system for storing the CCMS data and information has to be discussed and approved by the Purchaser. iv) The software shall allow engineers to access (read and write) the ladder diagrams of the PLC, remote PLC and Drives. Forcing-on and forcing-off of switches, contacts and relays on the PLC ladder diagram, Parameter adjustments and internal settings of both PLC and Drives 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. v) The On-Board CCMS shall be able to copy or upload PLC software program to each PLC within 2 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 a pendrive for printing. Time response graphs displaying different signals simultaneously shall be incorporated in the On-Board CCMS.
vi) 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. Original Licensed software shall be used, these include the operating system application software. One original licensed copy each of the software package shall be provided for every computer in the Agreement. All software instructions, including operating systems shall be in English language.
5.7.5
On-Board CCMS Hardware Requirements (1) The On-Board CCMS shall be mounted in an environmental controlled, industrial type cabinet that can withstand vibration. The On-Board CCMS shall consist of but not limited to the following items: i) Computer
(2)
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The personal computer shall consist of the following hardware: The CPU shall be a standard parameters or better processor with a clock speed of not less than 2.4GHz, at least 4GB on board memory, 512KB cache, 500GB hard disk with a speed of 7200rpm in SATA format, one wireless PCI card B/G/N, one unit of DVD Writer, key board, mouse, one unit of 19 LCD flat screen monitor, two (2) parallel COM ports and USB ports, an Ethernet card and a portable hard disk with 1TB memory for connection to the parallel interface for downloading of data and printer. Heat sink shall be installed with fan mounted on the heat sink. DVD drive shall be mechanically lockable. It is the intention of the Purchaser to standardize the make and model of the OnBoard CCMS computer. The details will be released to the Contractor ii) Remote Displays Remote Display Units shall be as a minimum One Line Text display units, of an approved design. Faults display code and text shall be agreed between the Contractor and Purchaser. Units shall be positioned in Operators Cabin and Checkers Cabin or Platform at ground level. 5.7.6 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 30 minutes, to afford access to all information in the event of power failure, either relating to the main generator or 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. The main screen shall lead the user to separate screens, divided into the following major application screens.
(3)
Example:
MAIN MENU DATA/CONTROL
SCREEN #1 HOIST
SCREEN #2 GANTRY
SCREEN #3 TROLLEY
SCREEN #4
SCREEN #5 SPREADER
SCREEN #6
SCREEN #7
(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: 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, Brake Chopper Units, Brakes, Contactors, Relays and other devices, applicable to the
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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, 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: Main Power Supply, Shore Supply, Hydraulic Motors and Pumps, and Spreader Functions (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. Only over-temperatures will be displayed for hoist trolley and gantry motors
The operating voltages and currents for all the Converters, Invertors, Braking Chopper Units, Brakes and Motors The status of the high voltage switches, low voltage switches, protection relays. 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 Cranes 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 (%). Hoist motion interlocks, Spreader interlocks, Slack Rope, Load Cell measuring. Hoist Inverter status, interlocks, performance and protection devices. Hoist Brake Function, Operation and Brake Proving shall be displayed Function and Operation of Limit Switches, Cam Switches, Encoders, TachoGenerators and Pulse Encoders. Hoist Speed, Slowdown, Speed Check, Stop and Positioning. Twistlock Bypass Log with time and date
ii) iii) iv) v) vi) vii)
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viii) ix) (7)
Landed Bypass Log with time and date Limit Switch/Interlock Bypass Log with time and date.
The following, as a minimum, data associated with the Trolley 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 (%). Trolley motion interlocks, Spreader interlocks, Trolley Inverter status, interlocks, performance and protection devices. Trolley Brake Function, Operation and Brake Proving shall be displayed Function and Operation of Limit Switches, Cam Switches, Encoders (Absolute and incremental) Trolley Speed, Slowdown, Speed Check, Stop and Positioning. Limit Switch/Interlock Bypass Log with time and date.
ii.) iii.) iv.) v.) vi.) vii.) (8)
The following, as a minimum, data associated with the Gantry 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 (%). Gantry Inverter status, interlocks, performance and protection devices. Gantry Brake Function, Operation and Brake Proving shall be displayed. Function and Operation of Limit Switches, Cam Switches, Encoders, TachoGenerators and Pulse Encoders. Gantry Speed, Slowdown, Stop and Positioning. Collision Bypass log with time and date
ii.) iii.) iv.) v.) vi.)
(9)
The following, as a minimum, data associated with the Spreader 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 (%). Spreader motion interlocks, Spreader Retract and Expand interlocks, Spreader Motor status, interlocks, performance and protection devices. Spreader Electrical Function, Operation and Proving shall be displayed Function and Operation of Limit Switches, Cam Switches, Encoders, TachoGenerators and Pulse Encoders. Spreader Stop and Positioning. Spreader Twistlocks, Lock and Unlock, including indication and By-Pass status. Function clock shall display actual operation time of Expand/Retract, Twistlock Operation and Flipper Operation.
ii.) iii.) iv.) v.) vi.) vii.) viii.)
(10)
The following, as a minimum, data associated with the General Crane Control System shall be displayed. i.) ii.) iii.) iv.) Emergency Stop operation where the status of individual stations shall be displayed in graphical format Green OK & Red Activated Main Generated Power Supply, Auxiliary Power Supply, and UPS function, status and performance. Function Operation and Status of Circuit Breakers, Fuses, Contactors, Relays and Protection devices, shall be displayed. Operator Mode Selection, Function and Status
5.7.7
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
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standard editor. All data shall be easily downloaded to a floppy disk 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 Purchasers 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 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 Purchasers 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. 5.7.8 Equipment Performance Data and Operation Log (1) The CCMS shall provide records on equipment performance and operation data. This data shall include but not limited to the following: i.) ii.) iii.) iv.) v.) vi.) vii.) viii.) ix.) (2) Frequency of breakdowns Twist Lock Count Main Hoist Hours Trolley Hours Gantry Hours Overlapping Main Hoist & Trolley Hours Occupied Time Average Cycle Time Number of containers handled according to the size and weight of the containers.
This 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. 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 Purchasers engineering personnel.
5.7.9
Remote Crane Condition Monitoring System (RCCMS) (1) General Specification The RCCMS shall allow engineering personnel to perform diagnostic, condition monitoring of the CCMS in the engineering workshop remote from the Cranes using a wireless network
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connection. The RCCMS shall be able to perform all the functions of the On-Board CCMS and the following additional requirements: i) All the information and functions on the Cranes On-Board CCMS specified in this Specification shall be available for the RCCMS. All the alarm and fault messages on the Crane, which requires the attention of engineering personnel, shall interrupt the RCCMS. The response time for the alarm and fault messages shall be less than 5 seconds. After the interrupt has been acknowledged, the present task shall be able to continue. The fault messages shall include but not limited to the following: a) b) c) d) e) iii) Crane ID Location Fault code / messages Part code Date/time reported
i)
There shall be a server for the CCMS by each drive supplier. The RCCMS computers shall be able to access to the On-Board CCMS of any Crane via the respective server and CCMS software.
5.7.10
RCCMS Software Requirements The RCCMS software shall be able to perform all the On-Board CCMS functions.
5.7.11
RCCMS Hardware Requirements
(1)
The RCCMS shall consist of but not limited to the following items: i) Computer
The personal computer shall consist of the following hardware: The CPU shall be a standard parameters or better processor with a clock speed of not less than 2.4GHz, at least 4GB on board memory, 1024KB cache, 500GB hard disk with a speed of 7200rpm in SATA format, one wireless PCI card B/G/N, one unit of DVD Writer, key board, mouse, one unit of 19 LCD flat screen monitor, two (2) parallel COM ports and USB ports, an Ethernet card and a portable hard disk with 1TB memory for connection to the parallel interface for downloading of data. The heat sink shall be installed with a fan mounted on the heat sink. It is the intention of the Purchaser to standardize the make and model of the RCCMS computer. The details will be released to the Contractor. ii) iii) iv) One unit of UPS with a minimum of 30 minutes One unit of laser jet printer. One unit of server. The function of the server is to allow RCCMS to access to all the information on On-Board CCMS on the cranes specified in this tender. It shall also enable the On-Board CCMS to send real time information, status and alarms by means of interrupts to the RCCMS. One unit of standby server. The function of the standby server is to automatically resume the servers function when the server is not functioning. Antennas (including mounting kit), base unit, power supplies and cables necessary to
v)
vi)
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receive wireless data from the RMG cranes and interface with the workshop server. Equipment to be mounted and located remotely in the workshop shall be supplied free of charge by the Contractor to the Purchaser in advance of the crane delivery. Remote equipment shall be installed by the Purchaser according to drawings and specifications provided by the Contractor.
5.7.12
Server(s) (1) The server shall allow the RCCMS computers to access to the On-Board CCMS computers including file transfer, crane diagnostic, receive status and alarm messages. It shall also enable the On-board CCMS computers to send status data and alarms by means of interrupts to the RCCMS and computers (outside the terminal). A standby server shall be configured to automatically take over the operation when the main server fails. The server shall be modular and upgradeable to enable all the On-Board CCMS to be served.
5.7.13
CCMS Reporting Format The CCMS reporting format shall be offered to the Purchaser for approval.
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6 6.1 6.1.1
COMMON ITEMS Walkways, Stairs, Ladders and Platforms Applicable Code or Engineering 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 shall be applied for flat structural surface if used as walkways. The design of walkways, stairs and ladders shall comply with the requirements of OSHA, Poland Regulation and all local regulations.
(2)
6.1.2
Stairway Requirements (1) (2) Access to the operators cab shall be by stairways with appropriate landings throughout. Landings shall be provided for stairs at intervals of not more than 8 meters. The gradient of stairs shall not exceed 50 degrees. Stairways shall be designed to avoid tripping, skidding, ducking or crawling. Clear headroom of 1.9m shall be maintained throughout the stairways. The height of kick plate from the stairway tread level shall be minimum 100mm. The kick plate shall be continuous along stairways, and constructed of minimum 100mm wide steel strip of minimum thickness 4.0mm. Stairway treads shall be expanded metal or open grid metal construction, hot dip galvanized. Stairs 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.
(3)
(4)
(5) (6)
6.1.3
Ladder Requirements (1) Vertical ladders are allowed at the ground level and last part of access to the operators cabin and the rise shall not be more than 5 meters. Approval must be obtained from the Purchaser if vertical ladders are used elsewhere. Ladders 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.
(2)
6.1.4
Platforms Requirements (1) Platforms shall be designed to avoid tripping, skidding, ducking or crawling. Clear headroom of 1.9m shall be maintained throughout the platforms. Platforms 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. A permanent inspection and maintenance platforms shall be provided on top of head block to facilitate cab maintenance from outside. Permanent inspection and maintenance platforms shall be provided under the trolley for inspection and replacement of wire ropes if access is required for this purpose. For NCSC design, where no maintenance is required, the platform may be omitted.
(2)
(3)
(4)
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6.1.5
