ZAŁĄCZNIK NR 5
ZAŁĄCZNIK NR 5
Specyfikacja Techniczna dla Mobilnych Żurawi Portowych 150 ton sztuk 2
Postępowania nr EU/33/MHC/ZZ/ o udzielenie zamówienia w trybie przetargu nieograniczonego na dostawę łącznie 2 sztuk Mobilnych Żurawi Portowych 150 ton w ramach projektu pt:
„Wyposażenie terminalu intermodalnego BCT w nowoczesne urządzenia przeładunkowe „
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Dokument podpisany przez XXXXXX XXXXXXXXX Data: 2024.08.26 14:43:34 CEST
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Digitally signed by Xxxx Xxxxxxxxxxx Date: 2024.08.26 15:28:55 CEST
Mobile Harbour Crane (MHC) SPECIFICATION – OVERVIEW
PROJECT
Supply of the following equipment defined within the Technical Specification: Two (2) Mobile Harbour Cranes
CAPACITY
Maximum lifting capacity under hook 150,000kg
Maximum lifting capacity spreader 65,000kg
DIMENSIONS
Working radius min 54 m
Maximum lifting height min 25 m ( maximum radius)
SPEEDS
Maximum travel speed 0-80 m/min
Hoisting /lowering speed 0-120 m/min
Slewing 0-1,6 rpm
Luffing speed 0- 65 m/min
MAIN DRIVE
Diesel-electric/diesel-hydraulic
Diesel Engine
The drive engine must meet the applicable exhaust emission standards EURO STAGE V Secondary Power Source Energy Saving Device:
Batteries, Ultracapacitors, Hydraulic accumulators
ELECTRICAL SYSTEMS
Main Voltage, frequency 400V, 50 Hz
MHC condition monitoring system On-board and remote
FEATURES
Engine block heater 230 V
Digital Services Standard Package Spreader Communication
Obstacle beacons for boom and tower tip, blinking Technical Training (Basic and Advanced) Operator Aid Cameras
Tower cub sun protection Folding seat in the tower cab
Cab with air condition and heating system
Tandem lift Assistant (includes Vertical Lift Assistant) Traveling with extended stabiliser beams
Predictive Services Smoke detector system
Fire extinguishing system (diesel + electrical room) Automatic lubrication of rope pulleys on tower and boom Automatic lubrication of chassis
Fuel level indicator at chassis Spreader (65t) – Twin-lift
Twin-twenty detection system (TTDS) on spreader Cable reel for auxiliary power supply with 50m cable Heating system for hydraulic oils tank
SITE CONDITIONS
Ambient Temperature Range -25°C to +45°C
Humidity Up to 95%
In Service Wind Sustained 22m/sec, Gust 25m/sec
DEFECT LIABILITY PERIODS (DLP)
