TECHNICAL SPECIFICATION FOR RUBBER TYRED GANTRY CRANES
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TECHNICAL SPECIFICATION
FOR
RUBBER TYRED GANTRY CRANES
FEBRUARY 2012
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 2
INDEX TECHNICAL SPECIFICATION C (I)
Functional requirement for the Crane
1.
General ..................................................................................................................................................................8 1-1. Project Description ........................................................................................................................................8 1-2. Terminal Site .................................................................................................................................................8 1-3. Overriding Requirement of the Purchaser .....................................................................................................8 2. Overall Design Criteria..........................................................................................................................................9 2-1. Type of Crane ................................................................................................................................................9 2-2. Type of Cargo ................................................................................................................................................9 2-3. Operating Environment and Design Aim.......................................................................................................9 2-4. Mode of Operation and Performance Target (MMBF)................................................................................10 2-5. Statutory Requirements and Minimum Design Standard.............................................................................10 2-6. Minimum Class of Crane.............................................................................................................................11 2-7. General Design Criteria ...............................................................................................................................11 2-7.1. Crane Particulars..................................................................................................................................11 2-7.2. Dimensional Restrictions .....................................................................................................................13 2-7.3. Yard Interface ......................................................................................................................................13 2-7.4. Electrical Facility Interface (Shore Power)..........................................................................................13 2-7.5. Communication Facility Interface (Radio) ..........................................................................................15 2-7.6. Climatic Conditions .............................................................................................................................15 2-7.7. Wind Conditions ..................................................................................................................................15 2-7.8. Lifting Loads and Stability ..................................................................................................................15 2-8. NOT USED..................................................................................................................................................16 2-9. Noise Control...............................................................................................................................................17 2-10. Operationally Critical Components .........................................................................................................17 3. Crane Structural Specification .............................................................................................................................17 3-1. General Requirement ...................................................................................................................................17 3-2. Material........................................................................................................................................................18 3-3. Calculations .................................................................................................................................................19 3-4. Loads ...........................................................................................................................................................19 3-5. Members Subject To Buckling ....................................................................................................................20 3-6. Fatigue Design Criteria................................................................................................................................20 3-7. Connection Designs .....................................................................................................................................20 3-8. Gantry Structure Stiffness............................................................................................................................21 3-9. Camber.........................................................................................................................................................21 3-10. Trolley Rails & Rail Fixing .....................................................................................................................21 3-11. Workmanship...........................................................................................................................................21 3-12. Quality Control of Structure Fabrication .................................................................................................23 3-13. Temporary Structures ..............................................................................................................................24 4. Functional Systems Devices & Equipment..........................................................................................................24 4-1. Main Hoist ...................................................................................................................................................24 4-1.1. Main Hoist Drive .................................................................................................................................24 4-1.3. Skew Control .......................................................................................................................................26 4-2. Trolley, Trolley Drive..................................................................................................................................26 4-2.1. Trolley Frame ......................................................................................................................................26 4-2.2. Trolley Drive .......................................................................................................................................27 4-2.3. Sway and Position Control ..................................................................................................................27 4-2.4. Power Feeder (Power Chain System) ..................................................................................................27 4-3. Gantry Drive ................................................................................................................................................28 4-3.1. Gantry Drive ........................................................................................................................................28 4-3.2. Steering ................................................................................................................................................29 4-3.3. Right Angle & Pivot Turn ...................................................................................................................29 4-3.4. Gantry Skew Control ...........................................................................................................................29 4-4. NOT USED..................................................................................................................................................29 4-5. Electrical House, Control Panel, Regenerative E.M.F. Absorbing Resistors..............................................29 Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 3 4-5.1. General Construction ...........................................................................................................................29 4-5.2. E-House Temperature Control.............................................................................................................30 4-5.3. Emergency Lights and Fire Control.....................................................................................................30 4-5.4. Back Power Absorbing Resistors.........................................................................................................30 4-5.5. Provision for Future Installation ..........................................................................................................30 4-5.6. Control Panel (in the Electrical house) ................................................................................................30 4-6. Operator’s Cab, Checker’s Cab ...................................................................................................................30 4-6.1. Construction General ...........................................................................................................................30 4-6.2. Cab Access...........................................................................................................................................31 4-6.3. Window Visibility ...............................................................................................................................31 4-6.4. Cab Dimension ....................................................................................................................................31 4-6.5. Cab Fittings..........................................................................................................................................32 4-6.6. Checker’s Cab......................................................................................................................................33 4-7. Personnel Lift ..............................................................................................................................................33 4-8. Headblock....................................................................................................................................................33 4-8.1. Headblock ............................................................................................................................................33 4-8.2. Two Wire (Bus) System ......................................................................................................................34 4-8.3. Baloney Cable......................................................................................................................................34 4-9. Spreader, Hook Beam ..................................................................................................................................34 4-9.1. Single Lift Telescopic Spreader...........................................................................................................35 4-9.2. Reeve in Spreader ................................................................................................................................38 5. Inter-Functional Systems & Components...........................................................................................................38 5-1. Mechanical System/Components.................................................................................................................38 5-1.1. Bearing, Seals ......................................................................................................................................38 5-1.2. Gearing ................................................................................................................................................38 5-1.3. Gear Reducers......................................................................................................................................39 5-1.4. Wire Rope Winch Drums ....................................................................................................................39 5-1.5. Wire Rope Sheaves..............................................................................................................................40 5-1.6. Wire Ropes ..........................................................................................................................................41 5-1.7. Shafts, Axles ........................................................................................................................................41 5-1.9. Metal Wheels .......................................................................................................................................42 5-1.10. Pins, Pin Brackets ............................................................................................................................42 5-1.11. Bolts.................................................................................................................................................42 5-1.12. Lubrication.......................................................................................................................................43 5-1.13. Bumper, Buffer ................................................................................................................................43 5-1.14. Rubber Tyres ...................................................................................................................................43 5-2. Hydraulically System/Components .............................................................................................................43 5-2.1. Standards .............................................................................................................................................43 5-2.2. Components Sources............................................................................................................................43 5-2.3. Operating Condition ............................................................................................................................43 5-2.4. Hydraulic Fluid Reservoir ...................................................................................................................44 5-2.5. Power Unit ...........................................................................................................................................44 5-2.6. Valve Mounting ...................................................................................................................................44 5-2.7. Relief Valve .........................................................................................................................................44 5-2.8. Flow Control Valve .............................................................................................................................45 5-2.9. Check valves........................................................................................................................................45 5-2.10. Servo Valves ....................................................................................................................................45 5-2.11. Control Valve...................................................................................................................................45 5-2.12. Solenoid Valves ...............................................................................................................................45 5-2.13. Piping...............................................................................................................................................46 5-2.14. Hoses ...............................................................................................................................................46 5-2.15. Assembly Test .................................................................................................................................46 5-2.16. Catch Basins ....................................................................................................................................46 5-2.17. Filters ...............................................................................................................................................46 5-2.18. Heat Exchangers ..............................................................................................................................47 5-2.19. Actuator ...........................................................................................................................................47 5-2.20. Application for Spreader..................................................................................................................47 5-2.21. Couplings.........................................................................................................................................47 5-2.22. Gauges .............................................................................................................................................47 5-2.23. Covers ..............................................................................................................................................47 5-2.24. Hydraulic Fluid ................................................................................................................................47 5-2.25. Load Sensing System.......................................................................................................................48 Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 4 5-3. Electrical & Electronic System/Components...............................................................................................48 5-3.1. General.................................................................................................................................................48 5-3.2. Main Power Supply .............................................................................................................................48 5-3.3. Power Factor Correction ......................................................................................................................48 5-3.4. Protection Against Power Surge ..........................................................................................................48 5-3.5. Protection against voltage dip/loss of power supply............................................................................49 5-3.6. Wiring ..................................................................................................................................................49 5-3.7. Marking and Identification ..................................................................................................................50 5-3.8. Conduit and Cable Tray.......................................................................................................................51 5-3.9. Electrical Trunking ..............................................................................................................................51 5-3.10. Motor ...............................................................................................................................................52 5-3.11. Brakes ..............................................................................................................................................52 5-3.12. Transformers....................................................................................................................................53 5-3.13. Resistors...........................................................................................................................................53 5-3.14. Enclosures........................................................................................................................................53 5-3.15. Meters, Counters..............................................................................................................................53 5-3.16. Limit Switches .................................................................................................................................54 5-3.18. Name Plate.......................................................................................................................................55 5-3.19. D. C. Power Supply .........................................................................................................................55 5-3.20. Encoders ..........................................................................................................................................55 5-3.21. Sensors.............................................................................................................................................55 5-3.22. Circuit Breakers ...............................................................................................................................55 5-3.23. Auxiliary Power Socket ...................................................................................................................56 5-4. Crane Motion Controls ................................................................................................................................56 5-4.1. Control System General.......................................................................................................................56 5-4.2. Programmable Logical Controllers (PLC) ...........................................................................................57 5-4.3. Power Supply.......................................................................................................................................58 5-4.4. Discrete I/O Modules...........................................................................................................................58 5-4.5. Real Time Clock Module.....................................................................................................................59 5-4.6. Motion Control Switches in Operator’s Cab........................................................................................59 5-4.7. Motion Control Panels .........................................................................................................................61 5-4.8. Remote Motion Controls .....................................................................................................................61 5-5. Operational Safety Interlocks ......................................................................................................................61 5-5.1. Main Motions Interlocks......................................................................................................................61 5-5.2. For Trolley Operation ..........................................................................................................................62 5-5.3. For Gantry Travel Operation ...............................................................................................................63 5-5.4. Spreader Functional Interlock..............................................................................................................63 5-5.5. Cab Entrance Door/Gate Interlock.......................................................................................................64 5-6. Communications ..........................................................................................................................................64 5-6.1. Intercom System ..................................................................................................................................64 5-6.2. Radio Communication System ............................................................................................................64 5-6.3. Data Communication System ..............................................................................................................64 5-6.4. Public Address System ........................................................................................................................64 5-6.5. Operation Centre / Maintenance Office Station...................................................................................64 5-7. Crane Condition Monitoring System (CCMS) ............................................................................................65 5-7.1. General.................................................................................................................................................65 5-7.2. CCMS Description...............................................................................................................................65 5-7.3. On-Board Crane Condition Monitoring System (On-Board CCMS)...................................................66 5-7.4. On-Board CCMS Software Requirements ...........................................................................................66 5-7.5. On-Board CCMS Hardware Requirements..........................................................................................68 5-7.6. Condition Monitoring ..........................................................................................................................68 5-7.7. Fault Diagnosis ....................................................................................................................................72 5-7.8. Preventive Maintenance.......................................................................................................................73 5-7.9. Equipment Performance Data and Operation Log ...............................................................................73 5-7.10. Remote Crane Condition Monitoring System (RCCMS) ................................................................73 5-7.11. RCCMS Software Requirements .....................................................................................................74 5-7.12. RCCMS Hardware requirements .....................................................................................................74 5-7.13. Server(s)...........................................................................................................................................75 5-7.15. CCMS Data Communication ...........................................................................................................75 6. Common Items ....................................................................................................................................................75 6-1. Walkways, Stairs, Ladders and Platforms ...................................................................................................75 6-1.1. Applicable Code/Std. ...........................................................................................................................75 Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 5 6-1.2. Stairway Requirements ........................................................................................................................76 6-1.3. Ladder Requirements...........................................................................................................................76 6-1.4. Platforms Requirements.......................................................................................................................77 6-1.5. Walkway Handrail Requirements ........................................................................................................77 6-1.6. Cab Access Platforms ..........................................................................................................................78 6-1.7. Walkway Requirements .......................................................................................................................78 6-2. Illumination and Lighting ............................................................................................................................78 6-2.1. Walkways, Stairs, Ladders, Cab Access ..............................................................................................78 6-2.2. Work Area Floodlights ........................................................................................................................78 6-2.3. Floodlights on Trolley .........................................................................................................................79 6-2.4. Emergency Lighting for Escape Routes...............................................................................................79 6-2.5. Lighting Control Switches ...................................................................................................................79 6-2.6. High Pressure Sodium Lamp and Ballast ............................................................................................79 6-2.7. Fluorescent Lamps...............................................................................................................................80 6-2.8. Access for Lights Maintenance............................................................................................................80 6-3. Painting and Protective Coating ..................................................................................................................80 6-3.1. Paint System General...........................................................................................................................80 6-3.2. Surface Preparation..............................................................................................................................81 6-3.3. Abrasive Blast Cleaning ......................................................................................................................82 6-3.4. Painting Generally ...............................................................................................................................83 6-3.5. Paint Systems.......................................................................................................................................85 6-3.6. Galvanising ..........................................................................................................................................87 6-3.7. Reinstatement of Protective Coatings at Site .......................................................................................87 6-3.8. Inspection and Sample Panels..............................................................................................................88 6-4. Purchaser’s Logo, Crane Numbers, Signs ...................................................................................................89 6-4.1. Purchaser’s Logo .................................................................................................................................89 6-4.2. Crane Numbers ....................................................................................................................................89 6-4.3. Crane Capacity Signs...........................................................................................................................89 6-4.4. Manufacturer’s Name Plates................................................................................................................90 6-4.5. Other Signs ..........................................................................................................................................90 6-5. Alarm, Warning Signals ..............................................................................................................................90 6-5.1. Gantry Travel Warning ........................................................................................................................90 6-5.2. Main Hoist Overload Warning.............................................................................................................91 6-5.3. Premature Twistlock Operation Warning ............................................................................................91 6-5.4. By-Pass Switch Abuse Warning ..........................................................................................................91 6-5.5. Electrical Control House A/C Warning ...............................................................................................92 6-5.6. Public Address/Warning ......................................................................................................................92 6-6. Emergency Stop Push Buttons.....................................................................................................................93 6-6.1. Locations .............................................................................................................................................93 6-6.2. Type .....................................................................................................................................................93 6-6.3. Emergency Stop Signs .........................................................................................................................93 6-7. Service Outlets.............................................................................................................................................93 6-7.1. Location ...............................................................................................................................................93 6-7.2. Type Model..........................................................................................................................................93 6-8. Fire Extinguishers ........................................................................................................................................94 6-8.1. Locations .............................................................................................................................................94 6-8.2. Type-Model .........................................................................................................................................94 6-9. Maintenance Tools and Equipment .............................................................................................................94 6-9.1. Mechanical Maintenance Tools ...........................................................................................................94 6-9.2. Electrical/Electronic Maintenance Tools .............................................................................................94 6-9.3. Hydraulic Maintenance Tools..............................................................................................................94 6-9.4. Special Tools and Equipment ..............................................................................................................94 6-9.5. Wear Gauges........................................................................................................................................95 7. Project Q.A. and Administrative Requirements...................................................................................................95 7-1. Document Submission (Project) ..................................................................................................................95 7-1.1. Project Organisation Chart (Shop & Site)............................................................................................95 7-1.2. Project Schedule (Shop & Site) ...........................................................................................................95 7-1.3. Project Progress Report .......................................................................................................................96 7-1.4. Quality Assurance Programme/ Manuals ............................................................................................96 7-1.5. Daily Plan and Report (Site Work) .....................................................................................................96 7-2. Document Submission (Technical)..............................................................................................................97 7-2.1. Submission Schedule ...........................................................................................................................97 Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 6 7-2.2. Conceptual Design...............................................................................................................................97 7-2.3. Drawings and Calculations for the Purchaser's Review.......................................................................97 7-2.4. Lubricant List.......................................................................................................................................98 7-2.5. Crane Delivery Method Statement.......................................................................................................98 7-2.6. Site Work Method Statement...............................................................................................................98 7-2.7. Commissioning Test Procedure. ..........................................................................................................99 7-2.8. Up-Dated Drawings .............................................................................................................................99 7-2.9. Training Programme ..........................................................................................................................100 7-2.10. Structural maintenance Program....................................................................................................100 7-2.11. Operation Manuals.........................................................................................................................101 7-2.12. Maintenance Manuals ....................................................................................................................101 7-2.13. As-Built Drawings .........................................................................................................................102 7-3. Shop Inspection & Tests ............................................................................................................................103 7-3.1. Shop Inspection and Verification.......................................................................................................103 7-3.2. Pre-Shipment Inspection and Test .....................................................................................................104 7-4. Shipment, Delivery and Site Work ............................................................................................................105 7-4.1. Clearance for Shipment .....................................................................................................................106 7-4.2. Notification of ETA Site....................................................................................................................106 7-4.3. Navigation Requirement ....................................................................................................................106 7-4.4. Berthing and Roll-off Requirements..................................................................................................106 7-4.5. Customs Clearance ............................................................................................................................107 7-4.6. Work Permits .....................................................................................................................................107 7-4.7. Site Safety and Security.....................................................................................................................107 7-4.8. Site Erection Area and Access...........................................................................................................107 7-4.9. Site Office Communication ...............................................................................................................107 7-4.10. Test Weight....................................................................................................................................108 7-4.11. Water, Electricity Supply...............................................................................................................108 7-4.12. Contractor’s Representatives. ........................................................................................................108 7-5. Site Inspection and Tests, Certification .....................................................................................................108 7-5.1. Commissioning Tests Application .....................................................................................................108 7-5.2. Defects List........................................................................................................................................108 7-5.3. Rectification Report...........................................................................................................................109 7-5.4. Commissioning Test ..........................................................................................................................109 7-5.5. Endurance Test. .................................................................................................................................109 7-5.6. Acceptance Certification....................................................................................................................110 7-5.7. Access for Remedial Work ................................................................................................................110 7-6. Training .....................................................................................................................................................110 7-6.1. Training Off-Site. ..............................................................................................................................110 7-6.2. Training On-Site (Operators).............................................................................................................110 7-6.3. Training On-Site (Maintenance) ........................................................................................................111 7-6.4. Special Training on the Operationally Critical Components Maintenance........................................112 7-6.5. Spare Parts .........................................................................................................................................112 7-6.6. Ordered Spare Parts ...........................................................................................................................112 7-6.7. Spare parts for Commissioning Work................................................................................................112
8.
APPENDICES I.
Structural Limit of the Crane
II.
Inspection Control Sheets
III.
Crane Interface Drawings 1. Container Stack General Layout 2. Typical Cross Sections-Container Stack Blocks and Crane Runways
IV. Reference Drawings and Data
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 7 1. 2. 3. 4. 5. 6. 7.
Crane Numbers at Ground Level Circuit Diagram for Net Handling House Logic Control Console Switches Layout Locations of Floodlights on the Trolley Operator’s Cab GCT Logo, Approved Colours, Warning Signs, Name Plates etc Type and Model of Labels and Cable Routing for AGSS and PDS 8. Overview and Configuration of Crane Condition Monitoring System (CCMS)
V.
List of Drawings / Calculations to be reviewed by the Purchaser (Minimum Requirements)
VI. List of Operation/ Maintenance Manuals and As Built Drawings
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 8 Section C.
TECHNICAL SPECIFICATION
C (I)
Functional Requirement for the Crane
1.
General
1-1.
Project Description To carry out the design, construction, delivery, installation, testing and commissioning of Two (2) units of 41 tonnes capacity electrical Rubber Tyred Gantry Cranes. The cranes shall be delivered to Gdynia Container Terminal S.A., Gdynia, Poland in a fully assembled and tested condition.
1-2.
Terminal Site The Cranes shall be delivered and installed on Gdynia Container Terminal on Energetykow 5, Gdynia, Poland (hereinafter referred to as GCT).
1-3.
Overriding Requirement of the Purchaser This Specification forms part of and is subject to the Conditions of Contract. Special attention of the Contractor is drawn to Clause 3. General Requirements of the Conditions of Contract for clarification of position of this Specification in relation to the overall and overriding requirements of the Purchaser. For the purposes of this Contract (including Clause 3 of the Conditions of Contract and relevant references within the Specification) acceptable routine maintenance shall be within the following general parameters. (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 acceptable routine maintenance shall be:
(3)
-
Preparing and over coating the existing paint system at year 20 after the issuance of the Commissioning Certificate.
-
Removing damaged parts of the paint system back to clean steel and repainting in isolated areas but not exceeding in aggregate more than 1%, 2% and 3% of the total surface area at years 5, 10 and 15 respectively.
-
The removal of the paint system back to steel and replacement of the paint system in areas aggregating more than the above percentages of the total surface area of the painted part of the Crane shall be Defects remedial works and not maintenance.
For items of electrical and mechanical equipment, controls, systems, components, fittings and fixings, acceptable maintenance shall be the periodic and routine
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 9 maintenance normally carried out on the various parts generally undertaken as establishment 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.
2. Overall Design Criteria 2-1.
Type of Crane The Crane shall be powered by shore power supply system, electrically driven rubber tyred travelling gantry crane with a self-driven trolley with a cab. The Crane drive and control shall be full AC inverter drive, with fully digitalised controls with PLC. The proposed drive and control system shall be a proven system successfully operating on a similar capacity crane in actual container handling operations.
2-2.
Type of Cargo The type of cargo to be handled by the Crane shall be 1 2 3 4
2-3.
ISO 20ft, 40 ft and 45ft containers including high-cube, half height, flat rack containers. Other types of container with ISO corner fittings at 20ft, 40ft, or 45 ft positions. Containers with overheight cargoes through an overheight cargo container lifting frame of the Purchaser. Damaged container with slings and shackles attached to lifting lugs of the spreader.
Operating Environment and Design Aim 1.
The Crane shall be operated and maintained on 24 hours per day basis in all weather conditions. All electrical, electronic, and mechanical equipment shall be nonhygroscopic, non-corroding suitable for use in conditions stated in 2-7.6, 2-7.7, 5-4 of this Specification. The Cranes shall conform to the noise requirements in this Specification.
2.
Special considerations shall be given in all aspects of the design for achieving accurate load spotting ability with quick sway/yaw damping, and ensuring full operational capability and safety for round the clock operations, including operation under heavy rain and/or falling snow.
3.
The Crane shall be exposed to non-technical personnel specifically at the ground level and in access to trolley/operator’s cab. The Contractor will provide adequate, safe and fool-proof protection in and around all equipment and fittings in these areas of the Crane.
4.
Ease of maintenance and safety of the maintenance staff shall be aimed at throughout the design to minimise total downtime of the Crane.
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 10
2-4.
Mode of Operation and Performance Target (MMBF) The Crane shall be manually controlled; all functions on the Crane shall be controlled fully by the operator from the operators cab position. The MMBF of the Crane will be ascertained by the Purchaser after its Commissioning. For the purpose of ascertaining MMBF the Crane will be put into operation under such conditions and circumstances as may exist or be required by the Purchaser from time to time including if the Purchaser elects operation for the purpose of the Purchaser’s business and/or for the specific purpose of ascertaining MMBF. No credit or allowance shall be given for the benefit of the Contractor in respect of conditions, circumstances, and operator’s performance. The MMBF is defined as: MMBF =
Twist Lock Count (TLC) for one week Number of Breakdowns of a Crane for one week
TLC = One TLC is defined as the operation of twist lock + hoisting + trolley + lowering + unlock. The actual MMBF shall be recorded on a weekly basis. Following completion of the Initial Trial Period, the Intermediate Trial Period and the Final Trial Period for a Crane the MMBF shall be calculated by dividing the total number of twist lock counts recorded during the final four-weeks by the total number of breakdowns in the same period. 2-5.
Statutory Requirements and Minimum Design Standard 1.
The Crane and its mechanism shall be designed and manufactured to comply in all aspects with the requirements of all latest, applicable state or local Polish and European Community laws, ordinances, rules, orders, or other legal or regulatory institutes.
2.
Where items are not covered by Poland / European Community Statutory requirements, the Crane and other Goods shall be designed and manufactured to at least the standards as specified in this Specification. For items which are not specified above, then to at least to the current applicable recommendations of the following organisations: AWS American Welding Society – Bridges and Dynamically Loaded Structures BSI
British Standards Institute
DIN
Deutsche Industrie Normen
FEM Federation European de la Manutention GB
Chinese Standard Institute
IEC
International Electro Technical Commission
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 11
IEEE Institute of Electrical and Electronic Engineers ISO
International Standards Organisation
JIS
Japanese Industrial Standards
UL
Underwriters Laboratory
The Contractor shall be required to submit to the Purchaser a full list of applicable standards used in the design of the Crane. 2-6.
Minimum Class of Crane Structures: Class of Utilisation State of Loading Group Classification Impact Factor Duty Factor
U7 Q2 A7 1.4 0.9
Normal Load Spectrum factor 0.80 of rated capacity. Mechanisms Mechanisms Hoist Trolley Travel Gantry Travel
2-7.
Class of Utilisation T7 T7 T7
State of Loading L3 L3 L3
Group Classification M8 M8 M8
General Design Criteria
2-7.1. Crane Particulars Major dimensions, clearances and performance requirements: (1)
Rated Load Under Spreader
41 tonnes.
(2)
Test load for overload test
51.25 tonnes under spreader.
(3)
Container type
ISO 20’, 40’, and up to 53’ containers with ISO corner fittings at 20’, 40’ or 45’ position.
(4)
Spreader
20’/40’/45’ telescopic type with power-operated retractable end flippers and moving side guides capable of handling 8’ and 8’ 6” wide containers.
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 12
(5)
Span (Gantry)
23.470mm (77’) centres of wheels.
(6)
Lift above ground
20,750 mm minimum to the lowest point of spreader (side guides/ lowered end flipper). Emergency hoist limit at 20,850mm to the lowest point of spreader. For the lowering, the headblock (spreader removed condition) must be able to be lowered onto the ground.
(7)
Overall Crane Length
Not more than 12,200 (40’).
(8)
Speed – Main Hoist
25m/min. minimum with 41 tonne load under spreader. 60m/min. minimum with empty spreader. Acceleration or deceleration time max. 6.0 s for empty spreader and 3s for rated load.
- Trolley
70m/min. minimum. Acceleration time max. 4.0 s. Deceleration time max. 3.0 s.
- Gantry
90m/min. minimum. Acceleration/Deceleration time max. 8.0s.
The above speeds must be achieved for crane operation under a sustained 20 meter/sec. wind condition. (9)
(10)
Skew adjustment (*)
±5 degrees Speed: 0.5 degree/second minimum
(*) Note 1
Skew adjustment systems shall be capable of changing attitude of a 41 Te container with 1.6 meter eccentricity.
Anti-sway/yaw
The Crane shall be provided with anti-sway dampening. The anti-sway system shall be capable of damping the spreader after the trolley has stopped with full deceleration at any operational speed with any operational load, to within 50mm of lateral displacement after 2 cycles of sway. The same criteria will apply to the yawing motion following the trolley stopping from any operational speed with full
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 13 deceleration, or after the end of the skew motion command. The system shall meet the above criteria measured at the spreader end beams expanded to the 45’ position between 3.0 meters above the ground level and the maximum lift. (11)
Number of gantry wheels
Eight (8) (Two in line per corner).