Walkway Handrail Requirements (1) The height of handrails shall be 1000mm to 1100mm and an intermediate rail height 685mm for a level walkway. The height shall be increased as necessary 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. A special permanent handrail or safety line shall be provided above inside top edge of trolley girders to prevent accidental fall of operators or maintenance personnel who are required to work on the girder. The design to be approved by the Purchaser. As an alternative, the Contractor may provide the two walkways below the top of the beam girder level. The actual level shall be a design that will not cause any inconvenience to both the operator and maintenance personnel. The height of kick plate from the walkway tread level shall be 100mm. The kick plate shall be continuous along walkways and platforms, and constructed of minimum 100mm wide steel strip of minimum thickness 4.0mm.
(2)
(3)
6.1.6
Cab Access Platforms The cab entrance platform or walkway at the access/transfer point shall be provided at the same level as cab platform, and shall be equipped with tubular frame construction, inward opening and self-closing (by gravity) hinged doors on trolley side and gantry structure side. Opening of the door shall prohibit the trolley motion.
6.1.7
Walkway Requirements (1) Walkways shall be designed to avoid tripping, skidding, duckling or crawling. Clear headroom of 1.9m shall be maintained throughout the walkways. Special non-skidding treatment shall be applied for flat structural surface if used as walkways. 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.
(2)
6.2 6.2.1
Illumination and Lighting Walkways, Stairs, Ladders, Cab Access
(1)
The supply voltage for lighting sources shall be as specified in 5.3.2 (4) (Main Power Supply). Special consideration to be given to minimize phase unbalance The lighting system shall provide adequate illumination for all ladders, platforms, walkways, machinery house and operator's cab.
(2)
6.2.2
Work Area Floodlights (1) A floodlight system shall provide adequate lighting to all work areas of the Crane. An illumination level of 150 Lux or more at the ground level measured at 7.5m either side of the centerline of the Crane along entire trolley travel range, and specifically 250 Lux or more under the trolley measured at ground level 7.5 metres either side of the centerline shall be achieved. Such floodlights shall not cause glare in the operators cab for the operator or shadows which make it difficult to safely operate the Crane. The gantry runways shall be well illuminated for viewing from operator's cab for gantry travel. These lights shall be installed at sufficiently high position to avoid glare to terminal tractor drivers.
(2)
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(3)
All floodlights are to be fitted with safety chains to prevent from falling off the structure if the main fixings fail. A photocell shall be installed to switch off floodlights in daylight but an override switch shall also be incorporated to energize the lights in case the photocell should fail to the open condition.
(4)
6.2.3
Floodlights on Trolley Powerful spot lights (4 nos. minimum) shall be mounted under the cab to provide excellent viewing of ground operations under the trolley at night. The floodlights shall be mounted such that it will not obstruct the view of the driver during container handling operation.
6.2.4
Emergency Lighting for Escape Routes Battery operated lamps shall be provided inside the operators cabin electrical control enclosure, enginealternator enclosure and on the trolley platform.
6.2.5
Lighting Control Switches Light switches shall be gathered in several convenient locations to allow centralized control. Three (3) - Onoff control switches for all the operational lights and walkway lights shall be located at ground access to the crane, near the Electrical Control House close to the operators passage and in operators cab to allow switching from any of the three (3) locations.
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. All work area lamps and flood lights shall be securely fixed to structures, protected against vibration and fitted with safety ropes to arrest the fall of the lamp should the main fixings fail.
6.2.7
Fluorescent Lamps The Fluorescent lamps shall be rapid-start type. Exterior lighting fixtures shall be specially designed for outdoor conditions. Externally mounted lighting fixtures shall have an IP55 class of protection.
6.2.8
Access for Lights Maintenance All light fixtures shall have safe access for replacement of bulbs.
6.3 6.3.1
Painting and Protective Coating Paint System General (1) The Contractor shall submit the preparation, cleaning, painting and protection against corrosion as specified hereafter, of the whole of the work to be provided in the Specification. (2) Surface not required to be painted, but which are adjacent to steel work which is to be cleaned and painted, shall be protected by appropriate masking during cleaning and painting of the adjacent work. (3) Special care shall be taken during manufacture to ensure that foreign matter is excluded from all working parts of the crane. (4) All parts of the crane shall be surface treated during manufacture to ensure their protection from the effects of moisture during storage, transport and erection. All bright surface and machined parts, including gear teeth, screws threads, etc., shall be protected by a suitable approved rust preventive compound. Particular care shall be taken with the protection of anti-friction bearings and enclosed gears and shafts.
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(5)
All metal surfaces shall be thoroughly cleaned to bare metal, removing rust, loose scale, dirt, grease, oil, dust and other foreign materials in accordance with 6-3.2 and 6-3.3 hereof. Particular care shall be used at joints and all other places to which access for cleaning is difficult. Faying surfaces of structural members intended to be clamped together by bolts shall be shot blast cleaned as specified in Clause 6-3.3(3) hereof and shall be given one coat of Epoxy zinc rich-primer, 25 microns thick. Coatings shall be used on faying surfaces of slip critical connections only if they have been qualified to provide the slip coefficient required by the connection design. Machined mating surfaces of all ferrous components (other than structural members) which are to be clamped together by bolts, in final assembly, shall be protected, as specified in Clause 6.3.1(4) above, after fabrication and just prior to final assembly shall thoroughly cleaned and smoothly coated with a suitable protective compound approved by the Purchaser. All structural steel plates and sections which shall form sealed internal surfaces shall be blast cleaned and prime coated using whole of plate blasting and painting with a suitable weldthrough primer. Angle or flat sections used for plate stiffening shall be similarly treated by mechanized treatment methods. Providing damage to such prime coating during fabrication is minimal, in the opinion of the Purchaser, power brush and cleaning of such pre-primed surfaces with a suitable approved solvent may be accepted in lieu of a second blast cleaning.
(6)
(7)
(8)
(10)
For the purposes of this Specification 6.3, the term External Surface shall include the following areas : (i) (ii) (iii) (iv) The exterior surfaces of all structural members. The whole of the surface of any object such as an equalizing beam or bogie. The whole surface of any component part such as a lug or cheek plate. The outside surface of any gearbox, motor, brake, bearing spacer, collar, track wheel (excluding the actual tread), rope drum (excluding the rope groove) or other similar mechanical or electrical part which is not protected from the weather by being enclosed in a cabin or housing. The outside surface of any guard, cabin or housing.
(v) 6.3.2
Surface Preparation (1) All castings shall be properly fettled and cleaned. All runners, veins, pins, etc., shall be carefully chipped off so that no lumps or rough areas are left. All welding slag and spatter shall be carefully cleaned off by chipping and power brush and, where necessary, grinding. All sharp edges shall be smoothly ground to a radius of not less than 1.6 mm. Any areas of surfaces which are to be blast cleaned as specified in 6-3.3 hereof, and which show any traces of oil or grease, shall be thoroughly degreased prior to such blast cleaning, using an approved solvent. The outside surface of sheet metal components, such as electrical cubicles, shall be dressed by means of a finishing machine or orbital sander to produce a smooth finish, free from weld protrusions, spatter, surface blemishes, etc.
(2)
(3) (4)
(5)
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All sheet metal components and thin walled section (below 3 mm in wall thickness) shall be degreased by an approved process in accordance with BS5493 and shall then be pickled, to remove all mill scale, mill bloom, accordance with BS5493. After appropriate neutralization and rinsing, such components, with the exception of those, which are to be galvanized, shall be given an approved chemical or electro chemical surface passivation and anti-corrosion treatments. (6) Particular care shall be taken to ensure that surfaces which have been prepared and cleaned for painting, other protective coating or treatment, are not re-contaminated by handling with bare hands or by exposure to any contaminating environment.
6.3.3
Abrasive Blast Cleaning 1. All un-machined steel and cast iron surfaces, apart from sheet metal components and thin walled sections (below 3 mm wall thickness) shall be abrasive blast cleaned, as specified hereunder, after all fabrication and hot work has been completed. The use of pre-blast pre-painted workshop primed steel plate may be accepted, subject to all mechanical and heat affected areas being suitably re-prepared to the equivalent of the Sa2.5 by either abrasive blast cleaning or other mechanical methods prior to the application of subsequent coatings. The welding on of lugs, brackets etc. after the application of undercoats or topcoats is considered to be poor construction practice, comprises the paint system and must therefore be avoided. Only when it can be shown to be physically impossible to carry out blasting after fabrication, will blasting and prime coating prior to fabrication be permitted. Contractor shall submit details of the blast cleaning proposed to be used, including type of equipment, type and grade of abrasive and profile height expected from use of such abrasive. External surfaces as defined in 6.3.1(9) shall be dry abrasive blast cleaned to a white metal finish in accordance with SIS005900 Sa2.5. Internal surfaces to be abrasive blast cleaned shall be dry abrasive blast cleaned to a finish in accordance with SIS005900Sa2. After blast cleaning, surfaces shall be fibre brushed or blown with clean dry air (provided adequate driers and oil mist filters are used in air lines) or vacuum cleaned to remove all blast products and abrasives from the entire surface, including pockets and corners. Blast cleaning shall not be performed on surfaces that may in the opinion of the Purchasers Representative, become wetted after blasting and before painting, or other protective coating, nor shall blasting operations be performed on surfaces the temperature of which is less than 3oC above the dew point of the surrounding air, or when the wet bulb temperature in the immediate neighborhood, as measured by a standard wet and dry bulb thermometer, differs from the dry bulb temperature by less than seven and one half (7.5) percent of the dry bulb temperature, nor shall blasting operations be performed when the temperature of the metal is higher than 38oC or lower than 10oC. Contractor shall ensure that all measuring equipment is available and tested to record the above conditions. All shall be in accordance with paint manufacturers recommendations and checked by Third Party Inspection Company Adequate precautions shall be taken to ensure that no damage to or contamination of partially or entirely completed portions of the work, or to machinery, occurs from blast cleaning. All free oil and moisture shall be effectively removed from the air supply lines of all blasting equipment, using adequate and approved filters and driers. Blast cleaned surfaces shall be kept free of all contamination before painting, etc., as required by 6-3.2(5) above
2.
3.
4.
5.
6.
7.
8. 9.
10.
11.
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12.
Operators shall wear fabric gloves of an approved type during cleaning operations and any area inadvertently touched by bare parts of the body, shall be immediately solvent cleaned by approved methods. All items of metal work to be painted shall be so treated not more than *four hours after surface preparation of each item has been completed. Any unpainted surfaces which have been subjected to conditions which might induce condensation of water thereon, or which have been left longer than the above specified *four hours after blast cleaning, shall be again blast cleaned before being painted. All painting shall be in accordance with paint manufacturers recommendations and with the paint manufacturers representative present on site during preparation and painting, verified by Third Party Inspection Company
13.
14.
15.
6.3.4
Painting General (1) All painting and coating operations shall be performed in a neat, thorough workmanlike manner. All paint and coating materials shall be in a thoroughly mixed condition at the time of application and shall be thinned only in accordance with the manufacturers instructions. Paint or coating material shall not be applied unless the temperature of the metal surface and the atmospheric conditions satisfy the requirements specified in 6.3.3(6) above. The first coating shall be applied as soon as possible after cleaning the surface, but in any case not longer than 2 hours after cleaning. (3) All surfaces to be coated shall be completely free of moisture, foreign surface matter and abrasive dust at the time of application of each coat. Each coat shall be uniform and free from runs, sags and other imperfections. Limitations on minimum and maximum inter-coat drying periods recommended by the paint manufacturer shall be strictly observed. (5) All paints shall be of approved colors which will be defined by the Purchaser during the design phase. The color of each coat shall differ from that of the previous coat to a sufficient extent to enable missed areas and uneven or inadequate covering to be readily apparent. The final coat shall be the specified color. (6) All paint shall be applied to the thickness as specified, and such paint thickness shall be gauged by a certified thickness gauge supplied by the Contractor. Paint shall be applied by approved spray equipment corresponding to the equipment recommended by the paint manufacturer for the particular type of paint. It is preferred that as far as practicable, semi-hollow components such as switchboard cubicles and consoles and any other smaller items where difficulty could be encountered in obtaining even coverage, be painted by means of electrostatic spray equipment. All welds and edges shall be double passed with each coat. (7) The Contractor shall, at his own expense, take all precautions and provide all equipment, including ventilation plant, which may be necessary to obviate health hazards arising from the use of specified paints and coating materials in confined spaces or elsewhere.