Entire MHC & accessories after taking-over 2 Years Structure 10 Years
Components repaired during DLP 1 Year or balance of DLP
Software upgrades Throughout DLP
Paint 10 Years
Galvanizing 10 Years
Table of Contents
MOBILE HARBOUR CRANE TECHNICAL SPECIFICATION 5
1 GENERAL TECHNICAL SPECIFICATION 5
1.1 MATERIALS 5
1.2 WORKMANSHIP 5
1.3 QUALITY CONTROL AND INSPECTION 5
2 MECHANICAL TECHNICAL SPECIFICATION 6
2.1 MECHANICAL DESIGN 6
2.2 GENERAL 6
2.3 DESCRIPTION OF WORKS 6
2.4 AREA OF USE 6
2.5 GENERAL DESCRIPTION 6
2.6 STRUCTURE 7
2.7 GROUP CLASSIFICATION OF CRANE COMPONENTS 7
2.8 LOAD CAPACITY 7
2.9 SPEED OF OPERATION 7
2.10 OPERATORS CABIN 7
2.11 ENGINE 9
2.12 FUEL TANK 9
2.13 WHEELS AND TIRES 9
2.14 BODYWORK 10
3 PAINTING SYSTEM 10
3.1. PAINTING SYSTEM 10
4 SAFETY, INSPECTION, DRAWINGS AND MAINTENANCE MANUALS 12
4.1. SAFETY PROVISIONS 12
4.2. INSPECTION 12
4.3. DRAWINGS 12
4.4. MAINTENANCE AND OPERATION MANUALS 12
5 TRAINING 14
5.1. PRODUCT TRAINING 14
6 MAINTENANCE TOOLS 15
6.1 ELECTRICAL/ELECTRONIC TOOLS 15
6.2 MECHANICAL TOOLS 15
7 ENDURANCE TEST 15
8 APPENDIX – Corporate Livery and Identification 16
Asset Number and Decals: 16
MOBILE HARBOUR CRANE TECHNICAL SPECIFICATION
1 GENERAL TECHNICAL SPECIFICATION
1.1 MATERIALS
1.1.1 Materials used in the MHC shall be new and of the best quality, suitable for the duty.
1.1.2 Materials shall be free from flaws. All castings shall be smooth, sharp and free from blowholes, with ample fillets, and correctly centralized cores. All structural sections and plate shall be free from scale.
1.1.3 No plates, flat bars or angles used in load bearing structural members, including platform supports, shall be less than 6mm thick.
1.2 WORKMANSHIP
1.2.1 Workmanship shall be of the highest standard
All plates, sections, etc. shall be straightened or curved as may be required by pressure and not by hammering.
1.2.2 Burrs on all material shall be removed before painting. Screw threads shall be accurately produced in accordance with designer’s specification and classification.
1.3 QUALITY CONTROL AND INSPECTION
1.3.1 The manufacturer shall submit evidence that a formal system of quality control is applied to all purchased materials and equipment.
1.3.2 Reasonable access shall be provided by the manufacturer to the Purchaser's inspecting authority which may be requested to attend the manufacturer's works, or works of the manufacturer's sub- contractors, during construction.
1.3.3 Load tests shall be carried out prior to shipment. Notwithstanding this the unit will again be checked and will undergo a full operational inspection including proof load test on arrival at the Purchaser’s site.
1.3.4 The following definitions determine the extent to which substitutions may be produced.
“OR APPROVED EQUAL” material, products, or service require approval by addendum prior to the proposal due date. Materials, products or services which the Vendor proposes to substitute, and which he/she considers equal to those specified, must be submitted to the Purchaser, Baltic Container Terminal (BCT), Head of Engineering, not later than 10 days prior to the proposal submittal due date. Requests shall be accompanied by complete technical data and such pertinent information and/or samples as necessary, or as specifically specified, to fully identify and apprise the material, product, or service. Approval of materials, products, or services deemed equivalent will be issued by addendum prior to the proposal submittal due date.
“OR EQUAL” materials, products, or services do not require approval prior to the proposal submittal due date. Materials, products, or services which the Vendor proposes to substitute and which he/she considers equal to those specified shall be submitted to BCT, Head of Engineering for approval. The proposed substitution shall anticipate necessary lead-time required for approval by the Terminal and procurement by the vendor. Such submittal shall be accompanied by complete technical data and such pertinent information as necessary to fully identify and appraise the material, product, or service. No increase in the contract price or time will be considered when substitution is not approved.
2 MECHANICAL TECHNICAL SPECIFICATION
2.1 MECHANICAL DESIGN
This section covers the provision by the Contractor for all labour and materials supplied:
2.1.1 to design, manufacture, ship and install the necessary mechanical materials, equipment and appurtenances;
2.1.2 to shop test as far as practicable and to field-test the entire mechanical equipment of the MHC.
2.2 GENERAL
2.2.1 Responsibility for the reliable operation of the equipment in accordance with the requirements of this Specification shall be borne entirely by the Contractor. The Contractor shall demonstrate with his drawings and specifications and with the required tests that the equipment is capable of performing all of the required functions with minimum of downtime.
2.2.2 The mechanical equipment shall be designed to be fully capable of operating the MHC reliably at the specified requirements on a continuous duty cycle, safely with minimum noise, vibration and maintenance.
2.2.3 All parts of the mechanical equipment shall be designed so that they may be easily assembled, adjusted, removed for replacement and easily accessible for lubrication, inspection, maintenance, and repair. Emphasis shall be placed upon quick replacement of faulty or worn parts as opposed to repair in place. Where necessary for access, permanent platforms, walkways, handrails, stairways and ladders shall be provided.
2.2.4 The design shall be system safe as far as practical so that the failure of a component or loss of power precludes accidental lowering or coasting out of control.
