Dostawę SUWNIC NABRZEŻOWYCH STS 2 szt w ramach projektu pt:

Załącznik nr 5

Postępowania nr EU/30/STS/ZZ/ o udzielenie zamówienia w trybie przetargu nieograniczonego na:

Dostawę SUWNIC NABRZEŻOWYCH STS 2 szt w ramach projektu pt:

„Zakup zeroemisyjnych suwnic nabrzeżowych dla zwiększenia intermodalnej konkurencyjności terminalu BCT w Gdyni”

Baltic Container Terminal Ltd.

Section 6.1

TECHNICAL SPECIFICATION FOR TWO (2) QUAYSIDE CONTAINER CRANES (QC)

November 2023

Baltic Container Terminal Ltd. Xxxxxxxxxxxxxx Xxx. 00,

00-000 Xxxxxx, Xxxxxx

Xxxx Xxxxxxxxxxx

Elektronicznie podpisany przez Xxxx Xxxxxxxxxxx Data: 2024.07.12 10:03:42

+02'00'

Signature Not Verified

Dokument podpisany przez XXXXXX XXXXXXXXX

Data: 2024.07.12 10:28:47 CEST

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TABLE OF CONTENTS

1 GENERAL 6

1.1 Project Description 6

1.2 Terminal Site 6

1.3 Overriding Requirement of the Purchaser 6

1.4 Quay Crane Specification Outline 7

2 OVERALL DESIGN CRITERIA 17

2.1 Type of Crane 17

2.2 Type of Cargo 17

2.3 Operating Environment and Design Aim 17

2.4 Mode of Operation 17

2.5 Statutory Requirements and Applicable Standards 17

2.6 Safety of Machinery 18

2.7 Definitions of Load Names and Load, Stability and Wheel Load Combinations 19

2.8 Operating, Stowed and Maintenance Modes 28

2.9 Design Rules 28

2.10 General Design Criteria 29

2.11 Noise Control 32

2.12 Operationally Critical Components 32

2.13 Duty Cycle 32

3 CRANE STRUCTURAL SPECIFICATIONS 34

3.1 General Requirement 34

3.2 Material 37

3.3 Calculations 40

3.4 Loads 42

3.5 Allowable Stresses 43

3.6 Members Subject to Buckling 43

3.7 Fatigue Design Criteria 44

3.8 Connection Designs 48

3.9 Boom Hoist Rope Failure 48

3.10 Gantry Structure Stiffness 48

3.11 Camber 49

3.12 Trolley Rails & Rail fixing 49

3.13 Workmanship 50

3.14 Quality Control of Structure Fabrication 52

3.15 Temporary Attachments 53

4 FUNCTIONAL SYSTEMS, DEVICES & EQUIPMENT 55

4.1 Main Hoist 55

4.2 Trolley, Trolley Drive, Associated Devices and Operator's Cab 57

4.3 Gantry Drive 59

4.4 Boom Hoist 62

4.5 Machinery House, Electrical Control House 62

4.6 Operator’s Cab, Control Stations, Checker's Cab 67

4.7 Personnel Elevator 70

4.8 Head-block 71

4.9 Spreader 72

4.10 Spreader Trailer 75

4.11 Hook Beam 75

4.12 Container Top Safety Frame (Lashing Cage) 76

4.13 Test Weight (Required) 77

5 INTER-FUNCTIONAL SYSTEMS & COMPONENTS 78

5.1 Mechanical System/ Components 78

5.2 Hydraulic System/ Components 81

5.3 Electrical & Electronic System/Components 84

5.4 Crane Motion Controls 96

5.5 Operational Safety Interlocks 101

5.6 Communications 106

5.7 Crane Condition Monitoring System (CCMS) 107

5.8 Trailer Positioning System (Required) 115

5.9 OCR System (Not Required) 115

5.10 Vessel profiling & Container Soft-Landing (SPS) (Required) 116

6 COMMON ITEMS 117

6.1 Walkways, Stairs, Ladders and Platforms 117

6.2 Illumination and Lighting 118

6.3 Painting and Protective Coating 119

6.4 Crane Livery, Purchaser’s Logo, Asset Numbers, Signs 126

6.5 Alarms, Warning, Signals & P.A. System 129

6.6 Emergency Stop Push Buttons 131

6.7 Fire Extinguishers 132

6.8 Maintenance Tools and Equipment 132

7 PROJECT ADMINISTRATIVE REQUIREMENTS 134

7.1 Document Submission (Project) 134

7.2 Design Drawings and Calculations 136

7.3 Quality Assurance Inspection and Test Protocols 137

7.4 Operation and Maintenance Instructions 139

7.5 Shop Inspection & Tests 141

7.6 Shipment and Delivery 145

7.7 Site Work 146

7.8 Site Inspection and Tests, Certification 148

7.9 Training and Familiarization 149

7.10 Spare Parts 151

7.11 Crane Model 151

8 APPENDICES 152

Appendix 1. Stipulated Components 152

Appendix 2. Crane Livery, Purchaser’s Logo, Asset Numbers 155

Appendix 3. Tools List 157

Appendix 4. Documentation Status Control Sheets 159

Appendix 5. Inspection / Test Control Sheets 164

Appendix 6. Standard Structural Details (Liftech) 172

Appendix 7. General Arrangement Drawing 183

Appendix 8. Crane Weights and Declared Wheel Loads 184

Appendix 9. Existing Stow Pin and Tie-Down Details 185

Appendix 10. Existing Quay Details 185

Appendix 11. Crane End Stop Details 185

1 GENERAL

1.1 Project Description

To carry out the design, construction, delivery, installation, testing and completion of rail mounted container handling quayside cranes. The cranes shall be delivered to Purchasers Site as defined in the General Conditions in a fully assembled condition with pre-shipment testing completed at the manufacturer’s site.

1.2 Terminal Site

The Cranes shall be delivered, commissioned and completed on the container-handling Berth at Site of BCT - Baltic Container Terminal LTD. (BCT), Gdynia, Poland

1.3 Overriding Requirement of the Purchaser

The Purchaser’s 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.

(2) For the paint system and galvanized components, acceptable routine maintenance shall be:

- Preparing and over coating the existing system at year 20 after the issuance of the Taking- over Certificate.

- Removing defective parts of the protection system back to clean steel and recoating in isolated areas but not exceeding in aggregate more than 1% and 2% of the total surface area at years 5 and 10 respectively.

- The removal of the protective system back to steel and replacement of the coating in areas aggregating more than the above percentages of the total surface area of the coated part of the Crane shall be Defects remedial works and not maintenance.

(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.

(4) The foregoing shall apply notwithstanding any inconsistent requirement or information in any maintenance instructions provided by the Contractor or otherwise put forward by the Contractor and any such inconsistent requirement or information shall not, and shall not be relied on by the Contractor, to relieve, limit or diminish any obligation or liability of the Contractor under the Agreement or otherwise including in relation to Defects.

1.4 Quay Crane Specification Outline

Crane Details and Accessories

SPEC. REF.	ITEM	SELECTION	COMMENT
General Crane Details & Accessories
	Number of cranes to buy	Two (2)
	Biggest vessel size to be served	Post Panamax 25 Rows
	Crane design: • Dual-box boom/girder • Mono-box	Dual box boom/girder	Manufacturer to propose
	Trolley type: • Rope towed • Direct-Drive	Rope Towed	Manufacturer to propose
4.9	Spreader	Twin-lift
	Lashing / Hatch cover platform	None	A hatch cover platform for storing 3 hatch covers. Located LS of LS sill beam
	Checker’s cabin:	Underneath LS Sill beam	Access to the checker’s cabin from inboard and outboard of the crane.
	Delivery method: • fully erected • semi-erected • erection on site	Fully erected
Accessories
4.9.3	Number of spare spreaders	One (1)	Twin-lift
4.10	Number of spreader trailers	One (1)
4.11	Number of hook beams	One (1)
4.12	Container Top Safety Frame (= Lashing cage)	Two (2) stored on crane	ICTSI standard: stored on crane A 20ft Container Top Safety Frame is typically stored on top of the landside sill- beam. If the CTSF shall be stored on a trailer (not included), BU to indicate the number of CTSF required per project.
4.13	Test Weight	Required	A test weight in the format of a 45ft container
6.8.2	Spreader Test Panel	One (1)	A test panel for operating and testing spreaders in the workshop.
6.8.3	Drive Simulator	None	A drive simulator as training aid to electrical technicians.
Electrical Details
	Electrical system and installation standard	IEC	Local standard is NEC, but IEC is acceptable for this project.
	Electrical system integration	Crane Manufacturer
	Trolley Power Supply: • Cable chain • Festoon system	Cable chain	Renowned global producers type required
	Remote Crane Condition Monitoring System	Required	Remote Crane Condition Monitoring via fiber optic link to maintenance workshop.
	Independent Main Hoist and Gantry Travel Inverters	Required	None = shared Main Hoist and Gantry Travel Inverters

SPEC. REF.	ITEM	SELECTION	COMMENT
	Independent Boom Hoist and Trolley Travel Inverters	None	None = shared Boom Hoist and Trolley Travel Inverters
	Emergency recovery drives	Independent drive for each motion	For emergency recovery operation of main hoist, boom hoist and trolley.
	Emergency Power Supply Socket	Include	Interlocked plug and socket arrangement between cranes for the supply of emergency power in the event of crane power failure.
	Load Weighing	A spreader- twist-lock built-in load weighing system to report container weight(s) to the TOS I andOverload	ICTSI Standard: Overload protection only A spreader-twist-lock built-in load weighing system to report container weight(s) to the TOS is an option
	RFID Access Control	None	No access to elevator control and e- rooms shall be granted without required coded tag. All requests for access to be logged with date and time stamp and ID tag number.
5.8	Trailer Positioning System	Two Directions	Laser scanner system with traffic light indication for stop positions for Terminal Tractors.
Błąd! Nie można odnale źć źródła odwoł ania.	Trailer Anti-Lift Protection System	None
Automation Features
5.9	Optical Character Recognition System (OCR)	Container number+cont ainer damage	Complete OCR System Required by renowned global producers
Błąd! Nie można odnale źć źródła odwoła nia.	Twist-lock Coupler Detection System	None
Błąd! Nie można odnale źć źródła odwoł ania.	Container Position Determination System (PDS)	None

SPEC. REF.	ITEM	SELECTION	COMMENT
5.10	Vessel profiling & Container Soft-Landing	Required	Container height sensor mounted on the trolley to detect potential container collisions while trolley travelling and soft- landing of spreader and containers.
Błąd! Nie można odnale źć źródła odwoł ania.	Anti-sway System	None
Błąd! Nie można odnale źć źródła odwoł ania.	Semi-Automation	Required
Błąd! Nie można odnale źć źródła odwoła nia.	Automated Back-reach Operation	None
Błąd! Nie można odnale źć źródła odwoła nia.	Fully automated crane operation including Remote Operation Stations	None
Błąd! Nie można odnale źć źródła odwoła nia.	Automated Lashing Platform	None

QC Principal Dimensions

ITEM	VALUE		COMMENT
Gantry rail span (centre to centre)	30.48	m
Centre of waterside rail to fender face	5.27	m
Beam of Design Vessel	63	m
Outreach from CL waterside rail to the service limit	72,500	mm	72,500mm to service limit, 73,000 mm to emergency end stop limit switch.
Back-reach from CL landside rail to the service limit	23,000	mm	23,000 mm to service limit, 23,500 mm to emergency end stop limit.

ITEM	VALUE		COMMENT
Minimum clearance required under back reach	N/A	m	-- mm minimum to avoid collision with high mast lights. A trolley back-reach travel limit, with bypass, is required in each position where the trolley travel would interfere with high mast lights. Gantry travel shall also be inhibited when trolley position would interfere with high mast lights.
Lift above top of waterside rail to lowest point of spreader twist-locks	55	m	55,000mm minimum to the lowest point of twist lock.
Lift below top of waterside rail to lowest point of spreader twist-locks	19	m	Minimum
Total lift	74	m
Clearance height under portal beam above waterside rail	12.5	m
Usable inside clearance between legs	18.3	m
Maximum allowed overall crane length with crane bumpers uncompressed.	27	m	27,000 mm maximum in bumper free condition. The bumpers shall be the widest positions on the crane.
Maximum width of boom or trolley, whichever the greater	<8,600	mm	With proposed dimension, it shall be possible to discharge or load a container adjacent to the bridge without interference between boom and bridge.
Trolley rail gauge	6,000	mm	Minimum
Trolley rail gauge (mono-box)	3,700	mm	Minimum
Gantry travel distance along quay from crossover feeding point	400	m

QC Lifting System

ITEM		VALUE		COMMENT
Spreader
2.1	Twin-Lift	Yes
2.2	Centre Spread	Yes
2.3	Compatibility with existing spreaders	Yes
Loads
2.4	Container type			ISO 20', 40', 45’ ISO and up to 53' containers with ISO corner fittings at 20', 40' or 45' position.
2.5	Maximum container load under spreader in twin-lift mode	65	MT	2 x 25.5MT
2.6	Maximum container load under spreader in single lift mode	51	MT	At reduced 60% speed
2.7	Maximum load under hook beam	75	MT	At full outreach
2.8	Test Load for overload test under spreader	81.25	MT	125% load
2.9	Test Load for overload test under hook beam	93.75	MT	125% load

QC Operational Speeds

ITEM		VALUE		COMMENT
Note:	Speeds: These speeds must be achieved for Crane operation with or against sustained wind speed of 20 meter/sec. (45MPH) Xxxxx shall be able to be moved to nearest stow pin position with or against sustained wind speed of 25 meter/sec. (55MPH)
Hoist speeds:
3.1	With max. container load under spreader • Acceleration time hoisting • Acceleration time lowering • Deceleration time hoisting • Deceleration time lowering	90	m/min
3.2		2	s
3.3		1.5	s
3.4		1.5	s
3.5		2	s
3.6	With empty spreader • Acceleration time hoisting • Acceleration time lowering • Deceleration time hoisting • Deceleration time lowering	180	m/min
3.7		4	s
3.8		3	s
3.9		2.5	s
3.10		4	s
3.11	Cargo beam in any load condition • Acceleration time • Deceleration time	40	m/min
3.12		3	s
3.13		2	s
Note:	Speeds for intermediate loads are in relationship to a constant power curve (except for cargo beam). Values for acceleration and deceleration may vary depending on motor and drive characteristics.
Trolley traverse speeds:
3.14	With or without maximum container load under spreader • Acceleration / Deceleration Time	220	m/min
3.15		4.5	s
3.16	• Acceleration / Deceleration Time	6.0	s	Mono-box
Boom hoist speeds:
3.17	Time from Stowed Mode to Operating Mode and vice versa	2.5	min
3.18	Time from Stowed Mode to Maintenance Mode and vice versa	2.0	min
Gantry travel speeds:
3.19	With or without maximum Container Load under Spreader	50	m/min
3.20	• Acceleration / deceleration time up to 50% operating wind load (WLO)	6	s	Gantry: Gantry travel with or against a maximum 50% operating wind load, WLO, with or without rated load, operating, stowed, Or maintenance boom mode. 50m/min. Acceleration/Deceleration time 6 sec

ITEM		VALUE		COMMENT
3.21	• Acceleration / deceleration time at maximum sustained operating wind	10	s	Gantry travel with or against the operating wind load, WLO, with or without the rated load, operating, stowed, or Maintenance boom mode. 50m/min Acceleration/Deceleration time 10 sec
Trim / List / Skew:
3.22	Trim adjustment with maximum container load	+/- 3	deg
3.23	Trim speed with maximum container load from centre position to maximum trim	5 – 10	s
3.24	List adjustment with maximum container load	+/- 5	deg
3.25	Max spreader horizontal drift in trolley direction from zero to max list position.	+/- 150	mm
3.26	List speed with maximum container load from centre position to maximum list	5 – 10	s
3.27	Skew adjustment with maximum container load	+/- 3	deg
3.28	Skew speed with maximum container load from centre position to maximum trim	5 – 10	s
Note:	Trim and skew adjustment systems shall be capable of changing attitude of a maximum weight container load with 1.6 m eccentricity in load centre.