(2)
(4)
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(8)
All joints, including bolt heads, bolt ends, nuts, washers and attachments, shall be painted, after the connection has been made, to complete the protection in the same system as that specified for the adjacent steel work. The Contractor shall submit full technical, application and service details from the manufacturer of the paints they propose to use. Proprietary Equipment The external surfaces of all mechanical and electrical equipment shall be protected by paint systems having durability comparable with that of the systems specified herein for other steel work in similar environment. Any equipment having external surfaces of materials which are subject to corrosion and which shall be exposed to the weather shall be protected by an approved paint system equivalent in durability to that used on the main structures.
(9)
(10)
(11)
Alternative Paint Systems Contractor may offer alternative paint systems to those specified, but such will only be considered if evidence is submitted to support claims that the systems offered are of at least equivalent durability to that of the system specified.
6.3.5
Paint Systems (1) External Steel Work After preparation and cleaning in accordance with 6.3.2 and 6.3.3 above all external steel surfaces with the exception of (a) galvanized surface and (b) machined surfaces referred to in Clauses 6.3.1(4) and 6.3.1(8) shall be given the following protective treatment: First Coat: Apply one (1) coat of a zinc rich primer, to a minimum dry film thickness of 75 microns. Second Coat: Apply one (1) coat of epoxy micaceous iron oxide primer / under coat, to a minimum dry film thickness of 100 microns. Third Coat: Apply one (1) coat of a high performance anti corrosive barrier coating based on polyurethane enamel, to a minimum dry film thickness of 50 microns. The topcoat colors shall meet ICTSI Terminal Equipment Color Specification. The Contractor shall submit a crane livery schedule drawing and color samples for the Purchasers approval N.B. Total Dry Film Thickness of system to be not less than 225 microns
(2)
Internal Unsealed Surfaces After preparation and cleaning in accordance with 6.3.2 and 6.3.3 above, all internal surfaces with the exception of (a) galvanized and non-ferrous surfaces (b) machined surfaces referred to in 6.3.1(4) and 6.3.1(8) hereof shall be given the following protective treatment:
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First Coat: Apply one (1) coat of epoxy zinc rich primer, to a minimum dry film thickness of 50 microns. Second Coat: Apply one coat of epoxy micaceous iron oxide primer / undercoat to a dry film thickness of 100 microns minimum. N.B. Total Dry Film Thickness of system to be not less than 150 microns. (3) Galvanized and Non-Ferrous Surface, both Internal and External Galvanized and non-ferrous components shall, after appropriate cleaning by an approved method, be given the following protective treatment: Galvanized and Non-Ferrous Surfaces, both Internal and External Surface Preparation: Ensure that all surfaces are free from all grease, oil or other contaminants by application of a degreasing solution formulated from a blend of solvent and emulsifier. Apply Degreaser liberally ensuring that material does not spill on existing paintwork, working well into the surface to be degreased. Allow 5-10 minutes for the solvent to take place. Flush with clean fresh water and allow to dry thoroughly prior to application of the primer coating. First Coat: Apply one (1) coat of micaceous iron oxide primer / undercoat to a minimum dry film thickness of 50 microns. Top Coat: Apply one (1) coat of a high performance anti corrosive barrier coating based on polyurethane enamel, to a minimum dry film thickness of 50 microns. N.B. Total Dry Film Thickness of system to be not less than 150 microns.
(4)
Motor, Gearboxes, etc. The external surfaces of all machinery such as motors, rope drums, gearboxes, couplings, etc. in exposed locations shall be given protective treatment as specified for external steel work, galvanized and non-ferrous surfaces in 6.3.5(1) and 6.3.5(3) above. The external surface of such machinery enclosed in housings or enclosures shall be given the protective treatment specified for internal steel work, galvanized and non-ferrous surfaces in 6.3.5(2) and 6.3.5(3) above. After preparation and cleaning in accordance with 6.3.2 and 6.3.3 above, all external surfaces of such machinery shall receive the following protective treatment:
First Coat: Apply one (1) coat of an epoxy zinc rich primer, to a dry film thickness of 75 microns. Second Coat (Top Coat):
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Apply one (1) coat of epoxy-based enamel, to a dry film thickness of 50 microns. Where it can be shown that proprietary items such as electric motors have received the basic preparation, the Contractor may with the approval of the Purchasers Representative on submission of technical details, complement such systems with additional coatings to bring the system up to the standard of the specified system. The contractor shall remain responsible for ensuring paint system compatibility. Painting of external surfaces of purchased components can comply to suppliers standard colors but the system must satisfy Technical Specification. (5) Horizontal Surfaces of Access Ways, etc. Area: Horizontal Surfaces of Access Ways
All horizontal surfaces used for pedestrian or traffic surfaces for access to any part of the crane for normal operation or maintenance procedures, including such surfaces on structural members, shall be given an approved special paint treatment. Such special treatment shall provide improved abrasion resistance and non-slip characteristics while providing protection and having durability not less than that of the top coating specified for each relevant environment, i.e. external or internal. Non Skid Powder shall be applied to second last coat while still tacky and allowed to set prior to application of final coating. 6.3.6 Galvanizing (1) General Components or surfaces required to be galvanized shall be prepared generally as specified in 63.2 hereof and shall than be either acid pickled in accordance with BS5493 or abrasive blast cleaned in accordance with Clause 6.3.3 hereof. Abrasive blast cleaning shall only be permitted on components or surfaces where there is no likelihood of distortion due to such cleaning method. After such cleaning, all components or surfaces so required by this specification shall be given a hot dipped galvanized coating conforming to the requirements of BS5493 Galvanizing of any component or surface shall only be carried out after completion of all fabrication work on such component or surface. No welding on any pre-galvanized component or surface will be tolerated unless the component or surface is to be subsequently re-galvanized.
6.3.7
Reinstatement of Protective Coatings at Site (1) Care shall be taken at all times to ensure that the protective coatings and treatment shall not suffer any damage during handling, transport and erection. After the components have been transported to the Site, assembled and welded where necessary, all protective coatings shall be carefully inspected and any areas where protective coatings have been damaged or found defective shall be clearly marked with orange colored spray paint or paint stick or chalk, for ready identification and remedial treatment. All weld slag and spatter or heat affected coatings on surfaces that have not been adequately protected during field welding, shall be completely removed and any high points on field welds shall be ground completely smooth.
(2)
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All such areas together with field welds, weld margins and burn marks shall be abrasive blast cleaned as specified in Clause 6.3.3 hereof, with due care of other areas of the coating to avoid further damage. All site abrasive blast cleaning shall be done with approved closed cycle vacuum blasting equipment. (3) Within two hours of cleaning as specified in 6.3.7(2) above, and before any contamination or discoloration can take place, the blast cleaned areas shall be recoated with the priming coat and to the thickness specified in 6.3.5 hereof for the relevant type of surface and location. Undercoats and top coats of the type and thickness, as specified in Clause 6-3.5 hereof, for the relevant type of surface and location shall subsequently be applied, with suitable feathering of coats to avoid ledging. Manufacturers recommendations regarding application and drying or inter-coat intervals shall be strictly observed. (4) Damage to paint coatings such as scratches or abrasions which, in the opinion of the Purchasers Representative, do not penetrate the total paint system may, at the discretion of the Purchasers Representative, be reinstated by cleaning with a suitable solvent and then touch up painting with the relevant primer(s), intermediate and top coats as directed by the Purchasers Representative. For all repair painting, the final coating shall comprise paint from the same batch as that originally used on the particular surface. Cleaning and repair painting of the crane or its equipment shall be carried out only when the conditions specified for the original cleaning and painting in 6.3.3(6) and 6.3.4(2) hereof, are satisfied. Painting shall not be permitted if there is dust being deposited on the surface to be painted or conditions are not in accordance with Clause 6.3.3(6). 6.3.8 Inspection and Sample Panels (1) Attention is drawn to Inspection Control Sheets which shall be designed and approved by the Purchaser. Inspection shall take place before and after preparation and coating and also on site. (2) Before any surface treatment is carried out, the Contractor shall supply to the Purchasers Representative, free of charge; a) Samples of each type and color of paint approved for use on the crane for testing. The Purchaser reserves the right to call for further random samples during the entire painting operation. Should the tests prove unsatisfactory, the entire batch shall be rejected and the Contractor shall take corrective action to re-blast and re-paint all sections painted using the rejected batch to the satisfaction of the Purchasers Representative. Two sample blast cleaned panels one panel cleaned in accordance with 6.3.3(3) and the other cleaned in accordance with 6.3.3(4) hereof, each panel measuring not less than 150mm x 150mm x 6mm, and adequately protected after cleaning by sealed clean polythene wrapping. If approved, the sample shall then be retained by the Purchasers Representative for comparison with the prepared steel work. Two steel panels for each painting system, at the commencement of painting operations, cleaned and painted in accordance with the relevant requirements of this specification with the exception of any site coat.
(5)
(6)
b)
c)
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One of each pair of panels is to be stepped to show the successive build up of the paint treatment and will be used as a standard of acceptance throughout the painting operations. 6.4 6.4.1 Purchasers Logo, Crane Numbers, Signs Purchasers Logo Purchasers logo shall be painted on outer sides of the main girders. The design of the logo shall be advised to the Contractor. The size shall be decided by the Purchaser. 6.4.2 Crane Numbers Crane number shall be displayed on the outer sides of the columns at the top and on side beams. The location and size to be advised by the Purchaser but a sample is provided in Appendix 3. 6.4.3 Crane Capacity Signs (1) Capacity signs showing the safe working load of the Crane shall be fitted to both sides of the gantry structure where clearly legible from the ground level. Capacity signs showing the safe working load of the spreader and spreader number which will be designated by the Purchaser during drawing approval process shall be fitted or painted on both sides of the spreader. Capacity of each lifting lug on the spreader shall be indicated near each lug. All capacity signs shall be in metric units = Metric Tonnes or in abbreviation MT.
(2)
(3) (4) 6.4.4
Manufacturers Name Plates (1) Manufacturers nameplate could be placed on the gantry structure only. The size and location must be approved by the Purchaser. A plate showing year and place of manufacturing, mfg. no., principal dimensions, speeds and capacity of the Crane shall be fitted in the operators cab. Manufacturers name plate shall be fitted on each major electrical and mechanical component showing type, capacity, serial number, manufacturers number manufacturing date etc, for future reference.
(2)
(3)
6.4.5
Other Signs (1) A plate indicating lift height of the Crane shall be fitted at upper front wall of the operators cab (in local language, size 75mm x 900mm). Wording shall be provided by the Purchaser in design stage. Each machinery shall be properly labeled for its direction of motion or operation and for any precautions to be taken before operation or maintenance. All labels and caution plates shall be in Polish language.
(2)
(3)
6.5 6.5.1
Alarm, Warning Signals