2.2.5 Parts, components, and purchased sub-systems shall be readily accessible in the country of operation.
2.2.6 All materials shall be identified by reference to the specification of an internationally recognized standard association with indication of equivalence to a local standard where applicable.
2.3 DESCRIPTION OF WORKS
2.3.1 The MHC shall comply with the requirements of the European Machine Guidelines, particularly Machinery Directive 2006/42/EC, Technical Specifications ,appropriate National and Local Standards, Statutory Orders, Regulations, Acts and Codes that apply. The MHC have to be provided with a declaration of conformity and the CE marking and symbol according to the relevant annexes of the Machinery Directive.
A certificate of conformity CE shall be supplied with the MHC on delivery.
2.4 AREA OF USE
Port areas and beyond.
2.5 GENERAL DESCRIPTION
2.5.1 The MHC shall be designed as a container-handling unit for heavy-duty terminal applications.
2.5.2 Mobile Harbour Cranes suitable for handling :
- General and project cargo with hook
- Containers with spreader
2.5.3 The design of the MHC shall recognize that the machine will be subjected to an arduous duty cycle. Particular attention shall be given to maintainability.
The MHC will be operating on a continuous 24 hour day, 7 days per week operation interrupted only as required for Contractors recommended maintenance.
2.6 STRUCTURE
2.6.1 The MHC shall be constructed from standard hot-rolled steel sections. The steel grades shall be of weldable quality not requiring special temperature conditions for repair works.
2.6.2 The structure shall be so designed that water pockets are not formed in any member or by the inter-section of members and be such that there shall be no unsealed blind areas where paint cannot be applied. Adequate drainage holes shall be provided to discharge water clear of the structure in all cases where there is a tendency for water to collect.
2.7 GROUP CLASSIFICATION OF CRANE COMPONENTS
Heavy load operation SWL>100 t A3 Standard load operation SWL < 100t A6 Spreader operation SWL<60t A8
Classification of individual mechanism as whole
Normal load Heavy load Spreader
Hoisting gear M8 M4 M8
Luffing gear M7 M7 M7
Slewing gear M6 M7 M6
Travelling gear M4 M4 M4
2.8 LOAD CAPACITY
2.8.1 The MHC shall be designed to
Maximum lifting capacity (hook) - 150 MT Maximum lifting capacity spreader - 60 MT
2.9 SPEED OF OPERATION
Hoisting /lowering speed 0-120 m/min
Slewing 0-1,6 rpm
Travel speed 0-80 m/min
Luffing speed 0- 65 m/min
.
2.10 OPERATORS CABIN
2.10.1 The MHC shall be provided with a weather-tight, totally enclosed, forced ventilated, air conditioned, single man, forward facing, forward control operator cabin, robustly designed and constructed to provide the Operator with a safe, practical and efficient working environment.
2.10.2 The air conditioning unit shall be sized to maintain internal cab temperature of 20°C maximum under all external ambient temperature conditions up to and including 35°C. An adjustable thermostat, within reach of a seated operator shall be provided.
2.10.3 Access
The cabin shall be equipped at least with a rear/side door opening
2.10.4 Noise Level
The maximum noise level at the operator’s head level shall not exceed the following decibel levels at the defined governed engine speeds with the MHC stationary on either concrete or asphalt pavement:
i) At operator’s head level with doors and windows closed
In operator’s cabin – engine idle speed max 68 db (A)
In operator’s cabin – engine governed speed max 75 db (A)
These noise levels shall be the maximum levels occurring while the MHC is operating on either a containers or general project cargo.
The combination of sound insulation, covering material and associated adhesives shall comply with local Health and Safety Requirements and the Contractor shall state the classification of this combination.
2.10.5 Windows
The cabin shall be fitted with fixed laminated front, rear and roof screens, door and off-side sliding windows mounted in rubber. All windows should be equipped with sun visors.
2.10.6 Windscreen Wipers and Washers
Electrically operated, self-parking windscreen wipers shall be provided for the front and rear windows.
2.10.7 Seat
An air suspended seat approved by Purchaser unit shall be fitted which has adjustments for height, distance from the front window, angle of squab, back rest and degree of suspension. The seat shall be covered in black ventilated, non-slip type material.
2.10.8 Air Conditioning and Ventilation
An adequate system of air conditioning and ventilation shall be provided such that the temperature inside the cabin can be maintained at 20oC in ambient temperature up to 45oC.