(12)
Gantry Wheels Steering
A hydraulic wheel jack up system shall be installed between each pair of wheels to allow free turning of the wheel pairs through 90 degrees. The complete cycle from activation of the wheel jack system, turning of the wheels through 90 degrees to raising the jacks shall be no more than 70 seconds. The gantry system shall also be designed to allow the wheels to adopt intermediate turning angles to allow pivot turning of the Crane. See 4-3.3.
2-7.2. Dimensional Restrictions (1)
The Crane profile shall be within the structures limit as defined in the drawing no. GCT-RTG-01 in Appendix I, to ensure safe operation of the Crane at any lane.
(2)
The spreader width must be kept within 2800mm when handling 8’-0” wide containers, and 2900mm when handling 8’-6” wide containers.
2-7.3. Yard Interface (1)
The Crane runway path is part of the reinforced concrete terminal pavement. Typical layout of runways is shown on the attached drawing in Appendix. III. The design should allow for cranes to safely pass other Cranes operating on adjacent runways, taking into account 1% cross grades and certain amount of drift of the Cranes.
(2)
NOT USED
2-7.4. Electrical Facility Interface (Shore Power) (1)
A shore power supply system shall be installed on the crane through H.V. cable reel system that shall permit the normal container operation. The power supply to the crane shall be 15 KV (±15%) 3 phase, 50Hz±5%, a suitable transformer shall be provided to convert the in-coming HV power supply down to match the crane electrical system circuitry.
(2)
The high tension trailing cable connection on the yard shall be terminated into specially designed HV junction boxes. Termination of the cable conductors and fibre waveguide in the plugs at the junction box shall be done by the Contractor. Termination of the Purchaser’s power supply cable and optics fibre cables into the
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 14 socket shall also be the scope of the Contractor. The high tension cable shall be supplied by contractor with a suitable cable reeling device. A sufficient length of cable to cover minimum 200 meters gantry travel range from the junction box shall be provided by the Contractor. The Contractor shall bring the Crane trailing cable end to the junction box and shall complete the cable connecting work with an approved cable joint kit. The supply and installation of the H.V. junction box shall be by others. The cable joints made at Site and high tension wiring shall be subject to the inspection requirements of the local power supply authority (3)
The high tension trailing cable shall be 15 KV ethylene propylene rubber insulated polychloroprene jacketed round type flexible power cable based on IECA Pub. S68 516 or the equivalent approved by the Purchaser. The conductor shall be stranded flexible conductor consisting of tinned annealed copper wires. The cable shall also carry the fibre- optic cable for the remote CCMS (refer to 5-7).
(4)
The HV cable reel shall be installed opposite to the operator cabin, the transformer on the electrical house side. The cable reel shall be installed within the restricted dimensions as set out in 2-7. The drive control system of the cable reel shall be designed to minimise abrupt starting, braking and excessive slack / tension in the cable when the Crane passes the cable feed point. Sensors to detect the above conditions shall be provided.
(5)
Cable guide wheels shall be installed near the gantry trucks to keep the high tension cable close to the ground level. The cable shall be laid inside the cable slot within a total wheel base of gantry trucks in one corner.
(6)
The system especially the high tension slip ring components shall be well protected from weather, having an IP rating of not less than 55.
(7)
The cable reel drive machinery and slip ring area shall be isolated by fencing or other means and to permit to access of authorised persons only. High tension warning signs shall be provided and fitted to the entrance of the fenced area.
(8)
A suitably sized space heater shall be provided for the slip ring enclosure. An indicator light indicating functioning or malfunction of the space heater shall be installed near the cable reel machinery and shall clearly visible from ground level. The slip ring enclosure shall have hinged, sealed and lockable access panels on both sides to provide for easy access for servicing and maintenance.
(9)
Limit switches to control gantry motion near the travelling limit (limited by cable length) shall be provided.
(10)
An override switch shall be provided to allow operation of the cable reel drive. This switch shall be enclosed in a lockable and weatherproof box mounted at ground level in the proximity of the cable plough arrangement.
(11)
The composite HT trailing cable shall incorporate not less than eight (8) numbers of low loss silica glass optical fibre waveguides. The cable reel mechanisms shall incorporate low loss connecting devices that allow the use of all waveguide
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 15 simultaneously linking the equipment on the crane to external devices. The standard for the waveguide shall be 60/125 micron. (12)
The optical waveguide shall be terminated with Avaya ST-2 type standard connectors unless otherwise specified. The composite cable shall be separated into power and optical fibre cables for termination work in the junction boxes on yard as well as the cable reel on the Crane.
(13)
The source of power supply shall be connected to CMS system (refer to 5-7) and also indicator in operator cabin.
2-7.5. Communication Facility Interface (Radio) NOT USED. 2-7.6. Climatic Conditions The Crane and other Goods shall be designed and constructed to be fully capable of operating safely and withstanding the following climatic conditions. (1) (2) (3) (4)
Ambient temperature -20oC to 40oC Relative humidity Max. 100% Dew point Max. 3oC Wind up to 25m/sec. without special warning during operation.
More stringent and specific requirements shall apply for individual crane and other Goods subsystems and components, which are separately specified in each relevant clause of this Specification. 2-7.7. Wind Conditions The entire Crane structure with all of its machineries, components, fittings, or accessories, and all tie-down equipment shall be designed and constructed to withstand following wind loading conditions. (1)
Allow for wind loading of sustained wind speed of 25m/sec. for safe load handling operation of the Crane.
(2)
For the stowed condition of the Crane: A wind loading of wind speed up to 43m/sec. shall be allowed for the condition that the Crane is out of service and stationary without any gantry tie downs, but trolley anchored.
2-7.8. Lifting Loads and Stability (1)
One side landing i)
A normal operating condition shall include the case of one side landing of a 45ft - concentric 41 tonnes weight container, in which case a set of main
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(2)
(3)
The calculations of the structural and mechanical components shall include calculation for this criterion.
Eccentric container handling i)
All structural, mechanical and electrical systems or system components shall be designed to be capable of handling continuously 28 Te gross weight containers with eccentricity of 1.2m in longitudinal (gantry) direction and 0.25m in transverse (trolley) direction. The eccentricity of container shall not cause any horizontal drift of the container during hoisting/lowering motion.
ii)
The Contractor shall submit for the Purchasers review, a design method to completely eliminate the possibility of lifting one end of a container by two twistlocks. The design shall incorporate a system to immediately detect this condition and to render the hoist motion inoperable. The spreader which stops with one end locked inside a container shall allow lowering only with attendance of maintenance personnel.
Fatigue condition All structural fatigue calculations shall include the case of continuous handling of a 28 Te gross weight container with 1.2m eccentricity in longitudinal direction. Minimum loading cycle to be 2 million cycle.
(4)
Dynamic snag load (catch load) 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)
(6)
2-8.
Stability (i)
The Crane shall be stable with a reasonable safety margin and shall not sustain damages when a dynamic snag load is applied at any trolley and hoisting position.
(ii)
The Crane shall be stable and shall not sustain any damage in the case when emergency push button is pressed during gantry travel with a rated speed with a 41 tonnes rated load suspended at the maximum lift height position in an operational gantry gradient of not more than two percent.
All other loading conditions forming the design criteria other than specified in this Specification shall be submitted to the Purchaser for review.
NOT USED
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Noise Control The Crane’s noise level shall conform to the following requirements: -
2-10.
(1)
The noise level inside the operator’s cab shall be below 75dB during operation, with air conditioner on, and doors and windows closed condition.
(2)
The noise level measured at a distance of 1 meter from any corner of the machinery house shall be below 85 dB
Operationally Critical Components (1)
The Contractor shall submit the inspection and replacement schedule for the operationally critical components to the Purchaser.
(2)
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 joints where failure could have catastrophic consequences).
3. Crane Structural Specification 3-1.
General Requirement
3-1.1. Deflection or oscillation of the structure shall not affect the Crane capacity and operating efficiency (particularly spreader positioning ability). 3-1.2. The main structure shall be designed so as not to sustain damage in the event of puncture of any one tyre. 3-1.3. The girder shall be designed to allow operator to escape from the operator’s cab to the walkway of the girder at any point of trolley travel range, in an emergency. The walkways along the full length of the girder members shall be mounted off the side of the girder members and not less than 800mm below the top flange of the girder. The “Power Chain” may also be mounted between the side of the girder and the walkway to afford protection against falling from the walkway to the inside of the crane. 3-1.4. Trolley rails shall comprise a standard rail section and be fitted to the girder through rail clips and a proven fastening system. The rail joints shall be welded and ground smooth. 3-1.5. The following equipment/machinery shall be fitted to the main structure. (1) (2) (3) (4)
Gantry drive machineries including 90 degree and an intermediate angle (for spin turn) steering mechanisms. Control panels and panel house. Starting equipment and control panel. Trolley power feeding system.
3-1.6. The following fittings shall be fitted to the main structure. (1)
Walkway, stairs, ladders and platforms (refer to 6-1).
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3-2.
Lighting for operation and for walkway, stairs, ladders and platforms (refer to 6-2) Intercom telephones (refer to 5-6.1). Travel warning device (refer to 6-5.1). Speakers and flashing strobe light at each of 4-corners. Service outlet (refer to 6-7). Emergency stop buttons (refer to 6-6). Four fire extinguishers; 5kg CO2 capacity, 1 at outside of panel house, 1 at trolley platform and one 2 kg at outside the driver’s cab.
Material
3-2.1 The whole of the materials used in the Crane shall be new, of the best quality and suitable for the duty intended. Mill certificates shall be obtained and records strictly maintained to match these to the various Crane sections produced during crane manufacture. The steel materials for all the stress members shall be selected from the materials which specification includes the notch toughness requirement at or below -20 deg. Celsius. 3-2.2 The steel used for the manufacture of the Crane shall conform as a minimum to one or more of the following standards most recent issue. Deutsche Industrie Norman (DIN) British Standards (BS) Japanese Industry Standards (JIS) American Standards (ASTM/API) Chinese Standard (GB) 3-2.3 Welded Joints Stresses at weld throats shall be calculated as the vector sum of the individual stresses applied to the weld throat. For fatigue design when calculating the stress range, the vector difference of the greatest and least vector sum stress may be used instead of the algebraic difference. Welded joint design shall conform to BS 5400: Part 10, BS 7608, and for static loads only AWS D1.1 - 2000. 3-2.4 Bolted Joints Bolted joint design shall conform to BS 5400: Part 10, BS 7608, and to the AISC Specification using 0.9 times AISC allowable values. Prying action due to distortion of the connection details shall be considered. Bolts subject to fluctuating tensile stress shall be checked according to BS 7608. Bolts governed by fatigue strength shall comply with ASTM A325. Structural bolted joints are not allowed unless approved in writing by Purchaser. 3-2.5 Pin Joint An effective lubrication system shall be provided for each pin Joint to prevent its seizure within the life of the structure. 3-2.6 Machinery bases Appendix 1 - Technical Specification Feb 2012
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All main drive machinery bases (Motors, brakes, gearboxes, bearing housings/pedestals, etc.) shall be machined; after all adjacent welding has been completed. All machinery mounts shall have adjustable locking screws for horizontal adjustment (forward and backwards, side to side) for the purposes of the equipment alignment. 3-2.7 Edge Finish All edges of structures shall be free from sharp edges or burrs. 3-2.8 Surface Finish (1)
All welding spatters shall be removed from structure surfaces.
(2)
The metal surfaces shall be cleaned and touched up with primer immediately after cooling down to prevent oxidation and the formation of rust.
3-2.9 Draining and Inspection Manhole
3-3.
(1)
All the structure shall be designed to drain water effectively. Any draining water shall not affect safety of operations or maintenance work under heavy rain. No water trap shall be allowed in any part of the crane structure. Adequate numbers of inspection manholes shall also be installed.
(3)
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.
Calculations
3-3.1 Submission to Purchaser
3-4.
(1)
Wheel loads, stability calculations, braking capacity and distance calculations for all motions, and peak power consumption calculations shall be submitted for Purchaser's review prior to commencement of detailed design.
(2)
Other data or design calculations at various stages of design shall be submitted from time to time as requested by the Purchaser as part of review process.
Loads
3-4.1 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. 3-4.2 The Contractor shall comply with BS2573: Part 1: 1983, Rules for the Design of Cranes.
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3-6.
Members Subject To Buckling (1)
The design of columns, beam columns, frames and beams subject to lateral buckling shall be in accordance with the AISC Specification. The design of flat plates, curved plates, and plate stiffeners shall be in accordance with a recognized method that considers the combined effect of shear, compression and flexure. The effects of biaxial stresses shall be included. Criteria given in FEM are acceptable.
(2)
For all structural plates, the ratio of the minimum clear dimension, b, to thickness, t, shall not exceed 60, i.e. 60 ≥ b/t.
(3)
The local buckling criteria given in the AISC and AISE standards are unacceptable because biaxial and combined stress effects are ignored. The choice of a practical method of calculation is left to the Contractor who shall state the origin of the method chosen.
(4)
Tension field action may be included for evaluating pure shear resistance during overload and stowed conditions, provided the tension field shear panels are designed for a factor of safety against collapse of at least 1.25. Tension field panels shall be assumed to have zero capacity to resist bending, bearing or axial stress.
Fatigue Design Criteria
3-6.1 Fatigue design shall generally conform to the requirements of BS 5400: Part 10 1980, except as modified in this section. Modifications to BS 5400 pertain primarily to the deletion of provisions that apply to bridges only, insertion of design load spectra applicable to container cranes and the addition of provisions for tubular joints. 3-6.2 When not specified in BS 5400, the requirements and recommendations in BS 7608 shall be followed. 3-7.
Connection Designs (1)
Connections shall be designed to resist artificial local loads imposed by a stress equal to the average of the allowable and the calculated stress, but they shall be designed for not less than 75% of the allowable strength of the member. Notice that whenever the calculated stresses are less than 50% of the allowable stress, the 75% requirement applies.
(2)
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.
(3)
Welded joint design shall conform to BS 5400: Part 10, BS 7608, and AWS D1.1, Section 9, except for Sections 9.2.1, 9.3, 9.4, 9.5 and 9.6 which contain information that is covered elsewhere in these Specifications.
(4)
Bolted joint design shall conform to BS5400: Part 10, BS 7608. Prying action due to distortion of the connection details shall be considered. Bolts subject to fluctuating tensile stress shall be checked according to BS 7608.
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3-8.
Gantry Structure Stiffness
3-8.1. Deflection or oscillation of the structure shall not affect the Crane capacity and operating efficiency (particularly spreader positioning ability). 3-8.2 The horizontal displacement at the girder level due to full acceleration or deceleration of trolley with a rated load, or full acceleration or deceleration of trolley while suspending a rated load at the maximum upper limit position, shall not exceed 30mm. 3-8.3 The main structure shall be designed so as not to sustain damage in the event of puncture of any one tyre. 3-9.
Camber The camber of the two main girders should make due allowance for deflection under load.
3-10.
Trolley Rails & Rail Fixing Trolley rails shall comprise a standard rail section and be fitted to the girder through rail clips and a proven fastening system. The trolley rails shall be supported by the girders with Gantrex type rail pads and steel plate to reduce vibration of trolley. The rail joints shall be welded and ground smooth.
3-11.
Workmanship
3-11.1 The whole of the structural fabrication and assembly shall be done in a through, workmanlike manner and shall follow the best modern practices in the manufacture of high-grade structures. The work shall be performed by workmen suitably skilled in their particular trades. 3-11.2 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 approved by the Purchaser. 3-11.3 Certification of the qualifications of each individual welder shall be submitted by the Contractor. Welds installed using unqualified procedures or welding performed by noncertified welders shall be subject to removal by the Contractor at his own expense. 3-11.4 The Contractor’s Quality Assurance team shall be required to keep an accurate log of the qualified welders on the job. This log will be subjected to examination at any time by the Purchaser or their site representative. 3-11.5 Welding procedures may be AWS prequalified or they shall be qualified in accordance with AWS by the approved testing laboratory. 3-11.6 Written procedures for all welded joints shall be submitted to the Purchaser. Procedures shall identify required inspections that may be critical to the specific welds. Procedures shall be identified on the drawings and shall be made available to all appropriate shop personnel. Procedures shall be prepared in a manner such that shop personnel can understand and use them without referencing the applicable codes. Appendix 1 - Technical Specification Feb 2012
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3-11.7 These requirements shall apply to all welding, burning, cutting and grinding on the crane structure. This includes welds for erection attachment, whether or not they are removed, and electrical clips and conduit supports. 3-11.8 The Contractor’s Quality Assurance team will ensure that all correct welding procedures are strictly followed by the welding personnel. Any welding work being seen to not meet accepted procedures shall be stopped immediately and logged as a non-conformance report. Continuation of this welding will then be subject to approval by the Purchaser’s Representative on site. 3-11.9 The Contractor’s Quality Assurance team will ensure that all welding during low temperatures is carried out under an appropriated welding procedure, as far as practicable, within an enclosed canopy to provide a controlled environment. The use of correct preheating procedures and welding rod hot boxes is essential and will be closely monitored by the Purchaser’s Representative. 3-11.10 To facilitate removal / replacement or regular maintenance, all unpainted metal surfaces shall be treated with an appropriate approved anti-corrosion treatment. i) Structural Pins-“Copper Kote”, “Copper-slip”, “Moly-slip”, or “Molybonum di sulphide” ii) Bearings, housings-grease iii) Tapped holes-“Never-Seize” iv) Bolts-“Never-Seize” 3-11.11 A325 and A490 bolts that are 7/8” (22mm) in diameter or less may be tightened to the required tension by any standard method. A325 and A490 bolts greater than 7/8” (22mm) diameter shall be tightened to the required tension by the calibrated wrench method only. The following supplemental requirements shall apply in addition to the requirements of the Specifications to structural joints using ASTM A325 or A490 bolts. (i) (ii)
(iii) (iv) (v)
(vi)
(vii)
Hardened washers shall be placed under the both the head and the nut. The contractor shall notify the Engineer if the highest and lowest torques measured during wrench calibration varies by more than 10 percent of the lowest torque, so they may develop the appropriate solution. If the range exceeds this tolerance, filed tightening may be erratic. The “snug tight” tension shall be approximately 50 percent of the specified tension and shall be achieved using a calibrated wrench. The sequence of bolt tensioning shall be shown on the drawings. After the snug tight condition is achieved, an initial tension of 75 percent of the final tension shall be developed in all the bolts. Only then shall the final tension be developed The final tension shall be verified by testing 10 percent of the bolts after all the bolts are tensioned. If the verification indicates loss of tension in some bolts, the Contractor shall notify the Purchaser. The Purchaser and the Contractor will develop the appropriate action. The flange contact bearing surfaces shall have at least 75% of the bearing crosssectional areas in contact. The outer surface of the flanges shall fit within 0.010in. (0.25mm) for 75% of the length of the edge and not more than 1/32in. (1mm) for the remaining 25% of the length.
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Bolt tension may be verified at locations selected by the Purchaser’s Representative. Bolt tension verification shall be performed by the Contractor in the present of the Purchaser’s Representative and in such a manner that the torque can be wrench gage read during verification.
3-11.12 Weld Testing and Inspection All welds shall be subjected to inspection by methods and extent, reflecting the critical nature of the welded connection. Welds shall meet the requirements for cyclically loaded structures of AWS D1.1-latest version. The specific method of weld inspections shall be shown on the drawings. Weld inspection procedures shall be submitted to the Purchaser. Testing, which shall be at the Contractors expense is required as follows:Weld All Welds Full Penetration Butt Welds (Compression) Full Penetration Butt Welds (Tension-as determined by stress levels due to operating loads combinations)
Type of Testing/Inspection 100% Visual 100% UT 1 X Exposure ≈ 400 mm per weld 100% UT 10% of length RT or 1 X exposure per weld length ≈ 400 mm which ever is the greater 100% UT 100% of length RT
Acceptance Criteria AWS D1.1-latest version AWS D1.1-latest version
AWS D1.1-latest version
Full Penetration Butt Welds in AWS D1.1-latest version Tension Bars (if applicable) Fillet Welds or Partial AWS D1.1-latest version Penetration Welds On FCM 100% of length MT On Non-FCM 10% of length MT (as nominated by the Purchaser’s Representative) Rejection of any portion of a weld inspected on a less than 100% basis shall require inspection of 100% of that weld. Ultrasonic testing of tension welds shall be done by or under the direct supervision of ASNT Certified LEVEL III personnel. 3-12.
Quality Control of Structure Fabrication
3-12.1 Quality Control shall be the responsibility of the Contractor. The Contractor must implement a written quality control programme and this programme shall be submitted to the Purchaser within 1 month of the date of the Agreement for comment. 3-12.2 The quality control programme shall follow the applicable requirements laid out in 7-1.4. For the structure fabrication this shall include but not be limited to the following: -
Inventory of incoming material, consumables components and machinery.
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Traceability procedures for materials together with traceability identification codes, which shall be serial and indexed to the controlled manufacturing procedures.
-
Cutting, fit up, welding, forming and dimensions of structural components.
-
Welding and inspection procedures identifying clearly the type and extent of NDT inspection carried out on the cranes structure.
-
Welding and inspection personnel qualification and certification (see 3-11).
-
Welding, machining, measuring and inspection equipment maintenance and calibration.
-
Machining, finish surfaces, bolting tensioning procedures.
-
Procedures for non-conformance (NCR) and Punch List (PL) reporting and rectification of defects.
-
Design and manufacturing drawing control and procedures for revisions, updates and reissue of drawings
-
Procedures for material cleaning, preparation blasting and painting.
A copy of a company standard QA manual prepared for the manufacture of similar cranes shall be submitted with the tender for examination as part of the tender assessment. 3-13.
Temporary Structures
3-13.1 Temporary Structures Connections details of temporary structures (such as lifting lugs, etc) fitted onto Operationally Critical Components must be reviewed by the Purchaser. 3-13.2 Sea-Fastening At least three months before the intended shipment, the Contractor shall submit seafastening structure connection details to crane structures for the Purchaser’s review, consideration and acceptance or otherwise. The submission shall also provide details of the proposed methods for removal of the temporary bracings and fixings. The Purchaser prefers a system that minimizes any “Hot Work” at the site to minimize the risk of damage to paintwork and the need for extensive paint system repairs. 4. Functional Systems Devices & Equipment 4-1.
Main Hoist
4-1.1. Main Hoist Drive (1)
The main hoist drive reduction gearbox shall be totally enclosed, oil bath lubricated type.
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(2)
Two AC servo operated disc brakes shall be fitted on the high speed pinion shaft. Each brake shall be rated at 150% full load motor torque and shall be capable of stopping and holding the maximum rated load from full rated speed. Final adjustment of brake torque shall be carried out during commissioning using appropriate calibration equipment.
(3)
Overspeed switches shall be fitted to the main hoist drums to shut down the drive and set the brakes if the load exceeds 115% of rated speed. Geared limit switch unit for the main hoist shall be electromagnetic type.
(4)
Pulse generator encoders shall be installed on the main hoist drums.
(5)
Acceleration from zero speed to a maximum speed or deceleration to zero speed shall be smooth and steeples for any load under spreader. (See 2-7. 1 (8) for speed/time requirements.).
(6)
There shall be two stages of the upper main hoist slow down to cater for an empty spreader and a loaded container in order to enhance performance of container handling. In the condition of empty spreader the hoist shall incorporate a lower slow down whilst the loaded spreader condition shall incorporate a higher slow down. Under each condition the emergency limit position shall not be tripped. The Contractor shall propose a method statement with calculations for the Purchaser’s review.
(7)
Frequent inching operation and plugging operation shall be catered for in the design.
(8)
The main hoist motor and brakes shall be fitted inside weather-proof enclosure. The enclosure shall be designed to provide for ease of motor and brake maintenance with suitable removable doors. Thermal cycling due to hot and cold climatic changes shall also be considered within the design of the enclosure.
(9)
The enclosure shall be equipped with an exhaust fan. Cool air may be drawn from any opening beneath the main hoist motor housing; however water shall not be drawn into the enclosure under any circumstances.
(10)
The main hoist wire ropes to the headblock shall not interfere with the stacked containers when the Crane is working on a single slot between two - five high stacks. Outside wire ropes shall be stationary during hoisting and lowering motion.
(11)
The main hoist reeving arrangement shall be such that these are no imbalance in the horizontal components of the resultant forces in the main hoist ropes, at the headblock-sheave level.
(12)
Load cells shall be provided for sensing the weight of the container suspended under the spreader. Display of the weight of the container shall be installed inside the operator’s cabin. The accuracy of the load cell reading shall be within +/-2%.
4-1.2. (Refer to 2-7. 1. (10))
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The Anti-sway/yaw device or sway/yaw damping system shall work effectively for a short distance travel as well as for a stop after full deceleration. The operation of the system shall not alter the elevation of the spreader with or without load at any height.
(2)
A simple mechanical anti-sway system which is a proven design and which preferably shall be based on a main hoist eight (8) single fall rope reeving system. Hydraulic type anti-sway system is not acceptable.
(3)
Details of the construction and performance of the mechanical anti-sway system shall be submitted with the tender document.
4-1.3. Skew Control
4-2.
(1)
The Spreader skew motion to be controllable up to its maximum angle of ±5 degrees. Speed ½degree/sec.
(2)
One push button switch on the control console shall automatically correct the spreader position to a ‘Zero skew’ position.
(2)
“Zero skew” position shall be indicated with a lamp on the panel in cab.
(4)
Screw jack mechanism shall be adopted for the skew control.
(5)
Limit Switch shall be installed to prevent over travel of the ball screw-jacks.
Trolley, Trolley Drive
4-2.1. Trolley Frame (1)
The trolley frame shall be fitted with the main hoist machinery, trolley drive machinery, anti-sway device, skewing device, operator’s cab, and buffers for forward motion and backward motion collision impact. The buffers shall be capable of absorbing and dissipating the impact of collision at full speed with rated load (refer to 5-1.13).
(2)
The trolley frame shall be fitted with safety lugs which shall support the trolley in case of wheel shaft failure.
(3)
The trolley frame shall have adequate jacking points for trolley wheel replacement work.
(4)
The trolley frame shall provide an emergency access from the operator’s cab to the walkways of the girder at any point of trolley travel range.
(5)
The trolley drive system, and wheel, shaft and bearing system shall be designed to facilitate fast replacement of components at any point on the girder.
(6)
The trolley frame shall be provided within safe maintenance platform and access to all of its components and machineries for maintenance.
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 27 (7)
The trolley frame shall be equipped with drop-pin type storm/gale stowage pin device. The stowage pin device shall allow a one-man operation to engage / disengage pins on both sides of the trolley from the girder. The stowage pin device shall allow approx. ±100mm trolley positioning allowance. The girder shall be marked for the operator to spot the storm/gale stowage position. The dropping of the stowage pin shall prohibit the trolley motion.