QC Design Criteria

ITEM		VALUE		COMMENT
Note: Below classifications are as per F.E.M. 1.001, 3rd Edition Revised 1998.10.01
Structures:
4.1	Class of Utilization	U 8
4.2	State of Loading	Q 3
4.3	Group Classification	A 8
4.4	Maximum Operating Cycles	4	million
Main hoist mechanism:
4.5	Class of Utilization	T 8
4.6	State of Loading	L 3
4.7	Group Classification	M 8
Trolley travel mechanism:
4.8	Class of Utilization	T8
4.9	State of Loading	L3
4.10	Group Classification	M8
Gantry travel mechanism:
4.11	Class of Utilization	T 5
4.12	State of Loading	L 3
4.13	Group Classification	M 6
Boom hoist mechanism:
4.14	Class of Utilization	T 5
4.15	State of Loading	L 3
4.16	Group Classification	M 6

Site Environmental Data

ITEM		VALUE		COMMENT
5.1	Maximum recorded ambient temperature	45	°C
5.2	Minimum recorded ambient temperature	-25	°C
5.3	Sample period	25	years
5.4	Maximum relative humidity	100	%
5.5	Maximum sustained operating wind speed	20	m/s
5.6	Maximum gust operating wind speed	25	m/s
	(without warning)
5.7	Maximum stowed wind speed	44	m/s
5.8	Tide – Datum reference type	N/A		Local datum type (Mean Water Low
				Springs or other)
				CHART DATUM (Mean Low Water =0m)
5.9	Extreme High Tide		m	Above datum
5.10	Extreme Low Tide		m	Below datum
5.11	Seismic zone reference

ITEM		VALUE		COMMENT
5.12	Seismic acceleration (max.)	0.2	g	The value to be taken into account by the crane designer for estimation of loads. Peak Ground Acceleration shall not be less than 0.1g

Vessel / Cranes Delivery Parameters

ITEM		VALUE		COMMENT
6.1 6.2	Minimum draft alongside xxxxx Xxxxxxx controlling draft from anchorage	15.5 13	m m
6.3	Maximum height restriction (air draft)	N/A	m
6.4	Bollard separation interval along quay	25	m
6.5	Bollard load capacity	2X90 MT

Quay Interface - Mechanical

ITEM		VALUE		COMMENT
Gantry Rail
7.1	Gantry rail type	A150	Type	DIN 536:1991 Grade 900
7.2	Gantry rail weight	150.3	kg/m
7.3	Gantry rail head width	150	mm
7.4	Height difference of LS rail above WS rail	0	mm	The landside rail is lower than the waterside rail by 0 mm. A vertical rail tolerance of ± 50 mm measured at the rail head surface from mean position throughout the gantry rail length shall be permitted.
7.5	Curved gantry rail • Minimum radius WS rail • Minimum radius LS rail	None		STS crane shall have the facility to
				traverse around a curved gantry rail.
				*CLARIFICATION: Gantry speed whilst
				traversing curved rail section shall be
				proposed by the Contractor and
				approved by the Purchaser.
7.6		None	m
7.7		None	m
Permitted Rail Loads
7.8	Vertical load limit WS rail – operational	80	MT/m
7.9	Vertical load limit LS rail – operational	80	MT/m
7.10	Overload limit WS rail – short duration	100	MT/m	Short duration impact or wind gust
7.11	Overload limit LS rail – short duration	100	MT/m	Short duration impact or wind gust
7.12	Stowed Condition WS	100	MT/m
7.13	Stowed Condition LS	100	MT/m
7.14	Horizontal load limit LS – operational	8	MT/m
7.15	Horizontal overload limit LS – short duration	10	MT/m	Short duration impact or wind gust
7.16	Horizontal load limit WS – operational	8	MT/m
7.17	Horizontal overload limit WS – short duration	10	MT/m

ITEM		VALUE		COMMENT
Permitted Wheel Loads
7.18	Load limit WS wheels – operational	95	MT/wheel
7.19	Load limit LS wheels – operational	95	MT/wheel
7.20	Overload limit WS wheels – short duration	115	MT/wheel	Short duration impact or wind gust
7.21	Overload limit LS wheels – short duration	115	MT/wheel	Short duration impact or wind gust
7.22	Stowed Condition WS	115	MT/wheel	Short duration impact or wind gust
7.23	Stowed Condition LS	115	MT/wheel	Short duration impact or wind gust
End of Travel Buffers
7.24	Centre height above rail	1,100	mm
7.25	Load capacity of existing fixed buffers	TBD	MT
Stow Pins & Typhoon Tie-downs
7.26 7.27 7.28 7.29 7.30	Stow pin slots - Waterside • Distance from C/L to C/L of rail • Length (parallel with the quay) • Width (perpendicular to rail) • Depth	Inboard and Outboard TBD TBD TBD TBD		mm mm mm mm	These can be as per crane manufacture preference with civil work following, or we can follow civil design and issue to crane manufacturer
7.31 7.32	Stow pin slots - Landside • Distance from C/L to C/L of rail	Inboard and Outboard TBD		mm	These can be as per crane manufacture preference with civil work following, or we can follow civil design and issue to crane manufacturer
7.33	Quantity and spacing long quay	TBD		m
7.34	Stow pin slot horizontal design load	TBD		MT
7.35	Typhoon Tie-downs	No			Manufacturer to propose
7.36	Checker’s cabin	Yes
7.37	Checkers cabin position	Land side With Dual Gated Access/Egress from Inboard and Outboard

Quay Interface – Electrical`

ITEM		VALUE		COMMENT
MV Power Supply
8.1	Crane power supply voltage	15	kV
8.2	Supply voltage tolerance	+/- 10	%
8.3	Main power supply frequency	50	Hz
8.4	Supply frequency tolerance	+/- 2	%
8.5	Supply network short circuit capacity	0.6	MVA
8.6	Fuse type in MV substation	TBD
8.7	MV Service cable length	400	m
8.8	MV Service cable specification	TBD
8.9	Number and specification of fibre optics at cross-over cable pit	18x62.5/125	Micron

ITEM		VALUE		COMMENT
8.10	Number and positions of cross-over cable pits assigned for all QC under this project	1
8.11	Number of MV cable strain relief drums assigned for all QC under this project	1
8.12	Diameter of MV cable strain relief drum	800	mm
8.13	MV cable connection method at cross- over cable pit	Termination Cabinet
8.14	Preferred MV cable type	Renowned global producers with integral FiO		Cable type to be reviewed during design review.
8.15 8.16 8.17 8.18	MV cable trench - Position • Distance from C/L to C/L of rail • Width • Depth	WS Inboard	mm mm mm
8.19	MV cable trench protection	None
8.20	MV cable pick-up position	LHS Portal WS Inboard		As viewed looking out to water
Local Electrical Parameters
8.21	Local Three Phase Voltage	400	V
8.22	Local Single-Phase Voltage	230	V
8.23	Frequency	50	Hz
8.24	Three phase plug type for shore supply and/or welding machines	CEE -4 pin + G
8.25	Single phase plug type for hand tools	C
Note: Refer to xxxx://xxx.xxx.xx/xxxxxxxxxx for identification of plug types
Local Specifics
8.26	Local Language	PolishEnglish		Signage, labelling, training and Maintenance and Operation documentation/manuals shall be in English and local language.

2 OVERALL DESIGN CRITERIA

2.1 Type of Crane

The Crane shall be a traveling gantry with a hinged straight boom at waterside, self-driven or rope-towed trolley type. The crane drive and control shall be supplied with a full AC inverter drive, fully digital control with PLC. The proposed drive and control system shall be a proven system successfully operating on a similar-capacity crane in actual container handling operations. The Crane shall be twin-lift, capable of handling 2 x 20 ft. containers in tandem with a twin-lift spreader.

2.2 Type of Cargo

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

(1) ISO 20ft, 40ft and 45ft containers including high-cube, half-height, flat rack containers.

(2) Other types of container with ISO corner fittings at 20', 40', or 45' position, 48ft and 53ft containers.

(3) 40ft and 45ft containers of weight up to 51 Metric Tonnes (MT).

(4) 2 x 20ft containers of weight each up to 32.5 MT.

(5) Containers with over-height cargoes through an over-height cargo container lifting frame belonging to the Purchaser.

(6) Hatch covers and containers of weight up to 50 MT.

(7) Damaged containers with slings and shackles attached to lifting lugs of the spreader.

(8) Heavy lift cargo

At least 75 MT beneath a Hook Beam attached to the head-block. The heavy lift shall be operable through the full hoisting range and across the full distance of trolley travel with 100 MT beneath hook beam at reduced outreach to be determined by the Contractor. The Contractor shall maximize the load capacity under hook beam according to his design.

2.3 Operating Environment and Design Aim

The Crane shall be operated and maintained on a 24-hour per day basis in all weather conditions. All electrical, electronic, and mechanical equipment shall be non-hygroscopic, non-corroding and tropicalized for use. Special considerations shall be given in all aspects of the design for achieving accurate load spotting ability while ensuring full operational capability and safety for around the clock operations, including operations under heavy rain conditions at night.

The Crane shall be exposed to non-technical personnel specifically at the ground level and passages from ground level to the operator's cab and from the operators cab to the boom operating station. In these areas of the Crane, the Contractor shall ensure that a high degree of personnel safety protection is provided around the equipment and fittings. Ease of maintenance and safety of the maintenance staff shall be considered throughout the entire design to minimize total down time of the Crane.

2.4 Mode of Operation

The Crane shall be manually controlled. All functions on the Crane shall be controlled fully by the operator.

2.5 Statutory Requirements and Applicable Standards

(1) The Crane and its mechanisms shall be designed and manufactured to comply in all respects with the requirements of applicable state and local country laws, ordinances, rules, orders, or other legal or regulatory instruments such as, but not limited to, the following: -

(2) Where items are not covered by statutory requirements the Crane and other Works shall be designed and manufactured to at least the standards as defined in this Specification, and for items which are not so specified to at least the current applicable recommendations of the following organizations: -

AISC American Institute of Steel Construction – ASD AISE Association of Iron and Steel Construction ANSI American National Standards Institute

ASNT American Society for Non-destructive Testing ASTM American Society for Testing and Materials

AWS American Welding Society – Bridges and Dynamically Loaded Structures

BSI British Standards Institute DIN Deutsche Industrie Normen

FAA Federal Aviation Administration

FEM Federation Europeane de la Manutention IEC International Electro-technical Commission

IEEE Institute of Electrical and Electronic Engineers ISO International Standards Organization

JIC Joint Industrial Council

JIS Japanese Industrial Standards NEC National Electric Code

NEMA National Electric Manufacturers Association SAE Society of Automotive Engineers

UL Underwriters Laboratory

*CLARIFICATION: Where the crane or any of its mechanisms/components do not comply with any of the above standards the Contractor must submit each non-compliant item for review and approval from the Purchaser.

(3) The Contractor shall be required to submit to the Purchaser a full list of applicable standards used in the design of the Crane.

(4) The specifications refer to various U.S. and international standards, materials, and procedures. If the Contractor believes that complying with the references is impracticable, the manufacturer may propose alternative standards. The alternates will be accepted provided they are, in the Purchaser’s opinion, at least equal to the referenced standards. The Contractor shall submit the alternatives with the bid including documentation demonstrating equivalence with the references. The Purchaser will review the proposed alternatives and decide if they are acceptable. If the Contractor submits the proposed alternatives four weeks before the bid date, the Purchaser will respond at least one week before the bid date. If the alternatives are submitted later than the four weeks before the date, the Purchaser may accept them, or may not accept them without review of the merits, and the bid shall be based on complying with the references.

(5) Where reference is made to a standard specification, e.g., AWS D1.1, the latest edition published before the date on the title page of this specification shall apply. If, however, the edition is stated, e.g., ISO 4628-/3-1982(E), the stated edition shall apply

2.6 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 is 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 Definitions of Load Names and Load, Stability and Wheel Load Combinations

Name Load

Description

BHRF	Boom Hoist Rope Failure Cargo Beam Lifting System Cargo Beam Rated Load	The loads, including dynamic effects, due to one of the independent boom hoist ropes failing. The trolley and lift system shall be in the parked position. The weight of the cargo beam, head-block, portions of the lifting ropes, sheaves and all other equipment which hangs from the main hoist ropes when the cargo beam is connected The greatest concentric load that can be lifted by the cargo beam without requiring any physical changes in the crane components. CBRL shall be a minimum of 61 metric tons.
CBLS
CBRL

COLL Collision Load The loads determined by dynamic analysis, assuming that the

xxxxx, while traveling at full speed with the power off, hits the crane stops or hits another stopped crane or (not concurrently) that the trolley traveling at full speed with the power off, hits its stops. Bumpers shall be provided so these loads govern only local components.

DL Dead Load The weight of the crane's structure including all permanently attached machinery and equipment.

EQO Operating Earthquake Load

EQS Stowed Earthquake Load

F Fatigue

Condition

IMP Impact

LATF

Trolley Lateral Load

The load imposed on the crane structure by an earthquake occurring during operation. EQO shall be a minimum of:

A. 0.2(DL + TL) or

B. The load required to tip the crane such that one corner lifts off of the rail

Loading shall be applied in the gantry and trolley travel directions, non-concurrently. The trolley shall be assumed to be at the most adverse position.

The load imposed on the crane structure by an earthquake occurring during stowed condition. EQS shall be a minimum of:

0.2(DL + TL) or

B. The load required to tip the crane such that one corner lifts off of the rail

Loading shall be applied in the gantry and trolley travel directions, non-concurrently.

See Section 3.7, Fatigue Design Criteria.

The loads due to vertical acceleration of the lifted load as sensed by the main hoist ropes. Impact loads shall be determined as described in Section 3 (Crane Structural Specifications)

The lateral trolley inertia force applied parallel to the travel direction shall be at least 0.10×(TL+LS+LLF) for fatigue combinations. The simultaneous inertia force applied perpendicular to the travel direction shall be one-fourth of the force applied parallel to the travel direction. Stresses due to LATF shall be combined with the stresses due to vertical loads. There shall be two starts and two stops for each cycle.

Name Load Description

LATT Trolley Lateral Load

LATG Gantry Lateral Load

The loads imposed on the crane due acceleration or deceleration of the trolley.

The lateral inertia force applied parallel to the travel direction shall be at least 0.10×(TL+LS+LL) for operating combinations. The simultaneous inertia force applied perpendicular to the travel direction shall be one-fourth of the force applied parallel to the travel direction.

The loads imposed on the crane due to positive or negative acceleration of the gantry.

The lateral force applied parallel to the travel direction shall be 1.5 times the maximum inertia force that can be developed due to acceleration or deceleration of the gantry drive system, except the minimum gantry inertia force shall be at least 0.05 times all weights present on the operating crane. The simultaneous inertia force applied perpendicular to the travel direction shall be of one- fourth of the force applied parallel to the travel direction.

LEGL Leg Lift The load imposed on the crane due to a 30 mm vertical

displacement of one leg relative to the other three legs. This is a parameter load for information only and is not to be used for stress calculations.

LIST List The effect of ±5 list of the spreader and rated load.

LL Lifted Load The weight of containers plus contents which shall be taken as 50

MT and shall be applied concentric to the geometric center of the container.

LLF

LS

OL1 OL2 OL3 OL4

OL1M OL2M

Eccentric Lifted Load

LLE

Fatigue Lifted Load

Lifting System

Overload Conditions 1,

2, 3 & 4 in the Operating Mode

Overload Conditions 1and 2 in the Maintenance Mode

The weight of 41 MT containers applied eccentric to the geometric center of the container 1220 mm toward either end longitudinally and 230 mm toward either side transversely.

Fatigue design shall be based on an effective container, which, for simplicity, is assumed to be equivalent to the actual spectrum of various weight containers including impact effects. The weight of the container plus its contents shall be taken as 30 MT and shall be applied eccentric to the geometric center of the container 760 mm longitudinally. The eccentricity should be considered at one side of the center of the container for half of the design cycles and the other side of the center for the remaining half of the design cycles. The vertical load does not need to be increased because of vertical acceleration. Forces due to horizontal accelerations shall be based on a container weighing 30 MT.

The weight of the spreader, head-block, portions of the lifting ropes, sheaves and all other equipment, which hangs from, the main hoist ropes and is supported by the container when the spreader is placed upon it.

Refer to Table 2.1 Load Combinations – Operating Modes in this section.

Refer to Table 2.2 Load Combinations – Stowed and Maintenance Mode in this section.

Name Load Description

OL1S OL2S

OP1 OP2 OP3

OP1M OP2M

OP1S OP2S

Overload Conditions 1 and 2 in the Stowed Mode

Operating Conditions

1, 2, & 3 in the Operating Mode

Operating Conditions 1 and 2 in the Maintenance Mode

Operating Conditions 1 and 2 in the Stowed Mode

Refer to Table 2.2 Load Combinations – Stowed and Maintenance Mode in this section.

Refer to Table 2.1 Load Combinations – Operating Mode in this section.

Refer to Table 2.2 Load Combinations – Stowed and Maintenance Mode in this section.

Refer to Table 2.2 Load Combinations – Stowed and Maintenance Mode in this section.

RL

S1S

S1M

ST1O ST2O ST3O ST4O

ST5O ST6O

Rated Load Container

Stowed Condition 1 in the Stowed Mode

Storm Condition 1 in the Maintenance Mode

Stability Conditions 1 thru 6in the Operating Mode

2 x 20’ long containers, 9'-6" high and 8'-6" wide weighing, with their contents, 50 MT total. The eccentricity shall be considered (see LLE).