Gantry Travel Warning
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(1)
4-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. One common amplifier for travel alarm sound and emergency warning sound shall be installed inside the panel house, and the alarm and warning sound shall be emitted through four (4) speakers installed at four corners of the crane. The gantry travel alarm sound shall be automatically activated and sustained during gantry motion. The alarm tone shall consist of an intermittent signal, sounding at 1 second for duration of 0.5 second. The emergency warning sound shall be activated by the operator by pressing down the foot switch on the floor of operations cab, and it shall override the travel alarm sound when pressed during gantry motion. The type of both travel alarm and emergency warning sounds to be approved by the Purchaser. The alarm sounder speakers shall be located at a maximum height of 2.5m above ground level. The generated signal level shall not be less than 95dB at 1 KHz at the point 1m forward of each speaker measured at a height of 1.5m above ground level. The signal shall not exceed the above limit by 3dB. The volume of the warning sounds to be adjustable at the amplifier independently for travel alarm sound and the emergency warning sound.
(2)
(3)
(4)
6.5.2
Main Hoist Overload Warning (1) Main hoist system shall include overload warning and tripping system. i) ii) iii) 80% load for over 3 second: Intermittent warning signal. 100% load for over 3 seconds: Continuous warning signal. 110% overload for over 3 seconds: Trip hoist motion. Allow lowering motion in slow speed only.
6.5.3
Premature Twistlock Operation Warning (1) 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. The landing signal shall allow a one (1) second time lag to indicate the completion of landing to the operator and to trigger interlock so that momentary landing completion signal do not activate interlock. The premature locking movement before the spreader is landed on a container shall be prohibited by means of electrical interlock on the logic control circuitry and mechanical interlock. There shall be no physical movement of the twist locks on the spreader even though the switch is turned to Lock position before landing is completed as described in 6-5.3(1) above. Audible and visual alarms noticeable at ground level and at inside the operators cab shall be activated by this premature turning of the lever type twist lock 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. The alarm tone shall be approved by the Purchaser. The premature unlocking movement while suspending the load with twist locks shall be prohibited by means of electrical interlock on the logic control circuitry and mechanical interlock. There shall be no physical movement of the twist locks on the spreader even though the switch is turned to Unlock position while the load is suspended with twist locks. Audible and visual alarms noticeable at ground level and at inside the operators cab shall be activated by this premature turning of the lever type twist lock 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. The alarm tone shall be approved by the Purchaser. The twist locks shall remain on its last position after power interruption. resumption of electrical power. i.e. failure and
(2)
(3)
(4)
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6.5.4
By-Pass Switch Abuse Warning (1) Twist lock interlock bypass push button When the Twistlock Interlock Bypass push button is depressed to overcome a difficult situation to carry out hoisting or lowering function, an alarm sound shall be broadcast through an independent amplifier through a speaker located outside the operators cab and facing downward. The hoisting speed and the trolley speed shall be slow-down mode. (2) Landing bypass push button When the Landing Bypass push button is depressed to permit the twistlocks to rotate without a landed signal, an alarm sound shall be broadcast through an independent amplifier (same as the one for twist lock interlock bypass push button) through a speaker located outside the operator's cab and facing 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 English language to be approved by the Purchaser.
6.5.5
Electrical Control House A/C Warning (1) *Electrical Control House shall be well insulated to keep the inside temperature below 25C all the time (Ref. to 4.5.2. (1)). The air conditioning system failure shall be indicated at outside of the room, and a warning buzzer in the operators cab shall be activated in case inside temperature of the panel room rises over 40 degree C. The air conditioner main circuit shall be activated when the engine is turned on and deactivated when the engine 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.
6.5.6
Public Address/Warning (1) One loudspeaker pointing down shall be mounted on the trolley or near the operators cab to broadcast the following warning sound: a. b. c. d. Twist lock interlock bypass push button. Landing interlock bypass push button. Premature Locking switching Premature unlocking switching
6.6
. Emergency Stop Push Buttons & Drive Lock Out The Emergency Stop and Drive Lock-Out circuit shall be a hard wired independent circuit that will stop all motions and isolate power to all drives, rectifier units, inverters and brake contactors. PLC shall be configured to monitor E-stop circuit for isolation and CCMS purposes.
6.6.1
Locations Total of Eight (8) Emergency Stop push buttons shall be installed on the Crane. a. b. c. d. Near Main Hoist motor. Near Trolley Travel motor(s). In Operators Cab (1 for engine stop, 1 for motion stop). Two at side beam ground level on the far side and two at side beam level on the near side facing inside and outside of the crane to be easily reached by ground operation personnel. Electrical Control House
e.
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Total of Four (4) Drive Lock-Out switches shall be installed as follows: a. b. c. 6.6.2 Type (1) Emergency stop pushbutton (self-latching) mushroom head switches shall be provided. All Emergency Stop buttons shall be recessed to prevent them from being actuated accidentally. Drive Lock-Out switches shall be a independent isolator switch which can be locked in the open position with a padlock or may be incorporated into an existing Emergency Stop Pushbutton through with a padlock could be applied to prevent reset. Near Hoist Motor In Operators Cabin Two (2) at Side- beam ground level, one (1) on the near-side and one (1) on the far-side
(2)
6.6.3
Emergency Stop Signs Adequate signs shall be provided in English & local language to clearly identify their locations to ground floor personnel. The size of the signboard shall be 300mm x 300mm minimum.
6.7 6.7.1
Service Outlets Location (1) Two independent service outlets (one pair) local voltage, 1-phase, local type shall be provided and mounted adjacent to each other as a combination at the following locations: i) ii) iii) Two pairs in the Operator's cab. Two pairs in the Electrical Control House. One pair at ground level, one each under each sill beam, facing inside of the Crane.
6.7.2
Type Model Matching plug of industrial type for each outlet (one plug per outlet) shall be supplied by the Contractor,
6.8
Fire Extinguishers All fire extinguishers shall be placed in a properly designed holder so that they are firmly secured and easily accessible. The lower part of the holder shall have a cylindrical wall of at least 150mm in height and 3mm in thickness. Drain hole shall be provided at the lower part to release water. A fast releasing type clip or fastener shall be installed at the upper part of the holder so that the fire extinguisher could be released quickly. This holder shall be welded onto a permanent structure member of the Crane.
6.8.1
Locations (1) (2) (3) Outside Electrical Control House one (1) of 5kg capacity. Outside drivers cab one (1) 5kg capacity On top of Trolley one (1) 5kg capacity.
6.8.2
Type-Model All the fire extinguishers shall be CO2 type, fitted in locked cabinets with emergency Break to Use glass.
6.9 6.9.1
Maintenance Tools and Equipment Mechanical Maintenance Tools (1) Four torque wrench with socket sets
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(2) (3) (4) (5) 6.9.2
Four Open Ended Spanner (Wrench) Set Four Ring Spanner (Wrench) Set Four Set long allen key sets Four Toolboxes
Electrical/Electronic Maintenance Tools (1) (2) (3) (4) (5) (6) (7) Four (4) notebook computers shall be provided per RMGs contract. With all relevant interfacing cables & programming software. Two (2) units of digital multi-meter. Two (2) clamp on ammeters One (1) Noise Meter One (1) Vibration Meter One (1) Light Measurement Meter One (1) Insulated Electrical Tool Kit
6.9.3
Hydraulic Maintenance Tools (1) Four (4) units of hydraulic jacks suitable for replacement of wheels.
6.9.4
Special Tools and Equipment (1) One unit of control panel for operating and testing spreaders in the workshop. 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. Special tools and jigs necessary for mechanical, electrical and electronic maintenance works shall be supplied with the Crane, and stored in appropriate locations of the Crane.
(2)
6.9.5
Wear Gauges (1) One (1) complete sets of stainless steel wear gauges to measure and indicate the allowable wear on components identified below shall be supplied with each Crane and stored in an appropriate storage box fitted on the Crane i. All wire rope sheave grooves. ii. Rope Drum grooves Each wear gauge shall be engraved with the component name to be gauged.
(2)
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7 7.1 7.1.1
PROJECT QA & ADMINISTRATIVE REQUIREMENTS Document Submission (Project) Project Organization Chart (Shop & Site) (1) The Contractor shall submit to the Purchaser a project organization chart within one (1) month after the date of the Agreement. The schedule shall show the organization of the Contractors 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.
(2)
7.1.2
Project Schedule (Shop & Site) (Program) (1) The Contractor shall submit to the Purchaser a project schedule within one (1) month after the date of the Agreement. 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) ii) iii) iv) v) vi) vii) viii) ix) x) xi) (3) Contract start date. Engineering Design Period. Submission of Drawing/Design Calculations. Procurement of Materials and Components. Manufacturing Periods for the main Structural Sections. Erection in the Contractors Facility. Shop Test and Commissioning. Transportation Period. Site Commissioning. Completion Date(s) Dates when Purchaser supplied information or permits are required
(2)
The Program shall be provided in MS Project format and shall be presented in a way that clearly shows each activity connected in a logical program 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 Program shall subsequently be updated and submitted to the Purchaser at intervals of no more than 1 month throughout the course of the project until the Taking-over Certificate has been issued. 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.
(2)
7.1.4
Quality Assurance Program/ Manuals (1) Contractor shall submit to the Purchaser a quality assurance program for review within one (1) month after the date of the Agreement. The program shall consist of General Quality Assurance Program, which states Contractor's general practice and organization to assure quality during design, procurement, fabrication and erection periods, and a Specific Quality Assurance Program. The Specific Quality Assurance Program 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
(2)
(3)
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Crane or other Goods to the Purchaser with proposed timing and locations of conducting such inspection and test. This Program must cover all the inspection and review items as set out in the Appendix "Inspection Control Sheet" and Appendix "Minimum Requirement for Drawings / Calculations / Data Submission". An organization chart with names of the quality assurance team personnel for the Agreement for each major stage of fabrication, delivery, commissioning and Defects Liability Period shall be included in this Program. 7.1.5 . Daily Plan and Report (Site Work) For the duration of the period of site work at the Purchasers Site, 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. 7.2 7.2.1 Document Submission (Technical) 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 provide evidence to the Purchaser that the requirements of the Specification are met by calculation but formal document submission and schedule for same shall be discussed and mutually agreed at the design review meeting. The design shall show clearly by drawings and description the following details: 7.2.3 General arrangement of the Crane Trolley and operators cab Hoist Drive System Trolley Drive System Gantry Drive System Rope reeving arrangement Anti-Sway System Spreader and Head-block Arrangement Trim System Arrangement Electrical Control House and Assembly Crane structure Gantry equalizers, bogies and wheel arrangement Collision Avoidance System Hydraulic System Inc. Schematic Diagram One Line Electrical Schematic Drawing
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 in digital format for review to the Purchaser. This information shall include but not be limited to the following: (1) Structural, mechanical and electrical calculations on all aspects of the Crane design, for example Stability and wheel load calculations Wind Load Analysis, methods and wind load calculations Crane structure stress calculations Fatigue analysis for all stress carrying structural members.
