siwz rmgs schedule 5 technical specification pdf

7/22/2019 SIWZ RMGs Schedule 5 Technical Specification PDF

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SCHEDULE 5

Procedure no. EU /03/RMG/ZZ/2011; EU/16/RMG/ZZ/2011for awarding acontract in the open tender procedure:

Supply of RMG Rail Mounted Gantry Cranes 2 units

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

RAIL MOUNTED GANTRY CRANE SPECIFICATION OVERVIEW

PROJECTSupply of the following equipment defined within this Technical Specification:

Two Rail Mounted Gantry Cranes with Cantilever Beam on one side for Intermodal ApplicationThe gantry cranes have to be designed for travel over curved rails.

Two 65 MT Twin Lift hydraulic Spreaders 20/40ft

One Piggy BackOne 60 MT Cargo Beam

CAPACITYContainers in single lift mode 20/40ft 51 MTContainers in twin lift mode 2x20ft 2x 32,5 MTPiggy Back Arms 51 MTCargo Beam At least 60 MT

DIMENSIONSGantry Rail Span 28.00 mRadius of two curvatures on the gantry rails:- radius of first curvature 900/872- radius of second curvature 2000/1972Cantilever (one side) 9.10 m (Waterside, Nearside)Lift above rails 12.00 mOverall crane width (bumper to bumper) 24.38 m

Clearance between legs 17.00 mGantry Travel 685 m

SPEEDSMain Hoist

Hoisting with rated load 20 m/minLowering with rated load 20 m/minHoisting with empty spreader 40 m/minLowering with empty spreader 40 m/min


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Page 2 of 109 RMG Technical Specification

TrolleyTrolley with or without rated load 100/120m/min

GantryGantry with or without rated load 150 m/min

ACCELERATION TIMESMain Hoist

Rated load 1.5 secEmpty Spreader 3.6 sec

Trolley 3.0 secGantry 7.0 sec

ELECTRICAL SYSTEMSMain Power Supply 15.0kV, 3-phase, 50 HzMain Power Cable Reel Location Landside, Farside legDrive Control System

Programmable Logic ControllersCrane Monitoring Local and RemoteCommunication Fiber Optic embedded in power cable

FEATURESGantry Articulation. The requirement is for RMG to travel over curved rails.Anti-sway systemTrim FunctionsSkew adjustmentSide-shiftGantry Wheel Brakes with high speed releaseAnti-collision for Crane to CraneChecker Cabin under sill beam at Ground LevelGround Level Control Station

SITE CONDITIONSAmbient Temperature Range -25C to +35CHumidity Up to 95%In Service Wind Sustained 22m/sec, Gust 25m/secStowed Wind Sustained 42m/sec

DEFECT LIABILITY PERIODS (DLP)Entire Crane & accessories after Taking-over 2 YearsComponents repaired during DLP 1 Year or balance of DLPCrane Structure 10 Years

Paint and Galvanizing 5 Years


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RMG Specification Page 3 of 109

Table of Contents

1 GENERAL

1.1 PROJECT DESCRIPTION 1.2 SITE 1.3 OVERRIDING REQUIREMENT OF THE PURCHASER

2 OVERALL DESIGN CRITERIA

2.1 TYPE OF CRANE 2.2 TYPE OF CARGO 2.3 OPERATING ENVIRONMENT AND DESIGNAIM 2.4 MODE OF OPERATION 2.5 STATUTORY REQUIREMENTS AND MINIMUM DESIGN STANDARD 2.6 SAFETY OF MACHINERY

2.6.1 C E D ........................................................... ..................... 112.7 MINIMUM CLASS OF CRANE 2.8 GENERAL DESIGN CRITERIA

2.8.1 C ....................................................................... .................................................... 122.8.2 D ........................................................................ ....................................... 132.8.3 ............................................................................................................................... 132.8.4 C (, ) ............................................................................... 142.8.5 C C ....................................................................................................................... 142.8.6 C ......................................................... ................................................................ ... 152.8.7 ............................................................................................................. 15

2.9 NOISE CONTROL 2.10 OPERATIONALLY CRITICAL COMPONENTS

3 CRANE STRUCTURAL SPECIFICATION

3.1 GENERAL REQUIREMENT 3.2 DESIGN

3.2.1 E ............................................................................................................. 173.2.2 .......................................................................................................................................... 18

3.3 MATERIAL 3.3.1 ......................................................................................................................................... 183.3.2 .............................................................................................................................................. 183.3.3 E .................................................................................................................................... 183.3.4 ............................................................................................................... ................. 183.3.5 D ..................................................................... ............................ 18

3.4 CALCULATIONS 3.4.1 ............................................................................................................... 193.4.2 A................................................. ................................................................ ............................. 193.4.3 C .................................................................. ............................................................... .. 193.4.4 D ....................................................... ................................................................ ................ 19

3.5 LOADS 3.5.1 C ....................................................................................................................... 193.5.2 E ................................................................................................................... 19

3.6 MEMBERS SUBJECT TO BUCKLING 3.7 FATIGUE DESIGN CRITERIA 3.8 CONNECTION DESIGNS

3.8.1 ....................................................................................................................................... 203.9 GANTRY STRUCTURE STIFFNESS


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3.10 CAMBER 3.11 TROLLEY RAILS &RAIL FIXING 3.12 WORKMANSHIP

3.13 QUALITY CONTROL OF STRUCTURE FABRICATION 3.14 TEMPORARY STRUCTURES

3.14.1 ................................................................................................................... 233.14.2 ................................................................................................................................ 23

4 FUNCTIONAL SYSTEMS DEVICES AND EQUIPMENT

4.1 MAIN HOIST 4.1.1 ..................................................................................................................................... 244.1.2 C ................................................................................................................................. 254.1.3 C .................................................................................................................................. 25

4.2 TROLLEY 4.2.1 ................................................................................................................................ 25

4.2.2 D .................................................................................................................................. 254.2.3 ................................................................................................................................ 26

4.3 GANTRY 4.3.1 D ................................................................. ............................................................... .. 264.3.2 .................................................................................................................................. 274.3.3 C ................................................................................................ ................................ 284.3.4 A ......................................................................................................... 294.3.5 CC ................................................................ ............................................................... ... 29

4.4 ELECTRICAL CONTROL HOUSE 4.4.1 C .................................................................................................................... 29

4.5 OPERATORS CAB 4.5.1 C .................................................................................................................... 30

4.5.2 C A..................................................................................................................................... 314.5.3 .......................................................................................................................... 314.5.4 E .......................................................................................................... 314.5.5 A C/ .............................................................................................................. 314.5.6 .............................................................. ............................................................... .. 324.5.7 C D .......................................................... ................................................................ ... 324.5.8 C ................................................................................................................................... 324.5.9 C C .............................................................. ............................................................... ... 33

4.6 PERSONNEL ELEVATOR 4.7 HEAD-BLOCK

4.7.1 ....................................................................................................................... 334.7.2 C ............................................................ ............................................................... ... 34

4.8 SPREADER 4.8.1 ................................................................ ........................................ 34