Refer to Table 2.2 Load Combinations - Stowed and Maintenance Mode in this section.

Refer to Table 2.2 Load Combinations - Stowed and Maintenance Mode in this section.

Refer to Table 2.3 Stability Combinations in this section.

XX0X XX0X XX0X XX0X

Stability Conditions 1 thru 4in the Stowed Mode

Refer to Table 2.3 Stability Combinations in this section.

ST1M ST2M ST3M ST4M

Stability Conditions 1 thru 4 in the Maintenance Mode

Refer to Table 2.3 Stability Combinations in this section.

SKT

Trolley Skew Load

SKG

Gantry Skew Load

		Where gage is the distance between the rails and wheel base is the distance center to center of the outermost wheels for SKT and the main equalizer pins for SKG.
		If the Contractor demonstrates that the trolley and/or gantry skew load is less than the value shown because of either electrical or mechanical drive controls, then the reduced load may be used accordingly.
SN	Snag Load	The load imposed on the crane due to the head-block and empty spreader traveling at maximum hoist speed becoming jammed in the ship's cell guides or being accidentally two-blocked against the underside of the trolley resulting in the kinetic energy of the rotating equipment being dissipated by elastic deflection of the machinery and the structure and special energy absorbing devices. See Section 4.1.4. (Snag Control)
SPRD	Leg Spread	The load imposed on the crane due to a 25 mm horizontal displacement perpendicular to the rail of the waterside legs relative to the landside legs. This is a parameter load for information only
		and is not to be used for stress calculations.

STL Stall Torque Load

The load developed by stalling any motor in the crane. The load shall be due to the stall and/or breakdown torque of AC drives. For the main hoist, stall torque load shall be the load induced by stalling the hoist motors with one end of a container or hatch cover dogged down or with all four corners dogged down concentrically.

Name Load

Description

The loads developed due to wheels rolling along a rail. The force shall be taken as acting normal to the rail and tending to skew the structure. The horizontal force, perpendicular to the gantry rail, at each corner shall be one fourth of the total vertical load due to:

S × ( DL + TL + LS + LL) .

S shall be determined from the following graph.

0.20

0.15

S 0.10

0.05

0.00

0 2 4 6

RATIO:

8 10 12

GAGE

WHEEL BASE

For the Boom Hoist, stall torque shall be determined based on the reduced stall torque when the boom is fully raised.

TL Trolley Load The weight of the trolley including all machinery and equipment

permanently attached, but excluding the weights included in LS. TRIM Trim The effect of ± 3° trim of the spreader carrying rated load.

WLO Operating Wind Load

WLS Stowed Wind Load

The load due to an operating wind speed of 20 m/s assumed uniform over the full height of the crane applied in any direction. The lifted container shall be the rated load container.

The load due to a storm wind speed of 28 m/s assumed uniform over the full height of the crane applied in any direction. The trolley shall be in the stowed position.

Name Load Description
WOL1 WOL2 WOL3	Wheel Loads for Overload Conditions 1, 2, and 3 in the Operating Mode. Wheel Loads for Overload Condition 1 in the Stowed and Maintenance Modes. Wheel Loads for Operating Conditions 1, 2, and 3in the Operating Mode. Wheel Loads for Operating Condition 1in the Stowed and Maintenance Modes.	Refer to Table 2.4 Wheel Load Combinations in this section. Refer to Table 2.4 Wheel Load Combinations in this section. Refer to Table 2.4 Wheel Load Combinations in this section. Refer to Table 2.4 Wheel Load Combinations in this section.
WOL1S WOL1M
WOP1 WOP2 WOP3
WOP1S WOP1M
XX0X XX0X XX0X WS2M	Wheel Loads Refer to Table 2.4 Wheel Load Combinations in this section. for the Stowed Conditions 1 and 2 in the Stowed and Maintenance Modes.

Wind loads shall be calculated using force coefficients from engineering references or from wind tunnel tests. Base reactions resulting from applied wind loads shall be equal to or greater than the reactions obtained from wind tunnel tests on suitable models for operating and stowed configurations. Wind tunnel test results shall include angled wind effects for wind from any direction.

Operating Mode Combinations For Stress Calculation—Boom Down
Condition Combination name		OP1	Operating OP2	OP3	OL1	Overload OL2 OL3		OL4
Dead Load	DL	1.0	1.0	1.0	1.0	1.0	1.0	1.0
Trolley Load	TL	1.0	1.0	1.0	1.0	1.0	1.0	1.0
Lifting System	LS	1.0	1.0			1.0		1.0
Cargo Beam Lifting System	CBLS			1.0
Cargo Beam Rated Load	CBRL			1.0
Lifted Load	LL					1.0		0.5
Eccentric Lifted Load	LLE	1.0	1.0
Impact	IMP		1.0	1.0
List	LIST	1.0	1.0		1.0	1.0	1.0
Trim	TRIM	1.0	1.0		1.0	1.0	1.0
Trolley Lateral Load	LATT		1.0
Gantry Lateral Load	LATG	1.0
Trolley Skew Load	SKT		1.0
Gantry Skew Load	SKG	1.0
Operating Wind Load	WLO		1.0	1.0	1.0	1.0
Stall Torque Load	STL				1.0
Collision Load	COLL					1.0
Snag Load	SN						1.0
Earthquake Load	EQO							1.0

For the special load case when one of the boom hoist ropes fails, combine DL+TL+BHRF with the dynamic effects of the failure.

Table 2.1: Load Combinations – Operating Mode

Stowed & Maintenance Mode Combinations for Stress Calculations
Condition		Operating		Overload		Storm
Mode		Combination Name
Maintenance Mode		OP1M	OP2M	OL1M	OL2M	S1M
Stowed Mode		OP1S	OP2S	OL1S	OL2S	S1S
Dead Load	DL	1.0	1.0	1.0	1.0	1.0
Trolley Load	TL	1.0	1.0	1.0	1.0	1.0
Lifting System	LS	1.0	1.0	1.0	1.0	1.0
Gantry Lateral Load	LATG	1.0
Gantry Skew Load	SKG	1.0
Operating Wind Load	WLO		1.0	1.0
Collision Load	COLL			1.0
Stowed Earthquake Load	EQS				1.0
Stowed Wind Load	WLS					1.0
Tie-downs in Place?		No	No	No	No	No

Table 2.2: Load Combinations - Stowed & Maintenance Mode

STABILITY COMBINATIONS
MODE	Operating						STOWED				MAINTENANCE
Stability Load Name	XX0X	XX0X	XX0X	XX0X	XX0X	XX0X	XX0X	XX0X	XX0X	XX0X	ST1M	ST2M	ST3M	ST4M
Dead Load DL Trolley Load TL Cargo Beam Lift System CBLS Cargo Beam Rated Load CBRL Lifting System LS Lifted Load LL Impact IMP Trolley Load Lateral LATT Gantry Load Lateral LATG Operating Wind Load WLO Stall Torque Load STL Collision Load COLL Stowed Wind Load WLS	1.0 1.0 1.0 1.0 1.0 1.5	1.0 1.0 1.0 1.0 1.5	1.0 1.0 1.0 1.15	1.0 1.0 1.0 1.0 1.0 1.15	1.0 1.0 1.0 1.15 1.0	1.0 1.0 1.0 1.5 1.0 1.0	1.0 1.0 1.0 1.5	1.0 1.0 1.0 1.5	1.0 1.0 1.0 1.15	1.0 1.0 1.0 1.2	1.0 1.0 1.0 1.5	1.0 1.0 1.0 1.5	1.0 1.0 1.0 1.15	1.0 1.0 1.0 1.2
Number of Legs Allowed to lift off	0	0	1	1	0	0	0	0	1	0	0	0	1	0

Table 2.3: Stability Combinations

NOTE: The snag load, SN, is not included in the stability combinations since the kinetic energy of the rotating equipment that is not dissipated cannot topple the crane.

EXAMPLE: ST1O is 1.0 DL + 1.0 TL + 1.0 LS + 1.0 LL + 1.0 LATT + 1.5 LATG with zero-legs allowed to lift off.

One leg allowed to lift off means one leg may lift off while the other three legs remain in contact with the gantry rail. Zero legs allowed to lift off means no legs may lift. All wheels shall remain in contact with the gantry rail.

The Contractor shall submit calculated corner uplift loads for all stability combinations as described above. Tie-downs may not be used for the stowed wind load condition.

Wheel Load Combinations—Service (Unfactored)
Boom	Position Mode	Operating			Overload			Stowed
Boom Down		WOP1	WOP2	WOP3	WOL1	WOL2	WOL3
Boom 45°		WOP1S			XXX0X			XX0X	XX0X
Boom Up		WOP1M			WOL1M			WS1M	WS2M
Dead Load	DL	1.0	1.0	1.0	1.0	1.0	1.0	1.0	1.0
Trolley Load	TL	1.0	1.0	1.0	1.0	1.0	1.0	1.0	1.0
Lifting System	LS	1.0	1.0	1.0	1.0		1.0	1.0	1.0
Lifted Load*	LL	1.0	1.0	1.0	0.5		1.0
Impact Gantry Lateral Load Operating Wind Load Earthquake Load Stall Torque Load Collision Load Stowed Wind Load Stowed Earthquake Load	IMP LATG WLO EQO/S STL COLL WLS EQS	1.0	1.0	0.5	1.0	1.0 1.0	1.0	1.0	1.0
Allowable Wheel Linear Loads, Land Side MT/meter of rail		80			100			100
Water Side		80			100			100
Allowable Wheel MT/wheel	Loads, Land Side	95			115			115
Water Side		95			115			115
Example: WOP1 Is 1.0 DL + 1.0 TL + 1.0 LS + 1.0 LL + 1.0 LATG The allowable wheel loads shall be calculated by multiplying allowable wheel linear load and average wheel spacing at each corner. If the wheel loads exceed the allowable values, provide calculated wheel loads with breakdown and proposal to reduce wheel loads. The Contractor shall submit calculated waterside and landside service wheel loads for the above combinations. *For the boom 45° and boom up positions, do not include the lifted load.
Allowable Horizontal Loads Perpendicular to rail
Operating condition				Seaside Rail (MT/m)			Landside Rail (MT/m)
Maximum load under operating condition				8			8
Maximum load under storm condition				10			10

Table 2.4: Wheel Load Combinations

2.8 Operating, Stowed and Maintenance Modes

Operating Mode

In the Operating Mode, the Boom will be in the fully lowered position

The primary operational function of the crane will be to load and unload container ships. The crane will handle containers, hatch covers and lashing gear. A secondary function will be the handling of non-containerized cargo.

Stowed Mode

In the stowed mode the boom will be raised to approximately 45° for clearance of vessels. The trolley shall be at the park position and no other load other than the empty lifting system will be on the hoist.

The Main Hoist drive shall be operational with the trolley at the park position and with an empty lifting system.

The Trolley drive shall be able to operate within the range from boom up normal stop and the extreme back- reach position

The Gantry drive shall be fully operational, and the forestays shall be constrained from lateral movement during gantry operation.

Maintenance Mode

In the Maintenance Mode the Boom shall be fully raised and in contact with the bumpers. The Trolley shall be at the park position and no load other than the empty lifting system will be on the hoist.

The Main Hoist drive shall be operational with the trolley at the park position and with an empty lifting system.

The Trolley drive shall be able to operate within the range from the boom up normal stop and the extreme back-reach position.

The Gantry drive shall be fully operational, and the forestays shall be constrained from lateral movement during gantry operation.

2.9 Design Rules

General

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:

According to F.E.M. 1.001, 3rd Edition Revised 1998.10.01

Class of Utilization U8

State of Loading Q3

Group Classification A8

Fatigue: Fatigue shall be based on cumulative damage analysis according to F.E.M. 1.001, 3rd Edition Revised 1998.10.01. The load spectrum shall consider a minimum of 4.0 x 106 design cycles with a 30.0 MT effective container weight with 760 mm eccentricity along the container longitudinal axis.

Structural Inspection Program: The structural inspection program shall be based on cumulative damage analysis.

Mechanisms:

According to F.E.M. 1.001, 3rd Edition Revised 1998.10.01

		(Hrs.)
Hoist	T8	50,000	L3	M8
Trolley Travel	T8	50,000	L3	M8
Gantry Travel	T5	6,300	L3	M6
Boom Hoist	T5	6,300	L3	M6

Mechanism Class of Utilization

Service Life

State of Loading Group Classification

2.10 General Design Criteria

Quay/Yard Interface

(1) Power Supply

(i) The power supply to the crane shall be 15kV ±5% 3 phase, 50Hz±2%.

(ii) The medium voltage trailing cable connection at the power-feeding pit on the quay shall be proprietary MV cable joint. The Contractor shall undertake termination of the cable conductors and fibre waveguide at the feeding pit. The medium voltage cable shall be supplied by the contractor along with a suitable cable reeling device and cable connection joint. A sufficient length of cable to cover 400 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 interlocked termination cabinet. The cable terminations made at Site and medium voltage wiring shall pass the inspection requirements of the local power Supply Company and Very Low Frequency test results shall be provided.

(iii) The medium voltage trailing cable shall be Prysmian Protolon (SMK) round type MV flexible power cable with integrated fibre optic data cables.

(2) Curved Gantry Rail (Not Required)

(i) Gantry travel around a curved section of quay rail shall be possible, minimum radius of rail curvature for landside and waterside rails shall be provided by Purchaser. The Contractor shall submit proposed method for achieving traverse of curved rail and proposed method including gantry speeds shall be approved by the Purchaser.

Figure 2.1 Curved rail details

(3) Wheel Loading

(ii) Up-lift load shall not be applied to the gantry rails.

(iii) The Contractor shall submit in its Tender for the Purchaser's review, the Declared Wheel Loads as defined in the Form of Tender to clarify vertical and horizontal loads under operational and stowed conditions.

(iv) The maximum wheel loads shall be calculated with the Trolley in the most severe position and with the wind acting in the most severe horizontal direction.

(v) 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 Defect and the Contractor shall not be entitled to dispute this on any grounds or in any circumstances.

(4) Stowage Pins

The Contractor shall submit for the Purchaser's review a design of adequate stowage pins to resist horizontal component of the forces applied to the Crane under its stowed condition. The stowage sockets in the quay deck shall be installed by others in accordance with dimension and load characteristics provided by the Contractor.

(5) Tie-downs

Storm tie-downs facilities shall be provided as permanent fixtures on the crane which may be quickly deployed without requirement for additional equipment. The contractor shall provide a detail drawing of the tie down interface with toleranced dimensions, load magnitudes and directions.

The design of the tie downs shall be such that one person without tools or additional equipment can attach all tie downs on a crane to the mating wharf embedded attachments within 30 minutes. Similarly, the tie downs can be unattached, and the crane made ready for gantry travel by one person without tools or additional equipment within 30 minutes provided there are maximum 4 tie downs per crane. The attachment and disconnection of the tie downs shall be demonstrated by Contractor and timed.

Communication Facility Interface (Radio, Fibre Optic)

The Crane shall be provided with fibre-optic cables and the necessary hardware for data transmission. Auxiliary Electrical Power Interface

The Purchaser will advise an approved locally available plug and socket arrangement for the shore supply during the design phase.

Climatic Condition

The Crane shall be designed and constructed to be fully capable of operating safely and performing as required by the Agreement (for condition (1) - (5) below) and withstanding the following climatic conditions.

(1) Ambient temperature -25 deg. C to +45 deg. C

(2) Relative humidity Max. 100%

(3) Dew point Max. 30 deg. C

(4) Sustained wind 20m/s

(5) Wind gust up to 25m/s without warning for normal working condition. This must be taken

into account with regards to operating stability and gantry power calculations.

More stringent and specific requirements shall apply for individual Crane sub-systems and components, which are separately specified in each relevant clause of this Specification.

Wind Loading Condition

The entire Crane structure with all of its machineries, components, fittings/accessories, and all equipment shall be designed and constructed to withstand the following wind loading conditions.

In the design calculations, the wind pressure for each condition shown below shall be assumed to act as uniformly constant over the total height of the structure in the parallel, perpendicular and angular wind directions.

(1) For operation of the Crane:

Allow for wind loading of sustained wind speed of 20m/second for safe load handling operation of the Crane.

(2) For the stowed condition of the Crane:

A wind loading of wind speed up to 44m/second shall be allowed for the condition that the Crane is out of service, boom in stowed or maintenance mode, gantry wheel brakes engaged, gantry stowage pins located in sockets in the quay with tie downs deployed.