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(2)
Load combinations for various design criteria. Design calculations for the hoist, trolley, gantry motion component parts Drive Motor sizing calculations Brake Sizing and capacity calculations Crane electrical load calculations. Lighting calculations. Anti-sway system component sizing calculation Gearbox sizing calculation Hydraulic System sizing calculation
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 the Appendix.
(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. Contractor shall submit any other documents as requested from time to time by the Purchaser. The Purchaser's comments on the drawings or submittals shall not waive Contractor's duties or obligations to achieve satisfactory performance of the Crane and all other Goods as set out in the Conditions of Contract, specifically Clause 3 and to otherwise comply with the Contract. The Purchaser undertakes no duty to the Contractor to identify nor notify to the Contractor any errors or omissions in the Contractor's design. One month before the shipment of the first Crane(s), the Contractor shall submit to the Purchaser four (4) sets of all drawings reviewed and if necessary revised according to the Purchaser comments or for other agreed reasons
(4)
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. The list shall specify the system to be lubricated, its volumetric capacity, Typical Manufacturer, Lubricant name, Specification and Grade. All the oil and lubricant used for the crane shall be selected from those available locally in country of operation and used by the Purchaser.
(2)
(3)
7.2.5
Sea Fastening (1) No later than one month before the intended shipment date, the Contractor shall submit a seafastening and loading proposal showing connection details of all sea fastenings which are connected to the crane structure for the Purchasers review. The submission shall also provide details of the proposed methods for removal of any temporary bracings and fixings.
(2)
7.2.6
Crane Delivery Method Statement (1) No later than two (2) months before the Delivery 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) and other Goods to the Purchasers quay deck. The method statement shall include: (i) (ii) The total area required for the roll-off operation. Full details of the transportation vessel and the stowage of the Crane(s)
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(iii) (iv) (v) (vi) (vii) (viii) (ix)
Sea Fastening Drawing showing details of the system used Orientation of the vessel when offloading Number and position of bollards and moor lines, Length and position of sea anchors. (if applicable) System of transferring the Crane to the quay deck All skid beams and skid beam centers. (If applicable) All positions and magnitude of loadings applied to the quay deck 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) ii) iii) iv) v) vi) vii) 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) Roll-off or Lift-off scheme and date of performance. Key activities of the commissioning and duration. Number of days required from the date the Crane is ready for starting up and load testing. Date the Crane will be Commissioned and handed over to the Purchaser. Date the Crane will be finally handed over to the Purchaser. Other key dates of significance.
7.2.8
Tests on Completion (1) No later than four (4) months before the arrival of the first Crane(s), The Contractor shall submit to the Purchaser for his approval a Tests on Completion Procedure. The Tests on Completion Procedure shall be in a form of a document and shall contain detailed field and function check procedure to fully demonstrate that the Crane and other Goods meet the requirements of the Agreement including suitability of the Crane for container handling operations. All crane functions and features shall be checked. 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. Provision shall be made within the procedure for the tester and the Purchasers Representative to initial and date each separate test. The Tests on Completion Procedure shall be duly completed by the Contractor following each individual test or each series of tests conducted at the Contractors facility or at site. Where necessary the Purchasers Representative shall verify the results. 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 for the Goods in question.
(2)
(3)
(4)
(5)
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.
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(2)
The Contractor shall demonstrate to the Purchaser 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.
7.2.10
Training Program (1) No later than three (3) months before the arrival of the Cranes, the Contractor shall provide a comprehensive training program to cover the theoretical and practical training requirements for the Ports Crane operators, electrical and mechanical tradesmen and electronic technicians. The program 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) and their systems 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 scope of training to be conducted for the disciplines shall be generally as outlined in 7.6. The language used for the training shall be according to the language used in the country of operation.
(2)
(3) (4)
7.2.11
Structural Maintenance Program (1) The fatigue criteria in this Specification are based on producing a damage tolerant design. Because of the scatter of fatigue performance and that usage may exceed the design conditions, there is a risk that a structure or component may fail in service. When fatigue cracks develop, the remaining structure should sustain the maximum working load until the cracks are discovered. Satisfactory performance of the damage tolerant design, therefore, depends on adequate methods of fatigue crack detection and the ability to repair or replace the damaged component. The intent of this section is to define a method of routinely inspecting for fatigue cracks to significantly improve the structural reliability. The inspection intervals defined below are based on fracture mechanics calculations and reliability analysis and on the fact that fatigue cracks can be classified as infant failures and aging failures. The first inspection should detect infant failures and the later periodic inspections should detect aging failures. Infant failures are primarily due to deficient fabrication, under estimation of the fatigue damage which may be due to deficient design or excessive loading, or a combination of all these. Aging failures are primarily due to cumulative damage from normal operations and properly designed and manufactured components. Since the integrity of the structure depends on the inspections and interpretation of the results and the choice of repair, it is important for the Contractor to review all reports. So copies of all inspection reports, reports of structural difficulties of any nature, and reports describing any modifications will be sent the Contractor and to the Engineer. Periodic structural inspection is required to detect cracks that have developed during the warranty period and the life of the crane. The Contractor shall repair, at his own cost, all defects and cracks on the cranes discovered during the structural warranty period of ten years from the Date of issue of Taking-over certificate, regardless of the cause. During the first ten years after the issue of the Taking-over certificate, the Contractor shall repair all cracks that are not the result of Purchasers misuse of the crane. No later than three (3) months before the arrival of the crane(s) 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) (ii) Inspection intervals Locations to be inspected
(2)
(3)
(4)
(5)
(6)
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(iii) (iv) (v) (vi)
NDT procedures to be used Reporting procedures Repair procedures Documentation showing the parameters used to determine the inspection intervals in accordance with the criteria specified below
(7)
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 Purchasers approval of the Contractors plan, the Contractor shall repair the defects at his expense. The Purchasers independent agency will inspect the repaired defects. If any of the repairs are not acceptable the Contractor shall make additional repairs as necessary. The cost of the inspection of the additional repairs shall be borne by the Contractor. 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. 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. 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.
(8)
(9)
(10)
INSPECTION INTERVAL vs. CUMULATIVE DAMAGE RATIO D = L/K1 OR 2 DETAIL B C D E F F2 G W TUBULAR 7.2.12 24 YEARS NFCM FCM 0.21-0.41 0.19-0.38 0.18-0.36 0.17-0.33 0.18-0.35 0.16-0.33 0.15-0.29 0.13-0.26 0.17-0.34 0.16-0.31 0.16-0.32 0.15-0.29 0.21-0.41 Not allowed 0.20-0.40 0.20-0.35 12 YEARS NFCM FCM 0.42-0.69 0.39-0.64 0.37-0.62 0.34-0.57 0.36-0.61 0.34-0.56 0.30-0.50 0.27-0.45 0.35-0.58 0.32-0.53 0.33-0.56 0.30-0.51 0.42-0.70 Not allowed 6 YEARS NFCM FCM 0.70-1.00 0.65-1.00 0.63-1.00 0.58-1.00 0.62-1.00 0.57-1.00 0.51-1.00 0.46-1.00 0.59-1.00 0.54-1.00 0.57-1.00 0.52-1.00 0.71-1.00 Not allowed 0.70-1.00 0.65-1.00 0.65-1.00 0.51-1.00
0.19-0.37 0.41-0.69 0.38-0.64 0.15-0.30 0.36-0.64 0.31-0.50 Inspection Interval Criteria
Operation Manuals (1) The Contractor shall provide 6-sets each of operating instruction manuals *(English and Polish language) to the Purchaser two (2) months before the date of the first Crane departure from the Contractor's manufacturing site. The operating instruction manual shall clearly state the startup 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.
(2)
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(3)
Corrections shall be made by the Contractor to the Manuals for any changes made in the instructions during the commissioning period, and the revised instruction manuals shall be submitted one (1) month after the notification of successful completion of the Tests on Completion of the first Crane(s) Two sets of above instructions shall be submitted in a CD ROM format.
(4) 7.2.13
Maintenance Manuals (1) The Contractor shall provide 6-sets each of maintenance manuals *(English and Polish language) to the Purchaser two (2) months before the date of the first Crane departure from the Contractor's manufacturing site. The maintenance manual shall include a complete list of wearing parts showing the allowable limit of wear for each part. The manual shall provide comprehensive full function test documents in accordance with format currently in use at Purchasers engineering department. Full function test document shall be designed so as to determine integrity and correct operation of all system functions, safety circuits and operating speeds of the Crane. Maintenance and service documents shall be separated into the appropriate hourly or date time intervals. The Purchaser will provide sample service and function test documents following placement of Contract. (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. The relevant parts of manuals shall be revised and resubmitted as soon as practicable by the Contractor for any changes in system or component design. Two sets of manuals in CD ROM shall be submitted.
(2)
(4)
(5) 7.2.14
As-Built Drawings The Contractor shall submit to the Purchaser 3 sets A1 size copies and two sets in CD ROM (English version, pdf format) of the following as-built drawings within 30 days after the date of issue of the Taking-over Certificate for the first Crane(s) to achieve Completion. (1) All drawings that were previously submitted for the Purchaser's review and revised as built as at the shipment date. Detailed drawings for wearing parts showing machining tolerances, wherever applicable, and wear limits: i) ii) iii) iv) v) vi) vii) viii) ix) x) (3) (4) Brake drums (or discs) Brake pads or shoes Wheels Sheaves Anti-friction bearings Bushes Bearing plates Oil seals and O-rings Table for consumable parts of electrical machineries All other wearing parts.
(2)
Detailed electrical control circuit drawings, control logic programs, and wiring diagrams. Full details of all bought-in equipment, drawings instructions, etc.
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(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 after the initial submission.
7.3 7.3.1
Shop Inspection and Tests Shop Inspection and Verification (1) Inspection and testing of the Crane shall be performed by the Contractor to verify or demonstrate the Crane's conformance to this Specification and the other Contract Documents, following the approved Specific Quality Assurance Program as stated in 7.1.4.(3). 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 Works at each of the following stages: i) ii) iii) iv) v) vi) Design. Fabrication and assembly; Pre-shipment; Upon Delivery; Tests pursuant to the Conditions of Contract, which, if successful will lead to the issue of a Taking-over Certificate. Such further tests as otherwise may be required that in the opinion of the Purchaser are pursuant to the Conditions of Contract.
(2)