Air-flow shall be arranged such that de-frosting and de-misting operations may be efficiently carried out on all primary windows.
2.10.9 Controls and Instruments
The Operator's cabin shall be equipped with the controls, instruments and warning alarms.
2.10.10 Flooring
To be designed to promote cleanliness by the elimination of recesses into which debris is likely to collect and where ribbed flooring is used to ensure that the ribs can be swept easily towards the door of the cabin.
2.10.11 Mobile Radio and Terminal RF Supply
Permanent mounting shall be provided inside the drivers’ cabin at the front right hand side at roof level in order that Purchaser can install a mobile communications radio unit. The enclosure shall permit a radio with the following maximum dimensions, H 6cm x W 19m x D 26cm, to slide into position and allow electrical connections to be made at the rear.
A regulated two Power Supply within the range 12 to 13.6 Volts DC (Negative Ground) shall be installed and protected through an appropriately sized circuit breaker. A cable shall be routed from a dedicated Circuit Breaker to the radio enclosure. Current drain characteristics for this type of radio equipment shall not exceed 10 Amps.
An aperture shall be provided at or near radio location for installation of coaxial R 58 cable connecting to an externally mounted aerial. Aperture shall be fitted with appropriate waterproof fitting ready for acceptance of coaxial cable.
2.11 ENGINE
2.11.1 The engine shall be in accordance with applicable in force emission standards and in full compliance with all latest Site, Region and/or Country environmental regulations applicable today and in near future.
2.11.2 The MHC shall be powered by a diesel/electric, diesel/hydraulic appropriately rated to provide continuous operation according to the specification hereby defined.
2.11.2 Exhaust shall be heavy-duty upswept type manufactured from stainless steel.
2.11.3 The engine shall be fitted with automatic shutdown “safety circuits” in event of loss of oil pressure, low coolant level or high water temperature. The system shall be “circuit safe” whereby interruption of an electrical signal will identify an unhealthy condition and shut down the engine. Indicators shall identify the reason for shut down and remain illuminated after the engine has stopped. A reset push button, out of the operator’s cabin, will permit the engine to be restarted for troubleshooting purposes.
2.12 FUEL TANK
2.12.1 A fuel tank shall be provided giving good access for refilling and maintenance yet suitably protected against impact damage. A strainer shall be incorporated into the filler neck and an inspection plate which will permit access for cleaning inside the entire tank. The capacity of the tank shall be minimum 6000 litters. An easily accessible water trap shall be provided in the fuel line designed to collect all impurities before the fuel reaches the injectors. The diameter of the fuel filler should be 70 mm.
2.13 WHEELS AND TIRES
2.13.1 Spigot mounted wheels shall be supplied for both front and rear assemblies. The Contractor shall determine the tire/rim size to suit the duty specified. Each terminal MHC must be equipped with a complete spare wheel.
2.14 BODYWORK
2.14.1 Heavy duty rolled steel sections and steel plate covers shall be provided to give full all round mechanical protection to the chassis members and to the side fittings such as, fuel tanks, batteries and hydraulic tanks.
Where steel plate covers are used to protect components, which require regular inspection, maintenance or replenishment then a means of easy access shall be provided. Particular care shall be given to the selection of hinges, which may be subjected to wear or corrosion because of the prevailing conditions.
2.14.2 Access, platforms, stairways and handrails shall comply with European Machinery Directives and European Standard EN 13586:2009-05.
2.14.3 All horizontal steel cover plates, which may be used for access, shall be treated with a proven, durable anti-slip surface.
2.14.4 Built-in recesses and/or steps shall be provided for access to and from ground level and where required corrosion resistant 'hand-holds' shall be fitted.
2.14.5 Where sections of the engine exhaust system are adjacent to an access route or where they may be used as handholds then substantial temperature shielding shall be provided.
3 PAINTING SYSTEM
3.1. PAINTING SYSTEM
3.1.1 During construction and after fabrication has been completed, the MHC shall be thoroughly cleaned and painted in a manner as specified using paint products approved by the Purchaser and in accordance with paint manufacturer’s instructions.