5 INTER-FUNCTIONAL SYSTEMS & COMPONENTS

5.1 MECHANICAL SYSTEM/COMPONENTS 5.1.1 B, ............................................................... ............................................................... .. 375.1.2 ......................................................................................................................................... 375.1.3 ............................................................. ............................................................... ... 375.1.4 D ......................................................................................... ...................... 375.1.5 ........................................................................................................................ 385.1.6 ................................................................... ............................................................... .. 395.1.7 , A .................................................................................................................. ................ 39

5.1.8 C....................................................................................................................................... 39


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5.1.9 ................................................................. ............................................................... .. 405.1.10 , B .......................................................................................................................... 405.1.11 B .............................................................................................................................................. 405.1.12 .................................................................................................................................... 40

5.1.13 B................................................................................................................................. 405.1.14 B ................................................................................................................................ 41

5.2 HYDRAULIC SYSTEM/COMPONENTS 5.2.1 ...................................................... ................................................................ ................ 415.2.2 C ............................................................... ...................................................... 415.2.3 C ................................................................. ..................................................... 415.2.4 .............................................................................................................. 415.2.5 .................................................................................................................................... 425.2.6 ............................................................................................................................. 425.2.7 ................................................................................................................................... 425.2.8 C ................................................................................... ..................................... 425.2.9 C ................................................................. ............................................................... .. 42

5.2.10 ................................................................................................................. ................. 425.2.11 C ............................................................................................................................... 435.2.12 ............................................................................................................................. 435.2.13 ............................................................................................................................................ 435.2.14 ............................................................... ............................................................... ............... 435.2.15 A ..................................... .......................................................... ................................ 445.2.16 ............................................................................................................................................................ 445.2.17 C B ................................................................................................................. ................. 445.2.18 ............................................................................................................................................ 445.2.19 A ......................................................... ............................................................... ................ 445.2.20 A .......................................................................................................... ..... 445.2.21 .......................................................................................................................................... 44

5.2.22 C ........................................................................................................................................... 445.2.23 .............................................................................................................................. 445.3 ELECTRICAL AND ELECTRONIC SYSTEM/COMPONENTS

5.3.1 ......................................................................................................................................... 455.3.2 .................................................................. ........................................ 455.3.3 D ........................................................................... 455.3.4 .................................................................................................... 465.3.5 D/ ....................................................................................... 475.3.6 ........................................................................................................................................... 475.3.7 ........................................................................................................... 485.3.8 C C B ................................................................................ 485.3.9 E ........................................................................................................................ 495.3.10

.......................................................................................................................................... 49

5.3.11 B ........................................................................................................................................... 505.3.12 ............................................................... ............................................................... ... 505.3.13 E ..................................................................................................................................... 505.3.14 , C........................................................................................................................... 515.3.15 ............................................................................................................................... 515.3.16 ............................................................................................................................... 525.3.17 ................................................................................................................. ................. 525.3.18 E ......................................................... ............................................................... ................ 525.3.19 C B ........................................................... ............................................................... ... 52

5.4 CRANE MOTION CONTROLS 5.4.1 C ................................................................................................................ 525.4.2 C (C) ...................................................................................... 53


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5.4.3 ................................................................................................................................ 545.4.4 D / .................................................................................................................... 545.4.5 C C ............................................................ ...................... 54

5.4.6 C ................................................................................................................ 555.5 OPERATIONAL SAFETY INTERLOCKS

5.5.1 ............................................................................................................... 565.5.2 .................................................................................................................... 575.5.3 ................................................................................... ...................... 575.5.4 ....................................................................................................... 585.5.5 C E D . ......................................................................... ............................... 58

5.6 COMMUNICATIONS 5.6.1 ........................................................................................................................... 595.6.2 C ...................................................................................................... 595.6.3 D C .............................................................. .......................................... 595.6.4 A ................................................................................................................... 59

5.6.5 C / ........................................................................... 595.7 CRANE CONDITION MONITORING SYSTEM (CCMS)

5.7.1 ......................................................................................................................................... 595.7.2 CC D ..................................................................... ..................................................... 605.7.3 B C C (B CC) ................................................ 605.7.4 B CC .................................................................. .................... 605.7.5 B CC .................................................................................... 615.7.6 C .............................................................. ...................................................... 625.7.7 D ............................................................ ............................................................... ... 645.7.8 E D ......................................................... ............... 655.7.9 C C (CC) ..................................................... ............ 655.7.10 CC .................................................................................................... 66

5.7.11 CC ...................................................................... ............................. 665.7.12 () ........................................................................................................................................ 675.7.13 CC ............................................................................................................... 67

6 COMMON ITEMS

6.1 WALKWAYS,STAIRS,LADDERS AND PLATFORMS 6.1.1 A C E .............................................................. ....................... 686.1.2 ........................................................................................................... ...... 686.1.3 .................................................................................................................... 686.1.4 ............................................................................................................... 686.1.5 ................................................................................................. 696.1.6 C A ................................................................................................ .................... 69

6.1.7 ................................................................................................................ 696.2 ILLUMINATION AND LIGHTING 6.2.1 , , , C A ......................................................................................... 696.2.2 A .................................................................................................................. 696.2.3 ............................................................... ..................................................... 706.2.4 E E ......................................................................................... 706.2.5 C ....................................................................... ....................................... 706.2.6 B ................................................................ ....................... 706.2.7 ........................................................................................................................ 706.2.8 A .............................. ............................................................... ........ 70

6.3 PAINTING AND PROTECTIVE COATING 6.3.1 .................................................................................................................... 70

6.3.2 ...................................................................................................................... 71


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6.3.3 A B C................................................................................................................. 726.3.4 ........................................................................................................................... 736.3.5 ................................................................................................................................ 746.3.6 ................................................................................................................................... 76

6.3.7 C ............................................................................... 766.3.8 ....................................................................................................... 77

6.4 PURCHASERS LOGO,CRANE NUMBERS,SIGNS 6.4.1 ......................................................................................................... .................. 786.4.2 C ............................................................................................................................. 786.4.3 C C ................................................................ ..................................................... 786.4.4 ........................................................................................................ 786.4.5 ................................................................... ............................................................... .. 78

6.5 ALARM,WARNING SIGNALS 6.5.1 ................................................................................................................. 786.5.2 ...................................................................................................... 796.5.3 ..................................................................................... 79

6.5.4 B A ......................................................................... ............................ 806.5.5 E C A/C .......................................................................................... 806.5.6 A/ ............................................................................................................... 80

6.6 EMERGENCY STOP PUSH BUTTONS &DRIVE LOCK OUT 6.6.1 ........................................................ ............................................................... ................ 806.6.2 .............................................................................................................................................. 816.6.3 E ................................................................................. .................................. 81

6.7 SERVICE OUTLETS 6.7.1 ........................................................................................................................................ 816.7.2 ................................................................................................................................... 81

6.8 FIRE EXTINGUISHERS 6.8.1 ........................................................ ............................................................... ................ 81

6.8.2 ................................................................................................................................... 816.9 MAINTENANCE TOOLS AND EQUIPMENT

6.9.1 ........................................................................................... ......... 816.9.2 E/E .............................................................. ......................... 826.9.3 ....................................................................................................... 826.9.4 E ........................................................................................................ 826.9.5 ................................................................................................................................ 82