(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. Inspection and test items shall generally include (but not limited to) the following fundamental items. i) i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) Materials and components sources and identification of standards applied. Workmanship overall. Inspection of Operational and Maintenance Safety, Test of all safety equipment and safety devices. Inspection of Operational Efficiency, Functional Test of all components equipped for operation. Inspection of Maintenance Efficiency, Functional Test and inspection of all equipment for maintainability. 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. Overload Tests including Stability Test and Measurement of Structural Deflection. Accessories Inventory. Operating Instruction and Maintenance Manual Review. Weight verification as necessary. Statutory inspection and tests. Wheel Load Verification (see 7.3.2 (6))
(4)
(5)
The Purchaser reserves the right for itself or any party authorized by the Purchaser to inspect the Crane or other Goods at any time including during fabrication and delivery. 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 the Conditions of Contract or any other obligation or liability of the Contractor.
(6)
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(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. At the same time, Contractor shall submit a list of calculated maximum structural stresses at critical points of the Crane structure. The Contractor shall verify the calculated stress level by actually weighing these moving weights after the fabrication and assembly are completed. The weight of trolley assembly, head block assembly and spreader assembly shall be weighed by a third party, who will issue an authorized certificate. The Certificate shall be submitted to the Purchaser. 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. 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.
(8)
(9)
(10)
(11)
(12)
7.3.2
Pre-Shipment Inspection and Test (1) (2) The Crane is to be fully erected in the Contractors facility and tested prior to shipment. The Contractor shall prepare a shop assembly and Crane erection program 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. 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. The Crane shall be fully lubricated in accordance with the manufacturers recommendation prior to any shop testing. A lubrication checklist shall be included in the test documentation. The assembled Crane shall be inspected and tested at the Contractors assembly facility. All installations and functions shall be verified for compliance to the Specification. The Crane testing shall include the following: (i) (ii) (iii) Verify trolley speed, acceleration according to Specification General Design Criteria) Verify hoist speeds, accelerations according to Specification General Design Criteria) 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 mechanical anti-sway.
(3)
(4)
(5)
(iv) (v)
Interlocks and limit switch settings, and software. 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 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.
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(vi) (vii)
Check structural alignment and integrity. Inspect and demonstrate that all electrical wiring and wiring components are installed and properly marked.
(6)
The Cranes static wheel loads shall not exceed the declared wheel loads. Should any Cranes static wheel load exceed any such wheel load this shall constitute a Defect and the Contractor shall not be entitled to dispute this on any grounds or in any circumstances. The Contractor shall be required to carry out appropriate and accurate tests in order to identify the static wheel loads of the completely assembled Crane complete with the rated load throughout the range of trolley travel. These tests shall verify that the static wheel loads do not exceed the declared wheel loads defined in the Form of Tender. These tests shall be carried out in the presence of the Purchaser or his representative.
7.4 7.4.1
Shipment, Delivery and Site Work Clearance for Shipment (1) The Crane(s) shall be totally assembled in the Contractor's yard and tested for functions of all the devices before shipment. The Load test is essential to be performed in the Contractor's yard. Heat run tests and operational check of interlocks and safety devices shall be performed through the permanent control gear and components installed on the crane in the Contractor's yard. The Engineer shall check pre-shipment test data and issue a formal approval before the cranes are loaded onto the delivery vessel.
(2)
7.4.2
Notification of ETA Site (1) The Crane shall be in fully assembled condition when delivered to the quayside of the Port.
(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 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. 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 or the yard. Specifically any loads on the quay apron waterside of the waterside crane rail beam; (overhung slab) is prohibited.
(3)
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 in the country of operation. The Cranes aviation warning lights shall be kept illuminated continually from the time the vessel carrying the crane approaches the Harbor. The temporary power source for the warning lights shall be prepared by the Contractor.
(2)
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 provided for in the Conditions of Contract calculated from the agreed time of
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berthing as set out in 7-4.2 (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. 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 and the Port generally from outside consulting engineers and elsewhere as necessary, and obtaining necessary clearance or permit for the works from government offices and all other competent authorities concerned. 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
(3)
(4)
7.4.5
Customs Clearance Refer to the Conditions of Contract
7.4.6
Work Permits All engineer/supervisors dispatched for start-up, testing and training shall obtain proper working visas for the Purchasers Site which must be valid for the 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 Port, and inside the Port. The Contractor and its subcontractors shall be responsible for protecting their own plant, tools, temporary site offices and other belongings from weather, fire or theft. The Crane and other Works shall be protected by the Contractor from fire, collision and any other possible risk until the Crane or other Works are Taken-over by the Purchaser. Erection All Risk insurance, Third Party Liability insurance, Workmens Compensation insurance and other necessary insurances shall be secured and maintained by the Contractor
(2)
(3)
7.4.8
Site Erection Area and Access Refer to Conditions of Contract
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 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 pipe work, valves, meters, cables, switchgear etc and shall pay for the cost of supply of water, diesel and electricity that he may require for any purpose.
7.4.12
Contractors Representatives
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(1)
One English / Local Language 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 shall stay in the Purchasers locality for the entire period from delivery to Taking over of the Crane to the Purchaser.
(2)
A sufficient number of qualified start-up engineers and training engineers shall be dispatched to the Port to handover the Cranes in an expeditious manner. The Contactor shall provide a qualified and competent Electro/Mechanical Service Engineer to remain on Site for a period of 3 months after issue of the final Taking-over Certificate. The Contactors Service Engineer will be required to provide support to the Purchasers maintenance engineers, assist with fault diagnosis and identification and to liaise with the Contractors office
(3)
7.5 7.5.1
Site Inspection and Tests, Certification Tests on Completion (1) The Crane or other Works shall be verified at Site as operational and safe under any load conditions prior to the Tests on Completion. 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. The Tests on Completion which will be as defined in the agreed Tests on Completion 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 or other Works are safe and conform to the Agreement. The Contractor shall correct or modify whatever aspect is found unsafe. The Crane(s) and shall pass the statutory tests, which will be carried out and witnessed by the Purchasers Representative. Application for inspection for the Commissioning Tests must be submitted to the Purchaser's in writing at least 2 days prior to the intended inspection date.
(2)
(3)
7.5.2
Defects List (1) The Purchaser or his representative shall be allowed to gain access to any part of the Crane(s) or other Goods during their assembly at the Contractors facility and at any other time for the purposes of inspecting part or completed works. If in their opinion certain parts of the works do not meet with the requirements of the Agreement, 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. 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) or other Goods.
(2)
7.5.3
Rectification Report (1) The Contractor will be obliged to correct these defects and any other defects before the Tests on Completion or within an appropriate timeframe approved by the Purchaser. 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.
(2)
7.5.4
Endurance Test (1) The Endurance Test forms part of the Tests on Completion. The Crane(s) shall be required to undergo a test to demonstrate the combined operation of all Crane systems and the reliability of
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the components. The endurance test shall consist of repetitive cycling as follows whilst handling the Cranes rated load i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) Pick up the container from roadway. Hoist 15 metres. Trolley forward 15 metres. Lower 15 metres on to ground. Wait 5 seconds. Hoist 15 metres. Trolley reverse 15 metres. Lower 15 metres on to ground. Unlatch and hoist 1 meter. Lower 1 meter and latch. Repeat the above cycle After each 30 minutes operation the Crane(s) shall gantry for a minimum of 125 meters to a transfer position, the wheel rotated through 90 degree, wait for 1 minute, wheels rotated through 90 degree and the Crane shall gantry 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, minor malfunctions which only require single reset will be accepted during the first 16 hours but the final 8 hours shall be fault free. In the event of a malfunction during the final 8 hours, the test shall be repeated until 8 hours of trouble free operation has been logged. Throughout the period of testing the current, voltage, speed, main drive mechanism temperature, noise and vibration shall be recorded at intervals of 60 minutes. Any malfunctions or problems and any remedial action taken during the test shall be recorded.
(3)
7.5.5
Taking-over Certificate (1) The Taking-over Certificate will be issued on successful completion of the Tests on Completion (including the Endurance Test), training as defined in Clause 7.5 and issuing of a Proof Load Certificate from an independent inspection authority acceptable to the local authorities.
7.5.6
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.
7.6 7.6.1
Training & Support Training Off-Site In advance of delivery of the crane, Contractor shall provide a 14 Day classroom/practical training course for four (4) supervisory maintenance engineers (Two Electrical Techs & Two Mechanics) at the manufacturing plant. Documentation is to be presented in English language. Cost of Training, Documentation, Economy air tickets (From and to Purchasers Site), accommodation and subsistence to be to the Contractors account.
7.6.2
Training On-Site (Operators) The Contractor shall carry out the operator training of the Purchaser's staff during the on-site commissioning period and for a period of seven (7) days following the Tests on Completion of the Crane or other Works. The training shall be conducted by qualified Contractors 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.
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(2) (3) (4) (5)
Instruction on lighting control. Instruction and hands-on training of normal container handling operation in the cab. Instruction and hands-on training of normal shutdown procedure. 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 Tests on Completion of the Crane or other Works. The training shall be conducted by suitable Contractor and Crane or other Goods component supplier trainers. The training shall cater for approximately four (4) groups of electrical maintenance staff, and four (4) groups of mechanical maintenance staff and the content of the training shall include but not be limited to the following: (1) (2) Instruction and hands-on training of starting and shutdown procedure. Instruction and explanation of all the devices on the Crane (separately for electrical and mechanical staff). Instruction of Start-stop procedure and checking points of all the devices or systems on the Crane. Lectures on electrical/electronic control systems of the Crane and adjustment method/standards both in a classroom and on the Crane. This shall include an appropriate period dedicated to the PLC (and electronic drive regulator if fitted) by the component Vendors qualified trainer. This shall also include an appropriate period dedicated to the spreader by the component Vendors qualified trainer. Lectures on mechanical/hydraulic systems of the Crane and adjustment method/standard both in a classroom and on the Crane. Lectures on Condition Monitoring System on the Crane and in a classroom. Inspection and Maintenance of Operationally Critical Components. Instruction on troubleshooting and repair. 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.