(8)
A mirror of non-breakable material construction shall be provided to assist viewing the far side of lifted container in a slot underside of the trolley frame.
(9)
Four pairs of heavy duty side guide rollers shall be fitted on both sides of the trolley frame at fore and aft to guide the trolley movement on the rail without running of misaligned trolley wheel due to uneven track way. The roller bearing of the rail side guide shall be heavy duty and design to carry calculated and imposed forces without damage.
4-2.2. Trolley Drive (1)
Trolley shall be driven by conventional “driven-wheel” system.
(2)
The gearbox input shaft shall be fitted with an AC servo operated disc brake rated at 150% full load motor torque. The installation of the brakes shall allow all round access for maintenance.
(3)
The reduction gears shall be totally enclosed, oil bath lubricated type.
(4)
Geared limit switch drive shall be by a proper gear reducer and a flexible coupling. Chain drive is not allowed.
(5)
Frequent inching operation and plugging operation shall be catered for in the design.
(6)
The trolley drive system design shall take into account effects of ±2% cross grades of the runway, and additional grades caused by deflection of the tyre due to moving loads. For the acceleration and deceleration time requirements refer to 2-7.1. (8).
4-2.3. Sway and Position Control (1)
The sway control shall bring the spreader to a stop following full deceleration of the trolley from full speed with any operational load to within +/- 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 cycles of sway.
4-2.4. Power Feeder (Power Chain System) (1)
An approved low noise weatherproof, heavy duty energy chain system design for rated speed of the trolley shall be proved from the junction boxes at the end of the fixed trolley girder to a similar junction boxes mounted on the moving trolley.
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 28 (2)
The energy chain shall have extra slots for extra cables (in addition to the specified spare wires) and shall be designed so replacement and cable replacement can be accomplished without dismantling or taking down the carrier assembly.
(3)
The chain design shall afford complete segregation of cables for power, control and data transmission. Cables shall be suitably rated, extra flexible round or flat form adequately sized (minimum wire diameter of 1.5mm square). The installation shall not generate mechanical damage to cables and be such that bend radius specified by the cable manufacturer is not exceeded. The installation, including junction box(es) terminations shall be EMC compliant. The required quantity of each size and type of conductor shall be provided plus with the exception of AC Motor power cables, 25% of each as spares. The supplier of the Energy Chain shall also supply the cables and cable glands.
4-3.
(4)
Access to the energy chain system shall be by a permanent walkway and platform. Manufacturer’s recommendations shall be adhered to strictly for installation detail and tolerances. A platform on the trolley can be used for access to the energy chain providing it provides safe access and hand rails are fitted.
(5)
The system design shall not generate water traps internally, between cables and chain material or externally between chain material or crane structure.
(6)
Two (2) spare fiber optical cables (62.5/ 125 multimode) shall be provided and installed from Driver’s cabin to the Electrical House.
Gantry Drive
4-3.1. Gantry Drive (1)
Eight (8) - rubber tyred wheels shall be provided for gantry drive. All the tyres shall be tubeless rubber tyres, minimum 40 ply.
(2)
Four (4) gantry motors shall be used for the gantry travel system. It is preferred that each gantry motor is driven by individual drive. The drives and motors shall be sized to meet the operational requirements for future possible installation of the AGSS.
(3)
The gantry drive, motors and brake system shall provide sufficient thermal capacity, torque and traction for all operating condition.
(4)
The gantry motor and brake shall be rated to be able to safely operate the unladen crane on a slope of ±3% with rated speed. The brake capacity to be sufficient to stop the Crane whilst not sustaining damages in the event that an emergency stop button is pressed during full-speed gantry travelling with 25 m/s tail wind.
(5)
Wheel yoke and equalizer beams shall be designed to allow simple removal of any wheel. Easily identifiable jacking points shall be provided on the wheel yoke. The
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 29 Jacking load and position shall be reviewed by the Purchaser to prevent overloading of crane runways. (6)
Wheels, dual chains and gears shall be fitted with safety guards. The guards or covers shall have greasing windows.
(7)
Robust tyre guards shall be provided on all wheels.
(8)
A sleeve shall be fitted between the gantry equalizer beam and the yoke wheel assembly enclosing the vertical yoke shaft. This sleeve shall be designed and fitted to all yoke shafts to allow for the bending movement of the gantry motion to be transmitted from the yoke shaft to the sleeve to eliminate shaft breakage.
(9)
All vertical gantry motor disc brake assemblies shall be fitted with a sealed steel cover fixed permanently by bolts in order to prevent water ingress.
4-3.2. Steering (1)
Proper manual control steering system for running on crane runways (both longitudinal and cross travel directions) shall be provided.
(2)
The drive and steering system shall be designed taking into account effects of ±1% cross grades with a rated load at any trolley position. Steering guide bars pointing at the inner edge of pathway of 1,500 mm wide shall be fitted on each wheel close to the ground level. These guide bars must be clearly visible by the operator.
4-3.3. Right Angle & Pivot Turn (1)
Each wheel shall be able to be turned 90 degrees for cross travel, or an intermediate angle to allow spin turn of the Crane for shifting the crane to another lane. The turning of the wheels shall be controlled by the operator in the cab. Positive locks to keep the wheel in position parallel, at an intermediate angle, or at 90 degrees to the sill beams shall be provided. An audible signal shall be given in the cab when all wheels have fully rotated and locked in the designated position. The maximum time to turn the wheels through 90 degrees shall be 70 seconds. Proximity switches shall be used for installation of the wheel turn and locking mechanism.
(2)
The limit switches for the hydraulic wheel jack system shall be “external type”.
4-3.4. Gantry Skew Control To enable better gantry skew control, each gantry motor shall be driven by individual drive for the gantry travel system. 4-4.
NOT USED
4-5.
Electrical House, Control Panel, Regenerative E.M.F. Absorbing Resistors
4-5.1. General Construction
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 30 (1)
The electrical control panels shall be housed in a walk-in type dust and weather proof panel house which is installed on top of cab end sill beam.
(2)
Special consideration shall be given for corrosion protection of the panel house and weather protection of resistor banks.
4-5.2. E-House Temperature Control The inside temperature of the panel house shall be maintained below 240C. Air intakes to the house or panels shall be filtered by non-corrosion washable mechanical filters. Over/under temperature protection with control interlock shall be provided. 4-5.3. Emergency Lights and Fire Control (1)
The panel house shall be equipped with ample lightings for maintenance work, and also battery operated emergency lights with door switch for unexpected shut off. The emergency lights should be last for at least 1.5 hours.
(2)
One (1) - 5 Kg portable C02 fire extinguishers shall be provided outside the panel house in a wall mounted cabinet.
4-5.4. Back Power Absorbing Resistors Regenerated back E.M.F. absorbing resistors shall be installed outside the panel house to avoid affecting the inside temperature of the panel house. 4-5.5. Provision for Future Installation NOT USED. 4-5.6. Control Panel (in the Electrical house)
4-6.
(1)
The control panels shall be of steel construction hinged door lockable type with full access from the front. Each panel shall be equipped with lights to facilitate maintenance work.
(2)
The panels with electronic control units shall be designed to maintain the inside air temperature below 40 0C at all times. Any air inlet for cooling air shall be equipped with air filters.
(3)
Each motion control panel shall be fitted with motor frequency meter, motor RPM meter, ampere meter and volt meters which indicate operating frequency, motor revolution, motor current, reference voltage and motor voltage.
Operator’s Cab, Checker’s Cab
4-6.1. Construction General (1)
The cabs shall be constructed of zinc plated mild steel, double bottom, double ceiling and double wall, fire proof, fully air conditioned and heated. The cab shall be water tight as operated in the conditions as specified in previous clauses.
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 31
(2)
The cab shall be fitted with a drain hole on the floor to drain out water due to rain ingress or cleaner’s hose water. A handy plug shall be fitted into the drain hole to avoid dropping of small materials and it shall be almost flush on surface of the floor.
(3)
The design of the cab to allow the operator to clean outside of all the glasses safely.
(4)
The cab connection to the trolley shall include anti-vibration mounts to reduce impact and vibration to the operator.
(5)
Shields shall be fitted above the windscreen to prevent wire rope lubricants from splashing onto the glass.
(6)
The operator’s cab shall be bolt mounted to the trolley and fitted with safety dropstop lugs, which shall prevent the cab from dropping off the trolley in case of supporting failure.
(7)
Sun visor shall be installed on all the window. The type of sun visor shall be approved by the Purchaser.
4-6.2. Cab Access Cab access shall be from a hinged door on one side of the cab. The door shall be self closing, with a latch to keep the door in open position. Electrical and mechanical interlock shall be provided to prohibit the trolley movement when the function is triggered. The access gates shall also be locked (closed) when the trolley is not at the trolley access platform. 4-6.3. Window Visibility Cab windows to provide as much views as possible including lower rear view. The rear side of the cab shall have a full height window. It shall protect the operator from the glare of the sun with fine screen type roll up sun shade on upper front, side and rear windows which have characteristics to allow vision through it. Window glass shall be non-glare and scratch resistant that meets the requirements of BS 857 safety glass with their both surfaces being flat, parallel and fine polished, giving clear undistorted vision. Full direct vision of a ground slot between two - 6 high stacks immediately below the front bottom window shall be ensured without supplemental devices, from the normal seating position of the operator. The front and bottom window shall be laid out symmetrical about the Crane centreline in left and right direction. The design of operator’s cab shall allow replacement of window glass to be carried out inside the cab. Protection shall be installed to prevent the window glass from falling off or out. 4-6.4. Cab Dimension Minimum inside floor width of the cab shall to be 2,500mm and length (fore and aft) 2,000mm excluding bottom glass frame.
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 32
4-6.5. Cab Fittings The operator’s cab shall be fitted with the following fittings and shall not in any way obstruct operator’s view required for Crane Operation. (1)
One right-hand and one left-hand control consoles. The consoles together with the chair shall be ergonomically laid out to minimize fatigue of the operator. For detailed requirements refer to 5-4.6.
(2)
One upholstered operator’s chair. The chair height and position forward and backward shall be adjustable to best suit each operator (oriental size). The operator’s console and chair shall be fixed (non-rotatable) and mounted on the same base. The access to the seat shall be via outside and front of control console.
(3)
Spreader ‘Landing’ (Amber) and ‘Lock’ (Red), ‘Unlock’ (Green) indicating lamps in a box fitted at lower (middle) front part of the cab.
(4)
Window wipers and washers Wipers and washers to ensure the view angle required for operation. Wipers and washers shall be fitted to front and side windows.
(5)
Communication equipment (refer to 5-6).
(6)
Split type air conditioning unit. Minimum 12,000 BTU Hr. Capacity.
(7)
Service outlet (two 13 amp, 220V, 50Hz with NFB).
(8)
Lights and light switches.
(9)
A foot rests for the operator (position to be adjustable for each operator).
(10)
D. C. outlet for radio communication equipment See Section 5-3.2 (6), (7) for details of this power supply complete with a battery relay to cut off battery supply after 300 - 500 seconds.
(11)
3 KW capacity heater (flat type) with manual heat level adjuster (independent of air conditioning unit).
(12)
Safety bars wherever necessary to prevent accidental fall of the operator or maintenance staff.
(13)
Siren foot switch (or call for emergency warning sound). For details see 6-5.1(2) for full description on the common amplifier.
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 33 (14)
One (1) - 2 kg CO2 fire extinguisher at outside near the door.
(15)
2 Spare MCB’s 220V, 1-phase, 13 Amp capacity.
(16)
Coat hook.
(17)
A foldable chair embedded into the wall at suitable level for use by operator trainer or a second operator inside the cab. The foldable chair shall be able to swing back to the wall with a latch when not in use and shall mount flush on the wall surface.
(18)
Spreader height indicator.
(19)
Container load indicator.
(20)
Demisters to lower front and floor windows shall be installed to cover full glass area.
4-6.6. Checker’s Cab NOT USED 4-7.
Personnel Lift NOT USED.
4-8.
Headblock
4-8.1. Headblock The Contractor shall propose a direct reeve-in type spreader, which does not have a separate headblock frame. (See 4-9.2 below). The headblock shall be designed fully adaptable to the existing spreaders (Bromma YSX40E) using for operation. (1)
Fittings The major fittings on the spreader are as listed below. All components on the headblock shall be laid out to maximise operator’s front view. The dimensions, sizes for all bolts, nuts, couplings etc shall be SI units (metric). i)
Main hoist sheave blocks. Arrangement to minimize the spreader rocking motion.
ii)
Baloney cable tub with guide ring.
iii)
Platform with handrails with access openings. Necessary access ladders to the ladders on the spreader shall be fitted.
iv)
A set of quick release pins and linkage to connect spreader. The pins shall be positively locked in either ‘Locked’ or ‘Unlocked’ position, which will be clearly indicated on the frame to be seen from outside.
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 34
Quick release pins shall be designed as a permanent component, which do not require replacement due to fatigue for the life of the Crane. The fatigue loading conditions shall be as specified in 2-7.8. For quick release pins type, each pin shall be fitted with a limit switch to detect the completely locked condition. Two triangular type guiding pieces on both sides of the spreader to match the triangular slots on headblock shall be used to guide the headblock onto the spreader so that the pins can go through easily to shorten the time for spreader replacement. Each pin shall be fitted with a seat and a handle for pushing in and pulling out operation. A special device to pull down the head block shall be provided to reduce the time for the spreader replacement process. v)
An electrical connector for the feeder cable for the spreader. For standardization purpose, the electrical connector shall be ODU type 310 55 poles.
vi)
Anti-sway or skew devices, if any.
vii)
Limit switches, junction boxes, etc.
(2)
All the fittings shall be securely fitted to the spreader to withstand frequent impact of landing.
(3)
The design to allow full access to the spreader terminal boxes and spreader control unit from either front or rear side for manual test operation while the spreader is engaged to the headblock. An interface shall be provided for remote accessing the spreader control system and shall enable full simulation and operation of all functions of the spreader at site during fault diagnostic by using the portal control panel (Refer to 6-9.4 (1)).
4-8.2. Two Wire (Bus) System CANOpen type communication system shall be provided for spreader signal communication between spreader and spreader control panel installed in the operator cabin. The two wire system shall also be able to communicate with the IFM system using on the existing spreaders for interchanging. 4-8.3. Baloney Cable
4-9.
(1)
Baloney cable shall have at least 42 nos. 3.5 sq. mm conductor wires.
(2)
All the wire connection shall be designed to withstand frequent impact of landing.
Spreader, Hook Beam One telescopic spreader shall be provided with the crane. The configuration and rated capacity of the spreader shall be as referred to in 2-7.1 (4). The spreader connections electrically and mechanically shall be fully compatible and interchangeable with the spreaders (Bromma YSX40E) currently operating in the terminal. The Contractor is
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 35 required to verify and hence design for the interchange-ability of all spreaders. The spreader shall have the following general requirements: 4-9.1. Single Lift Telescopic Spreader (1)
(2)
Spreader Frame i)
The structural frame shall be designed and constructed to have adequate safety factors to prevent premature fatigue failure within 2 million load cycles for which the criteria is set out in 2-7.8. Flared guides shall be provided at 4 corners of upper surface of the frame if headblock design is applied. The bottom plate of the twist lock box shall have a hardness of HS26 or more to reduce wear.
ii)
Access ladders from front and rear side to the platform on top of the head block shall be fitted to the main frame.
iii)
The spreader frame design to allow 100mm clearance between the lowest point of spreader frame and top of container when the spreader is landed on a container.
Spreader Hydraulic Unit NOT USED.
(3)
Spreader Twist Lock i)
Twist lock shape to fit ISO corner fitting.
ii)
Twist locks shall be floating type and fitted with sleeve type twist lock guides. A greasing nipple shall be fitted at a suitable position of the sleeve guide so that grease can be injected into the sleeve for lubrication between the sleeve and twist lock shank. Spherical washer and split ring collar (collet type) load bearing system shall be provided to transmit the twist lock load to the spreader end beam.
iii)
Twist lock movement from ‘Unlock’ position to ‘Lock’ position shall be prohibited by a mechanical and electrical interlocks unless four twist locks are confirmed to be fully inserted into corner fittings and the spreader is landed onto a container.
iv)
Twistlock movement from ‘Lock’ position to ‘Unlock’ position shall be prohibited by a mechanical and electrical interlocks unless complete landing of the spreader is confirmed. Main hoist motion is to be prohibited unless physical positions of all of the twist locks match the ‘Lock’ or ‘Unlock’ command switch position on the control console. A method of direct twist lock sensing is preferred.
v)
For spreader indication lamps in the cab, refer to 4-6.5. (3)
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 36
(4)
(5)
vi)
The design life of twist lock main assembly shall be minimum 2 million cycles.
vii)
NOT USED.
viii)
The hoisting motion shall stop immediately if only one side (2 twist locks) is locked inside two corner castings and the other side (2 twist locks) is locked outside the corner casting.
ix)
A twist lock counter shall be provided on the spreader. For function refer to 4-9.1(10).
Spreader Flipper, Side Guides i)
Four (4) - power operated side guides (easily and quickly be removable) shall be provided.
ii)
Side guides shall be capable of handling 8-0” wide containers and 8’-6” wide containers with corner fittings at 40’ container lifting points. The side guides must act on corner fittings of the containers. Changeover to 8’-0” or 8’-6” shall be controlled from the operator’s cab. Maximum width of side guides to conform to the dimensional restriction as stated in 2-7.2 (3).
Spreader Telescoping i)
Telescoping guide shoes or rollers shall be designed to allow easy and quick access and simple adjustment. Replacement of guide shoes shall be able to be performed without dismantling main frames.
ii)
Mechanical stoppers shall be fitted for 20’ and 40’ positions. Such stoppers shall be automatically engaged following operator’s command for desired spreader length.
iii)
Operating time for extension or retraction shall be less than 30 sec for 20’40’. The telescopic motion shall allow for approx. 3 seconds slow motion period after start and before stop of telescopic motion to minimise impact of start/stop on the driving system.
iv)
(6)
Telescoping mechanism shall be fitted at middle of the 20'-40' spreader complete with electrical and mechanical equipment. All this equipment shall be easily accessible for minimum down time.
Spreader Landing Probe i)
The landing probe shall positively detect the landing of the spreader on the container.
ii)
The landing probe shall be arranged to detect landing on a flat circular surface area of 150mm diameter around twist lock hole.
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 37
(7)
iii)
The landing probe diameter shall be 40mmφ minimum.
iv)
The hole for the landing probe on the bottom plate of twist lock box shall be chamfered to prevent jamming of the probe.
Spreader Lifting Lugs Lifting lugs for handling a damaged container or an odd shaped cargo with slings and shackles shall be fitted at four corners near each twist lock and 2 each at about one third point from each end of the main frame (total 8 lugs on spreader).
(8)
Spreader Protection i)
All mechanical and electrical components fitted on the spreader shall be protected from frequent impact and vibration of operation. All related fasteners shall be anti-loosening type.
ii)
All the electrical cables connected to the moving parts of the spreader shall be properly protected from damages due to interferences with stationary parts.
iii)
All the electrical parts including solenoid valve shall be protected from the weather.
iv)
Mechanical twist lock counter and spreader operating hour meters shall be fitted on the spreader.
v)
All solenoids (with LED indicators) shall be protected from electrical surge by use of proper surge absorbers.
vi)
Each individual position sensing proximity switch for twist lock “Locked” and “Unlocked” with LED indicator positioning shall be connected individually to the I/O unit in order to prevent any mis-indication and unsafe movement of twist locks caused by short circuit of any proximity switches failed during operation. Such short circuit status of a failed proximity switch shall immediately prohibit the main hoist or lower function until a new replacement proximity switch is in place. Alternatively the Contractor is allowed to use ‘fail to safe’ roller lever type limit switches
vii)
(9)
The Contractor shall consider that the landing probes at the 4 corners of the spreader can be fitted with 2 limit switches to detect empty spreader condition, landed condition and loaded condition with a container under the spreader. The electrical circuit shall be able to identify all 3 conditions as shown above to avoid lifting a container by one end of the spreader.
Visibility for Spotting
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 38 The inner lower edge lines of twist lock boxes of the spreader to be clearly visible by the operator for spotting the spreader onto the 40’ or 45’ container. (10)
Spreader Meters and Indication. i)
A twistlock counter shall be fitted on the spreader. The counter is required to record actual number of boxes loaded and unloaded by the crane. As such the counter shall be designed to register one count when the following combinations of motion are detected “locked…. hoisted….trolley….lower….unlock….”
ii)
A spreader operating hour meter shall be fitted on the spreader (power on cumulative hour).
4-9.2. Reeve in Spreader The Contractor shall propose a direct reeve-in type spreader, which does not have a separate Headblock frame. In this case the sheave block shall be attached to the spreader through hand operated quick release pins, which are positively lockable, and the baloney cable shall be connected near the cable tub with a multi-pin connector of Pile National. Safe and appropriate platforms and access to operate the quick release pins and the baloney cable connector shall be provided. The total number of the quick release pins shall be four (4). These quick release pins shall be designed as a permanent component which does not require replacement due to fatigue for the life of the Crane under loading conditions specified in 2-7.8.
5. Inter-Functional Systems & Components 5-1.
Mechanical System/Components
5-1.1. Bearing, Seals (1)
All the bearing shall be anti-friction bearings except for the shafts or pins with a limited small angle rotation such as the gantry truck equalizer pins or equalizer sheaves. For all types of bearings, effective means of lubrication and seal shall be provided. Oil less bearing or oil less bush is not allowed.
(2)
The bearing design shall be based on following life as a minimum requirement. For main hoist system : For trolley travel system: For gantry travel system:
(3)
40,000 hours 40,000 hours 40,000 hours
Bearing housing or retainer shall be a split type or bolt-down type to facilitate fast inspection and replacement work.
5-1.2. Gearing
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 39 (1)
The life of main hoist gearing design shall be specifically based on 300,000,000 accumulated number of reducer output shaft revolution.
(2)
Open gears are usually not allowed unless itemised approval is granted from the Purchaser.
(3)
All open gears, if applied, shall be properly covered or guarded for safety with covers or guards. The cover or the guard shall be easily removable and have adequate ports to lubricate and check the gears. Oil or grease tray of a removable type under each gear shall be provided to receive excess lubricant.
5-1.3. Gear Reducers (1)
The gear boxes shall be fitted with effective gear inspection windows, weather proof breathers and oil level gauges. The gear boxes shall be free from oil leakage. Dip stick type oil level gauge is specifically not allowed.
(2)
The gear boxes shall be designed to allow easy replacement of gear or gear shafts without removing the whole gear box assembly from its mounting base.
(3)
Drain pipes with shut off valves and end plugs shall be fitted to each gear box. An appropriate drain receiving space for each drain outlet shall be provided.
(4)
The bearings in each gear reducer shall be from single bearing manufacturer.
5-1.4. Wire Rope Winch Drums (1)
The main hoist drums shall be of rolled welded steel construction, statically balanced and complete with machined grooves for single layer winding of wire ropes.
(2)
The grooves on the drum shall be pitched so that there is clearance between neighbouring turns of rope on the drum and also clearance between the part of the rope leading onto, or leaving the drum, and the adjacent coil.
(3)
The bottom of the grooves should have a circular arc over an angle of not less than 120 degrees and the radius of the groove should not be less than 5% or more than 7½% larger than the nominal radius of the rope.
(4)
The diameter of the drum at the bottom of the groove shall not be less than 30 times the nominal rope diameter.
(5)
The maximum angle of fleet between the rope and a plane perpendicular to the longitudinal axis of the drum shall not exceed 2 degrees.
(6)
The drum shall be flanged at both ends.
(7)
The wire ropes shall be secured to the drum by a suitable clamping device. The design of this device will be subject to review by the Purchaser at the design stage.
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 40 (8)
The length of the hoist drum and wire ropes shall be such that when the headblock is at its lowest specified point at least three full turns of rope shall remain on the drum, and when the load is at its highest possible point at least one empty groove shall separate two adjacent ropes, depending on the drum configuration.
(9)
Attention should be given to the recommendation in BS.6570 1986.
(10)
Wire rope winch drum shall have machined grooves sufficient to lay wire ropes in single layer. One extra turn for services and appropriate number of dead turns for each wire rope end shall be allowed for on the drum.
(11)
The wire rope clamp shall be bolted clamp plate type.
(12)
Oil or grease tray of a removable type adequately segmented for easy removal by hand shall be provided under each wire drum to receive excess lubricant. Prevention against overflow of oily water out of trays during rainy operational condition shall be taken into consideration.
(13)
A removable screw lockable hinged cover over the wire drum shall be provided to prevent wire lubricant being washed off by rain or melted by the heat of the sun. A proper support to keep the cover in the opened position (withstanding the wind) shall be provided.
(14)
4 steel pipe type strong duty wire rope guards shall be fitted at mid level of the wire rope winch drum to protect the wire ropes from entanglement when spreader is at its maximum height emergency position. The clearance between main hoist wire rope and the surface of the guards shall be equal to half of the wire rope diameter.
5-1.5. Wire Rope Sheaves (1)
All wire rope sheaves shall be of centrifugally cast or forged steel construction with smoothly machined grooves. Fabricated or gravity cast sheaves are not acceptable.
(2)
The bottom of the grooves should have a circular arc over an angle of not less than 120 degrees, have an included angle of 52 degrees and the radius of the groove should not be less than 7½% or more than 15% larger than the nominal radius of the rope with 11% being the optimum. The Contractor is to furnish specific details of the proposed sheave profiles.
(3)
Wire rope sheaves shall have a minimum pitch diameter of 30 times the nominal rope diameter. Guide rollers (fairleads) shall have a minimum diameter of 5 times the rope diameter and the diameter of equalising shaves shall not be less than 18 times the rope diameter.
(4)
The maximum angle of fleet between the rope and a plane perpendicular to the axis of the sheave shall not exceed 2.5 degrees.
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 41 (5)
The surface of the groove of the sheave shall have a hardness value of minimum 321 on the Brinell Scale. The depth of the material hardened to this level shall be at least 3mm. A destructive sample test shall be done to demonstrate the compliance of hardening process.
(6)
All running sheaves shall be fitted with anti-friction roller bearings with grease fittings for pressure lubrication. White markings shall be painted on all running sheaves.
(7)
Minimum designed life of the sheave, specifically the groove and bearing retainer, shall match the bearing life of 25,000 hoists operating hours.
(8)
The pitch diameter shall be at least 30 times the wire rope diameter. An equalizer sheaves may have smaller diameter provided that the small radius will not reduce the safety factor of wire rope below specified value.
(9)
Application of hanger sheave (sheave mounted on swinging hanger) is not favoured and will only be accepted if it can be shown to be necessary to provided minimum fleet angles on main hoist ropes.