7 PROJECT QA & ADMINISTRATIVE REQUIREMENTS

7.1 DOCUMENT SUBMISSION (PROJECT) 7.1.1 C ( & ) ............................................................. ......................... 837.1.2 ( & ) () ............................................................. ........................ 83

7.1.3 ................................................................................................................ 837.1.4 A / ................................................................... ....................... 837.1.5 D ( ) .................................................................... ............................. 84

7.2 DOCUMENT SUBMISSION (TECHNICAL) 7.2.1 ..................................................................................................................... 847.2.2 C D ........................................................................................................................ 847.2.3 D C ' ................................................. ............... 847.2.4 ................................................................ ............................................................... .. 857.2.5 ............................................................................................................... ................. 857.2.6 C D ................................................................... ............................. 857.2.7 ....................................................................................................... 867.2.8 C ................................................................. ..................................................... 86

7.2.9 D D ...................................................................................................................... 86


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7.2.10 ....................................................................................................... ................... 877.2.11 ................................................................................................. 877.2.12 ....................................................................................................................... 88

7.2.13 ............................................................................................. ..................... 897.2.14 AB D ...................................................................... .................................................... 89

7.3 SHOP INSPECTION AND TESTS 7.3.1 .................................................................................................. 907.3.2 ................................................................................................ 91

7.4 SHIPMENT,DELIVERY AND SITE WORK 7.4.1 C .......................................................................... ....................................... 927.4.2 EA ................................................................................................................. 927.4.3 ........................................................................................................ ....... 927.4.4 B .................................................................. ............................ 927.4.5 C C ................................................................... ..................................................... 937.4.6 ................................................................................................................................ 93

7.4.7 ............................................................ ..................................................... 937.4.8 E A A ....................................................................................................... 937.4.9 C .................................................................... ........................................ 937.4.10 .................................................................................................................. ................. 937.4.11 , E ........................................................................ ....................................... 937.4.12 C ........................................................................................................ 93

7.5 SITE INSPECTION AND TESTS,CERTIFICATION 7.5.1 C ................................................................. ..................................................... 947.5.2 D .................................................................................................................... ................ 947.5.3 ...................................................................................................................... 947.5.4 E ............................................................................................................................. 947.5.5 C.................................................................................................................. 95

7.5.6 A ........................... ............................................................ ...................... 957.6 TRAINING &SUPPORT

7.6.1 .......................................................... ............................................................... ... 957.6.2 () ................................................................. ........................................ 957.6.3 () ....................................................................... ............................. 967.6.4 C C ( ) ................................................................................... 967.6.5 & ( ) ............................................................. 97

7.7 SPARE PARTS 7.7.1 ................................................................. ..................................................... 977.7.2 C ........................................................................................... 97

8 APPENDICES

8.1 APPENDIX 1DOCUMENT SUBMITTALS 8.2 APPENDIX 2INSPECTION/TEST CONTROL SHEETS 8.3 APPENDIX 3CORPORATE COLORS AND DECALS


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TECHNICAL SPECIFICATION

Functional Requirement for the Crane

1 GENERAL1.1 Project Description

To carry out the design, construction, delivery, installation, testing and completion of Two (2) units ofRail Mounted Gantry Cranes having a rated load of 2x32,5 Metric Tons in twin lift mode. The cranesshall be delivered in a fully assembled and tested condition.

1.2 SiteThe Cranes shall be delivered and completed at the Purchasers site which is referenced in the SpecialConditions.

1.3 Overriding Requirement of the PurchaserThe Purchasers overriding requirement is for the Works to be suitable in all respects for safe, efficientand continuous use under actual operational conditions in a modern, large capacity, internationalcontainer handling facility for a period of not less than twenty (20) years subject to fair wear and tear(excluding categorically any fatigue failure), and routine maintenance.

For the purposes of this Contract acceptable routine maintenance shall be within the following generalparameters.

(1) For steel structures and related component parts, fittings and fixings, acceptable routinemaintenance 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 itsfixings, etc. shall be Defects remedial works and not maintenance.

(2) For the paint system acceptable routine maintenance shall be:

- Preparing and over coating the existing paint system at year 10 after the issuance ofthe Taking-over Certificate.

- Removing defective parts of the paint system back to clean steel and repainting inisolated areas but not exceeding in aggregate more than 1% and 2% of the totalsurface area at years 5 and 10.

- The removal of the paint system back to steel and replacement of the paint system inareas aggregating more than the above percentages of the total surface area of thepainted part of the Crane shall be Defects remedial works and not maintenance.

(3) For items of electrical and mechanical equipment, controls, systems, components, fittings andfixings, acceptable maintenance shall be the periodic and routine maintenance normally carriedout on the various parts generally undertaken as established practices of the Purchaser.

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


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2 OVERALL DESIGN CRITERIA2.1 Type of Crane

The Crane shall be a, electrically driven, rail mounted gantry crane with a self-driven trolley and cab. TheCrane drive and control shall be full AC inverter drive, with fully digitalized controls with PLC. The proposeddrive and control system shall be a proven system successfully operating on a similar capacity crane inactual container handling operations.

2.2 Type of CargoThe type of cargo to be handled by the Crane shall be:

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

2 Other types of container with ISO corner fittings at 20ft or 40 ft positions such as 45ft, 48ft and53ft containers.

3 Containers with over-height cargoes through an existing over-height cargo container-lifting frameowned by the Purchaser.

4 Damaged container with slings and shackles attached to lifting lugs of the spreader.

5 General cargo by Cargo Beam (ramshorn hook)

6 Trailers by Piggy Back Arms

Note: Exclusive accessories for handling high cube, half height and flat rack containers are not included.

2.3 Operating Environment and Design Aim1 The Crane shall be operated and maintained on 24 hours per day basis in all weather conditions.

All electrical, electronic, and mechanical equipment shall be non-hygroscopic, non-corroding andtropicalized for use in conditions stated elsewhere in this Specification.

2 The Cranes shall conform to the noise requirements in this Specification.

3 Special considerations shall be given in all aspects of the design for achieving accurate loadspotting ability with quick sway damping, and ensuring full operational capability and safety forround the clock operations, including operation in heavy rain conditions.

4 The Crane shall be exposed to non-technical personnel specifically at the ground level and duringaccess to trolley/operators cab. The Contractor shall provide safe protection in and around allequipment and fittings in these areas of the Crane.

5 Ease of maintenance and safety of the maintenance staff shall be considered throughout thedesign to minimize downtime of the Crane.

2.4 Mode of OperationThe Crane shall be semi-automatic and manually controlled. All functions on the Crane shall be controlledby the operator.

2.5 Statutory Requirements and Minimum Design Standard1. The Crane electrical, electronic equipment and its mechanism shall be designed and manufactured

to comply in all aspects with the requirements of all latest, laws, ordinances, rules, orders, or otherlegal or regulatory institutes applicable in the country of operation.


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2. Where items are not covered by local statutory requirements, the Crane and other Goods shall bedesigned and manufactured to at least the standards as specified in this Specification. For itemswhich are not specified above, then to at least to the current applicable recommendations of thefollowing organizations:

AWS American Welding Society Bridges and Dynamically Loaded Structures

BSI British Standards Institute

DIN Deutsche Industrie Normen

FEM Federation Europeane de la Manutention

OSHA Occupational Safety & Health Administration

IEC International Electrotechnical Commission

IEEE Institute of Electrical and Electronic Engineers

ISO International Standards Organization

JIS Japanese Industrial Standards

UL Underwriters Laboratory

The Contractor shall define all standards used in the design of the Crane.