3.1.2 Painting system shall be suitable for “Exterior exposed polluted coastal
atmosphere” and in accordance with the following standard or equivalent: BS 5493 : 1977 Table 3. Part 3. SK3 – Blast clean surfaces to Sa 2.5 Typical time to first maintenance 10-20 years.
3.1.3 Colour
The colour scheme for the MHC shall be:-
i) Chassis including bumpers Traffic Black RAL 9017
ii) Operator’s Cab and wheels White
iii) Tower, boom
Traffic Orange RAL 2009
Refer to Appendix Two for details of paint scheme, Purchasers logo and asset number location.
3.1.4. Logo and Identity Number
The Purchasers Logo to be applied as defined in Appendix Two Plant Identity Numbers shall be applied as shown in Appendix Two.
4 SAFETY, INSPECTION, DRAWINGS AND MAINTENANCE MANUALS
4.1. SAFETY PROVISIONS
4.1.1 In the design and construction of the MHC, all local safety legislation shall be observed.
4.2. INSPECTION
4.2.1 Contractor shall submit a “Tests on Completion” schedule 4 weeks prior to “in house” testing for Purchasers review.
4.2.2 The Purchaser may carry out of inspections prior to and during manufacture at the Contractor's works either with one of his own inspectors or by an outside appointed inspector. The contractor shall allow access for the purpose of these inspections.
4.3. DRAWINGS
4.3.2 Following placement of the order, the contractor shall submit for review to the Purchaser general arrangement, fully dimensioned detail drawings and schematic diagrams.
4.3.3 The drawings and diagrams shall be checked by the purchaser so far as it is possible with the information in his possession.
4.3.4 Approval of drawings, whilst made in good faith, does not remove from the contractor his responsibilities and does not carry with it responsibility for subsequent alterations which the contractor may find necessary as the work proceeds.
4.3.5 The contractor shall provide two copies of the above drawings as modified and approved immediately prior to commencement of Acceptance Testing.
6.3.6 On completion of the contract, a copy of 'as made' drawings shall be supplied on disc or CD in PDF Format, and copies of spare part schedules shall be supplied at the Contractor's expense to the purchaser within one month of Completion.
4.3.7 The drawings shall include such details as:-
i) Circuit diagrams, wiring diagrams and schematic diagrams of all electrical equipment.
ii) Hydraulic schematics, piping diagrams.
iii) Fully dimensioned detail drawings of all major components and assemblies.
iii) General Arrangement of the MHC.
4.4. MAINTENANCE AND OPERATION MANUALS
4.4.1 Four copies of good quality printed maintenance instruction manuals per contract in English and Polish language covering in detail the operation and maintenance of the MHC shall be provided immediately prior to Acceptance Testing. A PDF copy of the maintenance manual shall also be provided separately.
4.4.2 The following shall be included in the Maintenance Manual:
i) Index.
ii) Full technical specification and detailed description of the terminal MHC as a whole and of each item of machinery and equipment for guidance of the maintenance staff and management. Where the Contractor's standard published literature is used, it shall be suitably edited to delete irrelevant information.
iii) General arrangement and layout drawings in PDF format (Minimum A2 size), with appropriate cross-referencing to other drawings), schematic diagrams for power and control circuits whether electrical or hydraulic etc. The control sequence shall be fully described. General arrangement drawings shall show all leading dimensions, and a visual chart of safe working loads.
iv) Performance characteristics, copies of Works and Site Test Certificates, recommended settings of adjustable features, necessary.
v) Detailed list of all "As-Fitted" drawings as called for under the contract and supplied separately.
vi) Recommended schedules and programs for inspection, lubrication and routine maintenance. Lubrication charts and specifications. Full technical details for operation, adjustment, maintenance and testing of equipment and control.
vii) A means shall be provided for systematic trouble shooting, to enable detection and analysis of faults, with recommendations as to dealing with different types of problems likely to arise. This shall take the form of a compendium of cause/effect/solutions based upon experiences reported by users of the equipment split between electrical and mechanical systems.
viii) Dismantling, repair, assembly, setting up and testing procedures and instructions, including electronic 'black box' units, for the whole of the equipment being purchased, fully illustrated. These shall include exploded views of all main components with part numbers shown to assist in dismantling and re-assembling complicated items and for identifying replacement parts.
ix) Spare parts lists, Contractor's part numbers and the actual source manufacturers (if applicable), part numbers, together with source manufacturers address for ease of cross reference identification when ordering.
x) Special tools and instruments required, if any, for testing, maintenance and repair work.
xi) Description of special safety features such as safety interlocks; limits; indication; warning and cut-out devices, etc. Testing adjustment and maintenance procedures for such devices and circuits. Special hazards and precautions to be taken by maintenance staff.