(10)
All sheaves shall be mounted by shaft and supported at both sides. Single side support with retainer ring is not allowed. If they form part of the anti-sway system.
(11)
All sheaves shall be designed with easy access and with ample space for maintenance and repair. The clamp and retainer shall be fitted opposite to the wire rope pulling force direction. Clamp and retainer bracket shall easily be removed for sheave replacement.
5-1.6. Wire Ropes (1)
The factor of safety shall not be less than 6 for all ropes.
(2)
Wire rope lubricant shall be carefully selected to minimize the dripping problems.
(3)
Wire rope dead end splice shall be a mechanical splice (wire rope clips and cotter socket are specifically not allowed), and the dead end fitting shall be articulated to allow rope end to move freely in long travel and cross travel directions.
5-1.7. Shafts, Axles (1)
Shafts shall be designed with due consideration for stress concentration at keyway, necks or other notches. All splines, gear teeth, or threads shall run out smoothly or shall be undercut and the surface finish shall be uniformly smooth and free from defects.
(2)
For any long shaft the torsional deflection shall not affect the coupling or gearing associated with the shaft.
(3)
Gearing axle brackets shall be a split type or a bolted type for simple removal of axle and bearing.
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Shafts shall be properly covered or guarded for safety.
5-1.8. Couplings (1)
All main drive couplings shall be supplied by an internationally recognised manufacturer of couplings.
(2)
Main driving shaft shall be fitted with flexible couplings. All coupling bolts shall be locked with a proper anti-loosening system such as lock wires. Grease nipples shall be fitted at OEM’s greasing positions.
(3)
Couplings shall be properly covered or guarded for safety. The cover or the guard shall allow easy access for lubrication of the coupling without removing entire cover or guard.
(4)
For any spline coupling a wear indicator with visible wear limit mark shall be provided. The grease nipple for the spline coupling shall be extended to the edge of the main hoist winch drum to facilitate easy maintenance.
(5)
A proper label in Polish shall be fitted at a conspicuous place to remind the greaser to carry out greasing in accordance with the maintenance plan.
5-1.9. Metal Wheels (1)
Trolley wheels shall be double flanged type, forged steel wheel with hardened tread. Minimum designed life shall be 40,000 trolley operating hours. If guide rollers are required, the guide rollers shall be designed to have a minimum operating life of 25,000 trolley operating hours. Prevention of falling down of guide rollers when failed shall be taken into design consideration. In normal operating condition, the guide rollers shall not cause any damages to the rail or associated fixtures.
(2)
Gantry tyre wheels shall be for tubeless pneumatic tyres to fit for tyres of international size. The wheels and rims shall be designed for the whole life of the Crane; the internal surfaces of the wheel, i.e. the area that will be within and covered by the tyre when fitted shall receive an anti-corrosion treatment in accordance with the following clauses: -
blasting 6-3.3 painting 6-3.4 and 6-3.5
5-1.10. Pins, Pin Brackets (1)
For the pins which require jacking or pulling for dismantling, adequate space for a jack or a puller shall be provided.
5-1.11. Bolts (1)
All bolts are to be manufactured to ISO-metric standard.
(2)
Tightening torque for all fitting bolts shall be clarified by the Contractor in a form of a bolt list clearly indicating bolt location, size, materials and quantities.
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5-1.12. Lubrication (1)
All the moving parts shall be effectively lubricated.
(2)
All the lubricant specified by the Contractor shall be locally available. The lubricants initially filled in manufacturer’s shops shall be pre-approved by the Purchaser for their compatibilities with those lubricants used by the Purchaser.
(3)
Any excess lubricant shall be trapped in removable trays or receivers.
(4)
All greasing nipples shall be stainless steel.
(5)
Compressed air pipes shall be installed from the ground to the girder. Two (2) air inlets shall be provided at ground level for connection to air compressor. Two air outlets shall be provided on the girder.
5-1.13. Bumper, Buffer Trolley buffers shall be fitted above the trolley platform at the four corners of the trolley frame. The buffers shall be capable of absorbing and dissipating the impact of collision at full speed with rated load. The buffer shall be of sufficient stroke so as to decelerate the trolley at no more than 4.90m/sec sq. (0.5G) at 50% rated trolley speed. 5-1.14. Rubber Tyres Gantry tyre wheels shall be for tubeless pneumatic tyres to fit for tyres of international size. Wheels dimensions should be 18.00-25 or 21.00-25. 5-2.
Hydraulically System/Components
5-2.1. Standards Hydraulic systems shall be designed in accordance with relevant international Standards. As a minimum all components must be capable of operating continuously i.e. pumps, valves etc. All hydraulic components shall be manufactured to ISO–metric standard. 5-2.2. Components Sources All components shall be sourced from internationally approved suppliers and the hydraulic systems shall use components, which are readily available in Poland and the European Community. 5-2.3. Operating Condition Under conditions of continuous operation, the pump inlet temperature of the fluid must not exceed 65 degrees C. The equipment shall operate efficiently in an ambient temperature range of minus 20 degrees C. to plus 35 degrees C. The system shall incorporate fluid over temperature protection which shall operate to indicate the fault and stop the operation of the pump.
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5-2.4. Hydraulic Fluid Reservoir The type of hydraulic fluid for the initial fill by the Contractor must be pre-approved by the Purchaser. All Hydraulic reservoirs/storage tanks shall be provided with adequate drainage facilities to permit the draining of the hydraulic fluid into waste oil receptacles through shut-off valves which can be easily accessed. Space shall be provided around and below the drain valve to allow this essential maintenance work without spillage. (1)
The capacity of the fluid reservoir shall be sufficient to contain all the fluid that can flow from the system into the reservoir. The fluid level shall be maintained at a safe working height to prevent cavitations in the pump during the operating cycle.
(2)
Reservoirs shall be equipped with clearly viewed flush mounted or protected fluid level indicators. They must be provided with markings indicating high level when pumps are stopped and low level when the pumps are in operation. Reservoirs shall be constructed to prevent entry of foreign matter, including fluid contamination and moisture.
(3)
Both fluid intake and return points shall terminate sufficiently below the minimum fluid level to prevent aeration.
5-2.5. Power Unit (1)
Positive displacement pumps and motors are preferred.
(2)
Means and good access shall be provided for filling and draining pump and motor casings in accordance with the manufacturer’s specifications.
5-2.6. Valve Mounting Wherever possible, valves shall be mounted so that their removal and replacement can be made without disconnecting pipe fittings. Adjustable valves shall be such that their settings, when made, will be maintained against vibration. 5-2.7. Relief Valve A pressure relief valve capable of relieving the maximum flow at the outlet of the pump shall be provided on the delivery side of the pump and there shall be no other valve between the pump and the relief valve. Relief valves shall reseat within 3% maximum of cracking pressure, and shall have a rated working pressure of not less than 150% of operating pressure. Relief valves subject to changeable back pressure shall be externally drained. Wherever possible, relief valve shall be used as safety reliefs and shall be set a minimum of 10% higher than maximum operating pressure. Solenoid operated directional valves shall have oil immersed or wet pin solenoids. Each solenoid shall have means for external mechanical actuation for testing. If internally drained, tank ports will not be subjected to more than 1,000 psi or Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 45 maximum pressure allowed by manufacturer, whichever is less. External drain lines shall be designed to minimize pressure surges and reduce backpressure. Four-way valves shall spring center or spring offset to a failsafe position upon electrical failure. 5-2.8. Flow Control Valve Variable flow control valves shall show the direction of operation for increase and decrease of throughput. Flow control valves shall be pressure and temperature compensated over the full range of flow for which the valve is rated. Flow setting shall be adjustable and shall have facilities for locking when proper flow setting is reached. Flow control valves must be adjustable to zero flow. 5-2.9. Check valves Check valves may be either ball type or piston type. Swing checks shall not be used. Check valves shall be spring loaded closed and have zero reverse flow. 5-2.10. Servo Valves Servo valves shall be rated for maximum operating flow with a maximum pressure drop of 400 psi across both ports combined. Servo valves shall have non-bypass type 3 micron absolute full flow filters on their supply lines. Each servo valve shall have externally adjustable null. 5-2.11. Control Valve All control valves shall be subplate mounted or cartridge type. Shut off valves, check valves and needle valves may be line mounted. Maximum flow rates and pressures through valves shall not exceed manufacturer’s rated flow and pressure. 5-2.12. Solenoid Valves (1)
All solenoid valves shall be 220VAC 50 cycles and shall be replaceable without disassembling the valve or removing it from the subplate or manifold.
(2)
All solenoid valves shall be protected from weather.
(3)
Valves including specifically solenoid valves shall be readily accessible to allow for any adjustment, operational check, or manual operation in an emergency.
(4)
Solenoids shall have continuous rating and be equipped with an LED indicator for indicating fault.
(5)
All solenoids shall be fitted with an independent surge absorber to absorb high voltage spike due to ‘close’ and ‘open’ of highly inductive load = solenoid.
(6)
Solenoid valves shall be equipped to provide remote signals to operator’s cab / computer control and to central data collecting point.
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5-2.13. Piping (1)
Welded joints in hydraulic pipe work shall not be allowed.
(2)
All rigid piping shall be securely supported to minimize vibration or movement. The length and method of supporting flexible piping shall be such as to avoid sharp flexing and straining, particularly at the end fittings. The spacing between adjacent rigid pipes and between rigid pipes and the surrounding steelwork etc. shall be sufficient to allow the pipe couplings to be secured with ease and without damage to adjacent pipes or couplings. All the piping shall be securely fixed to the structure and shall withstand internal and external vibration and impact.
(3)
Piping between actuating and control devices shall be as short as possible and pipes must be removable without dismantling equipment, components or adjacent piping.
5-2.14. Hoses (1)
Flexible hoses and couplings shall be in accordance with the requirements of the relevant international Standards and shall be of an approved type and manufacturer. All dimensions shall be in accordance to SI units (metric).
(2)
Flexible hose shall be protected from mechanical damages due to interference with structure, equipment, or any moving parts.
(3)
Where the pressure adjustment is critical, a pressure gauge port with shut off valve shall be provided in the line so that the pressure can be checked without disconnecting the lines.
(4)
Hoses shall be designed for burst pressures of 70 Mpa and shall be tested at 35 Mpa.
5-2.15. Assembly Test After assembly, the system shall be hydrostatically tested to 150% maximum pressure. 5-2.16. Catch Basins (1)
All hydraulic power units will have catch basins to collect leakage for the power unit and its components. The basin shall be sized to a minimum of 10% of the reservoir’s volume.
(2)
Catch basins shall be fitted with a manual valve equipped with drains. The drains shall either be accessible from crane walkways, machinery decks, the wharf, or from the trolley. Space shall be provided for a container to accept the drained fluid. Where the catch basin is compartmentalized, the various compartments shall be piped together to form a single drain point.
5-2.17. Filters
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Filters shall be full-flow, non-bypass type complete with visual condition monitoring. The filter may generally be fitted either in the intake, pressure, or return lines and shall have a 10 micron nominal filtration rating. When the filter is installed in the pressure or return lines the pump intake shall be fitted with a wire mesh screen (100 mesh or finer).
(2)
The filter shall be easily accessible for element replacement purposes without having to drain the reservoir and/or system.
(3)
A suitable magnet should also be fitted in the bottom of the reservoir between the return side of the reservoir and the suction strainers. Magnets shall be easily removable for cleaning.
5-2.18. Heat Exchangers Heat exchangers shall be installed and shall be air/ oil type sized to limit the maximum reservoir oil temperature to 48 deg c. All heat exchangers shall be provided with bypass valves to limit maximum operating pressure to 100 psi or less. 5-2.19. Actuator All actuators shall be laid out to allow easy removal and reinstallation. 5-2.20. Application for Spreader NOT USED. 5-2.21. Couplings (1)
Quick release couplings shall be provided and ample space provided between couplings for coupling and uncoupling of hoses.
(2)
The quick release couplings shall be match marked with ferrules on the connecting ends.
5-2.22. Gauges (1)
A delivery pressure gauge shall be provided. The gauge shall be connected via a fail to-safe valve and damping loops, and rigidly mounted on a structure. It can only be read by operation of a fail safe valve.
(2)
An oil level gauge on the reservoir shall be provided at a location convenient for inspection by direct eye-sight.
5-2.23. Covers Any cover for the hydraulic system must be manufactured in order to allow prompt and direct access to manually check the solenoid valves. This should be allowed without the need to remove the whole cover. 5-2.24. Hydraulic Fluid
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 48 The type of hydraulic oil for the initial fill by the Contractor shall be pre-approved by the Purchaser. 5-2.25. Load Sensing System The load sensing system shall include the installation of 4 No. compression type load cells. The Contractor shall make use of the load sensing system to measure and record the weight of each lifted container. The weight of the container shall be registered in the Purchaser’s RDS. 5-3.
Electrical & Electronic System/Components
5-3.1. General Electrical system shall be designed to allow for simultaneous operation of Main Hoist and Trolley motions, and Gantry and Trolley motions. 5-3.2. Main Power Supply (1)
Main drives A.C. motor voltage and control power voltage to be proposed by the Contractor.
(2)
A.C. motors - A.C. 380V 3-phase 50Hz.
(3)
Lighting
(4)
Alarm, intercom and other accessories - A.C. 220V 1-phase 50 Hz.
(5)
Window wiper and washer - D. C. 24V.
(6)
Radio communication equipment D.C. 24 V (5 Amp) and D.C. 12V (10 Amp)
- A.C. 220V 1 - phase 50 Hz.
5-3.3. Power Factor Correction The power factor of the entire system under normal working condition shall be not less than 0.9. 5-3.4. Protection Against Power Surge All electrical and electronic equipment shall be protected by transient surge suppressor installed as close as possible to each equipment, which requires protection from the surge in power and control circuit. The transient surge of the power supply shall be recorded as a permanent record for information to the maintenance personnel that there has been a surge in the line at specific time of such occurrence. Any electrical apparatus or device on the Crane or device on the Crane which may introduce a surge shall be properly designed to suppress surge within its own environment and shall not cause any interference to other equipment or control functions of the Crane. The followings are, but not limited to, particular areas which require special attention in terms of the transient surge suppression. i)
The incoming circuit shall be protected by suitable surge absorbers on A.C. three phase power supply lines to stabilize the incoming power in case of any surge in the
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 49 A.C. circuit. ii)
All rectifiers from A.C. to D.C. shall be protected by surge absorber on the A.C. side as well as the D.C. side to have a clean D. C. output and with a suitable zener diode to maintain the voltage at optimum level.
iii)
All A.C. contactors, D.C. contactors and relays shall be connected in parallel with suitable surge absorber to absorb transient surge due to make and break of coils contact and minimize the disturbance of voltage to the sensitive areas within the Crane.
iv)
All hydraulic solenoids shall be connected with surge absorber to be protected from any induced voltage which may cause burn off of the solenoid during operation.
v)
Critical items such as Programmable Logic Controllers, computers and I/O modules shall be protected from external transient surge by independent surge absorber on their power supply line.
vi)
Any other items considered vulnerable to any transient surge must be properly protected from transient surge to minimise interruption of Crane operation.
vii)
All brake coils shall be protected with an arrestor over voltage protection.
5-3.5. Protection against voltage dip/loss of power supply (i)
The power supply electrical circuit of the Crane shall be properly designed to minimise Crane recovery time in case of power supply failure in form of short duration voltage dip or a complete loss of power supply.
(ii)
The inverter drive for the Crane shall be designed so that in case of power supply voltage dip, it shall always trip the under voltage relay before burning the protection fuses and/or transistors. The electrical circuit shall be designed to allow simple and quick reset of the system by a push button fitted on the inverter drive control unit assembly.
(iii)
The A.C. line low voltage power supply beyond the transformer shall be connected in series with a properly designed A.C. current limiting reactor to reduce the short circuit current between the transformer and the Converter in case of a short circuit at the output circuit.
5-3.6. Wiring (1)
A minimum wire size shall be 3.5 sq mm, except for factory wired panels which may include smaller size wires. The Contractor shall ensure that all heavy current low voltage power cables are sized to include suitable derating for the temperature and space factor. All heavy current power wires shall be separated. (One group for each motor or electric device) The mixing of control wires and power wires shall not be acceptable and will be rejected by the Purchaser.
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 50 The Contractor shall submit all calculations on sizing of cables for review by the Purchaser. (2)
Wire shall be connected only at the terminal blocks in panels, control box, joint box, or at the terminal for electrical equipment. Wire shall not be joined other than at proper terminals. All conductor wires of 4 sq. mm or smaller shall be terminated at terminal strips and at components having screw type terminals with spade or ring tongue crimped solderless lugs. All wire end terminations shall be checked and where necessary retightened prior to the Commissioning Test.
(3)
All the wires shall be run in trunking or conduit. Cables shall be laid in orderly manner and according to the requirements of the IEE regulations. It is preferable that all the wires are so designed and installed inside the interior of the Structural System. All the wire run through holes and openings of structure shall be protected from insulation damages due to mechanical contact with structures. Control and signal wires shall be separated from power wires to avoid any interference causing false signals. Mufti-core cables may be run on cable trays or raceways with adequate cable clamps, and covered with sun-shield and mechanical protection covers.
(4)
At least 10% of control wires as spare wires shall be installed on all routes and specifically labelled as such.
(5)
Vertical long distance wiring shall be designed to prevent wire breakage due to suspension of self weight of wires or cables.
(6)
Wiring on the trolley, headblock and spreader shall be designed to withstand continuous vibration and impact.
(7)
Each wire shall be fitted with terminal lugs and marked at both ends with ferrule with number corresponding to the number in schematic diagram.
(8)
Additional cables and terminal boxes shall also be installed for intelligent identification system.
5-3.7. Marking and Identification (1)
All conductors (internal and external to panels) shall be suitably labelled at both ends with hot foil printed, plastic tubing wire markers in accordance with electrical drawings and wire schedules. All terminal blocks shall be properly marked as to block number and terminal number per drawings.
(2)
All terminal blocks shall be properly marked with the block number and terminal number as shown on the drawings.
(3)
Groups of cables entering junction boxes, cabinets, panels and pull boxes shall be tagged as to location of the other end.
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(4)
All panels, boxes and cabinets shall be marked on the outside using engraved plastic name tags fastened with stainless steel screws containing unit number and general function, name or description.
(5)
Individual control devices in cabinets shall be labelled by number description in accordance with the drawings using durable, heat resistant labels with permanent markings, and fixed in a manner designed to combat extreme hot and cold conditions over long periods.
(6)
Major control cabinets shall be labelled with engraved plastic description tags fastened with stainless steel screws.
(7)
The method securing cables within the control panels shall utilise a proper and correct method of attachment. The use of self adhesive pads to secure the cables to the panel walls shall not be acceptable.
5-3.8. Conduit and Cable Tray (1)
Conduit (rigid and flexible), with pull boxes at appropriate locations, shall be water proof and continuous. Inside of the conduit must be smooth, and inner edges of both ends must be rounded smooth.
(2)
Flexible conduit (Kopex heavy duty or equal approved type) with proper fittings shall be used between rigid conduit and pull boxes or terminal boxes of motors, brakes, limit switches and all other independently installed electrical equipment which require adjustment, realignment or removal for maintenance or are subject to vibration.
(3)
Rigid conduits shall be rigidly fastened to the crane structures.
(4)
All conduits shall be contained within the protection of the crane structures.
(5)
No conduit is to be installed across walkways or working platforms or in any way that could be considered to impede access, safety operation, etc.
(6)
For conduit runs of more than 6 metres a pull wire shall be left in place.
(7)
A drain hole shall be provided at the lowest point in each junction box.
(8)
Ladder type open electrical cable tray shall be hot dipped galvanised finished and fixed to the structure using stainless steel bolts and nuts. The type and fixing of the cable tray shall be reviewed by the Purchaser. Any cut edges on the hot dip galvanised cable tray or ladders shall have the sharp edges removed by grinding or filing and the raw surface area protected by a zinc rich primer immediately after suitable cleaning with clean solvent and prior to any degradation by rust.
5-3.9. Electrical Trunking
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Electrical trunking and trunking covers shall be free from sharp edges or sharp corners to protect the wires.
(2)
Trunking shall have appropriate partitions to separate power and control wires, and clamps to prevent excessive wire movement in the duct.
(3)
Trunking shall be designed to prevent water ingress. Nevertheless the trunking shall not trap any water in case of water ingress.
5-3.10. Motor (1)
The construction of all motors shall meet the requirements of BS 4999. The motors shall be sized according to FEM 3rd edition, booklet 4 – Selection of Motors. The minimum rating and duty of the motors, designated according to IEC 34-1 standard, shall be as follows: Motors Main Hoist motors Trolley travel motors Gantry travel motors
Minimum Ratings required Continuous rating, duty type S1. Continuous rating, duty type S1. S2 duty type, 60 minutes rating.
All AC motors shall be totally enclosed non-ventilated (TENV) type of IP 55 protection. All exposed moving parts of motors shall be adequately guarded. Motors for hoist and trolley shall be mounted horizontally. (2)
Motor terminal box shall be fitted facing an open space for maintenance.
(3)
All the main motors shall be fitted with space heaters.
(4)
Ample space shall be provided for inspection of AC Induction motor itself.
(5)
The main hoist motor and brakes shall be fitted inside an enclosure. The enclosure shall be designed to provide for ease of motor and brake maintenance with suitable removable doors. Thermal cycling due to hot and cold climatic changes shall also be considered within the design of the enclosure.
(6)
The enclosure shall be equipped with an exhaust fan. Cool air may be drawn from any opening beneath the main hoist motor housing; however water shall not be drawn into the enclosure under any circumstances.
(7)
All motors shall be connected with an earthing wire from the motor body to the nearest support metal structure to provide a proper earthing connection.
5-3.11. Brakes (1)
Ample space shall be provided around brakes for inspection and maintenance works.
(2)
Brake disc shall be dynamically balanced.
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Brakes disc shall not sustain damages due to an emergency stop operation.
(4)
Main hoist and trolley brakes shall be a peak impact damping type approved by the Purchaser. The deceleration shall be accompanied electrically and regenerative with the brakes applied only when the motion has slowed down to essentially stopped condition
(5)
Brake linings to be of non-asbestos material.
(6)
The main hoist brake shall be protected from ingress of grease from external rotating machinery.
(7)
If used, the main hoist thruster disc brakes shall be supplied from an internationally recognised supplier of brake systems The thruster brake, excluding consumable parts, shall have a life same as the crane
(8)
The main hoist thruster brakes and trolley brakes shall be fitted with limit switch to ensure brake ‘close’ or ‘open’ according to the command from the operator through electrical control at the PLC.
5-3.12. Transformers (1)
Transformer shall be dry type.
(2)
The location of transformers shall be selected not to raise panel temperature.
(3)
All transformers shall be connected with an earthing wire from the transformer body to the nearest support metal structure to provide a proper earthing connection.
5-3.13. Resistors (1)
Regenerated back E.M.F. absorption resistor bank shall be installed independent of electrical control house (panel house) in a position where it will not raise the temperature of control panels.
(2)
Resistor banks shall be protected from weather and properly shielded or fenced off to avoid accidental contact by operational and maintenance staff.
(3)
The Contractor shall ensure that the resistor banks have correctly designed removable louver covers in order to provide adequate cooling inside the resistor box. The design of the louver covers shall not allow the ingress of water under any circumstances.
5-3.14. Enclosures All external components mounted inside outdoor enclosures must be designed to allow for wind driven rain and conform to minimum class of IP55. 5-3.15. Meters, Counters
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All the meters shall be installed at the height not exceeding 1.7m from the floor level, but not below 1.2m from the floor level. All counters and meters shall be mechanical type unless specified by the Purchaser.
(2)
The following individual meters and counters shall be installed in addition to ordinary meters on the control panels. On the control panel house wall, protected from weather, facing outside in a position to be easily read by operators or engineers without entering the house. i)
Operation hour meters for main hoist, trolley travel and gantry travel.
ii)
Twist lock counter (count 1 for [Locked followed by Hoist …… Lowered followed by Unlocked])
iii)
Main hoist revolution counter shall be incorporated in the PLC for 300,000,000 hoist wire drum revolutions.
iv)
Net handling hour meter showing hours [main hoist + trolley - (overlap of hoist & trolley)]. The connection of this meter shall be by parallel connection of hoist brake (Normally open) contact with the trolley brake (Normally open) contact then connect the meter in series with the above two contacts to an AC source.
5-3.16. Limit Switches (1)
All the limit switches shall easily and quickly be accessible for adjustment and maintenance. All limit switches shall be adjustable in X, Y, and Z directions.
(2)
Application of proximity switch shall be ‘fail-to-safe’ application. Short circuit status created within the switch at the time of its failure must prevent further motion which is controlled by the switch, and such short circuit fault must be registered for tracing.
(3)
Special attention is drawn to the twist lock ‘Locked’ and ‘Unlocked’ signals from the proximity switches, which are not ‘fail-to-safe’. In order to avoid damage to the spreader and the container by lifting one end only, the proximity switches for ‘Locked’ and ‘Unlocked’ signal shall be individually connected to the PLC through an I/O module. The PLC when detected a short circuited proximity switch on ‘Locked’ or ‘Unlocked’ will immediately cut off the hoisting motion. Further motion will be restricted to lowering only
(4)
The Contractor can propose an alternative system of design incorporating roller lever type switches for the Purchasers review.
5-3.17. Space Heater (1)
Space heaters shall be fitted to the following locations
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All AC motors for main hoist, trolley and gantry travel. Limit switch enclosures. All control panels.
An indication light shall be installed external to each space heater location in order for the maintenance team to easily identify that the space heaters are functioning correctly.
5-3.18. Name Plate Electrical equipment shall be supplied with a nameplate immediately adjacent and symmetrical to the equipment. These nameplates shall contain appropriate inscriptions or identification markings to convey all relevant information appertaining to the characteristics of the equipment. 5-3.19. D. C. Power Supply The DC power supply shall be able to self regulate the output DC voltages to a constant value against variations in the input AC supply voltage. There shall be sufficient cooling / heat dissipating ability for the DC power supply. 5-3.20. Encoders Electronic absolute encoders shall be used for position feedback for main hoist and trolley travel. 5-3.21. Sensors All sensors installed on the spreader shall be wired in parallel. 5-3.22. Circuit Breakers 1.
All electrical circuit breakers shall be molded type circuit breaker, except otherwise specified.
2.
Circuit breakers shall be designed to isolate defective circuits such as over current or short circuit conditions.
3.
When the molded type circuit breakers are tripped, the lever shall stay at mid position to show that it is tripped. The lever shall be pushed down once before it can be switched “on” again. Mid position of the lever is to show that the outgoing circuit is faulty.
4.