2.6 Safety of Machinery2.6.1 Conformity with the EU Machinery Directive

(1) The crane shall comply with the requirements of the European Machine Guidelines, particularlyMachinery Directive 2006/42/EC. The cranes shall be provided with a declaration of conformity andthe CE marking and symbol according to the relevant Appendixes of the Machinery Directive. TheSupplier/ Contractor are solely and entirely responsible for all aspects of this conformity declarationand CE marking. A single electric power, control or hydraulic component failure or malfunction shallnot damage the crane or injure personnel. If possible, component failure or malfunction shall safelystop the crane operation. If this is not possible, a redundant system shall be supplied. The redundantsystem shall both safely stop the crane and prevent operation until maintenance personnel makecorrections. A means shall be provided so the maintenance personnel may routinely check eachredundant or backup system. The check procedure shall be included in the maintenance manual. Nocrane component shall change state as a result of a power failure. Powering or repowering the craneor any system within the crane shall not result in an unanticipated or potentially unsafe motion orcondition.

2.7 Minimum Class of CraneUnless otherwise stated, F.E.M. 1.001, 3rd Edition Revised 1998.10.01, and relevant other design standardsnoted in these Specifications, shall be used in the design of the Crane and its mechanisms.

Structures:

Class of Utilization U8

State of Loading Q3

Group Classification A8


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Mechanisms

Mechanisms Class ofOperation

State ofLoading

GroupClassification

Service Life

Hoist T8 L3 M8 50,000 Hrs.

Trolley Travel T8 L3 M8 50,000 Hrs.

Gantry Travel T8 L3 M8 50,000 Hrs.

2.8

General Design Criteria2.8.1 Crane Particulars

Major dimensions, clearances and performance requirements:

(1) Rated Load Under Spreader 65 Metric Tonnes (MT)One container 51 MT 10% eccentric loadingTwinlift of two 20 containers 2 x 32.5 MT evenly loadedLifting lugs 4 x 10 MT in the main frame and end beams

(2) Test load for overload test 81.25 MT under spreader.

(3) Lifted Load ISO 20, 40 and up to 53 containers with ISO corner fittingsat 20 or 40 position.

(4) Spreader 20/40 twin-lift telescopic hydraulic type.

(5)

(6)

Gantry Span

Cantilever (one end)

28,000 mm centers of wheels

9,100 mm (waterside)

(7) Lift above gantry rail 12,000 mm (One over 3 high Containers to provide minimumclearance of 625 mm to the lowest point of spreader (gatherguides).

12,400 mm to Emergency hoist limit at the lowest point ofspreader.

For lowering, the head-block (spreader removed condition)

shall be able to be lowered onto the ground.

(8) Overall Crane Length 24,380mm bumper to bumper overall.

(9) Speeds- Main Hoist 20m/min. minimum with 51 MT or 2x32.5 MT load under

spreader.

40m/min. minimum with empty spreader.

The Load-Speed relationship shall be on a power constantcurve.

Accelerations shall be:40m/min. with 0 MT under spreader. Acc./Dec = 3.6s20m/min. with 51 MT under spreader. Acc./Dec = 1.5s


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- Trolley 120 m/min. minimum.Acceleration time max. 3.0 s.Deceleration time max. 3.0 s.

- Gantry 150 m/min. with Rated load under spreader.

Acceleration/Deceleration time max. 7.0 s.150 m/min with No Load under spreader

The above speeds must be achieved for crane operation under a sustained 22 meter/sec. windcondition.

(11) Trim Adjustment 3.0 degreesSpeed: 0.5 degree/second minimumTrim adjustment system shall be capable of changing attitudeof a 51 MT container (40) with 1.2 meter eccentricity

(12) Side Shift Side Shift the spreader +200mm minimum from either side ofcenter

(13) Skew adjustment Skew adjustment the spreader 5 degrees with rated load

(14) Anti-sway The Crane shall be provided with electric anti-swaydampening.

The anti-sway system shall be capable of damping thespreader after the trolley has stopped with full deceleration atany operational speed with any operational load, to within150mm of lateral displacement after 2.5 cycles of sway. Thesame criteria will apply to the yawing motion following thetrolley stopping from any operational speed with fulldeceleration, or after the end of the skew motion command.The system shall meet the above criteria measured at thespreader in the 40 position between 3.5 meters above theground level.

(15) Number of gantry wheels Four (4) Wheels per corner (Min)

2.8.2 Dimensional Restrictions

(1) The total length of the Crane shall not exceed 24,380mm.

Possible Interference between Electrical Control House located on outside of main girder on mainpower cable reel side of crane and adjoining crane on same runway. Purchaser

(2) The crane manufacturer shall submit his preferred design drawing to show operational clearances

2.8.3 Yard Interface

(1) Power Supply(i) The power supply to the crane shall be 15.0 kV +10% 3 phase, 50Hz+ 2%.

(ii) The high voltage trailing cable connection at the power feeding pit in the yard shall beproprietary HV cable joint. The Contractor shall undertake termination of the cableconductors and fiber waveguide at the feeding pit. The high voltage cable shall besupplied by the Contractor along with the suitable cable reeling device and cableconnection joint. A sufficient length of cable to cover 350 meters gantry travel rangeeither side of the central feeding point shall be provided by the Contractor. Contractorshall bring the Crane trailing cable end to the feeder pit and shall complete the cableconnecting work with an approved cable joint kit. The cable joints made at site andhigh voltage wiring shall pass the inspection requirements of the local supplycompany and hi-pot test results shall be provided.


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(iii) The high voltage trailing cable shall be round type HV flexible power cable withintegrated fiber optic data cables.

(2) Gantry Rail and Wheel Loading

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

(ii) The Contractor shall submit in its Tender for the Purchasers review, the declared wheelloads as defined in the form of tenderer to clarify vertical and horizontal loads underoperational and stowed conditions.

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

(iv) Wheel loads shall under no circumstances exceed the Maximum Allowed Crane Loadsfigures as tabulated in the Form of Tender, DECLARED WHEEL LOADS AND OTHERLOADS OF THE CRANE. Should any or all of such loads exceed such Maximum

Allowed Crane Loads figures, this shall constitute a Detect and the Contractor shall notbe entitled to despite this on any grounds or in any circumstances.

(v) The gantry rails are level. A vertical tolerance of 50 mm measured at the rail headsurface from the mean position throughout the gantry rail length shall be permitted.

(vi) Gantry Rail The gantry rail is A100 type

(3) Stowage Pins The Contractor shall submit for the Purchasers review a design of adequate stowagepins to resist horizontal component of the forces applied to the Crane under itsstowed condition. The stowage sockets in the yard shall be installed by Purchaser inaccordance with the dimension and load characteristics provided by the Contractor.

2.8.4 Communication Facility Interface (Radio, RF)

(1) Permanent mounting shall be provided inside the drivers cabin with necessary installation.