4.4.3 Two copies of good quality printed Operation Manual per MHC in English and local language
/Polish/ covering in detail the operation and maintenance of the MHC shall be provided immediately prior to Acceptance Testing. A PDF copy of the maintenance manual shall also be provided separately.
4.4.4 The following shall be included in the Operation Manual:
i) Index
ii) Full technical specification and detailed description of the MHCas a whole and of each item of machinery and equipment for guidance of the Operation staff and management. Where the manufacturer's standard published literature is used, it must be suitably edited to delete irrelevant information.
iii) Description of special safety features such as safety interlocks; limits; indication; warning and cut-out devices, etc. Operating procedures for MHC. Special hazards and precautions to be taken by Operation staff.
(iv) The operating instruction manual shall clearly state the start up procedure of every device on the MHC including all bought-in equipment, and all the points to be observed or checked during the start up.
(v) Corrections shall be made for any changes made in the instructions during the commissioning period, and the revised instruction books shall be submitted one (1) month after the notification of successful completion of the Tests on Completion of the first Terminal Trailer(s)
Manuals | Language | Copies / Order |
Operators manual | Polish , English | 4 |
Maintenance manual | Polish , English | 4 |
Spare parts manual | English | 4 |
5 TRAINING
5.1. PRODUCT TRAINING
5.1.1 The Contractor shall provide detailed product training for four Purchaser’s engineers at the Purchaser’s Site for a period of three full working days.
5.1.2. The following shall be included;
i) Training documentation and or materials as required.
ii) Certificate of Attendance for each attendee of manufacturers training completed.
iii) Details of course content shall be submitted to the Engineer at least 1 months before the scheduled delivery date.
6 MAINTENANCE TOOLS
6.1 ELECTRICAL/ELECTRONIC TOOLS
(i) Two laptops /diagnostic tool/ with original software to communicate with Engine Control Module (ECM) and Transmission Control Module (TCM) shall be provided along with any instructions for use. The operating license shall be assigned to the Purchaser and training shall be provided for its application.
6.2 MECHANICAL TOOLS
The following mechanical tools shall be provided per contract:
(i) Plug-in pressure gauges for the Hydraulic System - two (2) sets.
(ii) Set of long access Xxxxx and Torx Keys to adjust hydraulic pumps, fit solenoids and maintain other hydraulic components - two (2) sets.
(iii) Torque Wrench with socket sets – two (2) sets.
(iv) Tool Box – two (2) sets.
7 ENDURANCE TEST
(1) The Endurance Test forms part of the Tests on Completion. The MHC (s) shall be required to undergo a test to demonstrate the combined operation of all Crane systems and the reliability of the components. The endurance test shall consist of repetitive cycling as follows whilst handling the Crane’s rated load
This cycle is a preliminary proposal and the final test cycle shall be determined by the Crane configuration and in agreement with the Purchaser.
(2) The cycling test shall be continued for a period of 24 hours, minor malfunctions which only require single reset will be accepted during the first 16 hours, but the final 8 hours shall be fault free. In the event of a malfunction during the final 8 hours, the test shall be repeated until 8 hours of trouble free operation has been logged.
(3) Throughout the period of testing the current, voltage, speed, main drive mechanism temperature, noise and vibration shall be recorded at intervals of 60 minutes. Any malfunctions or problems and any remedial action taken during the test shall be recorded.
8 APPENDIX – Corporate Livery and Identification
The following paint color scheme based on the RAL standard shall be used for the final finish coat. For comparison, the original register cards issued by RAL shall be the controlling reference.
PAINT COLOR | ITEM | COMMENTS |
Traffic Orange RAL 2009 | Main Structure | Exterior Only |
Traffic Black RAL 9017 | Chassis | |
Traffic White RAL 9016 | Wheel Rim |
Asset Number and Decals:
Description of Equipment | Purchaser’s Asset Number | Comment |
Asset Numbers color is Traffic Black RAL 9017 in Arial Bold Font x 250mm High | ||