Earth Leakage Circuit Breakers (ELCB) shall be used to protect the flood light system in individual branch so that only the affected area will lose the lighting and not the other healthy circuits. Circuit breakers shall be fitted indoors only. If fitted outside, it shall be enclosed inside a waterproof stainless steel box.
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5-3.23. Auxiliary Power Socket The Crane shall be equipped with an emergency power connection socket. This socket shall be connected to the output side of transformer set (on secondary side, low voltage) in the electric circuit and equipped with the mechanical selector switch and interlock for the changing of power supply (shore power through transformer / auxiliary power). The emergency connection socket shall give the possibility to connect auxiliary power source supplying to the crane in case of emergency such as damage of the shore cable or cable reel etc. The Contractor shall submit the circuit diagram to the Purchaser for review during design stage.
5-4.
Crane Motion Controls
5-4.1. Control System General The Crane control system design shall be based on a control system incorporating a programmable logical controllers (PLC) designed to the latest industrial standards. The programmable logical controllers are to be installed in the machinery house and operators cab which is operated in following environment and operating conditions. An external environment which ranges from +40ºC and 100% humidity to -20ºC. (1)
Environment - The entire system shall be designed to be operated in where installations are subject to prevailing heavy condensation. Equipment shall also be protected so as to resist the entry of small insects. All components shall be tropicalised-treated.
(2)
Degree of Protection - A minimum IP class (IEC 144 and 529) of IP41 is required for all in house, enclosed installations. Equipment of installations at open, exposed atmosphere shall have an IP class of IP55 as a minimum degree of protection. Finger protection against electrical hazard to operators or maintenance personnel shall be equipped according to the latest industrial standards.
(3)
Ambient Temperature - The system shall be designed to be operated in the atmospheric conditions surrounding the electrical components may be modified by systems that are proven and reliable e.g. heaters or air conditioning provided that the total system is fail safe.
(4)
Relative Humidity - The operating and storage humidity of this system shall have a range from 8% to 99% (non-condensing).
(5)
Vibration and Shock Resistance - The entire system shall be designed and installed with an adequate vibration and shock resistance of not less than 16.7 Hz at a 3 dimensional amplitude of minimum 3mm in vibration and 10G in shocks. This value shall be equivalent to JISO911 IIB - class 3 and JISO912 respectively.
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 57 (6)
Operating Voltage - The system shall be designed and operated with a power supply of 220VAC, single phase with an electrical potential tolerance of ±10% and a frequency of 50Hz with a frequency tolerance of ±2%. The Contractor shall install harmonic filters and power surge absorbers as a standard feature. The system shall have a minimum isolation resistance between external circuits and internal circuits of 50M ohm at 500VDC. An isolation voltage of up to 1500VAC for 1 minute is also required.
(7)
Duty Cycle - The system shall be designed to be operated 24 hours a day for the whole year round with a mean time between failure (MTBF) at the component level of not less than 30,000 hours and an operational mean time to repair (MTTR) of not more than ½ hour per component replacement and module replacement. The operating availability shall be not less than 99.997% per every continuous duration or period of 3 months.
(8)
One unit of Uninterrupted Power Supply (UPS) with a minimum of 15 minutes shall be provided to enable the system to back up all status data for an orderly shutdown in case of power failure so that all previous status data can be retrieved and safe operation can be resumed when the power is restored. The UPS shall support the following equipment during power failure: (i) (ii) (iii) (iv) (v)
PLC and discrete I/O modules. Public address system Intercom system Crane computer system and on-board CCMS. Trunk radio
5-4.2. Programmable Logical Controllers (PLC) (1)
The PLCs shall be of cartridge-insert type design with a rack that can provide the installation of power suppliers, I/O modules (as specified in the related clauses), etc. in a compact and low operating cost environment.
(2)
The PLCs shall be able to intercommunicate with each other through a network following the Open System Interconnection communication architecture. The PLCs shall comply with the requirements of IEC 11311 – 1 and 11311 – 2.
(3)
The racks shall be industrial type with a capability of expansion via simple communication interface between and among the racks. It is preferable to have a racking system of a minimum slot or cartridge-insert space for at least 8 modules which excludes the slots or cartridge-insert space for the power supply and CPUs.
(4)
The racks shall have a back-plate communication design and back-plate power supply distribution system. This is to achieve maximum feasibility in module replacement as well as minimize the mean time to repair when it is required.
(5)
The PLCs shall have multi-tasking, remote communication capabilities and supporting interrupts. The input interrupts shall be hard wired to the front of the logic processor module. When triggered, the logical processor immediately halts the
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 58 execution of the main control program and executes the interrupt routine associated with the given input interrupt. (6)
The PLCs shall have sufficient memory capacity to hold control algorithms for more than one process plus at least 30% redundant memory capacity. The program shall be stored in EEPROM and RAM. Facilities shall be incorporated on the PLCs to enable programming of the EEPROM. There shall be facilities and space provided for adding memories for future developments.
(7)
The complete cycle time of crane software inclusive of scanning all I/O modules as well as execution of control modules in one cycle shall not be more than 30 milliseconds.
(8)
The communication cables in between PLCs shall have 100% spare cables.
(9)
All parameters adjustments and internal settings of the Drives shall be available on the PLC.
5-4.3. Power Supply (1)
The power supply unit shall be a high efficiency, low loss, cartridge-insert type design with a fuse protected, surface mount input plug for connecting the main supply mounted to this power supply unit.
(2)
LED shall be equipped to show the healthy status of the incoming supply and the outgoing supply. This shall be a standard feature of this power supply unit.
(3)
The rating of the power supply shall be at least 25% more than the total normal consumption of all the modules that are connected or that are going to be connected in future.
5-4.4. Discrete I/O Modules (1)
The discrete I/O modules shall be designed from the latest industrial standards with cartridge-insert type installation and the modules are expected to be operated under an environment which is specified in 2-7.6.
(2)
The discrete I/O modules shall be designed to have an I/O points with 8, 16 and 32 in steps. All the I/O points shall be equipped with screw type fixtures, additional plug-in interfacing plugs or "swing arm" configuration for easy maintenance will be an advantage. All solid state output points shall be protected with quick-burnt fuse for system protection. Replacement of the quick-burnt fuse shall require no dismantle or disassembly of modules and racks. The I/O modules shall be equipped with LEDS which show the status of the inputs and outputs.
(3)
The maximum signal delay of the 'on' and ‘off' status of the output modules shall not be larger than 1ms and 9ms respectively. At the same time, the maximum signal delay of the 'on' and 'off' status of the input modules shall not be greater than 20ms and 25ms respectively.
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 59 (4)
The discrete I/O modules shall be equipped with a removable tab for wiring identification.
(5)
There shall be at least 20% spare I/O ports. Space in the cubicles or junction boxes for adding I/O modules shall be provided.
5-4.5. Real Time Clock Module (1)
The real time clock module shall be industrial type with a cartridge-insert type design. The real time clock module shall have the following seven date and time functions: i) ii) iii) iv) v) vi) vii)
Day of the week Year Month Day of the Month Hour Minutes Seconds
(2)
The real time clock module shall have an accuracy of not more than 60 seconds per year in temperature range from -20oC - 50oC.
(3)
The module shall have the capability to register the event logs together with the time clock and then send the logs to the communication module when command is executed.
5-4.6. Motion Control Switches in Operator’s Cab (1)
Main hoist and gantry motion control (right console) A right-hand control console shall control main hoist and gantry motion with one joystick controller. The controller shall be spring returned and lockable at zero notch and released by push button switch incorporated into the controller joysticks. Fore and aft movement for main hoist lowering and hoisting, left and right movement for gantry travel. Selection of motions on first-come-first-served basis. Cross interlock device shall be incorporated to the joystick controller.
(2)
Trolley motion control (Left console) A left-hand control console shall control trolley motion with one joystick controller. The controller shall be spring returned and lockable at zero notch and released by push button switch incorporated into the controller joysticks. Other motion control switches or control buttons shall be ergonomically laid out on control consoles.
(3)
Following motion control switches shall be laid out on both consoles similar to existing cranes (refer to Appendix IV). Telemecanique type motion control switches are preferred.
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 60 i) ii) iii) iv) v) vi) vii) viii) ix)
x) xi)
Twist lock ‘Lock/Unlock’ changeover switch. Flipper selector switch for ‘Left side’, Right side’. Flipper ‘Raise/Lower’ changeover switches. Spreader ‘Extend/Retract’ control switches. Spreader ‘Skew/Trim’ joystick. One push button switch to automatically correct spreader position to ‘Zero Skew’ position. Window wiper ‘On/Off’ switches. Window washer ‘On/Off’ switches. Warning siren push button switch. This warning siren push button switch shall activate the same amplifier speaker as the landing by-pass, twist lock by-pass alarm sound. Other control switches necessary for normal operation. Two emergency stop push buttons on each side console. -
to cut out main hoist, trolley and gantry power.
-
to turn off the whole crane.
The button shall be a mushroom type with raised guard to prevent accidental tripping. (4)
Following equipment start-stop switches and selectors are less frequently operated switches shall be installed either on the control consoles, or an independent panel within operator’s reach from his seating position. i) ii) iii) v) vii) Viii)
(5)
Spreader power supply ‘On/Off’ push button switch. Spreader motor selector switch (if any) Lighting switch. Exciter switch. Gantry wheel 90 degree steering switch.. Gantry wheel intermediate angle steering switch for spin turn.
Indicating lamps on the console i) ii) iii) iv) v)
Auxiliary power source ‘On’ indicator. Spreader position indicator (20’ or 40’). Spreader motor ‘No. 1’ or ‘No. 2’ (if any). Spreader ‘Zero Skew’ position indicator. Other indicating lamps as necessary to indicate operable condition with the lamp ‘On’.
All indicating lamps on the console shall be LED type. (6)
Interlock override spring return key switches Labels shall be provided for each switch and indicator in both English and Polish, and to be approved by the Purchaser.
(7)
Each console shall be provided with 220V AC outlet.
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 61 (8)
All push button control switches shall be LED illuminated.
5-4.7. Motion Control Panels (1)
Control panels shall be of steel construction hinged door lockable type with full access from the front. Each panel shall be equipped with lights to facilitate maintenance work.
(2)
Panels with electronic control units shall be designed to maintain the inside air temperature below 40 ºC at all times. Any air inlet for cooling air shall be equipped with air filters.
(3)
Each motion control panel shall be fitted with motor RPM meter, ampere meter and volt meters which indicate motor current, field current, reference voltage and motor voltage. 5-4.8. Remote Motion Controls NOT USED. 5-5.
Operational Safety Interlocks In addition to all the necessary protection of structural, mechanical and electrical/electronic system and system components, following interlocks are required.
5-5.1. Main Motions Interlocks (1)
Main hoist (hoisting or lowering) motion to stop: i)
At upper and lower hoist limits.
ii)
With brake malfunction.
iii)
With wire rope slack either with or without spreader.
iv)
With over-speed.
v)
With motor field loss (if any)
vi)
With motor over-heat.
vii)
Hoisting with an incomplete ‘lock’ position of twist lock after the spreader is landed on a load fitted with corner fittings.
viii)
Hoisting with an incomplete ‘unlock’ position of twist lock.
ix)
If the physical position of any of the twist locks are different from Lock/Unlock command switch position.
x)
With loss of lub oil pressure if forced lubrication is applied.
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(2)
xi)
Landing limit switch detected as not at its intermediate position (spreader attached with a container).
xii)
When the operator turns the twist lock switch from ‘unlocked’ to ‘lock’ or from ‘locked’ to ‘unlock’ while the spreader is not sat properly on top of a container. Operator must turn the twist lock switch back to original position to continue hoisting operation.
xiii)
While the gantry brake is energised.
Main hoist (hoisting or lowering) motion to slow down, or in slow speed: i)
Two main hoist slow downs shall be provided to cater for empty spreader and loaded with a container condition on hoisting. The proposed arrangement for both empty spreader slow down and spreader attached with a container slow down shall be submitted to the Purchaser for approval. Both cases shall not hit the emergency stop limit switch striker and sufficient height to clear the combination of 9 ½’ containers.
ii)
Lowering at near the lower hoist limit.
iii)
Hoisting until slack of the wire rope is taken up.
iv)
When ‘Twist-lock’ or ‘Landing’ by-pass is being depressed by the operator to alert people underneath the crane by an audible alarm that it is dangerous and by-pass of interlock is being used by the operator.
5-5.2. For Trolley Operation (1)
Trolley motion to stop: i) ii) iii) iv) v) vi)
vii) viii) (2)
At travel end limits. With motor field loss (if any). With brake malfunction. With motor overheat. With the storm stowage pin not in the raised position. When the operator turns the twist lock switch from ‘unlocked’ to ‘lock’ or from ‘locked’ to ‘unlock’ while the spreader is not sat properly on top of a container. Operator must turn the twist lock switch back to original position to continue trolley operation. With the cab access swing door/gate in “unlock or open” condition. With spreader landing signal.
Trolley motion to slow down, or in slow speed: i)
At near the travel limits forwards and backwards with a safety margin for full deceleration distance before hitting the end stopper.
ii)
When ‘Twist lock’ or Landing’ by-pass is being depressed by the operator to alert people underneath the crane by an audible alarm that an abnormal
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 63 operation is being carried out and by-pass of interlock is being used by the operator. 5-5.3. For Gantry Travel Operation (1)
Gantry motion to stop: i) ii) iii) iv) v) vi) viii) ix) x) xi) xii)
While turning wheels to or from 90 degree or intermediate spin turn angle steering position. With brake malfunction. With motor field loss (if any). With motor overheat. While the main hoist brake is energized. With turning wheels are not at the similar steering position. With anti-collision signal. With cable reel limit switch or travel limit. With cable reel motor over torque. With cable reel “cable snack” signal. With cable reel motor or control system fault.
(2)
Gantry travel warning gong sound and warning lights shall be kept activated while the gantry control lever is moved to either direction.
(3)
Gantry travel anti-collision device shall be installed on the Cranes to detect the proximity of another Crane which is likely to cause collision. The device shall have two settings – one to give audio warning signal to the operator and the other to bring the crane to an emergency stop.
5-5.4. Spreader Functional Interlock For Spreader Operation i)
Spreader twist lock movement shall be mechanically and electrically interlocked with the spreader landing detection so that ‘lock’ movement is prohibited unless all the twist locks are confirmed as inserted into the corner fittings. The landing signal shall allow for a one (1) second time lag (adjustable) to indicate the completion of landing to the operator and to activate the interlock.
ii)
The ‘premature unlocking’ movement while suspending the load with twist locks shall be prohibited by means of electrical interlock on the logic control circuitry. There shall be no physical movement of the twist locks on the spreader even though the switch is turned to ‘Unlock’ position. Audible and visual alarms noticeable at ground level and at inside the operator’s cab shall be activated by this premature turning of the level type twist lock switch and all motions of the crane shall be deactivated. Both audible and visual alarms shall cease when the twist lock switch is returned to its original position. Alarm tone shall be approved by the purchaser.
iii)
The twist locks shall remain on its last position after power interruption, i.e. failure and resumption of electrical power.
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5-5.5. Cab Entrance Door/Gate Interlock. Refer to 5-5.2. 5-6.
Communications
5-6.1. Intercom System (1)
A communication system which allows selective and partly (simultaneous) communication among the panel house and operator’s cab shall be installed. Hand sets shall be provided at operator’s cab and control house.
(2)
Signal to tractor drivers A green flashing light at each corner, of the gantry structure, which will be activated by Crane Operator in the cab by pressing a push button switch, shall be provided to draw attention of a tractor driver, who has positioned tractor-trailer under the Crane, to communicate with the Crane Operator.
5-6.2. Radio Communication System The radio and UHF set shall be provided by the Contractor as follows:
Radio master unit-Motorola MaxTrac F6 or the equivalent Power unit: Shunde SD 1732W2 or the equivalent Amplifier: DSP/MP-300PH Loudspeaker: DSP/PH10 30W or equivalent
The Contractor shall supply DC outlet for radio communication equipment (refer to 4-6.5 (10) and 5-3.2 (6), (7)). 5-6.3. Data Communication System This clause is not used. 5-6.4. Public Address System A public address system consists of an amplifier with a hand free microphone (goose neck type) shall be installed in the driver’s cab. Loud speakers of water-proof construction shall be installed at the following locations: i) ii)
At one of the legs of the enclosure side. At one of the legs of the electrical panel house side.
5-6.5. Operation Centre / Maintenance Office Station NOT USED.
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 65 5-7.
Crane Condition Monitoring System (CCMS)
5-7.1. General The Contractor shall supply, deliver, install and commission a Crane Condition Monitoring System (hereinafter referred to as the CCMS). The design of the CCMS shall facilitate future expansion in terms of capacity and functional features. The CCMS hardware and software shall be modular in design and construction to facilitate future expansion. There shall not be major re-configuration of the hardware and software modification and development. System expansion shall not be limited by the capacity of individual On-Board CCMS and PLCs. The Crane Condition Monitoring System shall be installed in the following locations: (1)
In the electrical house of each Crane (hereinafter referred to as the On-Board Crane Condition Monitoring System, On-Board CCMS).
(2)
In the maintenance base at the Engineering office building (hereinafter referred to as the Remote Crane Condition Monitoring System, RCCMS) 5-7.2. CCMS Description The On-Board CCMS and RCCMS shall incorporate alarm/fault monitoring and graphics display, the condition status monitoring with graphics display, the fault diagnostic functions, Crane operation and shall allow access to the programming logic and software (all of the above shall be in Polish language). These functions must be able to be downloaded as a softcopy and printed as a hardcopy. The PLC program must be able to download/upload from the electrical drives to the CCMS and vice-versa. The CCMS shall consist of but not be limited to the following elements: (1)
One (1) set of On-Board CCMS on each crane. This shall consists of a personal computer with monitor, key boards and CD driver, Licensed Microsoft Windows and Microsoft Office software, necessary associated peripherals and software. All hardware and software required for interface to the communication network and peripheral devices shall be included and approved by the Purchaser.
(2)
One (1) set of RCCMS. This shall consist of a personal computer together with monitor, key board and necessary associated peripherals and software. All hardware and software required for interface to the communication network and peripheral devices shall be included.
(3)
A laser jet printer to be installed in the Engineering office and its associated peripheral for printing necessary information from the RCCMS.
(4)
One (1) set of RCCMS server and a standby server for providing access to the cranes under the same drive system.
(5)
The Contractor shall provide free-of-cost technical training for the engineering staff of the Purchaser. The training program shall be submitted in the tender proposal. This training shall be conducted by Polish/English speaking personnel who are duly appointed as the representative of the Contractor.
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 66 (6)
The Contractor shall provide 3 sets of soft copies in CD-ROM and 6 sets, cost free, reproducible maintenance manual, operator manual, recommended spare part list and spare part manual to the Purchaser.
(7)
The Contractor shall submit a quotation upon practical completion date of the OnBoard CCMS to the Purchaser for a recommended spare part list of the On-Board CCMS for an operation period of 5 years continuously.
(8)
The Contractor shall also bind to guarantee to have a spare part be supplied after 5 years upon the practical completion of this contract.
(9)
The CCMS shall have proper documentation of circuit diagrams, source codes, hardware and software with user license, and associated peripherals.
(10)
The design overview of the CCMS is shown in Appendix IV. The Contractor shall submit within two (2) months after the date of award of contract, the CCMS system architecture for review by the Purchaser.
5-7.3. On-Board Crane Condition Monitoring System (On-Board CCMS) General Specification The On-Board CCMS is located in the electrical room of the Crane. The On-Board CCMS is designed to provide a diagnostic and condition / status real time monitoring of the crane control system. The On-Board CCMS shall consist of the necessary sensors and transducers to be installed on each crane and with in conjunction with the PLCs to provide continuous monitoring, diagnostics, data collection on the Crane’s operating systems. The system shall also provide crane operational data that is used to determine crane performance, maintenance scheduling, spare part details and daily/shift reports. 5-7.4. On-Board CCMS Software Requirements (1)
The On-Board CCMS and RCCMS operating system shall be real time, multitasking, multi-user operating system. The operating system shall allow the OnBoard CCMS and other programs to run simultaneously and allow the user to access any software without affecting the real time condition monitoring of the crane control system and the communication link between the On-Board CCMS and the RCCMS.
(2)
The Contractor shall develop a user interface software to meet the following requirements: i)
The software shall be able to run on Window XP operating platform. The operating platform and user interface software has to be approved by the Purchaser. All back-up copies of the software shall be stored in the CDROM or USB storage device.
ii)
The software shall incorporate alarm/fault monitoring and graphics display, the condition status monitoring with graphics display, the fault diagnostic functions, Crane operation and shall allow access to the programming logic and software (all of the above shall be in Polish language).
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iii)
The software shall be commercially available software and it shall serve as an interface to display on the screen all the captured data from the OnBoard CCMS. The software shall be able to generate but not restricted to historical trend charts/files, trending, alarm management and fault logging, crane maintenance and performance report, planned maintenance information. The Purchaser will release the reporting format and details to the Contractor and the Contractor shall comply with the same as part of the Works. The capacity of the memory shall be able to store not less than 500 fault messages together with the related fault records and at least 3 years of historical productivity data / information. The software shall be able to download or export data files to other commercially available software such as Microsoft Access, Microsoft Excel, and Microsoft Words etc. The export data files shall include but not be limited to ”txt”, “xle”, “doc” format.
iii)
The proposed structure for storing the CCMS data and information shall be Oracle database System.
iv)
The software shall allow engineers to access (read and write) the ladder diagrams of the PLC, remote PLC and Drives, Boolean logic and other software codes. Forcing-on and forcing-off of switches, contacts and relays on the PLC ladder diagram shall be available on the On-Board CCMS. Parameters adjustments and internal settings of both PLC and Drives shall be available on the On-Board CCMS. All as built electrical drawings shall be accessible by the On-Board CCMS. Key switch and password shall be available to authorized personnel to carry out any modifications as described above. There shall be three (3) levels of security for accessing to different levels of CCMS software. The exact details will be released to the Contractor by the Purchaser and the Contractor shall comply with the same as part of the Works.
v)
The On-Board CCMS shall be able to copy or upload PLC software programme to each PLC within 30 minutes. The On-Board CCMS shall be able to download all data files which shall include all real time information of the CCMS and time response graphs. This information shall be able to store in a CD-ROM or any USB storing device for printing using Microsoft Word / Excel / Access. Time response graphs displaying different signals simultaneously shall be incorporated in the On-Board CCMS.
vi)
The RCCMS operating system and software shall be the same as what is running under the On-Board CCMS.
vii)
The software in the On-Board CCMS shall be made accessible for the Purchaser to include additional or new monitoring points and to modify software for presentation, reports for future enhancements.
viii)
Original Licensed software shall be used, these includes the operating system application software. One original licensed copy of the software package shall be provided for each computer in the Agreement.
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5-7.5. On-Board CCMS Hardware Requirements
(1)
The On-Board CCMS shall be mounted in an environmental controlled, industrial type cabinet that can withstand vibration.
(2)
The On-Board CCMS shall consist of but not limited to the following items: i)
Computer The personal computer shall consist of the following hardwares: The CPU shall be an Intel Duel Core, or better, processor with a clock speed of not less than 2.4G, at least 2GB on board memory, 8MB cache, 500GB harddisk with a speed of 7200rpm in SATA format, one unit of DVD-RW with a speed of 16X, key board, mouse, one unit of 19” monitor, two (2) parallel COM ports and two (2) USB ports, an Ethernet card. The heat sink shall be force-ventilated by a fan unit. It is the intention of the Purchaser to standardize the make and model of the On-Board CCMS computer. The details will be released to the Contractor.
5-7.6. Condition Monitoring (1)
The status and condition for the electrical systems, sub-systems and all the essential components, Electrical, Mechanical and Hydraulic which are critical to the proper functioning of the crane shall be monitored, during all modes of operation and status of power supplies. The Contractor shall provide a UPS, suitably rated for 15 minutes, to afford access to all information in the event of power failure, either relating to the shore power.
(2)
The CCMS shall present all information, status, graphics and data in easy to read window display formats (in Polish language). The Purchasers preferred format for real time data, being graphical displays rather than numerical presentation of the relevant data.
(3)
The main screen shall lead the user to separate screens, divided into the following major application screens (in Polish language).
Example:
MAIN MENU
DATA/CONTROL
SCREEN #1
SCREEN #2
SCREEN #3
SCREEN #4
SCREEN #5
SCREEN #6
HOIST
GANTRY
TROLLEY
SPREADER
Power Supply
PERFORM ANCE
(4)
SCREEN #7
Principle functions and components, associated with each application shall be
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 69 displayed, in real time mode, on individual screens, such as, but not limited to: Motor Feedback Signals, i.e. Speed, Current, Voltage, Frequency, Torque Revolutions, Directions and Temperature. Reference signals of Controller, Ramp Generator and Acceleration/ Deceleration Ramps, Encoders, Pulse Generators. Performance, Operation, Positioning, Current, Voltage and Speeds of Converters, Inverters, Brake Chopper Units, Brakes, Contactors, Relays and other devices, applicable to the application. Hardware status of Limit Switches, Interlocks, Cam Switches, Sensors, Encoders, Fuses and other Protection devices shall be monitored and displayed in an approved format. Data relating to Loads, Component Operational Time and Operational hours of major devices, i.e. Motors, Converters, Inverters, and Brakes shall be displayed in an approved format. Provision shall be made for Status Warning, Alarm Trips and Faults to be displayed at all times on all screens. The system shall provide sub-windows, where operational performance of subassemblies can be monitored, such as, but not limited to: Shore Supply, Hydraulic Motors and Pumps, Wheel Turning operation and Spreader Functions.
Meters, such as all motors’ running hour and twistlock count. Performance includes fault message, summary and statistical data, i.e. MMBF, number of failure, total downtime & etc. (5)
The Contractor shall provide easy to access data of Systems, Parameter Settings of PLC and/or Drives and Components in easy to read formats. These systems and components shall include, but not limited to the following: Performance of the Drives (Inverters and Converters) which includes the AC Supply, AC Motor Control, DC Motor Control (if any), Operator Control, Motion Interlocks, Safety Interlocks, Sequence Interlocks. The temperatures for all AC Motors, DC Motors (if any), Gears, Reducers, Rope Drums for the Main Hoist, Gantry Travel, Trolley Travel. The operating voltages and currents for all the Converters, Invertors, Braking Chopper Units, Brakes and Motors. The status of the high voltage switches, low voltage switches, protections relay. A real time update of all Positioning / Distance sensors.