(2) A regulated Power Supply within the range 12 to 13.6 Volts DC (Negative Ground) shall be installedand protected through an appropriately sized circuit breaker. A cable shall be routed from thecircuit breaker to the radio enclosure. Current drain characteristics for this type of radio equipmentshall not exceed 20 Amps.

(3) An aperture shall be provided at or near the radio location for installation of a coaxial R58 cableconnecting to an externally mounted aerial. The aperture shall be fitted with a waterproof fittingready for acceptance of coaxial cable.

(4) A minimum of 6 similar Circuit Breakers rated for the appropriate DC Voltage and current, connected toscrew type terminal connectors plus negative and earth terminations shall be provided.

2.8.5 Climatic Conditions

The Crane and other Goods shall be designed and constructed to be fully capable of operating safely andwithstanding the following climatic conditions.

(1) Ambient temperature -25oC to +35oC(2) Relative humidity Max. 95%(3) Dew point Max. 30oC(4) Wind up to 25m/sec. without special warning during operation.(5) Storm Containing Lighting.


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More stringent and specific requirements shall apply for individual crane subsystems and components,which are separately specified in each relevant clause of this Specification.

2.8.6 Wind Conditions

The entire Crane structure with all of its machineries, components, fittings, or accessories shall be designedand constructed to withstand following wind loading conditions.

(1) For Operation:Allow for wind loading of sustained wind speed of 22m/sec. for safe load handling operation of theCrane.

(2) For the stowed condition of the Crane:A wind loading of wind speed up to 42m/sec shall be allowed for the condition that the Crane isout of service and stationary without any tie downs and wheels chocked. The Stability SafetyFactor under this condition shall be at least 1.4 (Stabilizing Moment divided by OverturningMoment)

2.8.7 Lifting Loads and Stability

(1) One side landingi) A normal operating condition shall include the case of one side landing of a 45ft -

concentric 51 MT weight container whereby the main hoist wire ropes on the landed sideare assumed slack and not carrying load.

ii) The calculations of the structural and mechanical components shall include calculation forthis criterion.

(2) Eccentric container handling

i) All structural, mechanical and electrical systems or system components shall be designed

to be capable of handling continuously 51 MT gross weight containers with eccentricity of1.2m in longitudinal (gantry) direction and 0.25m in transverse (trolley) direction. Theeccentricity of the container shall not cause any horizontal drift of the container duringhoisting/lowering motion.

ii) The Contractor shall submit for the Purchasers review, a design method to completelyeliminate the possibility of lifting one end of a container by two twistlocks. The designshall incorporate a system to immediately detect this condition and to render the hoistmotion inoperable. The spreader, which stops with one end locked inside a container,shall allow lowering only with attendance of maintenance personnel.

(3) Fatigue condition

The structural fatigue calculations must meet the requirements of F.E.M. 1.001, 3 rdEdition Revised1998.10.01.

(4) Stability

i. The Crane shall remain stable with a safety factor of at least as per the F.E.M. requirements(Righting moments compared with overturning moments) in the most extreme adverseoperating and stowed conditions

ii. No damage shall be sustained when a dynamic snag load is applied in any trolley andhoisting position.

iii. The Crane shall remain stable and not sustain any damage in the case when an emergency

push button is pressed during gantry travel with a rated speed with 2x32.5 MT rated load


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suspended at any lifting position in an operational gantry gradient of not more than twopercent.

(5) All other loading conditions forming the design criteria other than specified in this Specificationshall be submitted to the Purchaser for review.

2.9 Noise ControlThe Cranes noise level shall conform to the following requirements:

(1) The noise level inside the operators cab shall be below 75dB during operation, with air conditioneron, and doors and windows closed condition.

(2) The noise level measured at a distance of 1 meter from the main motion motors (main hoist,trolley and gantry) shall be below 75 dB with motors running at full speed.

*CLARIFICATION, Private residences are located within 200m of terminal whereby noise limits of 65dB during daytime and 50dB during night time are strictly applied. No relaxation of these values will be accepted.

(3) The noise level inside the Electrical Control House shall be below 85 dB during operation withheater/air conditioner on, and doors and windows in the closed condition.

(4) The Contractor shall include test results of actual noise levels within the Tests on Completiondocument.

2.10 Operationally Critical Components(1) The Contractor shall submit the inspection and replacement schedule for operationally critical

components to the Purchaser. Inspection schedules shall contain detailed instructions aboutthe components to be inspected along with the method and rejection criteria for inspection.

(2) The objective is to assist the Purchaser to establish a standard for maintenance and inspectionof operationally critical components (ie. those components and structural joints where failurecould have catastrophic consequences such as load fall or structure collapse).


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3 CRANE STRUCTURAL SPECIFICATION3.1 General Requirement

(1) Deflection or oscillation of the structure shall not affect the Crane capacity and operatingefficiency (particularly spreader positioning ability).

(2) Girders shall be designed to allow the operator to escape from the operators cabin to thewalkway of the girder at any point of trolley travel range, in the event of an emergency.

3.2 Design(1) The structure shall consist of sections, box members forming the gantry frame and girder.

(2) The sill beams, legs and girder and cantilever beams shall form a continuous rigid frame. Theconnections between these members shall be bolted or welded and be capable of resisting allcomponents of force.

(3) If the Contractor proposes to use flanged, bolted joints, they shall be made using ASTM A325or A490 bolts.

(4) Fracture critical members or member components, FCMs, are tension members or tensioncomponents of members whose failure would be expected to result in collapse of the crane,collapse of the trolley, or dropping the load. Tension members or tension components includethose portions of a flexural member that are subject to tension stress.

(5) The Contractor shall determine which member or member component is in the FCM category.All FCMs shall be identified on the drawings.

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

(7) Connections shall be detailed to provide a ductile structure capable of withstanding yieldingwithout brittle failure. Transitions shall be gradual. Changes in thickness or width shall beachieved using tapered or curved surfaces.

(8) Material used for longitudinal structural stiffeners shall be the same material (or have thesame material yield strength) as the plate to which it is attached. The use of differentgrade steels in the cross section of main structural components must be approved by thePurchaser.

3.2.1 Equipment and Materials

The following equipment/machinery shall be fitted to the main structure.

(1) Gantry drive machinery.(2) Gantry buffers.(3) Gantry wheel brakes with limit switches.(4) Cable reel with cable guide and limit switches.(5) Main hoist sheaves.(6) Stowage pins with limit switches.(7) Gantry travel operating station at ground level

.


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3.2.2 Fittings

The following fittings shall be fitted to the main structure.

(1) Walkways, stairs, ladders and platforms.(2) Lighting for operation and for walkway, stairs ladders and platforms.(3) Wind vane for anemometer at a high level where least affected by turbulence caused by own

crane structure during operation.(4) Intercom system.(5) Travel warning device.(6) Two speakers fitted at yard level on each sill beam facing inside of the crane.(7) Service outlets.(8) Emergency stop buttons.(9) Drive Lock-Out Switches.(10) Fire extinguishers.(11) Checkers cab.

3.3 Material3.3.1 General

All materials used in the Crane shall be new, of good quality and suitable for the duty intended. Millcertificates shall be obtained and records strictly maintained to match these to the various Cranesections produced during manufacture. The steel materials for all the stressed members shall beselected from the materials which specification includes notch toughness for service in an environmentwith temperature in the range -25 to +35C.