Load Lifting and Stability Condition

(1) One side landing

A normal operating condition shall include the case of a short side landing of a 45 ft.- concentric 41 MT weight container, in which case a set of main hoist wire ropes on the landed side is assumed slack and not carrying the load. Calculation for structural design and mechanical design shall take this case into consideration.

(2) Eccentric container handling

All structural, mechanical and electrical systems and system components shall be designed to take account of the eccentric forces involved in handling containers in the single lift and twin- lift operation in the following combinations.

Single lift condition

(i) 1-unit x 45ft container weighing up to 41 MT with eccentricity of 1.2m in longitudinal (gantry) direction and 0.25m in transverse (trolley) direction.

Twin lift condition

(ii) 2 units x 20ft containers each weighing up to 25.5 MT with eccentricity on each container of 0.6m in the longitudinal (gantry) direction and 0.25m in the transverse (trolley) direction.

(iii) 1-unit x 20ft container weighing up to 25.5 MT with eccentricity of 0.6m in the longitudinal (gantry) direction and 0.25m in the transverse (trolley) direction and 1 unit x 20ft container at 2 MT (empty) concentric.

Under conditions (ii) & (iii) the center distance between containers shall be a maximum of 7700mm.

(3) Fatigue condition

The structural fatigue calculations must include the cases that the Crane will be continuously handing containers configured respectively as outlined in 2.9.8(2), i), ii) and iii) above and the Cranes must be suitable for and able to perform as required for this.

(4) Dynamic snag load

A device shall be incorporated into the hoisting system to provide protection against snagging. The Crane shall not sustain any damage due to dynamic snag load. The Contractor shall submit structural calculations to prove that structures are safe under dynamic snag load.

(5) Stability

The Crane shall be stable with a reasonable factor of safety and shall not sustain any damage when a dynamic snag load is applied to the boom at the maximum outreach position.

(6) Other Loading Conditions

All loading conditions forming design criteria other than specified in this Specification shall be submitted to the Purchaser for review.

(7) Earthquake

The Crane shall also be designed to take account of earthquake loading to 0.2g which may be subjected to the structure both in service and out of service operation. See EQO and EQS loading, section 2.6.

2.11 Noise Control

(1) Special consideration shall be given to acoustic treatment to reduce noise breakout from the machinery house via the walls, floors, roof, winch wire rope openings, ventilation air intake / discharges.

(2) The maximum noise level measured 1 meter outside and under the machinery house shall not exceed 85 dB

(3) The noise level inside the operator’s cab, checkers cabin and electrical computer monitoring room shall be below 75 dB during operation, with air-conditioner on, and doors and windows closed.

2.12 Operationally Critical Components

The Contractor shall submit the inspection and replacement schedule for the operationally critical components to the Purchaser. The objective is to assist the Purchaser to establish a standard for maintenance and inspection of operationally critical components (i.e., those components and structural areas, joints, tension bars where failure could have catastrophic consequences). The following items shall be included in the list of Operationally Critical Components:

(1) Drum Couplings for the Main Hoist and Boom Hoist

(2) Service and Emergency Brakes for the Main Hoist and Boom Hoist

(3) Wire ropes

(4) Twist-locks for Head-block and Spreader

(5) Elevator

(6) Structural components as defined by the Contractor.

2.13 Duty Cycle

(1) The Crane(s) shall be capable of continuous duty cycle operation at speeds up to full speed with loads up to 50MT; the Crane(s) need not be capable of continuous duty cycle operation with container loads exceeding 50MT. Performance (speed and accelerations/decelerations) may be reduced at loads exceeding 50MT, but the Crane(s) shall have no other limitations preventing safe and efficient intermittent operation with container loads between 41MT and 50MT and shall be capable of “continuous” duty cycle operation with container loads of 50 MT for not less than one

(1) hour. The Crane(s) shall be easily maintained and suitable for operation in the atmospheric conditions described in Section 2.95

(2) The theoretical duty cycle for use in calculating times and equipment ratings of the main hoist and trolley drive systems shall consist of removing and replacing the containers of a typical hatch on vessel 23 containers wide with seven (7) high stowage above deck and nine (9) high below deck. The equipment ratings shall also consider the various worst-case container handling cycle paths encountered in container handling operations.

(3) The calculations shall be based on the following: -

(i) 55MT load each way.

(ii) All loads are lifted 1 meter clear of the highest obstruction in their travel path

(iii) All loads will be lowered to within 1 meter of surface they are to be set upon, stopped and then lowered onto the surface. Similarly, containers to be put in cells will be stopped 1 meter above the cell guides and then lowered into the guides.

(iv) A dwell time of 2 seconds will be allowed for engaging or disengaging twist-locks, and for entering cell guides. These are the only dwell times to be considered.

(v) Each motion accelerates travels and decelerates at the maximum rates for which the system is designed.

(vi) Hoist and trolley travel occur simultaneously whenever the container is clear of a cell. Ambient temperature is between +15⁰C and +40⁰C plus allowance for solar radiation which may increase surface temperatures to 50⁰C.

(vii) The cycle is repeated indefinitely.

(viii) The wind load is 50% of WLO, applied in the least favourable direction.

(ix) The Contractor shall submit for review, the theoretical duty cycle block diagram for the main hoist and trolley drive

(4) The theoretical duty cycle for the trim/list/skew system components shall consider the above main hoist and trolley duty cycle with the trim/list/skew system completing two full-range operations per container cycle.

(5) The theoretical duty cycle for the purposes of calculating times and equipment designs of boom drive shall be based on the following: -

(i) Raise boom from operating to stowed position at rated speed.

(ii) Lower boom from stowed to operating position at rated speed.

(iii) The cycle is to be performed four times with no dwell time.

(iv) The wind load is 50% of WLO, applied in the least favourable direction

(6) For the gantry drive, the theoretical duty cycle for purposes of calculating times and equipment designs shall consist of continuous gantry travel for 60 minutes with empty spreader at any speed to full rated speed against the most severe wind load (including diagonal wind) equivalent to 50% WLO, unless other specified operating modes govern the design.

3 CRANE STRUCTURAL SPECIFICATIONS

3.1 General Requirement

Design

(1) The term “AISC Specification” refers to the Specification for Structural Steel for Buildings, Allowable Stress Design and Plastic Design, June 1, 1989, with Commentary. The terms “AWS Specification,” “AWS D1.1,” and “AWS D1.1/D1.1M-2006” refer to the AWS D1.1/D1.1M-2006, Structural Welding Code - Steel, an American National Standard. Provisions for bridges and dynamically loaded structures shall take precedence. The terms “AWS D1.5,” and “AWS D1.5M/D1.5:2002” refer to the AWS D1.5M/D1.5:2002, Bridge Welding Code, an American National Standard. The structural design shall generally conform to the requirements of the AISC Specification except allowable stresses shall be as specified in this section.

(2) The gantry frame structure shall consist of sections, box or tubular members. The boom and trolley girder shall be either one or two girders. A trussed boom is not preferred but may be permitted with the Purchaser’s approval. Cover plates and back-to-back angles or channels shall not be used. Exterior surfaces of structural components shall be accessible for maintenance. Wire rope or strand shall not be used for structural members. Flattening or crimping of tubing will not be allowed unless approved in writing by the Engineer.

(3) Welded joints are preferable. Bolted joints will only be allowed when specifically approved by the Engineer. If the Contractor proposes to use bolted joints, he shall so indicate in his tender. Bolted joints shall be made using ASTM A325 or A490 bolts or bolts complying with equivalent ISO or British Standards. For Operating conditions, the joints shall be designed to meet the requirements for slip critical joints For Overload and Storm conditions the joints may be allowed to slip provided the slipping is not detrimental to the performance of the joint or the structure. Welds and bolts shall not share the load in any joints. The faying surfaces of all main structural friction-type bolted connections shall be machined. 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. The Contractor shall provide supporting documentation if faying surfaces of slip critical connections are coated.

(4) The sill beams, legs and portal beams shall form a continuous rigid frame. The connections between these members shall be welded and be capable of resisting all six components of force. Bolted joints may be allowed as provided above.

(5) The interiors of all members, large enough to crawl through, shall be accessible for periodic structural inspection. Members that cannot be internally inspected because of size or other practical reasons shall be sealed by welding. Sealed members shall be pressure tested at 10 kPa gauge pressure using soap film to demonstrate air tightness. Sections shall be designed to resist the test pressure without yielding. Stresses developed by a 20° C temperature change of the entrapped air shall not exceed

0.10 times the basic allowable stresses.

(6) 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 or dropping of the trolley or operator’s cab, or dropping the load. Tension members or tension components include those portions of a flexural member that are subject to tension stress. Examples of FCMs are stays and the tension flanges of the trolley girder, boom, and trolley girder support beams. Stiffeners used to increase plate buckling strength, and which are not used in the calculations as part of the structural section, may be classified non-fracture critical.

(i) The responsible structural engineer shall determine which member or member component is in the FCM category.

a. As a minimum, the responsible Structural Engineer shall consider the load case (DL + TL + LS + LL + IMP ± LATT) when determining if a member or member component is in tension for FCM classification. The trolley shall be considered in any position. The effect of one trolley corner lifting vertically out of the plane formed by the other three corners should also be included in the above combination when analyzing under-hung trolleys.

(ii) All FCMs shall be identified on the drawings.

(iii) FCMs shall be accessible for periodic structural inspections. Non-fracture critical members shall be accessible where practical for periodic structural inspections.

(iv) For FCMs, in-plane longitudinal stresses in cruciform joints shall be carried through a welded joint by a full penetration butt weld, i.e. complete joint penetration weld. The butt weld should be completed by fillet weld reinforcement on both faces of leg length at least equal to one fourth the thickness of the connected plate but not less than the minimum fillet weld size specified in AWS D1.1. The plate running through shall be checked before welding for laminar rolling flaws and after welding for lamellar tears. For FCMs, cruciform joints shall have redundant load paths. The design shall provide an alternate load path that does not rely on the strength of the plate subjected to through thickness stress.

(7) 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. The Engineer may require redesign of connections that, in his opinion, cause unnecessarily high stress intensity.

(8) Fillet welds deposited on opposite sides of a common plane of contact between two parts, “wrap around welds,” shall be interrupted at a corner common to both welds according to AWS D1.1, section

2.8.3.5. The ends of the interrupted welds shall be stopped at least 10 mm from xxx xxxx of the connected parts. Connection shall be detailed so wraparound welds do not occur. The faying surface at the weld interruption may be sealed by caulking.

(9) All pinned joints in the forestays and similar members shall include aluminum bronze bushings or other equivalent manufactured bearings at all rotating bearing surfaces. Backstays are not included in this requirement. All joints shall be designed assuming at least one bearing surface rotates. All bearing surfaces shall be lubricated. Pins shall not be used to resist forces that reverse during normal operating conditions.

(10) The structural analysis of the crane shall be performed or reviewed by the Contractor's responsible structural engineer and the structural detail design shall comply with Appendix 5 – “ Standard Structural Details”.

(11) A design life of four million moves shall be assumed. The assumption of a design life does not necessarily mean that the structure will no longer be fit for its purpose at the end of that period or that it will continue to be serviceable for that length of time without adequate and regular inspection and maintenance.

(12) The Contractor's responsible structural engineer shall be familiar with the following reference documents:

▪ F.E.M. 1.001, 3rd Edition Revised 1998.10.01

▪ Xxxxxx, S. J., Fatigue of Welded Structures, Edison Welding Institute, Columbus Ohio and Abington Publishing, 2nd ed., 1991.

▪ Xxxxx, Xxxxxxx X. and Xxxxxx, Xxxx X., Fracture and Fatigue Control in Structures, Xxxxxxxx-Hall, 2nd ed., 1987.

▪ Structural Stability Research Council, Guide to Stability Design Criteria for Metal Structures, Xxxxxxxx X. Xxxxxxxx, editor, Xxxx Xxxxx & Sons, 4th ed., 1988.

(13) A large sign shall be placed on the crane's leg near the access ladder In English and Local language stating:

“The structural integrity of this crane requires that no attachments or fixtures of any kind be welded to any part of the crane without prior written approval of the responsible Maintenance Manager.”

(14) Shop and field erection lugs that will not interfere with the operation of the crane may be left on when approved by the Engineer and Purchaser.

(15) The girder and boom design shall allow the operator to escape from the operator's cab to the walkway of the girder and the boom at any point of trolley travel range including under the machinery house in an emergency.

(16) The girder and boom design shall allow trolley wheel replacement works at any position on girder/boom of the trolley. In addition, the Machinery House structure shall be designed to permit the trolley wheels to be raised or lowered by the Machinery House maintenance hoist.

(17) The boom structure shall have sufficient torsional rigidity to avoid torsional deformation or overstress of the boom due to winds as specified and one side landing of container as specified.

Machinery on main structure.

The following machinery shall be fitted to the main structure of the Cranes.

(1) Gantry drive machinery.

(2) Gantry buffers.

(3) Power-operated storm brakes with limit switches.

(4) Cable reel with cable guide and limit switches. (proximity type)

(5) Main hoist sheaves.

(6) Boom hoist sheaves.

(7) Boom latches with limit switches. (proximity type)

(8) Trolley drive sheaves.

(9) Stowage pins with limit switches. (proximity type)

(10) Boom hoist, boom latch and gantry travel control station.

(11) Gantry travel operating station at ground level.

(12) Personnel Elevator.

(13) Trim/List/Skew adjustment devices. Fittings on Main Structure

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) Aviation warning lights.

(4) Wind vane for anemometer at a high level where least affected by turbulence caused by own crane structure during operation.

(5) Intercom system.

(6) Travel warning device.

(7) Two speakers fitted at quay level on waterside and landside facing inside of the Crane.

(8) Welding outlet.

(9) Service outlets.

(10) Emergency stop buttons.

(11) Drive Lock-Out Switches

(12) Fire extinguishers.

(13) Cab window cleaning platform.

(14) Checker’s cab.

3.2 Material

Material Standards and General Requirements

(1) All materials used in the Crane structure shall be new, of the best quality and suitable for the duty intended. Mill certificates shall be obtained, and records strictly maintained to match these to the various Crane sections produced during crane manufacture.

(2) Structural steel shall conform to the AISC Specification, Allowable Stress Design, chapter 5, section A3, Material, except as modified in this Section

(3) Structural steel subjected to a calculated tensile stress, except stairs, ladders, platforms and walkways shall conform to the current ASTM A 709/A 709M, Standard Specification for Structural Steel for Bridges, including the following supplementary requirements:

S60, Frequency of Tension Tests S93, Limitation on Weld Repair

and to ASTM A6/6M, General Requirements for Rolled Steel Plates, Shapes, Sheet Piling, and Bars for Structural Use

(4) The Charpy V-Notch impact requirements shall be based on the applicable temperature zone, according to ASTM A 709, Table 8, based on the environmental temperature range specified in the PROJECT REQUIREMENTS.

(5) Structural steel made to another specification may be substituted for ASTM A 709 providing it conforms to the specified requirements of A 709 and the other requirements of these Specifications. Acceptable specifications may include the following:

Deutsche Industries Xxxxxx (DIN) British Standards (BS)

Japanese Industry Standards (JIS)

Alternative steel specifications may be acceptable but will be subject to additional, agreed inspection and testing

(6) All FCM material, plates, sections and weld metal shall comply with AWS D1.5, Section 12. The term "engineer" in the code shall mean the Contractor's responsible structural engineer. The Purchaser will review the decisions of the Contractor’s responsible structural engineer for compliance with the AWS Specifications.

(7) Weld electrodes shall meet the requirements for H16 as defined AWS A4.3 (capable of depositing weld metal with maximum diffusible hydrogen content of 16 mL/100g) and be in accordance with Table 3.1 of AWS D1.1, except E60xx rods shall not be used. If welding in accordance to AWS D1.1 “low hydrogen” electrodes requirements, electrodes shall comply with AWS D1.1 Annex XI, section XI-6.2.2(2). Steel that requires Charpy V-notch testing shall be welded with electrodes having Charpy V-notch toughness in compliance with tables 4.1 and 4.2 of AWS D1.5 for NFCMs and FCMs, except that electrodes used for welding FCMs shall have a minimum toughness of 27 J.

(8) Plates, rolled sections and tubes shall have a minimum thickness of 8 mm unless otherwise noted.

(9) For fracture critical plates, cold bending is prohibited, and a hot-bending procedure shall be submitted for the Engineer’s approval. For cold bending of plates in primary structure (non-fracture critical), bending radii shall be identified on the drawing and be in compliance to AISC standards, or Engineer approved equivalent. For hot-bent plates, a procedure shall be submitted including but not limited to: heating/cooling times, radii of bending.

(10) 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 Purchaser.