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Threshold values for warning and shutdown shall be incorporated in the CCMS. Adjustment of the threshold values shall be made accessible to the Purchaser. Any abnormality in the Crane’s system and components shall be prompted and immediately displayed on the screen of the On-Board CCMS. A real time update of all speeds, motions and operations. All Ramps Actual Loads (6)
(7)
(8)
The following, as a minimum, data associated with the Hoist operation shall be displayed: i)
Controller Position of Forward, Reverse, Hoist, Lower, Left, Right and Zero, shall be displayed. Actual proportional position of Controller reference shall be displayed in an approved graphical format and indicates to the user actual percentage (%).
ii)
Hoist motion interlocks, Spreader interlocks, Slack Rope, Load Cell measuring.
iii)
Hoist Inverter status, interlocks, and performance and protection devices.
iv)
Hoist Brake Function, Operation and Brake Proving shall be displayed
v)
Function and Operation of Limit Switches, Cam Switches, Encoders, Tacho-Generators and Pulse Encoders.
vi)
Hoist Speed, Slowdown, Speed Check, Stop and Positioning.
The following, as a minimum, data associated with the Trolley operation shall be displayed: i)
Controller Position of Forward, Reverse, Hoist, Lower, Left, Right and Zero, shall be displayed. Actual proportional position of Controller reference shall be displayed in an approved graphical format and indicates to the user actual percentage (%).
ii)
Trolley motion interlocks, Spreader interlocks,
iii)
Trolley Inverter status, interlocks, performance and protection devices.
iv)
Trolley Brake Function, Operation and Brake Proving shall be displayed
v)
Function and Operation of Limit Switches, Cam Switches, Encoders, Tacho-Generators and Pulse Encoders.
vi)
Trolley Speed, Slowdown, Speed Check, Stop and Positioning.
The following, as a minimum, data associated with the Gantry operation shall be
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(9)
(10)
i)
Controller Position of Forward, Reverse, Hoist, Lower, Left, Right and Zero shall be displayed. Actual proportional position of Controller reference shall be displayed in an approved graphical format and indicates to the user actual percentage (%).
ii)
Gantry motion interlocks, Wheel Turning interlocks.
iii)
Gantry Inverter status, interlocks, performance and protection devices.
iv)
Gantry Brake Function, Operation and Brake Proving shall be displayed.
v)
Function and Operation of Limit Switches, Cam Switches, Encoders, Tacho-Generators and Pulse Encoders.
vi)
Gantry Speed, Slowdown, Stop and Positioning.
vii)
Hydraulic Wheel Turning, function, Operation and positioning.
The following, as a minimum, data associated with the Spreader operation shall be displayed: i)
Controller Position of Forward, Reverse, Hoist, Lower, Left, Right and Zero shall be displayed. Actual proportional position of Controller reference shall be displayed in an approved graphical format and indicates to the user actual percentage (%).
ii)
Spreader motion interlocks, Spreader Retract and Expand interlocks,
iii)
Spreader Motors status, interlocks, performance and protection devices.
iv)
Spreader Flippers, Up and Down.
v)
Function and Operation of Proximity and Limit Switches, Cam Switches, Encoders, Tacho-Generators and Pulse Encoders.
vi)
Spreader Stop and Positioning.
vii)
Spreader Twistlocks, Lock and Unlock, including indication and By-Pass status.
viii)
Function clock shall display actual operation time of Expand/Retract, Twistlock Operation and Flipper Operation.
The following, as a minimum, data associated with the General Crane Control System shall be displayed. i)
Emergency Stop operation where the status of individual stations shall be displayed.
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Main Generated Power Supply, Auxiliary Power Supply, Shore Power Supply and UPS function, status and performance.
iii)
Function Operation and Status of Circuit Breakers, Fuses, Contactors, Relays and Protection devices, shall be displayed.
iv)
Operator Mode Selection, Function and Status
5-7.7. Fault Diagnosis (1)
The faults and status data including historical data shall be stored in the On-Board CCMS database. All the data in the database shall be translated and stored in a suitable text file for a standard editor. All data shall be easily downloaded to a CD ROW or USB storage device. A zip function shall be available in the software for file compression.
(2)
The objective of the fault diagnosis is to assist Purchaser’s engineers to remedy the fault or confirm the exact nature of a fault within a very short time. All faults shall be coded with a suitable numerical code and the first fault causing an alarm, trip or crane stoppage shall be highlighted as first fault. Provision shall be provided that as a minimum the system shall display twenty (20) faults that may occur at any one time. This first fault shall be displayed clearly to assist the Purchasers engineers on the CCMS and remote display units. Faults interrupting crane operation shall be highlighted, either by flashing or appearing in a “Pop-up” window, regardless of screen selected and fault indication shall be only when crane motion or operation is selected.
(3)
The fault diagnosis shall be able to narrow down the faults to the exact components; safety interlocks failures, drive faults, PLC controller failures, remote interface device failure, remote communication failure and system communication failure. There shall be details and information on faulty component locations and possible remedy actions to be taken. There shall be intermediate fault tracing and measurements checkpoints and these functions shall be made available to Purchaser’s qualified personnel to input new parameters for troubleshooting purposes. The resolution and duration of these measurements are 10ms to 100ms and 5s to 50s respectively.
(4)
Drawings on electrical circuit, PCB layout, schematic drawing, software ladder and software device listing of crane control, Drives and PLC shall be made available in the fault diagnostic mode. Access to the information shall be easily obtainable on any CCMS screen. The CCMS shall store all faults in appropriate historic files in daily, weekly, monthly and yearly log folders, easily accessible and selection of data shall be by selecting a daily, weekly, monthly or yearly option.
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5-7.8. Preventive Maintenance (1)
The utilization hour of the consumable parts shall be recorded automatically and compared with the respective pre-set replacement interval. Adjustment of the replacement interval shall be made available to the Purchaser. The system shall prompt the user when a part is due for replacement. The system shall have sufficient capacity, which allows the Purchaser to add new consumable parts. The consumable parts shall include but not limited to the following: i) ii) iii) iv) v)
Brake pads and lining Brake shoes Wire ropes Bearings Oil and air filters
5-7.9. Equipment Performance Data and Operation Log (1)
The CCMS shall provide records on equipment performance and operation data. This data shall include but not limited to the following: i) ii) iii) iv) v) vi) vii) viii) ix) x) xi)
(2)
Frequency of breakdowns Twist Lock Count Main Hoist, Boom Hoist, Trolley, Gantry Hours and overlapping Main Hoist / Trolley Hours Occupied Time Mean Move Between Failure Mean Time to Repair Availability Breakdown Percentage Average Cycle Time Handling Capacity Number of containers handled according to the size and weight of the containers.
These data shall be available in trend graphs / charts plotted against time. The equipment performance and operation report format and the formulas for the equipment performance parameters shall be discussed and approved by the Purchaser before implementation. The Purchaser will release the exact details to the Contractor at design stage. The data shall be stored in the On-Board CCMS. The data shall be able to download or export data files to other commercially available software such as Microsoft Access or Excel & etc. All counters in the CCMS shall be able to be reset by the Purchaser’s engineering personnel but only with user-identify recording and the use of passwords.
5-7.10. Remote Crane Condition Monitoring System (RCCMS) (1)
General Specification
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 74 The RCCMS shall allow engineering personnel to perform diagnostic, condition monitoring of the CCMS in the engineering office remote to the Cranes. The RCCMS shall be able to perform all the functions of the On-Board CCMS as stated in Clause 5-7.4 and the following additional requirements: (i)
All the information and functions on the Cranes’ On-Board CCMS specified in this Specification shall be available for the RCCMS.
(ii)
All the alarm and fault messages on the Crane which requires the attention of engineering personnel shall interrupt the RCCMS. The response time for the alarm and fault messages shall be less than 5 seconds. After the interrupt has been acknowledged, the present task shall be able to continue. The fault messages shall include but not limited to the following:
(a) (b) (c) (d) (e)
(iii)
Crane ID Location Fault code / messages Part code Date/time reported
There shall be a server for the CCMS by each drive supplier. The RCCMS computers shall be able to access to the On-Board CCMS of any Crane via the respective server and CCMS software.
5-7.11. RCCMS Software Requirements The RCCMS software shall be able to perform all the On-Board CCMS functions as defined in clause 5-7.5. 5-7.12. RCCMS Hardware requirements The RCCMS shall consist of but not limited to the following items: (i)
Computer The personal computer shall consist of the following hardware: The CPU shall be a Intel Duel Core, or better, processor with a clock speed of not less than 2.4GHz, at least 2GB on board memory, 8MB cache, 300GB harddisk with a speed of 7200rpm in IDE format, one unit of DVD R/W with a speed of 16X, key board, mouse, one unit of 19” monitor, two (2) parallel COM ports and two (2) USB ports, an ethernet controller, fibre optic interface and a portable harddisk or USB storage device with 300GB memory for connection to the parallel interface for downloading of data. The heat sink shall be forceventilated by a fan unit.
(ii)
One unit of UPS with a minimum of 15 minutes.
(iii)
One unit of laser jet printer.
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(iv)
One unit of server. Details refer to 5-7.13.
5-7.13. Server(s) The server shall allow the RCCMS computers to access to the On-Board CCMS computers including file transfer, crane diagnostic, receive status and alarm message. It shall also enable the On-Board CCMS computers to send status data and alarms by means of interrupts to the RCCMS and computers (outside the terminal). The server shall be modular and upgradeable to enable all the On-Board CCMS to be served. 5-7.14.
CCMS Reporting Format The CCMS reporting format will be released to the Contractor, shall be reviewed and approved by the Purchaser.
5-7.15. CCMS Data Communication (1)
The data communication between the On-Board CCMS, Server(s) and RCCMS shall be through a Radio Frequency (RF) link data communication media. Contractor shall provide all necessary equipment and peripherals for the RF link data communication between the On-Board CCMS and the RCCMS.
(2)
The Contractor shall provide and install the following hardware and cables on the Crane for communication among the above servers and computers. -
Terminating boxes with ST connectors for fibre-optic cables inside the Operator’s Cabin.
-
One set of twelve cores multi-mode fibre-optic cable from the fibre-optic termination box in the Electrical House to the terminating boxes inside the Operator’s Cabin. Size of each core of the fibre-optic cables shall be 62.5/125 microns.
6. Common Items 6-1.
Walkways, Stairs, Ladders and Platforms
6-1.1. Applicable Code/Std. (1)
Walkways, stairways and platforms shall be designed to avoid tripping, skidding, ducking or crawling. Clear headroom of 2.1m shall be maintained throughout the walkways, stairways and platforms. Special non-skidding treatment and snow accumulation shall be applied for flat structural surface if used as walkways.
(2)
The design of walkways, stairs and ladders shall comply with the requirements of BS4211, BS5395, BSEN13586 and ISO11660. Design and construction shall be “Modular” such that all welding and “Hot-work” is carried out before the specified anti-corrosion treatment either blast and paint and/or hot dip galvanising.
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6-1.2. Stairway Requirements (1)
Access to the transformer house, electrical house, trolley platform, operator’s cab shall preferably be by stairways with appropriate landings throughout. (See also 61.3 (1).
(2)
Landings shall be provided for stairs at intervals of not more than 8 meters. The gradient of stairs shall not exceed 50 degrees.
(3)
Stairways shall be designed to avoid tripping, skidding, ducking or crawling. Clear headroom of 2.1m shall be maintained throughout the stairways.
(4)
The height of kick plate from the stairway tread level shall be minimum 200mm. The kick plate shall be continuous along stairways, and constructed of minimum 200mm wide steel strip of minimum thickness 4.0mm.
(5)
Stairway treads shall be expanded metal or open grid metal construction, hot dip galvanized.
(6)
Stairs shall be provided to allow ample and safe access to all sheaves, pins, wheels, carriers, ropes, machineries, switches and control equipment, etc., where preventive maintenance is necessary. At least 600mm clear passage around any machinery shall be provided.
(7)
An emergency vertical ladder with suitable landing platforms and safety hoops shall be provided. This emergency ladder shall be installed at the opposite side to the operator cabin access ladder, i.e. from top of main girder down to ground level.
6-1.3. Ladder Requirements (1)
Approval must be obtained from the Purchaser if vertical ladders are used elsewhere. Vertical ladders shall have stiles made of steel flat bars with special non-skidding treatment applied to the flat surface. Vertical or near vertical ladders of over 2 meter length shall be attached with safety hoops. The space within the hoop shall be sufficient for a man with tools to climb up or down the ladder and shall not be smaller than 650mm depth x 600mm width. Vertical straps for the hoops shall be spaced adequately to prevent a human body falling through.
(2)
Landings shall be provided for ladders at intervals of not more than 8 meters. The gradient of stairs shall not exceed 50 degrees.
(3)
Adequate safety straps or bars shall be provided between safety hoop of a ladder and handrail for a landing wherever there is a wide clearance which may allow accidental fall of personnel.
(4)
Access by ladder and/or platforms or landing shall be provided to allow ample and safe access to all sheaves, pins, wheels, carriers, ropes, machineries, switches and control equipment, etc., where preventive maintenance is necessary. At least 600mm clear passage around any machinery shall be provided.
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6-1.4. Platforms Requirements (1)
The inspection and maintenance platforms for the Transformer set shall be a folding type to minimise total width of Transformer house to create adequate safety clearances for the operation. When it is extended it may be allowed to project over the Structure Limit of the Crane.
(2)
Platforms shall be designed to avoid tripping, skidding, ducking, crawling or snow accumulation. Clear headroom of 2.1m shall be maintained throughout the platforms.
(3)
Platforms shall be provided to allow ample and safe access to all sheaves, pins, wheels, carriers, ropes, machineries, switches and control equipment, etc., where preventive maintenance is necessary. At least 600mm clear passage around any machinery shall be provided.
(4)
The vertical columns for cables between transformer housing and main girder at one end, between electric room and main girder at the other end shall be fitted with vertical ladders inside which shall be used to bind cables being mounted inside the columns. For binding requirement see 3-3. (2) vi) for details. Cable ladders external to the structural members may be acceptable subject to the approval of the purchases representative upon submission of details of mechanical protection details of the ladders, cable fixing, ease of access (i.e. removal of protection).
(5)
A permanent inspection and maintenance platforms shall be provided under the trolley for inspection and replacement of wire ropes and sheaves.
6-1.5. Walkway Handrail Requirements For a level walkway the height of the top handrails shall be 1100mm with two intermediate rails at heights of 350mm and 685mm. The height shall be increased as necessary to ensure safety of passage. The handrail shall be constructed with pipe, all welded joints finished smooth to same diameter as the pipe, and continuous along walkways platforms and stairways. The height of kick plate from the walkway tread level shall be 150mm. The kick plate shall be continuous along walkways, stairways and platforms, and constructed of steel strip on nominal width of 150mm, of minimum thickness 5.0mm. Handrails, i.e. the welded assembly of tubular steel and angle stanchions, shall be modular in construction and fully hot dip galvanised, after all fabrication works is completed. These modular sections shall be interconnected at transition points by a continuous top hand rail connected by galvanised sleeves, retained in position by two “grab” screws. The structural part of a walkway platforms or the side members of a stairway shall be either hot dip galvanised or blast cleaned and painted in accordance with the provisions of clause 6-3, but only after all fabrication works is completed. Appendix 1 - Technical Specification Feb 2012
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(2)
The Contractor can provide the two walkways attached below the top level of the Girder. The actual level shall be a design that will not cause any inconvenience to both the operator and maintenance personnel. As an alternative, the contractor may elect to supply girder access platforms generally at the level of the top flange of the girder. In this case, special permanent rails for the attachment of safety lines shall be provided above inside top edge of trolley girders to prevent accidental falling of operators or maintenance personnel who are required to work on the girder. The design shall be approved by the Purchaser.
6-1.6. Cab Access Platforms The cab entrance platform or walkway at the access/transfer point shall be provided at the same level as cab platform, and shall be equipped with pipe frame construction, inward opening and self-closing (by gravity) hinged doors on trolley side and gantry structure side. Opening of either of the doors shall prohibit the trolley motion by means of electrical and mechanical interlock protection. (See also requirement at Clause 4.6.2) 6-1.7. Walkway Requirements
6-2.
(1)
Walkways shall be designed to avoid tripping, skidding, duckling, crawling and snow accumulation. Clear headroom of 2.1m shall be maintained throughout the walkways. Special non-skidding treatment and snow accumulation shall be applied for flat structural surface if used as walkways.
(2)
Walkways shall be provided to allow ample and safe access to all sheaves, pins, wheels, carriers, ropes, machineries, switches and control equipment, etc., where preventive maintenance is necessary. At least 600mm clear passage around any machinery shall be provided.
Illumination and Lighting
6-2.1. Walkways, Stairs, Ladders, Cab Access A lighting system shall provide adequate illumination for all ladders, platforms, walkways, and access to transformer house, panel house and operator’s cab. The minimum illumination shall not be less than 20 lux in walkways, stairs, ladders and accesses. Energy saving light bulbs shall be considered and LED lighting appliance is preferable. Lighting fixtures located at outdoor shall be outdoor type. Incandescent type light bulbs shall be rough service type of IP55 class of protection. 6-2.2. Work Area Floodlights (1)
A floodlight system shall provide adequate lighting to all work areas of the Crane including penetration into bottom of a slot between two 6-high stacks. The illumination of 50 Lux or more at the ground level measured at 7.5m either side of the centreline of the Crane along entire trolley travel range, and specifically 80 Lux under the trolley measured at ground level 7.5 metres either side of the centreline
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 79 shall be achieved. Such floodlights shall not cause glare in the operator’s cab for the operator or shadows which make it difficult to operate the Crane safely. (2)
The gantry runways shall be well illuminated for viewing from operator's cab for gantrying. These lights shall be installed at sufficiently high position to avoid glare to tractor drivers.
(3)
All floodlights are to be protected with stainless steel wires to prevent from falling off the structure. The ballast for all the floodlights shall be grouped together, labelled individually and stored in a water proof stainless steel enclosure.
(4)
The illumination shall not be less than 100lux in operator cabin and electrical house.
(5)
Two working lights with water-proof switch shall be provided for maintenance works carrying out on trolley platform of illumination 100lux as minimum.
6-2.3. Floodlights on Trolley Powerful spot lights (4 nos. minimum) shall be mounted at lower sides of the cab to provide excellent viewing of a ground slot in between two 5 - high stacked containers at night. The floodlight shall be mounted such that they will not obstruct the view of the driver during container handling operation. Two (2) rotatable spot lights (rated at 360W) control individually shall be mounted (locations to be confirmed by Purchaser) to facilitate carrying out maintenance work by engineering personnel. 6-2.4. Emergency Lighting for Escape Routes Battery operated lamps shall be provided inside the operator’s cabin electrical control enclosure and on the trolley platform. 6-2.5. Lighting Control Switches Light switches shall be gathered in several convenient locations to allow centralized control. Two (2) sets of - On-off control switches for all the operational floodlight lights (one group) and walkway lights (second group) shall be located near the panel house on the route from ground to the operator’s cabin and also in the operator’s cab, to allow switching of both groups of lights from either locations. 6-2.6. High Pressure Sodium Lamp and Ballast (1)
The lamp shall be outdoor type and fitted with spring loaded anti-vibration bulb socket.
(2)
The ballasts shall be high power factor type of not less than 0.85 lagging. All the ballasts shall be installed inside a protective housing for protection from weather and concentrated at several conveniently accessible locations for ease of maintenance. Each ballast shall be match numbered with number of corresponding light. The ballast for floodlight on the cab shall be installed inside a weather proof box which is to be positioned outside near the operator’s cab.
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6-2.7. Fluorescent Lamps Fluorescent lamps shall be straight tube with minimum 24 inches long, rapid-start type, waterproof for outdoor application and equipped with steel guard, these lamps are the preferred type for stairway and platform lights. Energy saving lighting appliance such as LED lighting is preferable. 6-2.8. Access for Lights Maintenance All the light fixture shall have safe access for replacement of bulbs.
6-3.
Painting and Protective Coating
6-3.1. Paint System General (1)
The Contractor shall allow for the preparation, cleaning, painting and protection against corrosion as specified hereafter, of the whole of the work to be provided in the Specification.
(2)
Surface not required to be painted, but which are adjacent to steel work which is to be cleaned and painted, shall be protected by appropriate masking during cleaning and painting of the adjacent work.
(3)
Special care shall be taken during manufacture to ensure that foreign matter is excluded from all working parts of the crane.
(4)
All parts of the crane shall be surface treated during manufacture to ensure their protection from the effects of moisture during storage, transport and erection.
(5)
All bright surface and machined parts, including gear teeth, screws threads, etc., shall be protected by a suitable approved rust preventive compound. Particular care shall be taken with the protection of anti-friction bearings and greasing points, enclosed gears and shafts.
(6)
All metal surfaces shall be thoroughly cleaned to bare metal, removing rust, loose scale, dirt, grease, oil, dust and other foreign materials in accordance with 6-3.2 and 6-3.3 hereof. Particular care shall be used at joints and all other places to which access for cleaning is difficult.
(7)
Faying surfaces of structural members intended to be clamped together by bolts shall be shot blast cleaned as specified in Clause 6-3.3(3) hereof and shall be given one coat of Epoxy zinc rich-primer, 25 microns thick.
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Machined mating surfaces of all ferrous components (other than structural members) which are to be clamped together by bolts, in final assembly, shall be protected, as specified in Clause 6-3.1(4) above, after fabrication and just prior to final assembly shall thoroughly cleaned and smoothly coated with a suitable protective compound approved by the Purchaser.
(9)
All structural steel plates and sections which shall form sealed internal surfaces shall be blast cleaned and prime coated using “whole of plate” blasting and painting with a suitable high temperature shop primer. Angle or flat sections used for plate stiffening shall be similarly treated by mechanical (but not manual) treatment methods.
(10)
Providing damage to such prime coating during fabrication is minimal, in the opinion of the Purchaser, power brush and cleaning of such pre-primed surfaces with a suitable approved solvent may be accepted in lieu of a second blast cleaning.
(11)
For the purposes of this Specification 6-3, the term “External Surface” shall include the following areas: (i)
The exterior surfaces of all structural members.
(ii)
The whole of the surface of any object such as an equalising beam or bogie.
(iii)
The whole surface of any component part such as a lug or cheek plate.
(iv)
The outside surface of any gearbox, motor, brake, bearing spacer, collar, track wheel (excluding the actual tread), rope drum (excluding the rope groove) or other similar mechanical or electrical part which is not protected from the weather by being enclosed in a cabin or housing.
(v)
The outside surface of any guard, cabin or housing.
6-3.2. Surface Preparation (1)
All castings shall be properly fettled and cleaned. All runners, veins, pins, etc., shall be carefully chipped off so that no lumps or rough areas are left.
(2)
All welding slag and spatter shall be carefully cleaned off by mechanical cleaning method such as chipping and power brush and, where necessary, grinding.
(3)
All sharp edges shall be smoothly ground to a radius of not less than 1.6 mm.
(4)
Any areas of surfaces which are to be blast cleaned as specified in 6-3.3 hereof, and which show any traces of oil or grease, shall be thoroughly degreased prior to such blast cleaning, using an approved solvent.
(5)
The outside surface of sheet metal components, such as electrical cubicles, shall be dressed by means of a finishing machine or orbital sander to produce a smooth finish, free from weld protrusions, spatter, surface blemishes, etc.
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All sheet metal components and thin walled section (below 3 mm in wall thickness) shall be degreased by an approved process in accordance with BS5493 and shall then be pickled, to remove all mill scale, mill bloom, accordance with BS5493. After appropriate neutralisation and rinsing, such components, with the exception of those which are to be galvanised, shall be given an approved chemical or electro chemical surface passivation and anti-corrosion treatments. (6)
Particular care shall be taken to ensure that surfaces which have been prepared and cleaned for painting, other protective coating or treatment, are not recontaminated by handling with bare hands or by exposure to any contaminating environment.
6-3.3. Abrasive Blast Cleaning (1)
All unmachined steel and cast iron surfaces, apart from sheet metal components and thin walled sections (below 3 mm wall thickness) shall be abrasive blast cleaned, as specified hereunder, after all fabrication and hot work has been completed. The use of pre-blast pre-painted workshop primed steel plate which is treated within three months before used may be accepted, subject to all mechanical and heat affected areas being suitably reprepared to the equivalent of the Sa2.5 by either abrasive blast cleaning or other mechanical methods prior to the application of subsequent coatings. The welding on of lugs, brackets etc after the application of undercoats or topcoats is considered to be poor construction practice, comprises the paint system and must therefore is avoided. Only when it can be shown to be physically impossible to carry out blasting after fabrication will blast and prime coating prior to fabrication be permitted.
(2)
Contractor shall submit details of the blast cleaning proposed to be used, including type of equipment, type and grade of abrasive and profile height expected from use of such abrasive to the Purchaser or their representative at least 30 days before work commencing, for comment.
(3)
External surfaces as defined in 6.3.1(9) shall be dry abrasive blast cleaned to a white metal finish in accordance with SIS005900 Sa2.5.
(4)
Internal surfaces to be abrasive blast cleaned shall be dry abrasive blast cleaned to a finish in accordance with SIS005900Sa2.5.
(5)
After blast cleaning, surfaces shall be fibre brushed or blown with clean dry air (provided adequate driers and oil mist filters are used in air lines) or vacuum cleaned to remove all blast products and abrasives from the entire surface, including pockets and corners.
(6)
Blast cleaning shall not be performed on surfaces that may in the opinion of the Purchaser’s Representative, become wetted after blasting and before painting, or
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 83 other protective coating, nor shall blasting operations be performed on surfaces the temperature of which is less than 3oC above the dew point of the surrounding air, or when the wet bulb temperature in the immediate neighbourhood, as measured by a standard wet and dry bulb thermometer, differs from the dry bulb temperature by less than seven and one half (7.5) percent of the dry bulb temperature, nor shall blasting operations be performed when the temperature of the metal surface is higher than 38oC or lower than 10oC. Contractor shall ensure that all measuring equipment is available and tested to record the above conditions. (7)
Adequate precautions shall be taken to ensure that no damage to or contamination of partially or entirely completed portions of the work, or to machinery, occurs from blast cleaning.
(8)
All free oil and moisture shall be effectively removed from the air supply lines of all blasting equipment, using adequate and approved filters and driers.
(9)
Blast cleaned surfaces shall be kept free of all contamination before painting, etc., as required by 6-3.2(5) above. Operators shall wear fabric gloves of an approved type during cleaning operations and any area inadvertently touched by bare parts of the body, shall be immediately solvent cleaned by approved methods. All items of metal work to be painted shall be so treated not more than two hours after surface preparation of each item has been completed. Any unpainted surfaces which have been subjected to conditions which might induce condensation of water thereon, or which have been left longer than the above specified two hours after blast cleaning, shall be again blast cleaned before being painted.
6-3.4. Painting Generally (1)
All painting and coating operations shall be performed in a neat, thorough workmanlike manner. All paint and coating materials shall be in a thoroughly mixed condition at the time of application and shall be thinned only in accordance with the manufacturer’s instructions.