3.3.2 Steel

The steel used for the manufacture of the Crane shall comply with an internationally recognized engineeringstandard such as:

British Standards (BS)Deutsche Industrie Norman (DIN)Japanese Industry Standards (JIS)

Alternative codes will be accepted depending upon specifications and certification offered by the Contractorand approved by the Purchaser.

3.3.3 Edge Finish

All edges of structures shall be free from sharp edges or burrs.

3.3.4 Surface Finish

(1) All welding spatter shall be removed from structure surfaces.(2) The metal surfaces shall be cleaned and treated as defined in 6.3 (Painting and ProtectiveCoating).

3.3.5 Draining and Inspection Manhole

(1) The steel structure and mechanisms shall be designed to drain water effectively. Any drainingwater shall not affect safety of operations or maintenance work under heavy rain conditions. Nowater trap shall be permitted in any part of the crane structure.

3.4 Calculations


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3.4.1 Submission to Purchaser

(1) Wheel load, stability, braking capacity and drive power calculations for all motions, and peakpower consumption calculations shall be submitted for Purchaser's review prior to commencementof detailed design. Refer to Appendix 1 for detailed list of submissions

(2) Other data or design calculations at various stages of design shall be submitted from time to timeas requested by the Purchaser as part of review process.

3.4.2 Audit

The Purchaser reserves the right to carry out a detailed structural and mechanical audit of the designproposed by the Contractor.To facilitate this audit, the Contractor shall supply, in logical order, and in complete packages, allrelevant information on major elements and functional drives. This shall include

- Relevant drawings to show how the loads are being transmitted into the structure, to permitan integrated design audit.

- Relevant calculations.- Sufficient drawings to show how components elements make up the conceptual design.- Calculations to justify the selection of proprietary items such as hoist, trolley, gantry and

components e.g. motors, couplings reducers brakes etc.

3.4.3 Calculations

The design for the structure shall be calculated using the methods and procedures defined by internationallyrecognized design standards. The calculations shall be prepared and presented in a clear and precise formatand shall demonstrate all methods and assumptions used in each element of the design.

Other data or design calculations at various stages of design shall be submitted from time to time asrequested by the Purchaser as part of review process.

3.4.4 Drawings

The Contractor shall provide copies of the drawings showing construction details to enable supervisionof the fabrication and construction by either the Purchasers representatives or Third Party Surveyors.

Drawings forming part of the design packages, forwarded for audit purposes shall be provided in pdfformat at least A1 size so that they can be reproduced clearly upon receipt, to permit accurateexamination and assessment.

[The Purchaser warrants that it will respect commercial confidentiality of drawings provided and will onlyuse them for the purpose of assessing the design.]

3.5 Loads3.5.1 Load Combinations

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

3.5.2 Engineering Standard

The Contractor shall comply with FEM 1.001, 3rdEdition Revised 1998.10.01, Rules for the Design ofHoisting Appliances for calculation of stresses in structural components. Alternative standards such asBS are accepted providing the Contractor provides adequate justification and detailed reference.


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3.6 Members Subject To BucklingThe design of columns, beam columns, frames and beams subject to buckling shall be in accordance

with the FEM specification.

3.7 Fatigue Design Criteria(1) Fatigue design shall generally conform to the requirements of F.E.M. 1.001, 3rd Edition Revised

1998.10.01.

(2) Cumulative damage shall be evaluated for the normal operating conditions.

(3) The load spectra for development of the stress cycle spectra shall be presented by theContactor for approval by the Purchaser. The specified loads and cycles shall represent theeffects of the actual anticipated operating conditions.

3.8 Connection Designs(1) Connections shall be designed to resist artificial local loads imposed by a stress equal to the

average of the allowable and the calculated stress, but they shall be designed for not less than75% of the allowable strength of the member. Notice that whenever the calculated stressesare 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 appliedto the weld throat. For fatigue design when calculating the stress range, the vector differenceof the greatest and least vector sum stress may be used instead of the algebraic difference.

(3) Welded joint design shall conform to AWS D1.1 latest edition.

(4) Bolted joint design shall conform to the AISC Specification using 0.9 times AISC allowablevalues. Prying action due to distortion of the connection details shall be considered. Boltsgoverned by fatigue strength shall comply with ASTM A325.

3.8.1 Pin Joints

(1) All pins shall have angled lubrication drillings to avoid any change in direction that will hinderflow of grease nipple to the bearing surface.

(2) Eyebars and pin connected members shall be designed in accordance with the AISCSpecification using 0.9 times AISC allowable values, and shall be checked for fatigue usingeither the allowable net section stress range for Class F details or the stress concentrationfactors and the stress range for Class B details at the face of the hole. If the net section isgoverned by fatigue, then all other proportions shall be increased on a basis consistent with

the AISC requirements.

3.9 Gantry Structure Stiffness(1) Deflection or oscillation of the structure shall not affect the Crane capacity and operating

efficiency (particularly spreader positioning ability).

(2) The horizontal displacement at the girder level due to full acceleration or deceleration of trolleywith a rated load, or full acceleration or deceleration of trolley while suspending a rated load at themaximum upper limit position, shall not exceed 80mm.

(3) The main structure shall be designed so as not to sustain damage in the event of puncture of anyone.


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3.10 CamberThe two main girders shall be designed with an appropriate camber so that under loaded conditions themain girders are level.

3.11 Trolley Rails & Rail FixingTrolley rails may comprise standard rail and clips or welded square bar.

In the event that the rail is manufactured from square bar, the material specification for the bar and weldingprocedures, inclusive of pre-heat, post heat and electrode specification shall be provided within themaintenance manuals.

3.12 Workmanship(1) The whole of the structural fabrication and assembly shall be performed in a thorough,

workmanlike manner and shall follow the best modern practices in the manufacture of high-grade structures.

(2) Welders, welding operators and tackers shall be certified, for the material, processes and type ofwelding being performed.

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

(4) The Contractors Quality Assurance team shall be required to keep an accurate log of thequalified welders on the job. This log will be subjected to examination at any time by thePurchaser or his site representative.

(5) The Contractors Quality Assurance team will ensure that all correct welding procedures arestrictly followed by the welding personnel. Any welding work being seen to not meet acceptedprocedures shall be stopped immediately and logged as a non-conformance report. Continuationof this welding will then be subject to approval by the Purchasers representative on site.

(6) The Contractors Quality Assurance team will ensure that all welding during low temperatures iscarried out, as far as practicable, within an enclosed canopy to provide a controlled environment.The use of correct pre-heating procedures and welding rod hot boxes is essential and will beclosely monitored by the Purchasers Representative.

(7) A325 and A490 bolts (or their equivalent specification such as ISO/EN/DIN) that are 7/8(22m) in diameter or less may be tightened to the required tension by any standard method.A325 and A490 bolts greater than 7/8 (22mm) diameter shall be tightened to the requiredtension by the calibrated wrench method only. The following supplemental requirements shallapply in addition to the requirements of the Specifications to structural joints using ASTM A325or A490 Bolts:

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

(ii) The Contractor shall notify the Engineer if the highest and lowest torques measuredduring wrench calibration varies by more than 10 percent of the lowest torque, sothey may develop the appropriate solution. If the range exceeds this tolerance, filedtightening may be erratic.