Plate Through-Thickness Requirements

(1) Plates and sections subjected to through-thickness stress shall be given special attention during design, base metal selection, and detailing. The Contractor’s responsible structural engineer shall be familiar with the AISC Commentary on Highly Restrained Welded Connections, Engineering Journal,

third quarter, 1973 and the AWS D1.1 commentary, section C2.6.3, which discuss lamellar tearing and give guidance to minimize the probability of occurrence. Table 3.1 lists required UT testing and Z-Steel requirements for tension through-thickness welded connections. “Tension,” shall be determined by operating load combinations. “FCM” in the table shall be determined as described in Section 3.1.1(6). See Figure 3.1 for through-thickness plate connection details and nomenclature.

Tension

t

T

CL In-plane Plate

Tension

d

t

T CL Through-thickness Plate

CL In-plane Plate

CJP Welded Connection PJP or Fillet Welded Connection

Figure 3.1 Through-thickness plate connection details

Weld	In-plane Plate	Through- thickness Plate	Through- thickness Plate Thickness , T1 (mm)	Z-steel required?	Through- thickness Plate UT Required?	Comments
CJP	FCM	FCM & NFCM	> 16	Yes	Yes	Z 25, ISO-7778
		FCM & NFCM	≤ 16	No	Yes
	NFCM	FCM	> 16	Yes2	Yes	Z 15, ISO-7778
		FCM	≤ 16	No	Yes
		NFCM	> 25	No	Yes
		NFCM	≤ 25	No	No
PJP/ fillet	FCM	FCM & NFCM	All	N/A	N/A	Not allowed.
	NFCM	FCM	> 16	Yes2	Yes3	Z 15, ISO-7778
		FCM	≤ 16	No	Yes3
		NFCM	All	No	No

1See Figure 3.1 for nomenclature.

2Z-steel is recommended to reduce the frequency of repairing FCM plates subjected to through- thickness tension. The Contractor’s responsible structural engineer shall decide.

3UT of through-thickness plate prior to welding and after welding in the region under the welds, extending toward the in-plane plate as much as practical

Table 3.1: Tension Through-thickness Plate UT and Z-steel Requirements

(i) Z-Steel Requirements—As required in Table 3.1, plates subject to through-thickness tension stress shall be designated “Z-steel” material. Z-steel shall comply with the following in addition to the other requirements of this Specification:

a. ISO-7778: International Standard “Steel plate with specified through-thickness characteristics” using the following requirements:

b. For in-plane FCMs, the requirements of “Z 25” shall be used, as a minimum.

c. For in-plane NFCMs, the requirements of “Z 15” shall be used, as a minimum.

d. The sulphur content shall be a maximum of 0.01%. See AWS D1.5, Section

12.4.4.1 for reference.

e. Each plate with Z-Steel requirements shall be clearly identified in the plan

(ii) Plate UT Requirements—As required in Table 3.1, the region of the plate with through- thickness tension stress shall be UT-inspected to check for lamination before welding and again at least 36 hours after welding to check for lamellar tearing. The region tested shall extend the full length of the in-plane plate for a minimum width of (2t+T). See Figure 3.1. Acceptance criteria shall be based on ASTM A 578, Level C, as a minimum.

a. In general, for FCM and CJP connections with through-thickness tension, the through-thickness plates should be UT-inspected according to Section (2). For PJP or fillet welded tension connections with through-thickness plates thicker than 16 mm or with weld throats greater than 12 mm, the through-thickness plates should also be UT-inspected according to Section (2).

b. These through-thickness plate UT requirements are in addition to the weld NDT requirements specified in Section Table 3.1.

c. Through-thickness plate UT requirements shall be clearly identified in the plan.

Welded Joints

All welded joints shall be carefully designed and constructed to conform to the latest established standards to prevent fatigue failure. Cutting for edge preparation shall be performed by qualified person to achieve the correct angle, shape and smooth finish of the edges without any notches.

Intermittent welding shall not be permitted in areas exposed to the atmosphere (including interiors of non-airtight structures and interiors of structures such as the Machinery House and Electrical House) using continuous welding for those welds exposed to atmosphere.

Bolted Joints

(1) Bolted connections shall be made with high strength bolts. All connections made with high strength steel bolts shall conform to the "Allowable Stress Design Specifications for Structural Joints Using ASTM A-325 or A-490,” or Purchaser-approved equivalent. The coefficient of friction shall be determined in accordance with "Allowable Stress Design Specifications for Structural Joints Using ASTM A-325 or A-490."

(2) Structural bolt assemblies made with high-strength bolts shall be kept separated by production lot. Mixing of bolts and nuts from different production lots, even of the same diameter, grade, and length, shall not be permitted. Only pre-tested combinations of bolt lot, nut lot, and washer lot, as established by the supplier are permitted to be installed

(3) Bolted Joints of any box-sectioned structure shall be sealed at its gap between two main structures to prevent ingress of water into the box structure.

(4) The faying surfaces of all main structural friction-type bolted connections shall be machined.

(5) 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. The Contractor shall provide supporting documentation if faying surfaces of slip critical connections are coated.

(6) Installation and testing of high strength bolts shall comply to AISC standards.

Pinned Joints

An effective lubrication and rust preventive system shall be provided for each pin joint to prevent its seizure throughout the life of the structure.

Lubrication points shall be fully accessible to maintenance personnel utilising access ladders and platforms, alternatively where this is not deemed possible, remote greasing points shall be reviewed by the Purchaser.

Machinery Bases

(1) All main drive machinery bases (Motors, brakes, gearboxes, bearing housings/pedestals, etc.) shall be machined. Further welding in the area of a machined surface shall be prohibited after final machining.

(2) All machinery mounts shall have adjustable locking screws for horizontal adjustment (forward and backwards, side to side) for the purposes of the equipment alignment.

(3) Groups of equipment shall be mounted on rigid base frames with machined support pads, at least 12 mm wider than equipment foundations at all sides and pads supporting electric motors for main drives shall allow the motors to be pushed backwards to release them from couplings. Stainless steel shims shall be used, when shims are required. A means to achieve a minimum of 6mm of height adjustment shall be provided under electric motors in order to absorb shaft height differences from spare motors.

Edge Finish

All plate edges shall be ground with grinder to eliminate any sharp edges or burrs from cutting work. Surface Finish

All welding spatters shall be removed from structural surfaces and any other surfaces where weld spatter can be detrimental to the performance of the crane i.e., windows, hand-rails, trunking, electrical boxes etc.

Draining and Inspection Manholes.

(1) All the structure shall be designed to drain water effectively. Any draining water shall not affect safety of operations or maintenance work during heavy rain conditions. No water traps or ponding shall be allowed in any part of the crane structure.

(2) Appropriately, sized manholes shall be provided in all unsealed members to provide for internal inspection. The manholes shall be positioned such to allow access from each end of any unsealed member and particular attention for safety shall be given to those areas where manholes directly access onto or from vertical ladders.

3.3 Calculations

General

(1) Structures shall be analysed with the aid of an appropriate computer program.

(2) The mathematical model shall accurately simulate the real structure. When ancillary members are attached to the structure, these members must either be accurately modelled, or the connecting details shall be designed to allow for compatible deformations. The size of joints shall be taken into account. If a joint is modelled as pinned, it shall either be actually pinned or connected with a flexible element capable of flexing as required without overstress. The effect of axial load shall be included in the analysis of such flexible components.

(3) P-delta effects shall be included.

(4) Load paths shall be developed for all details. The calculations shall contain free bodies showing these load paths.

(5) Calculations based on the analysis of the preliminary structural design do not need to be revised to suit the final design unless there is a significant discrepancy between the preliminary and final

designs. After the design is complete and all changes have been made, a final computer analysis shall be run to verify that the design revisions do not significantly increase the calculated stresses. The allowable stresses for the verification analysis shall be the stated allowable stresses plus 3%.

(6) The initial wheel load and stability calculations shall be based on the calculated component weights. The final calculations shall be based on the weighed data.

Boundary Conditions

(1) The boundary conditions at the gantry rails shall be selected to suit the various load cases.

(2) For load combinations where one leg lifts off, proper boundary conditions shall be used and the gantry frame shall be checked for stresses using the allowable stress for the corresponding stress combination

(3) For Operating and overload modes

(a) For vertical loads:

The wheels shall be modelled as free to spread perpendicular to the rails and free to move parallel to the rails.

(b) For horizontal loads perpendicular to the gantry rails:

The wheels may be considered to be restrained in the direction perpendicular to the rails, at both the landside and waterside rails, and free to move parallel to the rails.

(c) For horizontal loads parallel to the gantry rails:

The loads due to driving or braking shall be taken according to driving and braking forces developed at each corner. The wheels shall be free to spread parallel and perpendicular to the rails.

Load cases to be considered for gantry travel around a curved section of quay rail (including Category 0 emergency stop), minimum radius of rail curvature for landside and waterside rails shall be provided by Purchaser.

(4) For Storm modes

(a) For vertical loads:

The wheels shall be modelled as free to spread perpendicular to the rails.

(b) For horizontal loads perpendicular to the gantry rails:

The wheels may be considered to be restrained in the direction perpendicular to the rails, at both the landside and waterside rails, and free to move parallel to the rails.

(c) For horizontal loads parallel to the gantry rails:

The reactions parallel to the gantry rails shall be taken by the stow pins.

The more adverse of the following two boundary conditions, considered separately shall be used:

i. The wheels restrained perpendicular to the rails at both the landside and waterside rails.

ii. The wheels free to spread parallel and perpendicular to the rails. The designer may restrict the motion of the wheels perpendicular to the rails by considering that the wheel motion will be limited by the clearance between the wheel flange and the rail. If this is done, the amount of motion shall take into account the expected clearances at the wheel to rail interface. Temperature effects may be neglected.

(5) The effect of the horizontal forces parallel and perpendicular to the rails shall be included in the calculation of truck and equalizer forces.

Submitted Calculations

(1) The calculations shall be submitted for information only and may or may not be reviewed by the Engineer. As least the following items shall be included in the calculation package:

3.4 Loads

General

Table of Contents

General description of computer programs used with definitions of any special terminology Listing of the governing specifications

Listing of all loads

Listing of load combinations and corresponding allowable stresses Calculations for determining the magnitude of each design load.

If a dynamic analysis is used to determine impact loads, this analysis may be submitted separately.

Dynamic analysis for one boom hoist rope failing.

Sketches showing computer input data including geometry, node numbers, member numbers, global axis, local axis, member properties and boundary restraints.

Stress calculations for members.

Stress calculations for joints and other details. Cumulative damage analysis

Gantry frame buckling analysis

Buckling analysis of plate elements, including stiffener sizing Stability calculations

Wheel load calculations

Computer output for the gantry frame and boom including the following information: Echo of input data, including descriptive sketches

Member forces for each of the specified individual loads. For moving loads, results need not be given for all members for each moving load position. However, maximum and minimum forces and the corresponding moving load positions shall be provided for all members.

Displacements at appropriate joints for each of the specified individual loads

Sum of forces at each node, computer results will not be accepted if this summary shows significant round-off error.

Period and mode shape for the lowest gantry frame mode of vibration excited when the trolley stops and starts.

Period and mode shape for the lowest gantry frame mode of vibration excited when the gantry stops and starts with the trolley located midway between the gantry rails.

Support reactions for each of the specified individual loads.

Cumulative damage ratios at critical zones of each connection or change of section

(1) The design shall incorporate all loads and load combinations pertinent to all in service and out of service conditions of the crane. The loads due to temperature effects, erection stresses, and others based on the Contractor's experience shall be included in the analysis if they cause significant stresses. If rational analysis indicates loads larger than specified, the larger loads shall be used.

(2) The Contractor shall comply with F.E.M. 1.001, 3rd Edition Revised 1998.10.01 for impact loading.

Stability

Loads and load factors for which stability shall be calculated are specified in Section 2, Table 2.3. Angled wind effects shall be included in WLO and WLS.

Stools shall be provided between the end of the sill beams and equalizer beams for increased stability.

3.5 Allowable Stresses

Load Conditions and Corresponding Allowable Stresses

(1) Load combinations are specified in Table 2.1 and Table 2.2. The allowable stresses for operating conditions, overload conditions, stowed conditions and fatigue shall be as specified by F.E.M.1.001 (3rd Edition Revised 1998.10.01).

(2) The basic allowable bearing stresses for pins shall be as shown in the table below. Bushings shall be used as shown below and as required by Section 3.8.4(2).

Pin	Bushing Required?	ALLOWABLE BEARING STRESS
		Operating		Storm & Overload
		Rotating Surfaces	Non- Rotating Surfaces	Rotating Surfaces	Non- Rotating Surfaces
Forestays and other components composed of links	Required	85 MPa (12 ksi)	0.4 x Fy	0.4 x Fy	0.8 x Fy
requiring bushings,
boom upper hinge,
and trolley girder
hanger pins (if
applicable)
Gantry equalizer pins and boom lower hinge	Not Required	85 MPa (12 ksi)	N/A	Section 3.5.1(1)	N/A
Other FCM	Not Required	0.4 x Fy	N/A	Section 3.5.1(1)	N/A
Other NFCM	Not Required	Section 3.5.1(1)	N/A	Section 3.5.1(1)	N/A

(3) For fatigue analysis, secondary effects must be included and there shall be no increase in the allowable cumulative damage.

Combined Stresses:

(1) The equivalent stress, fe, for members subjected to combined shear and axial stress and/or bending stress at a point shall be taken as:

(

f + f

2

2

x

y x

− f

f + 3 f

2

y xy

)

f e =

Where:

fx and fy are orthogonal axial stresses (tension is positive, compression is negative) and fxy is shear stress.

3.6 Members Subject to Buckling

The design of columns, beam columns, frames and beams subject to lateral buckling shall be in accordance with FEM.

(1) Flat and curved plates subject to buckling and crippling shall be analysed using a recognized classical buckling theory. As a minimum, coefficients against buckling and crippling established in the F.E.M. Specifications shall be used.

(2) For all structural plates, the ration of the minimum clear dimension, b, to thickness, t, shall not exceed 60, i.e., 60 ≥ b/t.

(3) Tension field action may be included for evaluating pure shear resistance during overload and stowed conditions, provided the tension field shear panels are designed for a factor of safety against collapse of at least 1.25. Tension field panels shall be assumed to have zero capacity to resist bending, bearing or axial stress.

3.7 Fatigue Design Criteria

General Design Considerations

Fatigue design shall generally conform to the requirements of F.E.M.1.001 (3rd Edition Revised 1998.10.01).

(1) Cumulative damage shall be evaluated for the normal operating conditions. For the gantry frame and boom, only fluctuating stresses due to variations in the lifted load and the trolley motion need to be considered. The effects of dead load, wind load and gantry travel and raising and lowering of the boom may be neglected.

(2) Stiffener ends shall be tapered at a slope of 2.5:1 or better. Stiffener fillet welds shall not extend around the ends of the stiffeners. Stiffener fillet welds shall be held back from the toe of the diaphragm weld a minimum of 10 mm or the thickness of the flange plate, whichever is greater.

(3) Frame and boom diagonal pipes, backstays, forestays, and other similar members connected at the ends with gusset plates shall be designed to include the effects of fluctuating stresses due to weak axis bending. The length of the gusset plate that can flex is the clear distance between the boss plate or pipe end weld toe to the connecting plate weld toe. The clear flexure distance, d, shall be a minimum 5.0(t), where “t” is the thickness of the flexing gusset plate. For forestay links, the clear distance between the boss plate toe welds shall be a minimum of 10.0(t), where “t” is the thickness of the forestay link plate. See Figure below.

Load Spectra and Cumulative Damage Analysis

(1) 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. The fatigue lifted load (LLF), lifting system (LS), trolley load (TL), and fatigue lateral trolley load (LATF) shall be used for the fatigue calculations of the crane structure.

(2) Definitions for move and cycles are as follows:

(i) One move: Lift the container from the ship, travel the trolley and set the container on the quay; or the reverse operation.

(ii) Single Cycle: Lift the container from the ship, travel the trolley and set the container on the quay with the lifting system supported by the container, pick the lifting system, return to the ship, set the lifting system on the next container and prepare to lift the container from the ship; or the reverse of the above. There is one move per single cycle.