(3) (4)
(5)
(6) (7) (8) (9)
7.6.4
Training for Critical Components (On Site)
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The operationally critical components (see 2.10) shall be defined and the Contractor shall prepare and present training on this subject separately. As a minimum, the following components shall be considered as Operationally Critical: 7.6.5 Spreader and Head-block Twistlocks Hoisting Wire Ropes Hoist Drum Coupling Hoist Brakes Steel Structure of the Crane
Training & Service Visits following Taking Over (On Site) (1) Six months after Taking Over the first crane, the Contractor shall provide one week service visit by competent, qualified service engineer for purpose of checking crane systems, preventive maintenance schedules and providing further, more detailed maintenance instructions. Two months prior to the end of the Defect Liability Period, Contractor to provide one week service visit by competent, qualified service engineer for purpose of checking crane systems prior to the Warranty expiring.
(2)
7.7 7.7.1
Spare Parts Ordered Spare Parts (1) The Contractor shall warrant in writing its capability for providing spare parts, spare components, repair and/or replacement services for a period of 15 years after date of issue of the Taking-over Certificate for each crane.
7.7.2
Spare parts for Commissioning Work (1) (2) The spare parts for the commissioning work shall be provided by the Contractor. The Contractor shall indemnify the Purchaser against any cost, loss or damage if the operational Crane(s) suffers stoppage due to the unavailability of an Ordered Spare Part which has been consumed by the Contractor during the commissioning period and not replaced before the issue of the Commissioning Certificate.
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8 8.1
APPENDICES Appendix 1 Document Submittals
List of Drawings / Calculations to be reviewed by the Purchaser (Minimum Requirements) (Information required to be submitted after confirmation of order) 1. Drawings and Specifications 1. Crane General Arrangement 2. Operator Visibility Diagram showing line of vision for operator within container stack 3. Trolley General Arrangement 4. Head-block General Arrangement 5. Spreader General Arrangement 6. Spreader Twist Locks Assembly 7. Head-block Twist Lock Assembly 8. Gantry Wheels & Equipment General Arrangement 9. Electrical Control House General Arrangement 10. Main Power Cable Reel General Arrangement 11. Operators Cab General Arrangement 12. Control Consoles & Chair Layout in the cab 13. Top Beam / Trolley Rail Clamp Arrangement 14. Tie Down Equipment (Gantry, Trolley if applicable) 15. Stowage Pin Arrangement 16. Walkways, Stairs & Platforms Layouts and Details 17. Rope Reeving Diagram with Rope End Fixing Details 18. Main Hoist Drive Arrangement 19. Trolley Drive Unit Arrangement 20. Gantry Drive Arrangement 21. Side Shift Arrangement 22. Trimming Device Arrangement 23. Wheels (Gantry and Trolley) Detail 24. Sheaves Detail with material, treatment and profile 25. One Line Diagram 26. Electrical Schematic Diagram 27. PLC Ladder Logic Diagram 28. Control Panels General Arrangement 29. Switch Gears General Arrangement 30. Annunciation Messages 31. Power Cable Specification and Sectional Dimension Drawing 32. Main Hoist Load Speed Curve 33. Checkers Cab General Arrangement 34. Air Conditioners 35. Anti-Collision System 36. CCTV System 37. All main structure general and detailed drawings. 38. All other structural general and detailed drawings as requested by Purchasers Purchaser reviewing engineer. 39. All other mechanical general and detailed drawings as requested by Purchasers Purchaser reviewing engineer. 40. All other electrical arrangement drawings as requested by Purchasers Purchaser reviewing engineer. 41. All loading, shipping, sea-fastening, and unloading drawings (arrangements and details)
2.
Calculations and Data 1. Stability Calculations (including Dynamic Snag Load Condition) 2. Wheel Loads, Tie Down Loads and Stowage Pins Loads Calculations 3. Peak Power Consumption Calculations 4. Stress Calculation for Critical Areas of Structure
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5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Noise Calculations Trolley and Gantry Buffer Load Calculations Gantry Braking Capacity and Braking Distance Calculations (under various wind load conditions up to braking limit) Main Drive Motor sizing calculations Main Drive Motor Selection & Configuration Data Wire Rope Fleet Angle Calculations Quay Loading Calculations for Roll-off Operations and Commissioning Hoisting and Trolley Brakes Calculations Structural Maintenance Program All other structural, mechanical, and electrical calculations as requested by Purchasers reviewing engineer.
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8.2
Appendix 2 Inspection / Test Control Sheets
The following six sheets provide a guide to the minimum inspection, test, reports and certifications which are required by the Purchaser. Codes depicted in the Inspection / Test Control Sheets are defined as follows:
By the Contractor M R T = = = Mill Certificate to be submitted Inspection Report to be submitted Test Report to be submitted
By the Purchaser, Engineer or Engineers Representative C1 W1 W3 = = = Certificates or reports to be produced Inspection / Test to be witnessed for 100% of the Works Inspection / Test to be witnessed at random for 5% - 20% of the Works
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Legs
Note:
Sill beams
Spreader Frame
I) Main Structure
Head-block Frame
Girders/Cantilever Beams
Trolley Structure Frame
RMG Specification M Chemical Properties Mechanical Properties M C1 C1 C1 C1 C1 C1 C1 C1 C1 C1 W3 W3 W3 W3 W3 M C1 C1 C1 C1 C1 W1 W1 W1 W1 W1 R W3 W3 W3 W3 W3 W3 W3 W3 W3 W3 M M M M M Hardness Visual Inspection and Weather Protection Check Dimensional Check Proof Load Test Breaking Test Function or Heat Run Test Dielectric Test Insulation Test Characteristics Test Painting Weighing Load Test (Note ) Deflection Measurement Inventory Preparation work for Ship/Pack M M M M M Non Destructive Test M M M M M C1 C1 C1 C1 C1 Welding Process and Welder Qualifications Edge Preparation check & Visual Inspection of Welds RMG Cranes Inspection Sheet (1 of 6)
C1
C1
C1
W3
C1
W1
W3
W3
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Note:
Reducer
Rope Drum
Wire Rope (Main Hoist)
Rope Sheave
Twistlocks (Head-block & Spreader
II) Machinery Equipment
Wheels (Gantry & Trolley)
Hydraulic Unit (Anti-sway)
Page 102 of 109 M M M M M T wi C1 C1 C1 C1 Chemical Properties Mechanical Properties M M M M M C1 C1 C1 C1 C1 M M C1 C1 C1 W3 W3 M C1 Non Destructive Test Hardness W1 Visual Inspection and Weather Protection Check R Dimensional Check Proof Load Test Breaking Test Function or Heat Run Test Dielectric Test Insulation Test Characteristics Test Painting Weighing Load Test (Note ) Deflection Measurement Inventory Preparation work for Ship/Pack T T M C1 W3 W3 C1 C1 Welding Process and Welder Qualifications Edge Preparation check & Visual Inspection of Welds RMG Cranes Inspection Sheet (2 of 6) W1 R R R R R T R W3 T T W3 C1 T W3 W3 C1 W3 W3 W3 W1 C1 W1 W1 W1 W1
Note: Trolley Drive Anti-sway Device
Head-block
Gantry Drives
Main Hoist Drive
Chemical Properties Mechanical Properties Welding Process and Welder Qualifications Edge Preparation check & Visual Inspection of Welds Non Destructive Test Hardness W1 W1 W1 W1 W1 Visual Inspection and Weather Protection Check R W3 Dimensional Check Proof Load Test Breaking Test T T T T T W3 W3 W3 W3 W3 Function or Heat Run Test Dielectric Test Insulation Test Characteristics Test W3 W3 W3 W3 W3 Painting T W1 Weighing Load Test (Note ) Deflection Measurement Inventory Preparation work for Ship/Pack
III) Devices Subassembly (Sheet 1 of 2)
RMG Specification R R R R RMG Cranes Inspection Sheet (3 of 6) W3 W3 W3 W3
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RMG Cranes Inspection Sheet (4 of 6)
Welding Process and Welder Qualifications Edge Preparation check & Visual Inspection of Welds
Mechanical Properties
Non Destructive Test
Chemical Properties
Characteristics Test
Dimensional Check
Load Test (Note
III) Devices Subassembly (Sheet 2 of 2)
Spreader W1 Air Conditioner in Operators Cab & Electrical House Operators Cab, Cab Fittings and Control Stations Trolley Assembly W1 Electrical House W1
R W3
T W1 W3
T ( T ) W1 ( W 1 )
R W1 C1
T C1 T
W1
W3
W3
W1
R W3 W3
T W1 W1
R W3
T W1 T W3
T W1
Note: 1. Item in ( ) shall be carried out at Site. 2. Load Test includes Rated Load Test, Overload Test and Intermediate Load Test
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Preparation work for Ship/Pack
Visual Inspection and Weather Protection Check
Function or Heat Run Test
Deflection Measurement
Proof Load Test
Insulation Test
Dielectric Test
Breaking Test
Inventory
Weighing
Hardness
Painting
SCR Unit
AC Motor
Control Panel
Limit Switches
Magnetic Brake
Chemical Properties Mechanical Properties Welding Process and Welder Qualifications Edge Preparation check & Visual Inspection of Welds Non Destructive Test Hardness W1 W1 W1 W1 W1 Visual Inspection and Weather Protection Check R C1 Dimensional Check Proof Load Test Breaking Test Function or Heat Run Test C1 R Dielectric Test T C1 T R R C1 C1 Insulation Test R R C1 C1 Characteristics Test Painting Weighing Load Test (Note ) Deflection Measurement Inventory Preparation work for Ship/Pack
IV) Electrical Equipment
RMG Specification R R R RMG Cranes Inspection Sheet (5 of 6) C1 R T T R C1 W3 C1 C1 C1 C1
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RMG Cranes Inspection Sheet (6 of 6)
Welding Process and Welder Qualifications Edge Preparation check & Visual Inspection of Welds
Mechanical Properties
Non Destructive Test
Chemical Properties
Characteristics Test
Dimensional Check
Load Test (Note
Proof Load Test
Insulation Test
Dielectric Test
Breaking Test
V) Total Crane Assembly, Accessories and Manuals
Crane Assembly W Accessories Wear Gauges 1 W3
T W1 ( W 3 )
T C1
(T) W3
(T) (T) W1 ( W 1 )( W 1 )
( W 1 )( W 1 )
( W 1 )( W 1 )( W 1 )
W3
W 1 W1 ( W 1 )
( W 1 ) Ro-Ro Method Statement & Program
W 1
Operating Instructions W 1 Maintenance Manual W1 Oil & Lubricant List W1
Note: 1. Item in ( ) shall be carried out at Site 2. Load Test includes rated load test, overload test and intermediate load test. 3. The vertical deflection of the top beams shall be measured at rated load and overload. Vertical and horizontal measurements of trolley rails and top beam straightness at no load shall be recorded.
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Preparation work for Ship/Pack
Visual Inspection and Weather Protection Check
Function or Heat Run Test
Deflection Measurement
Inventory
Weighing
Hardness
Painting
8.3
Appendix 3 Corporate Colors and Decals
CORPORATE COLORS In accordance with Clause 6.3.5 (Paint systems) of the Technical Specification for RMG Crane, the following paint color scheme based on the RAL standard shall be used for the final finish coat. For comparison, the original register cards issued by RAL shall be the controlling reference. PAINT COLOR Traffic Orange RAL 2009 ITEM Main Steel Structure Trolley Bogie Beams Hydraulic Power Units & Cylinders Traffic White RAL 9016 Operators Cabin Electrical House Traffic Yellow RAL 1023 Spreader Stairways Handrails Buffers Guards Ladders Platforms Fenders Head-block Traffic Red RAL 3020 Pastel Green RAL 6019 Traffic Grey RAL 7042 Gather Guides on Spreader Gantry Travel Guides Operators Cabin Floor of Operators Cabin Floor of Electrical House Interior except floor Exterior only Exterior & Interior Excluding Flippers Treads of Stairways shall be left in galvanized condition The steel structure of end of travel buffer and cylinders. Around machinery, wheels, couplings etc. Including hoops Around wheels COMMENTS
RMG Specification
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PURCHASER ASSET NUMBERS The following Asset Numbers have been allocated to equipment which is to be supplied under this Agreement and may be summarized as follows: Item 1 2 Description of Equipment RMG Crane RMG Crane Asset Number 01 02 Comment Applied on outer sides of the waterside columns and sidebeams (8 pos)
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DECALS RMG Crane Telescopic Spreader In accordance with Clause 6.4.3 (2) of the Technical Specification for the RMG Crane, the following selfadhesive laser cut decals and signage shall be fitted to the spreader (local language). All decals are additional to Manufacturers Serial Number Plate, Safety, Length Indication and Maintenance decals. The Contractor shall submit a drawing showing locations, specification and dimension of all decals for approval by the Purchaser prior to manufacture. Spreader manufacturers nameplate will be permitted but the size and position shall be approved by the Purchaser before manufacture. RMG Crane Decals applied in 8 positions on each crane, white background and black letters as per sample format.
- END -
RMG Specification
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SCHEDULE 5