(2)
Paint or coating material shall not be applied unless the temperature of the metal surface and the atmospheric conditions satisfy the requirements specified in 63.3(6) above. The Purchaser may consider granting approval to the application of paint at temperature less than 10ºC but this shall be on a case-by-case basis subject to the use of paint material specially prepared and formulated for this condition. The first coating shall be applied as soon as possible after cleaning the surface, but in any case not longer than 2 hours after cleaning.
(3)
All surfaces to be coated shall be completely free of moisture, foreign surface matter and abrasive dust at the time of application of each coat.
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(4)
Each coat shall be uniform and free from runs, sags and other imperfections. Limitations on minimum and maximum inter-coat drying periods recommended by the paint manufacturer shall be strictly followed.
(5)
All paints shall be of approved colours (refer to Appendix IV). The colour of each coat shall differ from that of the previous coat to a sufficient extent to enable missed areas and uneven or inadequate covering to be readily apparent. The final coat shall be the specified colour.
(6)
All paint shall be applied to the thickness as specified, and such paint thickness shall be gauged by a certified thickness gauge supplied by the Contractor. Paint shall be applied by approved spray equipment corresponding to the equipment recommended by the paint manufacturer for the particular type of paint. It is preferred that as far as practicable, semi-hollow components such as switchboard cubicles and consoles and any other smaller items where difficulty could be encountered in obtaining even coverage, be painted by means of electrostatic spray equipment. All welds and edges shall be double passed with each coat.
(7)
The Contractor shall, at his own expense, take all precautions and provide all equipment, including ventilation plant, which may be necessary to obviate health hazards arising from the use of specified paints and coating materials in confined spaces or elsewhere.
(8)
All joints, including bolt heads, bolt ends, nuts, washers and attachments, shall be painted, after the connection has been made, to complete the protection in the same system as that specified for the adjacent steel work.
(9)
The Contractor shall submit full technical, application and service details from the manufacturer of the paints they propose to use to the Purchaser or their representative at least 30 days before work commencing, for comment.
(10)
Proprietary Equipment The external surfaces of all mechanical and electrical equipment shall be protected by paint systems having durability comparable with that of the systems specified herein for other steel work in similar environment. Wherever possible special paint treatment of approved quality shall be specified in the ordering of proprietary items. Any equipment having external surfaces of materials which are subject to corrosion and which shall be exposed to the weather shall be protected by an approved paint system equivalent in durability to that used on the main structures.
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Alternative Paint Systems Contractor may offer alternative paint systems to those specified, but such will only be considered if evidence is submitted to support claims that the systems offered are of at least equivalent durability to that of the system specified. Refer also to 6-3.5(1) hereafter.
6-3.5. Paint Systems (1)
External Steel Work After preparation and cleaning in accordance with 6-3.2 and 6-3.3 above all external steel surfaces with the exception of (a) galvanised surface and (b) machined surfaces referred to in Clauses 6-3.1(4) and 6-3.1(8) shall be given the following protective treatment: First Coat: Apply one (1) coat of epoxy zinc rich primer, to a minimum dry film thickness of 75 microns. Second Coat: Apply one (1) coat of epoxy micaceous iron oxide primer / under coat, to a minimum dry film thickness of 100 microns. Third Coat: Apply one (1) coat of a high performance anti corrosive barrier coating based on polyurethane enamel, to a minimum dry film thickness of 50 microns. N.B. Total Dry Film Thickness of system to be not less than 225 microns.
(2)
Internal Unsealed Surfaces After preparation and cleaning in accordance with 6-3.2 and 6-3.3 above, all internal surfaces with the exception of (a) galvanised and non-ferrous surfaces (b) machined surfaces referred to in 6-3.1(4) and 6-3.1(8) hereof shall be given the following protective treatment: First Coat: Apply one (1) coat of epoxy zinc rich primer, to a minimum dry film thickness of 50 microns. Second Coat: Apply one coat of epoxy micaceous iron oxide primer / undercoat to a dry film thickness of 100 microns minimum. N.B. Total Dry Film Thickness of system to be not less than 150 microns.
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(3)
Galvanised and Non-Ferrous Surface, both Internal and External Galvanised and non-ferrous components shall, after appropriate cleaning by an approved method, be given the following protective treatment: Galvanised and Non-Ferrous Surfaces, both Internal and External Surface Preparation: Ensure that all surfaces are free from all grease, oil or other contaminants by application of a degreasing solution formulated from a blend of solvent and emulsifier. Apply Degreaser liberally ensuring that material does not spill on existing paintwork, working well into the surface to be degreased. Allow 5-10 minutes for the solvent to take place. Flush with clean fresh water and allow drying thoroughly prior to application of the primer coating. First Coat: Apply one (1) coat of micaceous iron oxide primer / undercoat to a minimum dry film thickness of 100 microns. Top Coat: Apply one (1) coat of a high performance anti corrosive barrier coating based on polyurethane enamel, to a minimum dry film thickness of 50 microns. N.B. Total Dry Film Thickness of paint system to be not less than 150 microns.
(4)
Motor, Gearboxes, etc. The external surfaces of all machinery such as motors, rope drums, gearboxes, couplings, etc. in exposed locations shall be given protective treatment as specified for external steel work, galvanised and non-ferrous surfaces in 6-3.5(1) and 6-3.5(3) above. The external surface of such machinery enclosed in housings or enclosures shall be given the protective treatment specified for internal steel work, galvanised and nonferrous surfaces in 6-3.5(2) and 6-3.5(3) above. After preparation and cleaning in accordance with 6-3.2 and 6-3.3 above, all external surfaces of such machinery shall receive the following protective treatment: First Coat: Apply one (1) coat of an epoxy zinc rich primer, to a dry film thickness of 75 microns. Second Coat (Top Coat): Apply one (1) coat of epoxy based enamel, to a dry film thickness of 50 microns.
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Where it can be shown that proprietary items such as electric motors have received the basic preparation, the Contractor may with the approval of the Purchaser’s Representative on submission of technical details, complement such systems with additional coatings to bring the system up to the standard of the specified system. The contractor shall remain responsible for ensuring paint system compatibility. (5)
Horizontal Surfaces of Access Ways, etc. Area: Horizontal Surfaces of Access Ways All horizontal surfaces used for pedestrian or traffic surfaces for access to any part of the crane for normal operation or maintenance procedures, including such surfaces on structural members, shall be given an approved special paint treatment. Such special treatment shall provide improved abrasion resistance and non-slip characteristics while providing protection and having durability not less than that of the top coating specified for each relevant environment, i.e. external or internal. Non Skid Powder shall be applied to second last coat while still tacky and allowed to set prior to application of final coating.
6-3.6. Galvanising (1)
General Components or surfaces required to be galvanised shall be prepared generally as specified in 6-3.2 hereof and shall than be either acid pickled in accordance with BS5493 or abrasive blast cleaned in accordance with Clause 6-3.3 hereof. Abrasive blast cleaning shall only be permitted on components or surfaces where there is no likelihood of distortion due to such cleaning method. After such cleaning, all components or surfaces so required by this specification shall be given a hot dipped galvanised coating conforming to the requirements of BS5493. Notwithstanding the requirements of BS5493, the minimum thickness of coating at any point shall be not less than 200 microns. Galvanising of any component or surface shall only be carried out after completion of all fabrication work on such component or surface. No welding on any pregalvanised component or surface will be tolerated unless the component or surface is to be subsequently regalvanized.
6-3.7. Reinstatement of Protective Coatings at Site (1)
Care shall be taken at all times to ensure that the protective coatings and treatment shall not suffer any damage during handling, transport and erection.
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After the components have been transported to the Site, assembled and welded where necessary, all protective coatings shall be carefully inspected and any areas where protective coatings have been damaged or found defective shall be clearly marked with orange-coloured spray paint or paint-stick or chalk, for ready identification and remedial treatment. All weld slag and spatter or heat affected coatings on surfaces that have not been adequately protected during field welding, shall be completely removed and any high points on field welds shall be ground smooth. All such areas together with field welds, weld margins and burn marks shall be abrasive blast cleaned as specified in Clause 6.3.3 hereof, with due care of other areas of the coating to avoid further damage. All site abrasive blast cleaning shall be affected with approval closed cycle vacuum blasting equipment.
(3)
Within two hours of cleaning as specified in 6-3.7(2) above, and before any contamination or discoloration can take place, the blast cleaned areas shall be recoated with the priming coat and to the thickness specified in 6-3.5 hereof for the relevant type of surface and location. Undercoats and top coats of the type and thickness, as specified in Clause 6-3.5 hereof, for the relevant type of surface and location shall subsequently be applied, with suitable feathering of coats to avoid ledging. Manufacturer’s recommendations regarding application and drying or intercoat intervals shall be strictly followed.
(4)
Damage to paint coatings such as scratches or abrasions which, in the opinion of the Purchaser’s Representative, do not penetrate the total paint system may, at the discretion of the Purchaser’s Representative, be reinstated by cleaning with a suitable solvent and then touch up painting with the relevant primer(s), intermediate and top coats as directed by the Purchaser’s Representative.
(5)
For all repair painting, the final coating shall comprise paint from the same batch as that originally used on the particular surface.
(6)
Cleaning and repair painting of the crane or its equipment shall be carried out only when the conditions specified for the original cleaning and painting in 6-3.3(6) and 6-3.4(2) hereof, are satisfied. Painting shall not be permitted if there is dust being deposited on the surface to be painted or conditions are not in accordance with Clause 6-3.3(6).
6-3.8. Inspection and Sample Panels (1)
Attention is drawn to Inspection Control Sheets in Appendix II of this Specification. Inspection shall take place before and after preparation and coating and also on site.
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Before any surface treatment is carried out, the Contractor shall supply to the Purchaser’s Representative, free of charge; a)
Samples of each type and colour of paint approved for use on the crane for testing. The Purchaser reserves the right to call for further random samples during the entire painting operation. Should the tests prove unsatisfactory, the entire batch shall be rejected and the Contractor shall take corrective action to re-blast and re-paint all sections painted using the rejected batch to the satisfaction of the Purchaser’s Representative.
b)
Two sample blast cleaned panels one panel cleaned in accordance with 63.3(3) and the other cleaned in accordance with 6-3.3(4) hereof, each panel measuring not less than 150mm x 150mm x 6mm, and adequately protected after cleaning by sealed clean polythene wrapping. If approved, the sample shall then be retained by the Purchaser’s Representative for comparison with the prepared steel work.
c)
Two steel panels for each painting system, at the commencement of painting operations, cleaned and painted in accordance with the relevant requirements of this specification with the exception of any site coat. One of each pair of panels is to be “stepped” to show the successive build up of the paint treatment and will be used as a standard of acceptance throughout the painting operations.
6-4.
Purchaser’s Logo, Crane Numbers, Signs
6-4.1. Purchaser’s Logo Purchaser’s logo shall be painted on outer sides of the main girders. (For Purchaser’s logo refer to the Appendix IV). The size shall be decided by the Purchaser. 6-4.2. Crane Numbers Crane number shall be painted on outer sides of the main girders and on ends of gantry equalizers. (For general location and size refer to the appendix IV). Colour to be white letter on Blue background. 6-4.3. Crane Capacity Signs (1)
Capacity signs showing the safe working load of the Crane shall be fitted to both sides of the gantry structure where clearly legible from the ground level.
(2)
Capacity signs showing the safe working load of the spreader and spreader number which will be designated by the Purchaser during drawing approval process shall be fitted or painted on both sides of the spreader.
(3)
Capacity of each lifting lug on the spreader shall be indicated near each lug.
(4)
All capacity signs shall be in metric units = ‘Tonnes’ or in abbreviation ‘Te’.
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6-4.4. Manufacturer’s Name Plates (1)
Manufacturer’s name plate could be placed on the girder structure only. The size and location must be approved by the Purchaser.
(2)
A plate showing year and place of manufacturing, mfg. no., principal dimensions, speeds and capacity of the Crane shall be fitted in the operator’s cab.
(3) Manufacturer’s name plate shall be fitted on each major electrical and mechanical component showing type, capacity, serial number, manufacturer’s number manufacturing date etc, for future reference.
6-4.5. Other Signs
6-5.
(1)
A plate indicating lift height of the Crane shall be fitted at upper front wall of the operator’s cab (in Polish and English, size 75mm x 900mm). Wording shall be provided by the Purchaser in design stage.
(2)
Each element of machinery shall be properly labelled for its direction of motion or operation and for any precautions to be taken before operation or maintenance.
(3)
Labels and caution plates shall be in Polish and English. Other signs shall be subject to the approval of the Purchaser in English. throughout the painting operations.
Alarm, Warning Signals
6-5.1. Gantry Travel Warning (1)
Four (4)-flashing electronic type strobe warning lights shall be installed at four corners of the crane. These lights shall be activated automatically by gantry motion. The type must be approved by the Purchaser.
(2)
One common amplifier for travel alarm sound and emergency warning sound shall be installed inside the panel house, and the alarm and warning sound shall be emitted through four (4) speakers installed at four corners of the crane. The gantry travel alarm sound shall be automatically activated and sustained during gantry motion. The alarm tone shall consist of an intermittent signal, sounding at 1 second for duration of 0.5 second. The emergency warning sound shall be activated by the operator by pressing down the foot switch on the floor of operations cab, and it shall override the travel alarm sound when pressed during gantry motion. The type of both travel alarm and emergency warning sounds to be approved by the Purchaser.
(3)
The alarm sounder speakers shall be located at a maximum height of 2.5m above ground level. The generated signal level shall not be less than 95dB at 1 KHz at the point 1m forward of each speaker measured at a height of 1.5m above ground level. The signal shall not exceed the above limit by 3dB.
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The volume of the warning sounds to be adjustable at the amplifier for travel alarm sound and the emergency warning sound independently.
6-5.2. Main Hoist Overload Warning (1)
Main hoist system shall include overload warning and tripping system to satisfy statutory requirement. i)
80% load for over 3 second: Intermittent warning signal.
ii)
100% load for over 3 seconds: Continuous warning signal.
iii)
110% overload for over 3 seconds: Trip hoist motion. Allow lowering motion in slow speed only.
6-5.3. Premature Twistlock Operation Warning (1)
Spreader twist lock movement shall be mechanically and electrically interlocked with spreader landing detection so that ‘lock’ movement is prohibited unless all the twist locks are confirmed to be inserted into the corner fittings. The landing signal shall allow a one (1) second time lag to indicate the completion of landing to the operator and to trigger interlock so that momentary landing completion signal do not activate interlock.
(2)
The ‘premature locking’ movement before the spreader is landed on a container or hatch cover shall be prohibited by means of electrical interlock on the logic control circuitry and mechanical interlock. There shall be no physical movement of the twist locks on the spreader even though the switch is turned to ‘Lock’ position before landing is completed as described in 6-5.3(1) above. Audible and visual alarms noticeable at ground level and at inside the operator’s cab shall be activated by this premature turning of the lever type twist lock switch and all motions of the crane shall be deactivated. Both audible and visual alarms shall cease when the twist lock switch is returned to its’ original position. The alarm tone shall be approved by the Purchaser.
(3)
The ‘premature unlocking’ movement while suspending the load with twist locks shall be prohibited by means of electrical interlock on the logic control circuitry and mechanical interlock. There shall be no physical movement of the twist locks on the spreader even though the switch is turned to ‘Unlock’ position while the load is suspended with twist locks. Audible and visual alarms noticeable at ground level and at inside the operator’s cab shall be activated by this premature turning of the lever type twist lock switch and all motions of the crane shall be deactivated. Both audible and visual alarms shall cease when the twist lock switch is returned to its original position. The alarm tone shall be approved by the Purchaser.
(4)
The twist locks shall remain on its last position after power interruption, i.e. failure and resumption of electrical power.
6-5.4. By-Pass Switch Abuse Warning
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For difficult situation during operation when encountered by the operator to handle containers, an “interlock override spring return key switch” shall be installed on the console or near the console apart from normal operational control switch group to overcome difficult situations that may be encountered during container handling operations. The key switch shall be spring return type key switch.
(2)
Twist lock interlock bypass spring return key type switch - When this is turned to handle a difficult situation in order to carry out hoisting or lowering function, an alarm sound shall be broadcasted by an independent amplifier through a speaker located outside the operator’s cab and face downward. The hoisting speed and the trolley speed shall be at slow down mode since this is a difficult condition and safety is required.
(3)
Landing bypass spring turn key switch - When this spring return key switch is turned to allow the twist locks to turn in case of difficult condition, such as deformed containers, an alarm sound shall be broadcasted by an independent amplifier (same as the one for twist lock interlock bypass spring return key switch) through a speaker located outside the operator’s cab and face downward. The hoisting speed and trolley speed shall be at slow down mode since it is an abnormal condition and safety is required.
(4)
Labels shall be provided for each switch and indicator in both Polish and English.
6-5.5. Electrical Control House A/C Warning Control house shall be well insulated to keep the inside temperature below 25 deg. C all the time (Ref. to 4-5.2. (1)). The air conditioning system failure shall be indicated at outside of the room or indication of warning in the CMS, and a warning buzzer in the operator’s cab shall be activated in case inside temperature of the panel room rises over 40 degree C. The air conditioner main circuit shall be activated when the power supply is turned ‘on’ and deactivated when the power supply is cut off. Duplicate air conditioning units shall be provided to ensure that the failure of one unit does not stop the crane operation. Each unit shall be rated to maintain the set conditions independently of the other. 6-5.6. Public Address/Warning (1)
An independent public address amplifier shall be installed inside the operator’s cab and protected against interference by a key-locked cover door.
(2)
The public address amplifier shall be activated in case of ‘premature locking’ and ‘premature unlocking’ of the twist lock lever type switch with an alarm sound through a speaker outside the driver’s cab. The alarm shall be deactivated when the lever type twist lock switch is returned to its proper position.
(3)
The public address amplifier shall be activated in case of turning the twist lock bypass or landing by-pass key type spring return switch to ‘On’ position with an alarm sound through the speaker same as above (2). The alarm shall be deactivated when the spring return key switch is released and to the ‘off’ position.
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Emergency Stop Push Buttons The emergency stops shall be hard wired independent circuit that will stop all motions and isolate power to all drives. PLC shall be configured to monitor E-stop circuit for isolation and CCMS purposes.
6-6.1. Locations Total eight (8) emergency stop push buttons shall be installed on the Crane. 1
Near Main Hoist motor.
1
Near Trolley Travel motor.
2
In Operator’s Cab (1 for motion stop).
4
Two each at panel side and cable reel side sill beams or other Purchaser’s approved position, at ground level facing outside and inside of the Crane to be readily reached by ground operation personnel.
6-6.2. Type Mushroom head emergency stop pushbutton (self latch) switches shall be provided. All emergency stop buttons shall be recessed to prevent it from being actuated accidentally. 6-6.3. Emergency Stop Signs Adequate signs shall be provided in Polish and English to enable easy identification of their locations to ground level personnel. The size of the sign board shall be 300mm x 300mm minimum.
6-7.
Service Outlets
6-7.1. Location (1)
Two independent service outlets (one pair) which conform to BS1363 and AS3122 standard respectively, with ground, 220V, 1-phase, 13 Amp. capacity shall be provided and mounted adjacent to each other as a combination at following locations: i) ii) iii)
One pair in the Operator's cab. One pair in the control panel house on the wall. One pair at ground level, one each under cabe reel side and panel side sill beam, facing inside of the Crane.
6-7.2. Type Model
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6-8.
Fire Extinguishers All fire extinguishers shall be placed on a properly designed holder so that they are firmly secured and easily accessible. The lower part of the holder shall have a cylindrical wall of at least 150mm in height and 3mm in thickness. Drain hole shall be provided at the lower part to release water. A ‘fast releasing’ type clip or fastener shall be installed at the upper part of the holder so that the fire extinguisher could be released quickly. This holder shall be fixed permanently to a permanent structural member of the Crane.
6-8.1. Locations (1) (2) (3) (4)
Outside panel house – one (1) of 5kg capacity. Outside transformer house – one (1) of 5kg capacity. Outside driver’s cab – one (1) of 2kg capacity Trolley frame – one (1) of 5kg capacity
6-8.2. Type-Model All the fire extinguishers shall be CO2 type of local Government approved model, and shall be locally refillable by a government approved contractors. 6-9.
Maintenance Tools and Equipment
6-9.1. Mechanical Maintenance Tools i)
One (1) piece of torque wrench with socket sets (for adjustment of rail bolts).
6-9.2. Electrical/Electronic Maintenance Tools (i) (ii)
Two (2) computer notebooks shall be provided. Five (5) units of digital multi-meter equivalent to “Fluke 87 model”.
6-9.3. Hydraulic Maintenance Tools NOT USED. 6-9.4. Special Tools and Equipment (1)
One unit of portable control panel for operating and testing spreaders in the workshop and at site for maintenance and fault diagnostic. The panel shall incorporate functions of push button switches, selector switches, indicator lamps, PLC, input / output devices, spreader multi-pin connector, cables and all parts and
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Special tools and jigs necessary for mechanical, electrical and electronic maintenance works shall be supplied with the Crane, and stored in appropriate locations of the Crane.
6-9.5. Wear Gauges i)
2 - complete sets of wear gauges which can indicate the amount of wear, made of steel plate, shall be supplied with the Crane stored in an appropriate storage box fitted on the Crane for, a. b. c.
ii)
All the sheave grooves. All the gears for main hoist, trolley travel (including rack and pinion) and gantry travel. Trolley wheels.
Each wear gauge shall be clearly marked with component name to be gauged.
7. Project Q.A. and Administrative Requirements 7-1.
Document Submission (Project)
7-1.1. Project Organisation Chart (Shop & Site) (1)
The Contractor shall submit to the Purchaser a project organisation chart within one (1) month after the date of the Agreement.
(2)
The schedule shall show the organisation of the Contractor’s resources, which he intends to employ in the total project from shop manufacturing through to the site commissioning phases. This will clearly identify the departments involved, the people responsible for each and the number of personnel directly involved in administering the project.
7-1.2. Project Schedule (Shop & Site) (1)
The Contractor shall submit to the Purchaser a project schedule within one (1) month after the date of the Agreement.
(2)
The project schedule shall be presented in the form of a timed schedule covering all activities appertaining to the manufacture of the Crane(s). The contents shall include but not be limited to the following: i) ii) iii) iv) v) vi)
Contract start date. Engineering Design Period. Submission of Drawing/Design Calculations. Procurement of Materials and Components. Manufacturing Periods for the main Structural Sections. Erection in the Contractors Facility.
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Shop Test and Commissioning. Transportation Period. Site Commissioning. Completion Date(s)
The project schedule will be provided in a format approved by the Purchaser and shall be presented in a way that clearly shows each activity connected in a logical programme sequence. Each activity shall show the duration, early start and early finish and shall identify the critical path of the project.
7-1.3. Project Progress Report (1)
The project schedule shall subsequently be updated and submitted to the Purchaser at intervals of no more than 1 month throughout the course of the project.
(2)
The monthly update will show actual progress against the original baseline so that effect of any slip or improvement in progress can be easily identified.
7-1.4. Quality Assurance Programme/ Manuals (1)
Contractor shall submit to the Purchaser a quality assurance programme for review within one (1) month after the date of the Agreement.
(2)
The programme shall consist of General Quality Assurance Program, which states Contractor's general practice and organisation to assure quality during design, procurement, fabrication and erection periods, and a Specific Quality Assurance Programme.
(3)
The Specific Quality Assurance Programme is particularly for the Cranes and Related Equipment in this Contract, which shall include drawings / data submittal schedule for review of drawings by the Purchaser and key inspection and test items during fabrication and delivery up to hand over of the Crane or other Goods to the Purchaser with proposed timing and locations of conducting such inspection and test. This Programme must cover all the inspection and review items as set out in Appendix II "Inspection Control Sheet" and Appendix V "Minimum Requirement for Drawings / Calculations / Data Submission". An organisation chart with names of the quality assurance team personnel for the Agreement for each major stage of fabrication, delivery, commissioning and Defects Liability Period shall be included in this Programme.
7-1.5. Daily Plan and Report (Site Work) . For the duration of the period of site work at the Purchaser’s premises, the Contractor shall submit, at daily intervals in a form approved by the Purchaser, his progress of activities and tests carried out. This daily plan shall also indicate weather conditions, number of Contractors personnel and sub-contractors engaged at site together with the activities planned for the next day. Appendix 1 - Technical Specification Feb 2012
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7-2.
Document Submission (Technical)
7-2.1. Submission Schedule The Contractor shall submit technical information at the times outlined below for the Purchaser’s review. 7-2.2. Conceptual Design The Contractor shall, submit to the Purchaser a conceptual design, within 1 month from the date of the Agreement which outlines his proposal for the Crane and other Goods. The design shall show clearly by drawings and description the following details: -
General arrangement of the Crane Trolley and operators cab Rope reeving arrangement Transformer and Electrical House Shore power supply system Lower Crane structure Gantry equalisers, bogies and wheel arrangement.
7-2.3. Drawings and Calculations for the Purchaser's Review Following review and acceptance of the conceptual design and prior to the fabrication or ordering of components, the Contractor shall submit detailed drawings and calculations for review to the Purchaser. This information shall include but not be limited to the following: (1)
Three (3) sets of structural, mechanical and electrical calculations on all aspects of the Crane design, for example -
(2)
Stability and wheel load calculations Crane structure stress calculations Fatigue analysis for all stress carrying structural members. Load combinations for various design criteria. Design calculations for the hoist, trolley, and gantry Crane electrical load calculations. Lighting calculations. Skew and anti-sway system
Three (3) sets of general arrangement and design drawings showing all elements, sub elements, component parts, layouts, structure details, connections of the Crane. The drawings shall include but not be limited to those items listed in the List contained in Appendix V.
(3)
General arrangement drawings, calculations and drawings other than listed in above list, which clarifies further details, shall be submitted from time to time at the request of the Purchaser for review.
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Three (3) -copies each shall be submitted for the review. Contractor shall submit any other documents as requested from time to time by the Purchaser. The Purchaser's comments on the drawings or submittals shall not waive Contractor's duties or obligations to achieve satisfactory performance of the Crane and all other Goods as set out in the Conditions of Contract, specifically Clause 3 and to otherwise comply with the Contract. The Purchaser undertakes no duty to the Contractor to neither identify nor notify to the Contractor any errors or omissions in the Contractor's design. One month before the shipment of the first Crane(s), the Contractor shall submit to the Purchaser four (4) sets of all drawings reviewed and if necessary revised according to the Purchaser comments or for other agreed reasons
7-2.4. Lubricant List (1)
The Contractor shall supply a complete list of oil and lubricants to be used on the Crane three (3) months prior to the test of the Crane in Contractor's shop for the Purchaser's approval.
(2)
All the oil and lubricant used for the crane shall be Shell lubricating oils.