(3) Double Cycle: Lift the container from the ship, travel the trolley and set the container on the quay with the lifting system supported by the container, pick the container from the quay, return to the ship, set the container on the ship with the lifting system supported by the container and prepare to lift the container from the ship; or the reverse of the above. The same container may be set and picked; the trolley does not need to be relocated between setting and picking. There are two moves per double cycle

(4) The range of each cycle shall be as shown in Figure 3.1: Design Cycle Spectrum

Fig 3.1 Design Cycle Spectrum

Fig 3.2: Typical Single-Cycle Stress Spectrum

Time

ta lifting system is set on container; stress is due to trolley only

ta to tb lifting system and container are lifted; stress is due to trolley plus lifting system and container plus impact

tb to tc trolley travels

tc to td lifting system and container are lowered and set; stress is due to trolley only td to te lifting system is lifted

te to tf trolley returns

tf to ta lifting system is set on container

Fig 3.3: Typical Double-Cycle Stress Spectrum

Time

ta lifting system is set on container; stress is due to trolley only

ta to tb lifting system and container are lifted; stress is due to trolley plus lifting system and container plus impact

tb to tc trolley travels

tc to td lifting system and container are lowered and set; stress is due to trolley only

td to te lifting system and container are lifted; stress is due to trolley plus lifting system and container plus impact

te to tf trolley returns

tf to ta lifting system and container are lowered and set; stress is due to trolley only

3.8 Connection Designs

General

(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.

Welded Joints

(1) 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.

(2) Welded joint design shall conform to AWS D1.1.

(3) For end-loaded fillet welds with lengths up to 60 times the leg dimension, it is allowed to take the effective length equal to the actual length. For lengths greater than 60 times the leg dimension, the effective length shall be limited to 60 times the leg dimension

Bolted Joints

(1) Bolted joints shall be provided in accordance with the “Specifications for Structural Joints using ASTM A325 or A490 Bolts” or another PURCHASER-approved recognized international standard. A490 bolts shall be used only with approval of PURCHASER. 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, or Purchaser-approved equivalent.

Eye-bars and Pin Joints

(1) Eye-bars and pin connected members shall be designed in accordance with the AISC Specification using 0.9 times AISC allowable values and shall be checked for fatigue using either the allowable net section stress range for Class F details or the stress concentration factors and the stress range for Class B details at the face of the hole. If the net section is governed by fatigue, then all other proportions shall be increased on a basis consistent with the AISC requirements.

(2) All pinned joints in the forestays and similar members composed of links undergoing constant relative motion shall include aluminium bronze bushings or other equivalent manufactured bearings at all rotating bearing surfaces. Backstays are not included in this requirement. All joints shall be designed assuming at least one bearing surface rotates. All bearing surfaces shall be lubricated. Pins shall not be used to resist forces that reverse during normal operating conditions

3.9 Boom Hoist Rope Failure

(1) The boom structure shall be designed for hoisting with one set of falls in the event the other set fails. The design load shall include the effect of shock loading due to one rope breaking. The allowable stress shall be 1.5 x basic allowable stress.

3.10 Gantry Structure Stiffness

(1) The structural stiffness of the gantry frame shall be adequate for proper operation of the crane for all design load cases. Deflection or oscillation of the structure shall not affect the Crane capacity or operating efficiency.

(2) Deflection shall be defined as the calculated distance the point in question moves from the unloaded state to the loaded state relative to the global coordinate system. All secondary effects, including catenary action may be neglected. Note that since all secondary effects are neglected, the actual deflections will exceed the calculated deflections.

(3) The calculated vertical deflection at the maximum outreach due to a parameter load equal to (TL + LS

+ LL) applied at the maximum outreach shall not exceed 200 mm. The effect of catenary sag in the forestays may be neglected

(4) Calculated horizontal displacement of the gantry structure and boom/girder at the boom/girder level due to acceleration/deceleration of gantry or trolley shall not exceed following figures with the trolley at extreme outreach/back-reach positions:

i) In gantry direction (parallel to gantry rail), due to parameter lateral load of 0.05*(DL + TL + LS + LL) applied in the gantry travel direction with the trolley at the maximum outreach:

a. At the maximum outreach position: ±250 mm

b. At the gantry leg tie beam position: ±100 mm

ii) In trolley direction due to a parameter lateral load of 0.10*(TL + LS + LL) in the trolley travel direction at the boom elevation

a. At any point: ± 15mm

(5) The structural stiffness of the gantry frame shall be adequate for proper operation of the Crane for all design load cases

i) Ratio of the natural period of the gantry frame in the trolley travel direction and the natural period of the hanging load shall be designed to prevent the frame from experiencing magnified dynamic displacements due to trolley motion. The natural period of the first mode of vibration in the direction parallel to the trolley shall be less than 1.5 s.

ii) Recent jumbo cranes have experienced magnified dynamic displacements due to gantry acceleration. Gantry acceleration and deceleration times shall be adjusted to an integer multiple of the natural period of the first mode of vibration in the direction parallel to the gantry travel motion to minimize these effects. This does not apply for E-stops.

3.11 Camber

(1) The trolley runway shall be cambered so the trolley path is approximately level when the trolley travels from the maximum back-reach to maximum outreach. Local camber is not required in the following cases:

The calculated deflection of the trolley runway between supports is less than the span divided by 800.

The calculated local deflection of the boom runway at the maximum outreach is less than the distance between the outer forestay pin and the outreach divided by 400.

The calculated deflection of the trolley runway between the forestay connections is less than the distance between these divided by 800.

The calculated deflection of the trolley runway between the boom hinge and the inner forestay connection is less than the distance between these divided by 800.

If there is a backstay, the calculated deflection of the trolley runway between the back-reach and the landside trolley girder support beam is less than the distance between these divided by 800.

If there is no backstay, the calculated deflection at the back-reach is less than the distance between the back-reach and the landside trolley girder support beam divided by 400.

(2) The load for camber calculations shall be:

DL + TL + LS + 1 LL

2

*CLARIFICATION: For this project the camber shall be achieved by way of forestay adjustment, so the trolley path is approximately level when the trolley travels from the maximum back-reach to maximum outreach.

3.12 Trolley Rails & Rail fixing

(1) Trolley rail shall be continuously supported on a structural member with a continuous web centred under the web of the rail. Where the rail will trap water on the girder and/or boom, frequent drains shall be provided through the girder and boom.

(2) Rail support surfaces shall meet the rail levelness and alignment criteria of FEM 8.2.2. Shims shall not be used.

(3) The trolley rails shall consist of a standard rail section and shall be secured with bolted rail clips. If welded studs are used, the studs shall be fillet welded to the structure. The use of resistance “stud gun” welding is not allowed. Gantrex type rail pads shall be installed under the entire length of the trolley rails. Alternative systems will be considered according to the Contractor’s proven recommended system.

(4) The rail base and mounting surface shall be painted before rail installation.

(5) The rail joints shall be joined with complete penetration welds and ground smooth to accurately machined templates except for the joint at the girder-boom transition.

(6) Each rail run shall be secured against axial movement with welded shear bars mating with milled slots in the trolley rail

(7) The joint at the girder-boom transition shall be designed to minimize the impact of trolley wheels crossing over the joint and maximize the life of the rail ends. The rail sections on either side of the boom hinge joint shall be designed to the following requirements:

(i) Material hardness shall be a minimum of 300 BHN. The rail section shall be machined all over to insure solid contact with the supporting rail beam.

(ii) When traversing the hinge point, the trolley wheel shall bear on both rails for a distance equal to at least twice the head width of the rail by means of a square stepped (S) rail cut.

(iii) The rail sections on each side of the hinge shall be supported directly on machined surfaces of the trolley rail support beam to prevent vertical movement of one with respect to the other. The rail support surfaces shall be machined when the boom is fitted to the trolley girder at shop assembly to insure level surfaces. The rail supports shall be designed to transmit maximum wheel load across the rail joint and shall not affect the load on the hinge bearing. The rail sections on either side of the boom hinge joints shall be joined to the trolley rails by welding. The rail joint shall be at least 100 mm away from the vertical plane of the closest hinge in the trolley travel direction.

(iv) The supporting structure shall be as rigid as possible and shall support the rail as close to the hinge point as practical.

(v) In addition, access of maintenance personnel to the boom joint area to safely effect repairs is of prime importance and the access design shall be approved by the Purchaser.

(8) Rail sections shall be readily available in the Purchaser’s country of operation.

(9) The rails shall be supported by continuous 7 mm reinforced rail bearing pads with the exception of the area adjacent to the boom hinge joint. Rail support at the boom hinge shall be machined rail support structure bearing on the special machined rail sections as described above. Rail clips and mounting details shall be acceptable to the rail pad manufacturer for use with its product.

(10) In addition, the access of maintenance personnel to the boom joint area to safely effect repairs is of prime importance and the access design shall be approved by the Purchaser.

3.13 Workmanship

General Requirements

(1) Work shall conform to the requirements of the AISC Specification, Allowable Stress Design, and the cyclically loaded structures requirements of AWS D1.1. Welding procedures and electrodes shall be shown on the drawings.

(2) In addition to these Specifications, all welding, inspection, and weld repair on fracture critical members shall comply with AWS D1.5, Section 12, “AASHTO/AWS Fracture Control Plan (FCP) for Non-Redundant Members.”

(3) The whole of the structural fabrication and assembly shall be completed in a thorough, workmanlike manner and shall follow the best modern practices for the manufacture of high-grade structures. The work shall be performed by workmen who are appropriately skilled in their particular trade.

Welding

(1) Welders, welding operators and tackers shall be certified, for the material, processes and type of welding being performed, by an independent testing laboratory within 6 months prior to performing such work. The certifying laboratory will be subject to approval by the Purchaser.

(2) Certification of the qualifications of each individual welder shall be submitted by the Contractor. Welds performed using unqualified procedures or welding completed by non-certified welders shall be subject to removal by the Contractor at his own expense.

(3) The Contractor’s Quality Assurance team shall be required to maintain 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.

(4) The Contractor’s Quality Assurance team will ensure that all correct welding procedures are strictly followed by the welding personnel. Any welding work being seen to not meet accepted procedures shall be stopped immediately and logged as a non-conformance report. Continuation of this welding will then be subject to approval by the Purchaser’s representative on site.

(5) The Contractor’s Quality Assurance team will ensure that all welding during low temperatures is carried out, as far as practicable, within an enclosed canopy to provide a controlled environment. The use of correct pre-heating procedures and welding rod hot boxes is essential and will be closely monitored by the Purchaser’s Representative.

Bolted Joints

(1) To facilitate removal/ replacement or regular maintenance, all unpainted steel fixings shall be treated with an anti-seize compound.

(2) Bolts that are 22 mm in diameter or less may be tightened to the required tension by any standard method in the AISC manual.

(3) A325 and A490 bolts greater than 22mm diameter shall be tightened to the required tension by the calibrated wrench method only. The following supplemental requirements shall apply in addition to the requirements of the Specifications to structural joints using ASTM A325 or A490 Bolts:

(i) Hardened washers shall be placed under the both the head and the nut.

(ii) The Contractor shall notify the Engineer if the highest and lowest 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.

(iii) The “snug tight” tension shall be approximately 15 percent of the specified tension and shall be achieved using a calibrated wrench.

(iv) The sequence of bolt tensioning shall be shown on the drawings.

(v) After the snug tight condition is achieved, an initial tension of 75 percent of the final tension shall be developed in all the bolts. Only then shall the final tension be developed.

(vi) The final tension shall be at least 70% of the specified tensile strength of the bolt.

(vii) 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.

(viii) The projected flange contact bearing surfaces shall have at least 75% of the bearing cross- sectional area in contact. The outer surface of the flanges shall fit within 0.25 mm for 75%

of the length of xxx xxxx and not more than 1.0 mm for the remaining 25% of the length, as shown below.

Tw

Tf

1

1

Tw + 2 Tf

Maximum edge clearance between flanges: 0.25 mm (0.01 in) for 75% of xxx xxxx length and not more than 1.0 mm (1/32 in) for the remaining length.

Projected flange contact bearing area: 75% firm bearing contact area, minimum

(ix) Bolt tension may be verified at locations selected by the Purchaser’s Representative. Bolt tension verification shall be performed by the Contractor in the presence of the Purchaser’s Representative and in such a manner that the torque can be wrench gage read during verification.

3.14 Quality Control of Structure Fabrication

General

(1) Quality Control shall be the responsibility of the Contractor. The Contractor must implement a written quality control program and this program shall be submitted to the Purchaser within 1 month of the date of the Agreement.

(2) The quality control program shall follow the applicable requirements laid out in 7.1.4 (Quality Assurance Program). For the structure 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

Lofting, 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 - Workmanship). Welding, machining, measuring and inspection equipment maintenance and calibration Machining, finish surfaces, bolting

Procedures for non-conformance reporting and rectification of defects

Design and manufacturing drawing control and procedures for revisions, updates and reissue of drawings

Procedures for painting

(3) At least one of the Contractor's quality control employees shall be assigned full-time to each shop during fabrication including subcontractor's shops. If fabrication is subcontracted, the subcontractor's own quality control personnel may be used to supplement the Contractor's quality control employee

Weld Inspection

(1) All welds shall be subjected to inspection by methods and extent, reflecting the critical nature of the welded connection.

(2) Welds shall meet the requirements for cyclically loaded structures of AWS D1.1. The specific method of weld inspections shall be shown on the drawings. Weld inspection procedures shall be submitted to the Purchaser.

(3) The extent of NDT performed by the Contractor, at his expense, shall be as shown below. The acceptance criteria shall be AWS D1.1. For inspections less than 100%, the majority of the inspection sampling shall be at areas most likely to develop cracks, such as weld ends and welds around corners.

Weld	Type of Testing/ Inspection	Acceptance Criteria
All Welds	100% Visual	AWS 1.1 – 2006
Full Penetration Butt Welds (Compression, Tension, or Alternating stress)	100% UT if possible, by joint geometry, 100% MT where UT is not possible	AWS 1.1 – 2006
Full Penetration Butt Welds in Tension Bars (Forestays and Backstays)	100% UT + 100% MT	AWS 1.1 –2006
Fillet Welds or Partial Penetration Welds:
On FCM (forestays, backstays, etc.)	100% of length MT	AWS 1.1 –2006
On Non- FCM	10% of length MT (as selected by the Purchaser’s Representative if present)

(i) Rejection of any portion of a weld inspected on a less than 100% basis shall require inspection of 100% of that weld.

(ii) Ultrasonic testing of tension complete penetration welds shall be performed by or under the direct supervision of an ASNT certified Level III individual. UT inspection of compression complete penetration welds and MT inspection shall be performed by an NDT Level II inspector or by an NDT Level I under the supervision of an NDT Level II, as required by AWS D1.1, section 6.14.6.

3.15 Temporary Attachments

Sea-Fastening

At least two months before the intended shipment, the Contractor shall submit sea-fastening structure connection details to crane structures for the Purchaser’s review and obtain Purchaser’s agreement before shipment on temporary structure removal and crane structure clean up procedures at site.

Other Temporary Attachments

(1) Connections details of temporary attachments (such as lifting lugs, etc.) fitted onto Operationally Critical Components must be approved by the Purchaser.

(2) Temporary attachments shall not degrade the fatigue class of the primary structure.

(3) Any temporary attachments welded to FCMs shall be removed, ground smooth, and MT-inspected. The Contractor shall inform the Purchaser’s representative, so he can witness the inspection.

4 FUNCTIONAL SYSTEMS, DEVICES & EQUIPMENT

4.1 Main Hoist

Main Hoist drive

The main hoist drive system for the Crane shall consist of two AC motors with two calliper disc brakes driving through a foot mounted gear reducer and shall have the following features:

(1) The main hoist drive reduction gearbox shall be a totally enclosed, oil bath lubricated type.

(2) Two Thruster calliper operated disc brakes shall be fitted on the high-speed pinion shaft. Each brake shall be rated at a minimum of 150% full load motor torque and shall be capable of stopping and holding the maximum rated load from full rated speed

(3) Each Hoist Rope Drum shall have a spring set, electrically or hydraulically released calliper disc brake mounted on the drum flange. Each brake individually shall be capable of stopping the decent of the maximum eccentric rated load without assistance from a maximum over-speed condition. The controls shall cause the drum brakes to remain released under normal container handling operations.

(4) Over-speed switches shall be fitted to both of the main hoist drums to shut down the drive and set the brakes if the load exceeds 115% of rated speed. This feature is to protect either hoist drum in case of drum coupling failure.

(5) One heavy duty, absolute position encoder shall be installed on each of the main hoist drums (total of two encoders)

(6) Acceleration from zero speed to a maximum speed or deceleration to zero speed shall be smooth and stepless for any load under the head-block.

(7) Frequent inching (low speed) operation and plugging (floating) operation shall be allowed.

(8) The main hoist wire ropes to the head block shall not interfere with the stacked on-deck containers when the crane is working on a single slot. Outside wire ropes shall be stationary during hoist and lowering motion.

(9) Any openings on the machinery house wall for the passage of all wire ropes shall be protected from water ingress. Protection of the wall against sagging ropes shall be provided.

(10) The main hoist system shall include an overload warning and tripping system. The system shall detect the load under the spreader or the load hook of the hook beam in 3 levels and activate a warning signal or trip hoisting motion as shown below:

i) 80% load for over 3 sec. Intermittent warning signal

ii) 100% load for over 3 sec. Continuous warning signal.

iii) 110% load. Trip hoist motion. Allow lowering motion only.