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

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


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

developed.

(vi) The final tension shall be verified by testing 10 percent of the bolts after all the boltsare tensioned. If the verification indicates loss of tension in some bolts, the Contractorshall notify the Purchaser. The Purchaser and the Contractor will develop theappropriate action.

(vii) Flange contact bearing surfaces shall have at least 75% of the bearing cross-sectionalareas 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 theremaining 25% of the length.

(viii) Bolt tension may be verified at locations selected by the Purchasers Representative.Bolt tension verification shall be performed by the Contractor in the presence of the

Purchasers Representative and in such a manner that the torque can be wrench gageread during verification.

(8) Weld Testing and Inspection

All welds shall be subjected to inspection by methods and extent, reflecting the critical natureof the welded connection.

Welds shall meet the requirements for cyclically loaded structures of AWS D1.1-2006. Thespecific method of weld inspections shall be shown on the drawings. Weld inspectionprocedures shall be submitted to the Purchaser.

Testing, which shall be at the Contractors expense is required as follows:-

Weld Type of Testing/ Inspection Acceptance Criteria

All Welds 100% Visual AWS 1.1 2006Full Penetration Butt Welds(Compression)

25% UT AWS 1.1 2006

Full Penetration Butt Welds(Tension as determined by stresslevels due to operating loadcombinations.

100% UT AWS 1.1 2006

Full Penetration Butt Welds inTension Bars (if applicable)

100% UT AWS 1.1 2006

Fillet Welds or Partial

Penetration WeldsOn FCMOn Non- FCM

100% of length MT10% of length MT(as nominated by the PurchasersRepresentative)

AWS 1.1 2006

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

Ultrasonic testing of tension welds shall be done by or under the direct supervision of an ASNT CertifiedLEVEL III *or equivalent qualified person.

3.13 Quality Control of Structure Fabrication


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(1) Quality Control shall be the responsibility of the Contractor. The Contractor must implement awritten quality control program and shall be part of the Contractors Quality Assurance Manualthat shall be submitted to the Purchaser for review within 1 month of the date of theAgreement. The Quality Assurance Manual shall also contain the Contractors Inspection andTesting Specification.

(2) The quality control program shall follow the applicable requirements laid out in 7.1.4. For thestructural fabrication this shall include but not be limited to the following:- Inventory of incoming material, consumables components and machinery.

- Traceability procedures for materials together with traceability identification codes,which shall be serial and indexed to the controlled manufacturing procedures.

- Cutting, fit up, welding, forming and dimensions of structural components.

- Welding and inspection procedures identifying clearly the type and extent of NDTinspection carried out on the cranes structure.

- Welding and inspection personnel qualification and certification (see 3.12).

- Welding, machining, measuring and inspection equipment maintenance andcalibration.

- Machining finishes surfaces, bolt tensioning procedures.

- Procedures for non-conformance (NCR) and Punch List (PL) reporting and rectificationof defects.

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

- Procedures for material cleaning, preparation blasting and painting.

3.14 Temporary Structures3.14.1 Temporary Structures

Connections details of temporary structures (such as lifting lugs, etc) fitted onto Operationally CriticalComponents must be reviewed by the Purchaser.

3.14.2 Sea-Fastening

At least three months before the intended shipment, the Contractor shall submit sea-fastening structureconnection details to crane structures for the Purchasers review, consideration and acceptance orotherwise. The submission shall also provide details of the proposed methods for removal of thetemporary bracings and fixings. The Purchaser prefers a system that minimizes any Hot Work at thesite to minimize the risk of damage to paintwork and the need for extensive paint system repairs.


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4 FUNCTIONAL SYSTEMS DEVICES AND EQUIPMENTLifting lugs shall be provided for all sub-assemblies such as reducers, gantry / trolley / hoist/ hydraulic tanks

etc. These should be installed on each assembly, clearly identified and marked (stamped) with SWL.

4.1 Main Hoist4.1.1 Main Hoist

(1) The Main Hoist system shall consist of one (1) AC Motor, two (2) AC servo operated brakes,Reduction Gear and one (1) wire rope drum.

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

(3) Couplings which connect the hoist gearbox to the hoist drum shall be manufactured by aninternationally recognized manufacturer of this type of component. Wear indication marks shall beprovided in a convenient place for viewing without dismantling of any components.

(4) Two (2), AC servo operated disc brakes shall be fitted on the high-speed pinion shaft. Each brakeshall be rated at 150% rated motor torque and shall be capable of stopping and holding themaximum rated load from full rated speed. The calculated setting torque of each brake shall be atleast 10% less than the full capacity of the brake.

(5) A calculation of brake compliance for the defined duty shall be provided from the brakemanufacturer.

(6) Over-speed switch shall be fitted to the main hoist motor to shut down the drive and set thebrakes if the load exceeds 115% of rated speed.

(7) Heavy duty, pulse encoder, of IP55, shall be installed on the main hoist motor for closed loopspeed feedback and control and a cam limit switch shall be installed at the hoist rope drum shaftfor hoist limit switches and slow down checks. The encoder shall be mounted externally from themotor/fan casing.

(8) Acceleration from zero speed to a maximum speed or deceleration to zero speed shall be smoothand stepless for all load combinations.

(9) There shall be two (2) stages of upper hoist slowdown to cater for an empty spreader and aloaded spreader in order to enhance performance of container handling. For this function asoftware limit switch system track limit switch shall be provided using an absolute encoder onthe hoist drum to calculate exact hoist position at all times.

In the condition of empty spreader, the hoist shall incorporate a lower slow down whilst the loadedspreader condition shall incorporate a higher slow down position using position from absolute

encoder and lock/unlock signals

Under each condition the emergency upper hoist limit shall not be tripped. The Contractor shallpropose a method statement with calculations for the Purchasers review.

(10) Frequent inching operation and plugging operation shall be catered for in the design.

(11) The hoist brakes, pads and disc shall be protected from the weather with an easily removable oraccessible enclosure, so designed to allow access to all components for maintenance.

(12) Outboard wire ropes shall be stationary during the hoisting and lowering motions and all dead-endwire ropes shall be terminated with Wedge Sockets.


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4.1.2 Sway Control

(1) The Anti-sway/yaw device or sway/yaw damping system shall work effectively for a short distancetravel as well as for a stop after full deceleration. The operation of the system shall not alter theelevation of the spreader with or without load at any height.

(2) A simple anti-sway system which is of proven design shall be provided.

(3) The sway control shall bring the spreader to a stop following full deceleration of the trolleyfrom full speed with any operational load to within 150mm at any lifting height as measured atthe bottom corners of the 40 container or the twist lock of an empty spreader. It shall becapable of bringing the spreader to a stop to within 2.5 cycles of sway.

4.1.3 Trim Control

(1) The Spreader trim motion to be controllable up to its maximum angle of 3 at a speed 0.5 persec minimum

(2) One push button switch on the control console shall automatically correct the spreader position toa Zero List position.

(3) Zero List position shall be indicated with a lamp on the panel in cab.