7-2.5. Crane Delivery Method Statement (1)
No later than three (3) months before the arrival of the first Crane(s), the Contractor shall submit a method statement for the Purchaser’s approval for the roll-off or lift-off of the Crane(s) and other Goods to the Purchaser’s quay deck. The method statement shall include: (i) (ii) (iii) (iv) (v) (vi) (vii) (viii)
(2)
The total area required for the roll-off operation. Full details of the transportation vessel and the stowage of the Crane(s) Orientation of the vessel when offloading Number and position of bollards and moor lines, Length and position of sea anchors. (if applicable) System of transferring the Crane to the quay deck All skid beams and skid beam centres. (If applicable) All positions and magnitude of loadings applied to the quay deck during the offloading operation.
The proposal shall also show a period of occupancy and the length of the Purchaser's berth required for roll-off or lift-off operation
7-2.6. Site Work Method Statement (1)
No later than three (3) months before the arrival of the first Crane(s), the Contractor shall submit to the Purchaser a site work method statement for the Purchasers approval showing all activities from arrival of the Crane(s) through to acceptance. The method statement shall include:
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i) ii) iii) iv) v) vi) vii)
The total area required to commission the crane(s) and to store the loose items and spare parts. (This will be strictly subject to the Purchasers approval) Roll-off or Lift-off scheme and date of performance. Key activities of the commissioning and duration. Number of days required from the date the Crane is ready for starting up and load testing. Date the Crane will be Commissioned and handed over to the Purchaser. Date the Crane will be finally handed over to the Purchaser. Other key dates of significance.
7-2.7. Commissioning Test Procedure. (1)
No later than four (4) months before the arrival of the first Crane(s), The Contractor shall submit to the Purchaser for his approval a Commissioning Test Procedure.
(2)
The Commissioning Test Procedure shall be in a form of a document and shall contain detailed field and function check procedure to fully demonstrate that the Crane and other Goods meet the requirements of the Agreement including suitability of the Crane for container handling operations. The procedure shall describe the tests to be performed, the indications to be measured and the method by which they are measured. It shall contain the design or acceptable values of each measurement along with blanks in which the tester can enter the measured values.
(3)
Provision shall be made within the procedure for the tester and the Purchaser’s Representative to initial and date each separate test.
(4)
The Commissioning Test Procedure shall be duly completed by the Contractor following each individual test or each series of tests conducted at the Contractor’s facility or at site. Where necessary the Purchaser’s Representative shall verify the results.
(5)
The Contractor shall submit the completed Commissioning Test Procedure no later than one (1) month after the notification of successful completion of the Commissioning Test for the Goods in question.
7-2.8. Up-Dated Drawings (1)
No later than one (1) month after the date of the Agreement, the Contractor shall submit to the Purchaser full details of the Contractor’s system of drawing management, which shall be maintained throughout the project.
(2)
The Contractor shall demonstrate to the Purchaser that a logical system of drawing administration exists. And the system shall clearly establish to the Purchaser, the procedures and current practices in place which deal with alterations, modifications and re-issue of drawings from the design stage through to the as built drawings. Such system shall, as a minimum, provide for two (2) copies of each and every drawing amended relating to this contract and which is during the course of the contract, to be forwarded to the Purchaser for their remain and approval if
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 100 appropriate. A system of issuing “internal” change without notice to the Purchaser is not acceptable. 7-2.9. Training Programme (1)
No later than three (3) months before the arrival of the Cranes, the Contractor shall provide a comprehensive training programme to cover the theoretical and practical training requirements for the Port’s Crane operators, electrical and mechanical tradesmen and electronic technicians. The programme shall be aimed at all aspects of the Crane in the respective disciplines in order to provide the trainees with a sound basic knowledge of the Crane(s) and their systems
(2)
The Contractor shall use the training personnel from the sub-contracted suppliers where possible and shall not rely upon untrained trainers or site commissioning personnel.
(3)
The scope of training to be conducted for the disciplines shall be generally as outlined in 7-5
(4)
The language used for the training shall be Polish/English.
7-2.10. Structural maintenance Program (1)
The contractor shall submit a Structural Maintenance Program for review. The program shall be based on the principles of fracture mechanics. This program shall include: (i) (ii) (iii) (iv) (v) (vi)
Inspection intervals Locations to be inspected NDT procedures to be used Reporting procedures Repair procedures Documentation showing the parameters used to determine the inspection intervals in accordance with the criteria specified below.
(2)
The first structural inspection will be made during the defect liability period, but later than after 200,000 moves, in accordance with the Structural maintenance Program. The inspection results will be given to the Contractor. Within 30 days, the Contractor shall submit a plan to repair any defects found. Upon Purchaser’s approval of the Contractor’s plan, the Contractor shall repair the defects at their expense.
(3)
Later inspections will be made according to the recommended inspection interval, which shall be included in the Structural Maintenance Program. The inspection interval shall be determined according to the following table “Inspection Interval Criteria”. Locations where the cumulative damage ratio is less than the minimum 24 year values do not need to be included in the Structural Maintenance Program. The first inspection period will begin after completion of the first inspection during Defect Liability Period.
(4)
The inspection method shall be selected to detect fatigue cracks. Only the critical locations need to be inspected by NDT. The critical locations on all members are those locations where fatigue cracks, if any, would be expected to initiate. The inspected region shall extend
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 101 a reasonable distance beyond the critical point. MT shall be used at the critical locations of fillet welds and UT shall be used at the critical locations of butt welds. VT shall be used at all locations of potential fatigue cracks. (5)
The Contractor shall provide permanent access ladders and platform at all inspection locations, with inspection interval of 12 years or less. Access shall meet applicable safety laws and regulations.
INSPECTION INTERVAL VS. CUMULATIVE DAMAGE RATIO D = L/K1 OR 2 DETAIL 24 YEARS 12 YEARS 6 YEARS NFCM FCM NFCM FCM NFCM FCM B 0.21 0.41 0.19-0.38 0.39-0.64 0.70-1.00 0.65-1.00 C 0.18-0.36 0.17-0.33 0.37-0.62 0.34-0.57 0.63-1.00 0.58-1.00 D 0.18-0.35 0.16-0.33 0.36-0.61 0.34-0.56 0.62-1.00 0.57-1.00 E 0.15-0.29 0.13-0.26 0.30-0.50 0.27-0.45 0.51-1.00 0.46-1.00 G 0.17-0.34 0.16-0.31 0.35-0.58 0.32-0.53 0.59-1.00 0.54-1.00 F2 0.16-0.32 0.15-0.29 0.33-0.56 0.30-0.51 0.57-1.00 0.52-1.00 G 0.21-0.41 Not 0.42-0.70 Not 0.71-1.00 Not allowed allowed allowed W 0.20-0.40 0.19-0.37 0.41-0.69 0.38-0.64 0.70-1.00 0.65-1.00 TUBULAR 0.20-0.35 0.15-0.30 0.36-0.64 0.31-0.50 0.65-1.00 0.51-1.00 Inspection Interval Criteria 7-2.11. Operation Manuals (1)
The Contractor shall provide operating instruction manuals (in Polish and English) to the Purchaser two (2) months before the date of the first Crane departure from the Contractor's assembly yard.
(2)
The operating instruction manual shall clearly state the start up procedure of every device on the Crane including all bought-in equipment, and all the points to be observed or checked during the start up.
(3)
Corrections shall be made by the Contractor to the Manuals for any changes made in the instructions during the commissioning period, and the revised instruction manuals shall be submitted one (1) month after the notification of successful completion of the Commissioning Test of the first Crane(s)
(4)
Two sets of above instructions shall be submitted in a CD ROM format.
(5)
Please refer to Appendix VI for the list and quantity of operation manuals.
7-2.12. Maintenance Manuals (1)
The Contractor shall provide maintenance manuals (in Polish and English) to the Purchaser two (2) months before the date of the first Crane departure from the Contractor's assembly yard.
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 102 (2)
The maintenance manual shall include a complete list of wearing parts showing the allowable limit of wear for each part.
(3)
The manual shall include maintenance intervals and procedures for all the bought-in equipment, and also calibration instructions and standards for meters, gauges and any components which require periodical calibration to allow calibration by the Purchaser's maintenance staff.
(4)
The relevant parts of manuals shall be revised and resubmitted as soon as practicable by the Contractor for any changes in system or component design.
(5)
Two sets of manual in CD ROM shall be submitted.
(6)
Please refer to Appendix VI for the list and quantity of maintenance manuals.
7-2.13. As-Built Drawings The Contractor shall submit to the Purchaser 3-full size copies and three sets in CD ROM (in Polish/English version, Auto-Cad or Acrobat format) of the following as-built drawings within 30 days after the date of Commissioning Certificate for the first Crane(s) to achieve Commissioning. Please refer to Appendix VI for the list and quantity of as built drawings. (1)
All drawings that were previously submitted for the Purchaser's review and revised as built as at the shipment date.
(2)
Detailed drawings for wearing parts showing machining tolerances, wherever applicable, and wear limits: i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv)
Brake drums (or discs) Brake shoes Wheels Sheaves Anti-friction bearings Bushes Bearing plates Oil seals and O-rings Wire rope drum Wire rope drum coupling Rail Gears Rack and pinion Table for consumable parts of electrical machineries All other wearing parts
(3)
Detailed electrical control circuit drawings, control logic programs, and wiring diagrams.
(4)
Full details of all bought-in equipment, drawings instructions, etc.
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 103
(5)
List of structural connection bolts and machinery fitting bolts with tightening torque value for each location/size. The Contractor shall revise and resubmit drawings for replacement in case any modification or revision is made on the Works after the initial submission.
7-3.
Shop Inspection & Tests
7-3.1. Shop Inspection and Verification (1)
Inspection and testing of the Crane shall be performed by the Contractor to verify or demonstrate the Crane's conformance to this Specification and the other Contract Documents, following the approved Specific Quality Assurance Programme as stated in 7-1.4.(3).
(2)
Without limitation to the Purchaser's rights under the Agreement, the Contractor and the Purchaser shall agree to the content, nature and extent of the review, inspection and tests to be carried out to any of the Goods at each of the following stages: i) ii) iii) iv) v) vi)
Design. Fabrication and assembly; Pre-shipment; Upon Delivery; Tests pursuant to Clause 13 of the Conditions of Contract, which, if successful will lead to the issue of a Commissioning Certificate. Such further tests as otherwise may be required that in the opinion of the Purchaser is pursuant to Clause 9 of the Conditions of Contract.
(3)
The Contractor shall notify the Purchaser of the date and place of each key inspection or test, at least three (3) weeks prior to the date when the key inspection or test is to be made.
(4)
Inspection and test items shall generally include (but not limited to) the following fundamental items. i) ii) iii) iv) v) vi) vii)
viii)
Materials and components sources and identification of standards applied. Workmanship overall. Painting Inspection of Operational and Maintenance Safety, Test of all safety equipment and safety devices. Inspection of Operational Efficiency, Functional Test of all components equipped for operation. Inspection of Maintenance Efficiency, Functional Test and inspection of all equipment for maintainability. Rated Load Tests, 1/2 Loads Tests, 1/4 Load Tests and No Load Tests including Anti-sway Function Test and Measurement of Speeds and accelerations. Overload Tests including Stability Test and Measurement of Structural Deflection.
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 104 ix) x) xi) xii)
Accessories and Spare Parts Inventory. Operating Instruction and Maintenance Manual Review. Weight verification as necessary. Statutory inspection and tests.
(5)
The Purchaser reserves the right for itself or any party authorised by the Purchaser to inspect the Crane or other Goods at any time including during fabrication and delivery.
(6)
Any inspection or test results verified by the Purchaser shall not waive Contractor's duties or obligations to achieve satisfactory performance of the Crane in actual operation as set out in Clause 3 of the Conditions of Contract or any other obligation or liability of the Contractor.
(7)
The Contractor shall submit to the Purchaser a list of designed weights of the moving loads, namely, the trolley, operator cab and spreader, and any other moving loads, when the design of these components are completed.
(8)
At the same time, Contractor shall submit a list of calculated maximum structural stresses at critical points of the Crane structure.
(9)
The Contractor shall verify the calculated stress level by actually weighing these moving weights after the fabrication and assembly are completed.
(10)
The weight of trolley assembly, operator cab assembly and spreader assembly shall be weighed by a third party, who will issue an authorised certificate. The Certificate shall be submitted to the Purchaser.
(11)
The Contractor shall be responsible for maintaining the calculated stress level within allowable limits. If there are differences between the designed weights and the actual measured weights, the Contractor shall re-submit calculations of all stress levels based on the true weights to show that the levels are maintained within requirements. Any stress levels over the allowable limit will require a redesign to be carried out by the Contractor.
(12)
The recalculation and if necessary the redesign plan shall be submitted to the Purchaser for review no later than commencement of the pre-shipment Crane assembly load test.
7-3.2. Pre-Shipment Inspection and Test (1)
The Crane is to be fully erected in the Contractor’s facility and tested prior to shipment.
(2)
The Contractor shall prepare a shop assembly and Crane erection programme including all tests and dimensions to verify the proper installation and assembly of the Crane’s components. The drawings shall include assembly procedures, drawings, dimensional acceptance criteria, structural member dimensional checks, structural frame alignment dimensions, structural pin and bore fits, structural bolt torques and machinery alignments.
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 105
7-4.
(3)
The Contractor shall inspect the assembly of components and Crane erection throughout the process to verify and to be satisfied that the requirements of the Specification are being fully complied with in all respects.
(4)
The Crane shall be fully lubricated in accordance with the manufacturer’s recommendation prior to any shop testing. A lubrication checklist shall be included in the test documentation.
(5)
The assembled Crane shall be inspected and tested at the Contractor’s assembly facility. All installations and functions shall be verified for compliance to the Specification. The Crane testing shall as a minimum include the following: (i)
Verify main hoist, trolley and gantry speed, acceleration according to Specification (See 2-7.1)
(ii)
Verify power supply according to Specification (See 2-7.4)
(iii)
The sway control and anti-sway system shall be set up and tuned under a range of load conditions. Verify the sway control and the effectiveness of the mechanical anti-sway.
(iv)
Skew motions.
(v)
Interlocks and limit switch settings, and software.
(vi)
Brake dynamic torque values shall be verified for each drive by driving through each brake and calculating the braking torque from the current draw. Thermal capacity of the brakes shall be verified in the same manner with torque, time and brake revolutions recorded. All brakes shall have their linings properly burnished or seated to the manufacturer's recommendations prior to conducting these tests.
(vii)
Wheel turning.
(viii)
Spreader functions.
(ix)
Check structural alignment and integrity.
(x)
Inspect and demonstrate that all electrical wiring and wiring components are installed and properly marked.
(xi)
Emergency stop and all safety protections.
(xii)
On-Board CCMS
(xiii)
Endurance Test (See Clause 7-5.5)
Shipment, Delivery and Site Work The crane(s) shall be delivered by self-propelling transportation vessel.
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7-4.1. Clearance for Shipment The Crane(s) shall be totally assembled in the Contractor's yard and tested for functions of all the devices before shipment. The Load test is essential to be performed in the Contractor's yard. Heat run tests and operational check of interlocks and safety devices shall be performed through the permanent control gear and components installed on the crane in the Contractor's yard. 7-4.2. Notification of ETA Site. (1)
The Crane shall be in fully assembled condition when delivered to the quayside of the Port.
(2)
The Contractor shall notify the Purchaser of the estimated time of arrival of the marine transport vessel ("ETA") which is carrying the Goods (or any part of the Goods) at least 14 days prior to such ETA. Upon receiving such notice, the Purchaser shall tentatively allocate a berth at Site for delivery and unloading of the Goods. The Contractor shall confirm to the Purchaser the date of actual departure of the vessel from the loading port and thereafter the daily Noon position of the vessel together with an up-dated ETA by daily facsimile transmission to the Purchaser. The exact berthing time and berthing position for the vessel shall be agreed and fixed at least one day prior to the ETA between the Purchaser and the Contractor based on the Contractor's daily position and ETA report.
(3)
The Crane shall be rolled off or lifted off from a vessel onto the designated position of the quay, then shifted to a designated test position by the Contractor. Such operations shall in no way over-stress any part of the piled quay deck or the yard. Specifically any loads on the quay apron waterside of the waterside crane rail beam (overhung slab) are prohibited.
7-4.3. Navigation Requirement (1)
The Contractor shall be responsible for following all necessary procedures to ensure the safe passages of vessels whilst navigating in the Port. The Contractor shall maintain close contacts with the relevant Poland Maritime Authorities and Port Authority.
7-4.4. Berthing and Roll-off Requirements (1)
In order to minimize the occupation of the Purchaser’s facilities, the contractor shall finish all necessary preparation before berthing to Purchaser’s terminal.The time allowed for the vessel to stay at the Purchaser's berth for the delivery and unloading of the Goods shall be as provided for in the Conditions of Contract calculated from the agreed time of berthing as set out in 7-4.2 (2) above notwithstanding the actual time of the berthing of the vessel.
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 107 (2)
The vessel must leave the berth as soon as practicable after completion of the unloading even if this occurs before the expiry of the time allowed as referred to in Clause 7-4.4. time limit. The Contractor shall inform to the Purchaser the estimated time of departure (“ETD”) of the vessel at least four (4) hours before such ETD.
(3)
All the necessary calculations, design, engineering, preparation works and clean up works for the roll-off and shifting the Crane to a designated test position and testing at the Site shall be the responsibility of the Contractor. The preparation works shall include obtaining necessary technical information of the quay and the Port generally from outside consulting engineers and elsewhere as necessary, and obtaining necessary clearance or permit for the works from government offices and all other competent authorities concerned.
(4)
The Contractor shall have obtained all necessary approval, clearance, permits etc required for the site works prior to the vessel departing from the Contractor’s facility
7-4.5. Customs Clearance The consignee for shipment of all the Goods shall be the Contractor. Import declaration and cost thereof shall be the responsibility of the Contractor. 7-4.6. Work Permits All engineer/supervisors dispatched for start-up, testing and training shall obtain proper working visas for Poland which must be valid for entire estimated and, if longer, actual period of stay. 7-4.7. Site Safety and Security (1)
The Contractor shall comply with the Purchaser's security requirements for making entry or exit to and from the Port, and inside the Port.
(2)
The Contractor and its subcontractors shall be responsible for protecting their own plants, tools, temporary site offices and other belongings from weather, fire or theft. The Crane and other Goods shall be protected by the Contractor from typhoon, fire, collision and any other possible risks until the Crane or other Goods is Commissioned and handed out to the Purchaser.
7-4.8. Site Erection Area and Access NOT USED. 7-4.9. Site Office Communication The Contractor shall at his own cost provide for the installation of a telephone line for outside call and facsimile purposes. Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 108
7-4.10. Test Weight The load test weights shall be provided by the Contractor for the load testing and adjustment of the Crane. 7-4.11. Water, Electricity Supply The Contractor shall at his own cost provide for the installation of suitable metering equipment, supply fix and dismantle after use all pipework, valves, meters, cables, switchgear etc and shall pay for the cost of supply of water, diesel and electricity that he may require for any purpose. 7-4.12. Contractor’s Representatives.
7-5.
(1)
One Polish/English speaking principal site engineer shall be dispatched prior to arrival of the Crane(s) to plan and coordinate the work and to communicate with and report to the Purchaser. He shall stay in the Purchaser’s locality for the entire period from delivery to Commissioning, Final Acceptance of the Crane to the Purchaser.
(2)
A sufficient number of qualified start-up engineers and training engineers shall be dispatched to the Port to handover the Cranes in an expeditious manner.
Site Inspection and Tests, Certification
7-5.1. Commissioning Tests Application (1)
The Crane or other Goods shall be verified at Site as operational and safe under any load conditions prior to the Commissioning Tests. Only minor items pertaining to maintainability which do not affect the safety of operations or maintenance work may be allowed by the Purchaser as a pending item for correction at the time of the Commissioning Certificate. These items shall form part of the Defects List. Refer to 7-6.
(2)
The Commissioning Tests which will be as defined in the agreed Commissioning Test Procedure. (See Clause 7-2.8) The Contractor shall show the Purchaser by documentation or by physical demonstration (in either case as determined by the Purchaser) that all functions of the Crane or other Goods are safe and conform to the Agreement. The Contractor shall correct or modify whatever aspect is found unsafe. The Crane(s) and shall pass the statutory tests, which will be carried out and witnessed by the Purchaser’s Representative.
(3)
Application for inspection for the Commissioning Tests must be submitted to the Purchaser's in writing at least 2 days prior to the intended inspection date.
7-5.2. Defects List (1)
The Purchaser or his representative shall be allowed to gain access to any part of the Crane(s) or other Goods during their assembly at the Contractors facility and at any other time for the purposes of inspecting part or completed works. If in their opinion
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 109 certain parts of the works does not meet with the requirements of the Agreement, or is deemed as bad practice or poor workmanship, then these shall be noted as a defect and informed to the Contractor in a list. (2)
The compilation and provision of this list by the Purchaser or his representative will in no way relieve the Contractor from his obligation to provide defect free Crane(s) or other Goods.
7-5.3. Rectification Report The rectification of defects in the defects list shall be carried out in a thorough and workmanlike manner. The Contractor shall prepare and submit to the Purchaser a rectification report that confirms defect completion together with a description of the action taken.
7-5.4. Commissioning Test The Contractor shall carry out a series of tests as outlined and defined in the Commissioning Test Procedure in order to prove that all requirements and functions of the Crane(s) or other Goods meets with the Agreement. The Crane(s) or other Goods will be required to undergo inspection and test and performance trials in order to achieve a Commissioning Certificate. The contractor shall submit a commissioning test programme to the purchaser at least 30 days before commencing for comment. 7-5.5. Endurance Test. (1)
The Endurance Test forms part of the Commissioning Test. The Crane(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 i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii)
Pick up the container from roadway (3 meters from leg centre). Hoist 15 metres. Trolley forward 10 metres. Lower 15 metres. Wait 5 seconds. Hoist 15 metres. Trolley backward 10 metres. Lower 15 metres. Unlatch and hoist 1 meter. Lower 1 meter and latch. Repeat After each 30 minutes operation the Crane(s) shall be gantried for a minimum of 125 metres at full speed to a transfer position, the wheel rotated through 90 degree, wait for 1 minute, wheels rotated through 90 degree and the Crane gantried back to the original test position.
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This cycle is a preliminary proposal and the final test cycle shall be determined by the Crane configuration and in agreement with the Purchaser. (2)
The cycling test shall be continued for a period of 24 hours and in the event of a malfunction shall be continued until 24 hours of trouble free operation has been logged. The rate of the endurance test shall not be less than 20 cycles per hour through the testing period.
(3)
Throughout the period of testing the current, voltage, speed, main drive mechanism temperature, noise and vibration shall be recorded at intervals of 30 minutes. Any malfunctions or problems and any remedial action taken during the test shall be recorded.
7-5.6. Acceptance Certification (1)
The Commissioning Certificate will be issued on successful completion of the Commissioning Test, training as defined in Clause 7-5 and issuing of Inspection Certificate from the Local Labour Bureau.
(2)
The Final Acceptance Certificate will be issued on successful completion of the Initial Trial Period as defined in Clause 2-4
7-5.7. Access for Remedial Work Following the issue of the Commissioning Certificate, the Contractor shall be allowed access to the Crane(s) for remedial work only with the approval of the Purchaser. 7-6.
Training
7-6.1. Training Off-Site. The Contractor shall conduct training at his works for the Purchaser's operation and maintenance personnel (total 4 persons) for a minimum period of 2 weeks. This training shall be at the Contractor's account, including air-fare, transportation and boarding. The Overseas Training shall be conducted in Polish/English. 7-6.2. Training On-Site (Operators) The Contractor shall carry out the operator feminization training of the Purchaser's staff during the on-site commissioning period and for a period of seven (7) days following the Commissioning Test of the Crane or other Goods. The training shall be conducted by suitable Contractor trainers in Polish/English. The training shall cater for approximately eight (8) groups of operators and the content shall include but not be limited to the following: (1)
Instruction and hands-on training of the cranes start-up procedure.
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(2)
Instruction on lighting control.
(3)
Instruction and hands-on training of normal container handling operation in the cab.
(4)
Instruction and hands-on training of normal shutdown procedure.
(5)
Instruction on the use of equipment for emergency. Emergency stop buttons Escape route Fire fighting equipment Communication
7-6.3. Training On-Site (Maintenance) The Contractor shall carry out the maintenance training of the Purchaser's staff during the commissioning period and for a period of seven (7) days following the Commissioning Test of the Crane or other Goods. The training shall be conducted by suitable Contractor and Crane or other Goods component supplier trainers. The training shall cater for a group of approximately five (5) electrical maintenance staff, and a similar group of mechanical maintenance staff and the content of the training shall include but not be limited to the following: (1)
Instruction and hands-on training of starting and shutdown procedure.
(2)
Instruction and explanation of all the devices on the Crane (separately for electrical and mechanical staff).
(3)
Instruction of Start-stop procedure and checking points of all the devices or systems on the Crane.
(4)
Lectures on electrical/electronic control systems of the Crane and adjustment method/standards both in a classroom and on the Crane.
(5)
Lectures on mechanical/hydraulic systems of the Crane and adjustment method/standard both in a classroom and on the Crane.
(6)
Lectures on Condition Monitoring System on the Crane and in a classroom.
(7)
Inspection and Maintenance of Operationally Critical Components.
(8)
Instruction on trouble shooting and repair. Instruction on emergency equipment. Emergency stop buttons
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[ GCT - RUBBER TYRED GANTRY CRANES ] Page: 112 Escape route Fire fighting equipment Communication (9)
Instruction on routine maintenance of devices and preventive maintenance plan, including explanation of special tools, gauges or jigs.
(10)
The Contractor shall provide 6 sets, cost free, reproducible maintenance manual, operator manual, recommended spare part list and spare part manual to the Purchaser.
7-6.4. Special Training on the Operationally Critical Components Maintenance. The operationally critical components (see 2-10) shall be presented and the Contractor shall therefore prepare and present the training this subject separately. 7-6.5. Spare Parts 7-6.6. Ordered Spare Parts The Contractor shall warrant in writing its capability for providing spare parts, spare components, and repair and/or replacement services for a period of 20 years after the Final Acceptance of the Crane. 7-6.7. Spare parts for Commissioning Work (1)
The spare parts for the commissioning work shall be provided by the Contractor in addition to the Ordered Spare Parts and Additional Spare Parts.
(2)
The Contractor shall indemnify the Purchaser against any cost, loss or damage if the operational Crane(s) suffers stoppage due to the unavailability of an Ordered Spare Part which has been consumed by the Contractor during the commissioning period and not replaced before the issue of the Commissioning Certificate. -End-
Appendix 1 - Technical Specification Feb 2012
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