(11) The load sensing system shall include the installation of load cells.

(12) A key switch shall be provided in the E House, which shall permit selection of either hoist motor so that the hoist system may operate at 50% load/speed with only one motor operating.

(13) Eccentric Loading conditions shall immediately stop the up motion of the Main Hoist and flag a fault to the CMS and operator interface panels, and further hoisting shall be prevented. The operator shall be able to lower the spreader at a reduced speed until the condition is cleared.

(14) All points requiring lubrication will be lubricated with the automatic greasing system

*CLARIFICATION: For this Project Contractor to specify the maximum load allowed under spreader when operating one hoist motor at base speed.

Sway Control (Not required for this project)

(1) An electronic sway control system shall be provided as an option and priced separately.

(2) The electronic sway control shall be a closed loop system which verifies the no sway condition and provides sway correction where required. Sway correction with a stopped trolley shall not move the load beyond its present sway excursions.

(3) The sway control shall bring the spreader to a stop within +/- 50mm at any lifting height as measured at the bottom corners of the 40’ container or the twist lock of an empty spreader. It shall be capable of bringing the spreader to a stop to within 2 swings.

(4) While operating the trolley drive, the operator may hoist or lower at the same time without affecting load sway.

(5) The electronic sway control system shall be capable of operating in semi-automatic or manual assist modes or being switched off completely.

(6) In the manual assist mode, the electronic sway control shall be transparent to the operator. The operator shall be able to command speed with the trolley master switch and the load shall be brought to that speed with no sway. The operator may change the speed command before the load reaches the command speed and the load will respond to the revised speed command with no sway.

In the semi-automatic mode, the trolley is moved automatically to a predetermined position such as a truck lane or position over a vessel.

(7) Details of the construction and performance of the electronic anti-sway system shall be submitted with the tender documents.

Trim, List, Skew Control

(1) Each of trim, list or skew motion to be controllable independently from two other motions up to its maximum angle as specified, from any attitude of the head-block.

(2) One push button switch on the control console shall automatically reset the spreader position to a 'Zero trim, Zero list, Zero skew' position.

(3) Trim, skew and list indicators shall be installed in the cab. Each indicator shall indicate angle of trim, skew and list.

Snag Control

(1) Snag control shall be provided to limit mechanical and structural loads to their design limits. The snag control device shall have the following features:

i. It shall be of hydraulic type and absorb energy by fluid flow over relief valves or by a functionally similar hydraulic circuit.

ii. It shall allow powered reset after a snag incident. Replacement of parts, manual adjustment or manual charging of an accumulator does not meet the intent of this requirement. Resetting shall be by keyed switch in the electrical house.

iii. Automatically compensate for internal leakage. External leakage is not acceptable.

iv. Meet all the requirements of the hydraulic section of this Specification.

v. Snag analysis shall consider the activation time of relief valves. Response time shall be certified by the valve manufacturer.

vi. Snag device shall be set not to trip for any rope load less than 125% of any operating rope load including design impact and eccentricity.

vii. Electrical Control Supplier/ Designer shall certify motor and brake response times used in snag analysis. Strip chart recording during the Commissioning Test shall verify this data.

viii. A convenient means shall be provided for maintenance personnel to periodically field-verify pressure setting of relief valves. Verification procedures shall be included in the Maintenance Instruction Manual. Verification of relief valve settings shall be performed on the crane using installed equipment and shall not require the use of additional equipment other than hand tools.

ix. The snag analysis shall investigate all possible snag load combinations to ensure sufficient energy absorbing capabilities. The minimum snag and two-blocking cases to be investigated are:

(1) Two blocking empty spreader and head-block at the full speed; spreader at maximum trim and list.

(2) Jamming in ship’s cell, 18 m above gantry rail elevation, of a full speed empty spreader and head-block for both of the following occurrences:

a. One side only jams, two hoist ropes snag.

b. Both sides jam, four hoist ropes snag.

x. The Contractor shall provide a method statement showing the system of design of the snag control for review by the Purchaser and the snag device shall be demonstrated at crane Tests on Completion.

(2) Malmedie Snag Overload and ISC Coupling System (SOS) (Not Required)

xi. Auto wire rope de-tensioning function.

xii. Auto reset of SOS after snag event.

xiii. ISC Couplings (motor-reduced coupling)

Catenary Rope Support

(1) The main hoist and trolley towropes (if fitted) shall be supported by two rope towed catenary support trolleys, one on the landside of the main trolley and one on the waterside. The drive of the catenary trolleys shall be such that they will continuously maintain their position midway between the main trolley and its end of travel. The trolley and catenary runway shall allow for catenary trolleys to be out of position by 300mm in either direction before the catenary tow ropes must be adjusted.

(2) The rope supports on the catenary trolleys shall be either sheaves or rollers. Where the rope does not fleet across the surface, sheaves should be used. Means shall be provided to either restrain the rope on the roller or sheaves or provide sufficient gather devices that will ensure that the rope will return to the sheaves or roller surface. Support rollers and sheaves shall be equipped with anti- friction bearings.

(3) The catenary trolley towropes shall be terminated with fully adjustable connectors located within fully guarded access platforms. The towropes shall be automatically hydraulically tensioned to maintain proper rope tension during normal operation and to compensate for rope stretch.

(4) The catenary trolleys shall have hold down brackets which will positively keep the catenary trolleys from jumping the rails.

(5) If the waterside catenary trolley is on the boom when the boom rises, the waterside catenary trolley shall be left hanging from the tow ropes and the tow ropes shall have a minimum safety factor of 8 in this condition.

*CLARIFICATION: In case of trolley encoder failure, the trolley can be moved to the park position using the bypass switch.

4.2 Trolley, Trolley Drive, Associated Devices and Operator's Cab

Trolley Frame

(1) The trolley frame shall be fitted with hydraulic buffers in the front and rear directions of motion. These buffers shall be capable of absorbing and dissipating without bottoming, the impact energy of collision at full speed with rated load.

(2) The trolley frame shall be fitted with safety drop-stop lugs, which shall prevent the trolley from dropping off the girder in case of wheel shaft failure. Appropriate side guide rollers shall also be provided for the main trolley.

(3) The trolley frame shall have adequate jacking points and free access for the replacement of trolley wheels.

(4) The trolley frame shall provide an emergency access from the operator's cab to the walkways of the girder or the boom at any point of trolley travel range including under the machinery house.

(5) Trolley wheel, shaft and bearing systems shall be designed to facilitate fast replacement of components at any point on the girder or the boom.

(6) The trolley frame shall be provided with a safe maintenance platform allowing risk free access to all of its component parts for maintenance.

(7) All points requiring lubrication will be lubricated with the automatic greasing system Trolley Drive

The trolley drive system design shall be based on a full rope driven system with an option for a direct drive type. Depending upon the submitted design and the system chosen, the following shall be incorporated as a minimum.

(1) Full Rope Driven Trolley

i) The tow rope drive shall be mounted on a rigid base located in the machinery house and shall consist of an AC electric motor and brake driving a grooved drum through a totally enclosed foot mounted helical gear reducer.

ii) A thruster calliper operated disc brake shall be fitted on the high-speed pinion shaft and shall be rated at 150% full load motor torque.

iii) Trolley Drum shall have a spring set, electrically or hydraulically released calliper disc brake mounted on the drum flange. The brake shall be used to prevent drum movement due to gearbox backlash after service brakes have been applied. The controls shall cause the drum brake to remain released under normal container handling operations and not be closed under emergency stop conditions.

iv) A power operated automatic rope-tensioning device shall be provided for the trolley drive wire ropes.

v) Heavy duty, absolute position encoders shall be installed on the trolley drums.

vi) Frequent inching operation and plugging operation shall be allowed.

vii) The trolley wire rope system shall allow simple quick adjustment of alignment of the trolley.

viii) If the Contractors design induces “racking” of the trolley rope drum backwards and forwards causing impact to the gearbox gears, it shall be prevented by installing a flange mounted brake to the rope drum.

ix) The normal trolley parking position shall be approximately 5-meter waterside of the landside rail.

(2) Direct Driven Trolley (Not Required)

i) The trolley shall be propelled by AC motors and gearboxes mounted onto the trolley and shall drive the support trolley wheels directly.

ii) Each gearbox input shaft shall be fitted with a thruster calliper operated disc brake rated at 150% full load motor torque.

iii) The design of the driving arrangement shall consider the need to minimize or exclude lay-shafts or drive transmission shafts. Preference will be given to a drive system which provides for reliable operation and ease of maintenance.

iv) The Contractor shall submit, for the review of the Purchaser, details of a trolley positioning system which uses an absolute encoder coupled directly to an idler wheel. Positive high friction contact with the rail will be essential for use with the direct drive trolley arrangement.

v) The trolley park position shall be as defined in 4.2.2 (1) vii)

Trolley Tow Rope Tensioner

(1) A hydraulically operated towrope tensioning system shall be provided and shall maintain proper rope tension during normal operation and compensate for unequal rope stretch. The tensioning device shall be designed for continuous operation.

(2) The design and installation of the hydraulic system shall meet the requirements outlined in the Hydraulic System section of this specification.

(3) All points requiring lubrication will be lubricated with the automatic greasing system

*CLARIFICATION: Trolley rope tension system shall be fully automatic, including over-tension and under tension protection/interlocks utilizing inductive proximity switches.

Semi-Automatic Trolley Operation

THIS CLAUSE NOT USED FOR THIS CRANE SPECIFICATION

Power Feeder

(1) Power and control cables shall be routed to and from the trolley by a proprietary cable chain or festoon system.

(2) The Contractor shall submit design calculations which are approved by the cable chain/festoon manufacturer to demonstrate appropriate considerations in respect of the following parameters:

• 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.

(3) Cable carriers shall have extra slots for extra cables (in addition to the specified spare wires).

(4) The cable system shall include 20% spare control wires of each type/size and 6 cores fibre-optic cables.

(5) All cables shall be purchased from the cable carrier supplier and confirmed suitable for the application.

(6) If cable chain is selected, manufacturer shall attend site prior to crane taking over for final inspection and sign off.

4.3 Gantry Drive

Gantry Drive

(1) The gantry drive motors, and brake system shall provide sufficient thermal capacity, torque and traction for all operating conditions, allowing for reduced speed, gantry operation with any two motors out of service.

(2) Acceleration and Deceleration forces shall not result in wheel loads which exceed the allowable values defined earlier.

(3) The gantry drive and motors shall be capable of accelerating, driving a distance of 400m and decelerating with and against the operating wind load without adverse heating of any component.

(4) The gantry service brakes shall comprise monitored (open/closed feedback) electromagnetic, spring applied double disc brakes, flange 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.

*CLARIFICATION: Gantry motor brakes shall have a quick manual release handle lockable in the brake open position. The handle position shall be monitored by sensors and interlocked with the gantry drive system.

(5) 3rd party gantry motors shall be painted in ICTSI livery as per Appendix 2

(6) 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. All enclosed gearing shall be oil-bath lubricated. Open gearing shall not be used unless specifically approved by the Purchaser.

(7) Drive components shall be protected by their location or by substantial fenders against damage by vehicular traffic, in addition fenders shall not create trapping points for dockside personnel and shall incorporate a push away system to prevent personnel injury due to dragging, pinching or trapping.

(8) The gantry trucks shall be equipped with safety lugs to support the truck in case of wheel or wheel shaft failure.

(9) 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.

(10) Wheels and gearboxes shall be fitted with robust safety guards. The guards or covers shall have inspection windows.

(11) Rail scraper shall be provided in front of the outer and inner wheels at each corner.

(12) 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.

(13) Proximity switches shall be fitted to the buffers to detect crane to crane or crane to buffer condition and inhibit gantry motion in that direction. Radar sensors such as Banner shall be used for crane to crane anti-collision (slow down and stop)

(14) Proximity type limit switches to prohibit gantry travel motion when the stowage pins are inserted into the ground socket shall be provided.

(15) Gantry motion shall be prohibited whenever the hoist motion is activated.

(16) All points requiring lubrication will be lubricated with the automatic greasing system 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.

(2) The arrangement of the stowage pins shall suit the sockets provided by others in the quay deck.

(3) A suitable latching device shall be provided for securing the pins in their raised and lowered position.

(4) The design of the pin raise/lower system shall reflect the ease of manual operation in one man requiring a minimum of force to complete either the engagement or disengagement of the pin.

(5) Proximity type limit switches shall be installed to detect the position of the stowage pins and the gantry drive shall be disabled unless all stowage pins are in the raised position.

Wheel Storm Brakes

(1) Wheel brakes shall be provided on sufficient number of idler wheels and be capable of holding the crane under sustained storm wind of 30m/sec with gantry brakes released and stowage pins in the disengaged condition.

(2) 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.

(3) 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.

(4) Hand pumps for manually releasing the rail brakes shall be provided.

MV Cable Reel

(1) Cable Reel

(i) The cable reel shall be installed on the right-hand portal beam. 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 to detect the above conditions shall be provided.

(ii) The cable guide device shall be fitted with a belt-lifting device with nylon rollers to facilitate the opening of covered cable trench systems by renowned global producers

(iii) The mono spiral cable reel shall be manufactured entirely from stainless steel.

(iv) 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.

(v) 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.

(vi) 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 in English and local language shall be provided and fitted to the entrance of the fenced area.

(vii) Maintenance and inspection access to both inboard and outboard of cable reel via walkways/platforms shall be provided.

(viii) A suitably sized space heater shall be provided for the slip ring.

(ix) Limit switches to control gantry motion near the traveling limit (limited by cable length) shall be provided.

(x) 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.

(2) MV Trailing Cable

(i) The cable shall be renowned global producers (SMK) round type with three conductors, suitable for 15kV with ground and embedded fibre optic cables for data transmission. Sufficient length of cable shall be installed to provide for the full length of 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.

(ii) The composite cable shall incorporate minimum 18 numbers of low loss silica glass optical fibre waveguide. The cable reel mechanisms shall incorporate low loss connecting devices that allow the use of all waveguide simultaneously linking the equipment on the crane to external devices. The standard for the waveguide shall be 62.5/125 micron.

(iii) The medium voltage trailing cable connection at the power feeding pit on the quay shall be a proprietary type of MV cable termination cabinet. The Contractor shall undertake termination of the MV cable conductors and fibre 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 connection kit. The cable joints made at Site and medium voltage wiring shall pass the inspection requirements of the local power supply company and “Hi-Potential or VLF” test results shall be provided.

(iv) The maximum number of MV cables residing in the cable slot shall be three (3).

4.4 Boom Hoist

Boom Hoist Drive

(1) The boom hoist drive reduction gearbox shall be a totally enclosed oil bath lubricated type.

(2) The drive assembly shall include one thruster operated calliper disc brake on the high-speed pinion shaft and one fail safe, spring set disc type friction brake mounted on the boom hoist rope drum flange. The caliper disc brake shall be rated at 150% of full load motor torque. The disc type friction brake shall be rated to be capable of arresting and holding the boom in any position. This disc brake shall be activated in the event of either over-speed of the drum, excessive motor torque, loss of electrical power or operation of a boom hoist emergency stop button.

(3) Two independent wire rope systems shall be installed, and the boom structure shall be designed so that failure of one rope system does not damage the boom. Speltered type rope socket connections shall not be accepted.

(4) Sensors shall be provided to detect boom hoist slack rope and stop motion if slack rope occurs other than when the boom is in the horizontal position. The slack rope sensor reset button shall be installed near to the boom hoist drum so that rope condition is observed following a slack rope incident and before further hoisting is permitted.

(5) An over-speed switch shall be fitted to the boom hoist drum to shut down the drive and set the brakes if the load exceeds 115% of rated speed.

(6) A heavy duty, absolute position encoder shall be installed on the boom hoist drum.

(7) All openings in the machinery house wall for the passage of the boom hoist wire ropes shall have protection for rope slapping and from water ingress. Excess water on the ropes shall be suitably trapped on entry to the machinery house and drained to a suitable location.

(8) A facility on the crane and detailed procedure shall be provided in the maintenance manual for inspection, maintenance and replacement of the boom hinge bearings and pins. This shall include provision for relieving the loads on the bearings, removal of the pins and bearings and support of the boom sections under all maintenance conditions. Permanent platforms shall be provided for access.

(9) All points requiring lubrication will be lubricated with the automatic greasing system

Boom Latch

(1) The boom latch system shall include a boom-locking device which will eliminate any relative movement between the boom and the mast structure for the wind loading conditions.

This locking device is preferred to be designed as an integral part of the boom latch for normal operating and stowage purposes. The locking operation shall be controlled from the boom operating station.

(2) A set of hydraulic boom buffers shall be provided.