(4) The system shall be electrically operated.

4.2 Trolley4.2.1 Trolley Frame

(1) The trolley frame shall be fitted with the main hoist machinery, trolley drive machinery, trimdevice, operators cab, and buffers (or buffer reaction stoppers) for forward motion andbackward motion collision impact. The buffers shall be capable of absorbing and dissipating

the impact of collision at full speed with rated load.

(2) The trolley frame shall be fitted with safety drop-stop lugs which shall support the trolley incase of wheel or axle failure.

(3) The trolley frame shall have jacking points for trolley wheel replacement work and wheel-bearing housings shall be split to permit wheels and axles to be dismantled easily.

(4) The trolley frame shall provide a safe emergency access from the operators cab to thewalkways of the girder at any point of trolley travel range.

(5) The trolley frame shall be provided within safe maintenance platform and access to all of itscomponents and machineries for maintenance.

(6) A mirror of break resistant material shall be provided to assist viewing the far side of liftedcontainer in a slot underside of the trolley frame. The mirror position shall be easy for theoperator to adjust.

(7) Two pairs of heavy duty side guide rollers shall be fitted on one side of the trolley frame atfore and aft to guide the trolley movement. The cam following roller bearings of the rail guideshall be heavy duty and strong enough to resist damages by horizontal force.

(8) An electrically operated maintenance hoist for carrying tools and components up to 500kgcapacity shall be installed on the trolley platform. Total time to raise rated load from ground totrolley shall be less than 1 minute. The hoist motor shall be provided with overload protection.

4.2.2 Trolley Drive


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(1) The Trolley shall be driven by one (1) or two (2) trolley motors, dependent upon the Contractorsdesign.

(2) The trolley brake(s) shall be rated at 160% of rated motor torque.

(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 isnot permitted. The design of the coupling shall be such that when the coupling is required to bedismantled, it is not required to shift the gearbox or trolley motor.

(5) The trolley drive system, and wheel, shaft and bearing system shall be designed to facilitate fastreplacement of components at any point on the girder. The replacement of a trolley wheel shallnot take longer than 1 hour with 2 people.

(6) Frequent inching operation and plugging operation shall be catered for in the design.

4.2.3 Power Feeder

(1) Power and control cables shall be routed to and from the trolley by a proprietary cable chainsystem.

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

(1) Cable clearance and bend radius within each carrier link, inclusive of manufacturersrecommended allowances.

(2) Adequate allowance for cavity fill including manufacturers recommended safety factors.In any case less than 60% of the total cavity cross sectional area.

(3) Even and symmetric weight distribution within each carrier cavity.

(4) Appropriate consideration for separation of dissimilar cables and regard for cablereplacement.

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

(4) The cable system shall include 20% spare control wires of each type/size and 6 cores fiber opticcables.

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

(6) Access to the energy chain system shall be by a permanent walkway and platform. Manufacturersrecommendations shall be adhered to strictly for installation detail and tolerances. A platform onthe trolley may be used for access to the energy chain providing it provides safe access and handrails are fitted.

(7) The system design shall not generate water traps internally, between cables and chain material orexternally between chain material or crane structure.

4.3 Gantry4.3.1 Gantry Drive

(1) The gantry drive motors and brake system shall provide sufficient thermal capacity, torque and

traction for all operating conditions.


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

(3) The gantry drive and motors shall be capable of accelerating, driving a distance of 300m anddecelerating with and against the operating wind load without adverse heating of anycomponent.

(3) The gantry service brakes shall comprise electromagnetic, spring applied double disk brakesmounted to each gantry motor. The dynamic rating shall be greater than 100% of maximummotor torque but not greater than 150% of the maximum motor torque. The brake thermalcapacity must be sufficient to stop the crane from rated speed with a following maximumoperating wind whilst not sustaining damage in the event that an emergency stop button ispressed without any aid of wheel or rail brakes. Each brake shall be supplied with a strong,lightweight, latching rain proof enclosure. Brakes shall set after an adjustable time delay of nogantry operation. The brake rating and design calculation shall be submitted or formallyapproved by the brake manufacture and submitted to the Engineer for review.

(4) Storm wheel brakes shall be provided on sufficient number of idler wheels and be capable ofholding the crane under sustained storm wind of 40m/sec in combination with gantry brakesand with stowage pins in the disengaged condition. The braking calculation shall assumecoefficient of friction between wheel and gantry rail to be 0.12. The brake spring life shall begreater than 1,000,000 cycles and the brakes shall provide for 10mm float with cleaningpads. Wheel brakes shall be spring applied and hydraulically released acting upon idler wheelflanges which are designed for brake installation. The hydraulic power units shall bemanufactured and supplied by the wheel brake manufacturer. Hand pumps for manuallyreleasing the rail brakes shall be provided.

(5) The gantry drive shall be self-contained within its drive truck, motors shall drive through atotally enclosed, oil lubricated, helical and/or spiral bevel gearbox with one motor and onemotor driving one wheel. The motor shall be flange mounted to the reducer.

(6) Drive components shall be protected by their location or by substantial fenders against damageby vehicular traffic.

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

(8) Each truck and equalizer beam shall have proper jacking points to facilitate jacking for simpleremoval of any wheel without dismantling trucks or equalizer beams. Jacking load and positionshall be approved by the Purchaser to prevent overloading of quay structure.

(9) Wheels and gearboxes shall be fitted with robust safety guards.

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

(11) Hydraulic Buffers or bumpers shall be installed at 4-corners of the crane. These shall becapable of absorbing and dissipating the impact energy of collision at full traveling speed.

(12) Limit switches to prohibit gantry travel motion when the stowage pins are inserted into theground socket shall be provided.

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

4.3.2 Stowage Pin

(1) Hand operated stowage pins shall be provided and shall be designed to hold the crane underthe wind conditions defined. The design to size the pin and its supporting structure shall notconsider the clamping force of the rail brakes or the force of the motor brakes.


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(2) The arrangement of the stowage pins shall suit the stowage pin recess in the yard, drawingsand relevant details will be supplied by the purchaser.

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

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

(5) Limit switches shall disable the gantry drive unless all stowage pins are in the raised position.

4.3.3 HV Cable Reel

(1) Cable reel

(i) The cable reel shall be installed on one of the legs, or as agreed. The drive controlsystem of the cable reel shall be designed to minimize abrupt starting; braking andexcessive slack / tension in the cable when the Crane passes the cable feed point.Sensors/switches to detect the above conditions shall be provided.

(ii) The mono spiral cable reel shall be manufactured entirely from stainless steel or be hotdip galvanized after all fabrication and machining work is completed.

(iii) Cable guide wheels shall be installed near the gantry trucks to keep the high voltagecable close to the ground level. The cable shall be laid inside the cable slot within thewheelbase of the gantry trucks in one corner.

(iv) The system shall be well protected from weather especially in the vicinity of the highvoltage slip ring components and the slip ring enclosure shall be stainless steel.

(v) The cable reel drive machinery and slip ring area shall be fenced off to allow access ofauthorized persons only. A high voltage warning sign shall be provided and fitted to theentrance of the fenced area.

(vi) A suitably sized space heater shall be provided fo

siwz rmgs schedule 5 technical specification pdf

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