Technical Specification of a RMG x 2 units /RMG CRANE /

RAIL MOUNTED GANTRY CRANE SPECIFICATION OVERVIEW

m/min m/min m/min m/min

1.5 3.6 3.0 7.0

sec sec sec sec

15.0kV, 3-phase, 50 Hz Landside, Farside leg

Local and Remote Fiber Optic embedded in power cable

2 Years 1 Year or balance of DLP 10 Years 5 Years

RMG Technical Specification

3.10 3.11 3.12 3.13 3.14 3.14.1 3.14.2 4

RMG Technical Specification

RMG Technical Specification

RMG Technical Specification

RMG Technical Specification

Structures: Class of Utilization State of Loading Group Classification U8 Q3 A8

Test load for overload test Lifted Load

(4) (5) (6) (7)

RMG Technical Specification

(12) (13) (14)

Side Shift Skew adjustment Anti-sway

(3) Stowage Pins

RMG Technical Specification

RMG Technical Specification

RMG Technical Specification

RMG Technical Specification

Type of Testing/ Inspection 100% Visual 25% UT

Acceptance Criteria AWS 1.1 2006 AWS 1.1 2006

AWS 1.1 2006

AWS 1.1 2006

100% of length MT 10% of length MT (as nominated by the Purchasers Representative)

AWS 1.1 2006

RMG Technical Specification

RMG Technical Specification

(3) (4) 4.2 4.2.1 Trolley

(2) (3) (4)

RMG Technical Specification

(9) (10) (11)

RMG Technical Specification

Operators Cab Construction General

RMG Technical Specification

(7) (8) (9) (10)

RMG Technical Specification

(13) (14) (15)

(16) (17) (18) (19) 4.5.9

Personnel Elevator This clause is not used no personnel elevator is required.

(i) (ii) (iii)

(v) (vi) (vii) (viii) (2)

(2) 4.8 Spreader

RMG Technical Specification

RMG Technical Specification

INTER-FUNCTIONAL SYSTEMS & COMPONENTS

(6) (7) (8)

RMG Technical Specification

(3) (4) (5)

RMG Technical Specification

RMG Technical Specification

(5) (6) (7)

Application for Spreader Spreader shall be hydraulic