(3) Proximity type limit switches (excluding EE Stop) for control of motions and indication lamps or signals shall be reliable weatherproof type. The control logic shall be based on a fail-to-safe principle.

4.5 Machinery House, Electrical Control House

Construction

(1) The machinery house shall be designed to provide a weatherproof protected area for the location of the major machinery and electrical control equipment on the crane. The major electrical control equipment shall be housed in a separate air-conditioned room (the control panel room) within the machinery house.

The machinery portion of the enclosure (not including the electrical room) shall not be less than 12.0m x 16.0m in size.

(2) The machinery house shall be constructed to maintain an air temperature inside the machinery house of not more than 5 deg. C above the ambient temperature without air conditioning. The outside surface of the machinery house shall be flat.

(3) Machinery house shall have a minimum of two access/egress ways to/from the exterior, locations shall be decided during design review.

*CLARIFICATION: 1.4mm galvanized corrugated steel with flat signboard attached for ICTSI logo is acceptable.

(4) The floor of the electrical control room and quiet (PLC) room shall be manufactured from composite fireproof material completely fitted with an approved (UL or equivalent) insulated flooring material/matting rated at ≥1000 volts to provide anti-static and electric shock protection, if rubber matting is used this shall be fitted to the room dimensions and fixed securely using non-metallic fastening so as to prevent tripping hazards, any fitted floor matting shall allow for floor panels to be easily removed. Ample space provided for accommodating all the hardware equipment for Crane Condition Monitoring System.

(5) Electrical house shall have a minimum of two access/egress ways to/from the exterior, locations shall be decided during design review.

(6) All electrical cables installed underneath the floor shall be accessible and shall be run in cable tray.

(7) The access doors shall be outward opening metal hinged type with non-corrosive heavy-duty hardware locks and safety glass windows in upper panels. The door shall be self-closing. A drip shield shall be provided over the door. The locations of doors shall be at the front and the rear wall of the machinery house.

(8) An access with permanent ladders to the top of the roof shall be provided. Handrails along the perimeter of the roof shall also be provided.

(9) Equipment or permanent ladders shall be provided for accessing lights and other fittings on the ceiling for maintenance work.

(10) Ample maintenance space around each piece of machinery shall be provided for its adjustment, inspection and removal or replacement.

(11) A space to place lubricants in drums and pails shall be provided for which the floor shall be raised and surrounded by a bund wall with facilities for draining accumulated oil into portable receptacles.

(12) A hatch shall be provided in the deck with its size permitting the removal of the largest piece of equipment within the machinery house to the ground level with the aid of the maintenance hoist. The hatch cover shall be a sliding type with adequate handles for opening and closing by one or two persons easily. If necessary, the removal may be designed to utilize the maintenance hoist. The position of the hatch shall allow for adequate personnel access to all four sides in the opened position. Socketed, removable handrails shall be provided around the hatch opening. Purpose built storage facilities for the handrails when not in use shall be provided adjacent to the hatch. A separate hatch opening on the floor of its position in between two main girders shall be provided to lift components to and from the top of the trolley with the maintenance hoist. This hatch may also be used by the operator to escape from the cab via the trolley into the machinery house.

(13) A work bench with a 150mm vice shall be provided in the machinery house adjacent to, or with integral power sockets for power tools.

(14) One steel locker with door lock shall be installed in the machinery house to store drawings tools, wear gauges, first aid kit box, cleaning materials – minimum dimensions 1500H x 900W x 000X.Xx addition one steel locker with door lock shall be provided inside the Control Panel Room – minimum dimensions 1500H x 900W x 400D.

(15) A working table (tabletop size minimum 750mm x 1200mm) and a chair shall be provided in the Control Panel Room.

(16) The machinery house shall be provided with an access walkway around all four sides to allow for maintenance.

(17) A removable grease shield shall be provided between the wire rope drum(s) and nearby equipment (motors, brakes, hydraulic units etc.).

Fittings, Facilities

The machinery house shall contain main machineries and a fully air-conditioned Control Panel Room. Push button switches for the main control circuit, the main motion power source, and the lighting control switches shall be installed outside the Control Panel Room.

Special consideration shall be given to acoustic treatment to reduce noise breakout from the machinery house via the walls, floor, roof, winch wire rope openings, ventilation air intake/discharges, etc.

(1) Main machinery in machinery house.

The Machinery house shall contain following main equipment:

i.) Main high-tension power supply source switch panels and their remote-control switches. ii.) Main hoist drive machinery.

iii.) Boom hoist drive machinery.

iv.) Trolley drive machinery (if rope towed trolley)

v.) Main hoist, trolley, gantry and boom hoist motion drive control panels, cubicles, etc. located in the Control Panel Room.

vi.) Transformers.

vii.) Auxiliary power source panels. * These are to be located in E-room. viii.) Auxiliary motor starter and control panels.

ix.) Automatic greasing system

In addition to (1) above, the following auxiliary equipment and fittings shall be installed in the machinery house: i.) LED Lighting in order to produce sufficient lighting for maintenance work.

ii.) A minimum of two (2) ventilation fans (forced draft, with air filter at air intakes) iii.) Maintenance hoist.

iv.) Intercom unit

v.) Specific meters and counters. vi.) Fire extinguisher,

vii.) Welding outlet

viii.) Rope Re-Reeving system ix.) Service outlet

x.) Workbench.

xi.) Air compressor with CE Certyficate xii.) Locker.

xiii.) 300 Amp AC welding set with 75m welding lead.

xiv.) Harmonics Suppressor. Not required if ALM used (Regulated to meet IEEE 519)

xv.) Power factor correction, ALM used but shall maintain near unity power factor when crane is idle with air conditioning running.

xvi.) E-room de humidifier

xvii.) Two (2) air conditioners for Control Panel Room.

xviii.) Two LED (2) hand lamps (guarded type with hook) complete with 10 m of cable and plug.

Ventilation

Ventilation shall be provided by a sufficient number (minimum of 2) of forced draught ventilator fans to achieve ten (10) air changes per hour (ACH), fans shall be mounted in the sidewalls of the machinery house. The ventilation system design shall provide a positive pressure within the machinery house whilst maintaining the required temperature.

Illumination and Lighting

Internal illumination in the machinery house and electrical control room shall be provided by LED type lighting and shall be arranged to provide a uniform illumination in all areas of not less than 200lux throughout the entire area as a default condition. A second level of lighting shall be provided to increase the LED lighting level to 400 lux when required for maintenance and inspection functions.

Emergency Lighting System

Emergency lighting operated by individual rechargeable batteries shall be provided in the machinery 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.

Air Conditioning and Climate Control

*CLARIFICATION: Air conditioning units shall be available from the Polish market including spare parts and support.

(1) The Control Panel Room shall be well insulated to keep the inside temperature regulated at 25⁰C ± 2⁰C at all times. Warning of failure of the system shall be indicated as shown in 6.5.6 (Electrical Control House Air Condition Warning).

(2) To reduce the frequency of cutting in/cutting out of the air conditioners, a temperature sensor shall be installed in parallel with the main control of the air conditioners. The air conditioner main circuit shall be powered on with the activation of the main motion control source and powered off with 30 minutes time delay after the main motion control source is cut off. Duplicate air conditioning units shall be provided to ensure that the failure of one unit does not stop the crane operation. Each unit shall be rated to maintain the set conditions independently of the other.

(3) CONTRACTOR shall provide (n>=2) sets of flush mount Cassette Type Air Conditioner units as stipulated in components list (through type is not permitted) for the electrical room which are sufficiently rated to maintain Electrical room temperature at 25deg.C or below. CONTRACTOR shall also pre-mount an additional one unit of air conditioner as a spare in case the in-service unit fails. Total n+1 air conditioner units will be provided for E-room on the crane. One ceiling mounted unit is not rated to maintain the set conditions independently of the others. It is acceptable to allow the air conditioning units to run continuously CONTRACTOR must ensure this does not have a detrimental effect on the power factor the consequence being the consumption of reactive power when the cranes are idle.

(4) To ensure panel room uniform temperature, temperature sensors shall not be installed in one location or installed in groups.

(5) Air conditioning power and control voltage shall be provided by a stabilized voltage ±5% of supply voltage.

(6) Air conditioning installation shall explicitly follow manufacturer’s recommendations and verified by TPI; indoor and outdoor units, including all system components and pipework shall be fully tested and commissioned, free from defects and signed off by manufacturer accredited installation engineer prior to vessel departure.

(7) Contractor shall provide compressor type de-humidifier units controlled by humidistats which are sufficiently rated to maintain an e-room relative humidity of ≤ 65%. Warning of failure of the system shall be indicated as shown in 6.5.6 (Electrical Control House Humidity Warning).

*CLARIFICATION: De humidifier shall be of a recognized manufacturer available from the Polish market including spare parts and support,

Fire Protection

(1) An automatic system to detect and extinguish fire in the Machinery House, Control Panel Room and/or the Computer Room shall be installed with full legislative compliance in the country of crane destination, in addition full technical and spare part support shall be available in the country of crane destination.

(2) The system shall include a smoke detector in each individual electrical panel of the electrical room(s) and other smoke detectors positioned according to fire code recommendations in the open spaces or near to sensitive equipment such as transformers and switchgear.

*CLARIFICATION: For this project smoke and thermal detectors shall be fitted in E-room (minimum 3 of each type) and with 1 detector of each type the in PLC room, in addition 2 detectors of each type shall be fitted in the M-house in close proximity to the transformers and switchgear, no extinguisher system shall be installed in M-house.

Extinguisher system shall be of Aerosol type such as Stat-X

Fire alarm and extinguisher system installation, commissioning and testing shall be signed off by Manufacturer’s representative at crane manufacturing site as a minimum and at crane destination if required by local legislation.

The Purchaser shall review and approve the fire detection and extinguisher system.

(3) 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.

(4) The system shall include an automatic fire extinguisher system within the electrical panel and computer rooms designed for electrical fires without damaging electrical components.

Maintenance Hoist

(1) A maintenance hoist which can vertically lift any fully assembled component in the machinery house and lower it to ground level shall be installed in the machinery house. Minimum capacity shall be 10 MT and an overload protection system shall be incorporated.

(2) All the motions of the hoist shall be operated by electric motors, controlled by a pendant switch with ample cable length for handling loads in various locations.

(3) Hoisting and lowering speed for the light load shall be controlled manually to higher speed to shorten the operating time.

(4) The pendant switch shall have push buttons for slow speed hoisting and lowering to allow fine inching control.

(5) Maintenance crane shall have access and maintenance platforms with handrails to facilitate crane maintenance and M-House ceiling lamp replacement.

(6) All points requiring lubrication will be lubricated with the automatic greasing system

Rope Re-Reeving System

(1) Power shall be provided by means of a 5HP, drip proof motor (with soft start) in the Machinery House and arranged to conveniently re-xxxxx the main hoist, trolley (if applicable) and boom hoist wire ropes during routine rope replacement.

(2) Power shall be provided by means of a 5HP, drip proof motor with totally enclosed gear case and a motor mounted, magnet release, spring set brake. The re-reeving motor shall be controlled by a portable, remote, wireless control device which will allow the operator to walk from the supply drum to the rewind drum and monitor the re-reeving process throughout the machinery house.

*CLARIFICATION: Reeving motor shall incorporate soft start, with the required current boost for starting a full reeving reel, reel control shall be by inching and non-latching.

(3) The supply reel shall have a manually operated friction brake for controlling pay-out of the new rope from the supply reel during reeving and an automatic level winding device for level winding the used cable on to the empty reel during re-reeving. The brake shall be operated from the same level as the motor re-reeving device and shall include an adjustable locking or dogging system to maintain constant wire rope tension without the operator having to continuously use the brake handle. The brake shall be located on the side of the supply reel nearest the take-up reel and shall be clearly visible to a person standing next to the take-up reel.

(4) The rope reeving frame and shaft or arbor diameter shall be sized for use with all standard cable reels which could typically be supplied by wire rope manufacturers.

(5) The rope re-reeving system shall also include an elevated work platform complete with access ladder, handrails, toe-boards and which provides unrestricted access to three sides of both the powered take- up reel and supply reel. There shall be a minimum of 2m of vertical headroom clearance above the platform deck.

(6) Conveniently located accessible pad eyes shall be provided for tying off the wire ropes during the re- reeving process.

(7) The cable reel spool shafts shall be designed to ensure that different size (width) cable reels will remain engaged into the drive pins (both powered side and take-up-side).

(8) The supply and rewind drum shafts / arbor shall be provided with greasable bushings. The arbors shall be designed to be easily and quickly removed and replaced when the rope drums are removed and re- installed.

M-House Roof Solar Panel System

(1) The Contractor shall provide a proprietary solar panel system mounted on the machinery house roof with the aim of providing auxiliary power to crane, the PV system design shall be reviewed and approved during the design review; for this system, no batteries or power storage shall be required.

4.6 Operator’s Cab, Control Stations, Checker's Cab

Control Cab on Trolley

(1) Operator's cab shall be an “Ergo-Cab” manufactured renowned global producers constructed of mild steel, double skinned wall, insulated, fully welded, weatherproof and fully air-conditioned. Minimum floor width of the cab to be 2100mm, and length (fore & aft) 2500mm.

(2) The design of the cab shall allow the operator to clean inside and outside of all the windows safely.

(3) Cab access shall be from a hinged door on the side of the cab fitted with a heavy duty lockable stainless- steel handle. The door shall be self-closing, outward opening, with a latch to keep the door in the open position.

(4) Cab shall be fitted with a permanent escape ladder and access to the trolley.

(5) Cab windows to provide as much view as possible with a single “walkable” bottom window in front of the operator and two walkable bottom windows to the rear. 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.

(6) Wall windows shall be double glazed with tinted safety glass having a hinged window to the front, two sliding (single glazed) windows to the side and fine screen heavy duty industrial type roll up sunshades fitted to all upper windows.

(7) A protective shield shall be fitted above the windscreen to prevent wire rope lubricants from splashing onto the glass.

(8) Particular attention shall be given to isolating the operator from shocks and vibration. The connection of the cab supports shall incorporate an effective anti-vibration system and the design of the operator’s chair shall incorporate a suspension system.

(9) Cabin Electrical Panels shall incorporate adequately sized trunking taking into account additional cables which may be required to interface crane controls.

(10) The operators cab shall be bolt mounted to the trolley and fitted with safety drop stop lugs, which shall prevent the cab from dropping off the trolley in case of support failure

(11) Cab Fittings

The operator's cab shall be fitted with following fittings and shall not obstruct the operator's views required for crane operations.

i) One right-hand and one left-hand control console each with stainless steel hinged top covers. The consoles together with the chair shall be ergonomically designed to minimize fatigue of the operator. Master controllers shall be with mechanical gate interlock preventing hoist and gantry simultaneous movements.

ii) One upholstered operator's chair with air cushioned seat. The chair shall be a renowned global producers suspended from the ceiling with electrical height adjustment of at least 200mm.

The chair height and position (fore and aft movement) shall be adjustable to best suit each operator.

The chair shall be equipped with a suitably rated safety belt to restrain the operator during an emergency stop condition with the trolley traveling at maximum speed.

The position and height of the armrest of the operator’s chair shall be adjusted independently. Operator controls shall be positioned to provide primary functions within the armrests and secondary controls within reach within a hinged side panel. Additional controls may be mounted in a fixed side panel.

iii) An Indicator light panel shall be mounted in the lower front part of the cab to display the following conditions:

▪ Spreader 20ft position (Amber)

▪ Spreader 40ft position (Amber)

▪ Spreader 45ft position (Amber)

▪ Twist-locks LOCKED (Red)

▪ Twist-locks UNLOCKED (Green)

▪ Spreader LANDED (Amber)

▪ Hoist Slack Rope (Amber)

▪ Hoist Overload (Red)

▪ Hoist Snag Load (Red)

▪ High Wind (Red)

iv) 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.

v) Rear view mirrors fitted to both sides of cabin

vi) Communication equipment.

vii) Digital spreader height and load indicator.

viii) Analogue anemometer.

ix) A split unit air conditioning system.

x) Service outlet (two)

x) Interior lighting system shall provide 2 x 18W equivalent LED lights with integrated E-Light and additional 2 x spotlights integrated into the ceiling panel. Two-way control switches shall be mounted at the door and one within reach of the seated operator.

xi) Footrests for the operator (positions to be easily adjustable to suit individual operator).

xii) Service Outlets 24 V (10 Amp.) and 12 VDC (20 Amp.) for radio communication equipment. Both DC sources shall be stabilized within + 2.5% and - 10% of the rated voltage.

xiii) Safety bars wherever necessary to prevent accidental fall of the operator or maintenance staff.

xiv) Siren switch incorporated into RH Master Controller Joystick.

xv) Fault code and message panel