AREVA Federal Services LLC - feandc.com Crane runway girder, runway rails, rail clips, and crane runway stops shall be sized and provided by Demag. ... AREVA Federal Services LLC

AREVA Federal Services LLC

Title: KW Annex Crane Procurement Specification

Document No: 445577-SPEC-M-001 Rev. No: D Page 2 of 12

Project No: 01949.03.P001.48 Project Name: Modified KW Annex Design

REVISION HISTORY

REV. CHANGES

A 60% Design Review

B 60% Design Submittal

C 90% Design Review

D 90% Design Submittal





TABLE OF CONTENTS

1.0 INTRODUCTION ................................................................................................................................... 4

2.0 PURPOSE ............................................................................................................................................. 4

3.0 REFERENCE DOCUMENTS ................................................................................................................. 4

4.0 SCOPE OF SUPPLY ............................................................................................................................. 4

5.0 GENERAL PARAMETERS AND SPECIFICATIONS.............................................................................. 6

6.0 COMPONENT FEATURES .................................................................................................................... 7

APPENDIX A: .................................................................................................................................................. 12





1.0 INTRODUCTION

An overhead bridge crane is required in the KW Annex Sludge Loading Bay to remove the STS cask lid for access to the top of the STSC, and to assist in making and breaking nozzle connections. The proposed Sludge Loading Bay that will house the crane, is a dual system steel frame and reinforced concrete structure approximately 53 ft long, 29.5 ft wide, and 36 ft high. A mezzanine work area will exist inside the building at a level approximately 20 ft above the KW Annex ground floor and will be used by operators to perform various functions in the Annex. The bridge crane will also be used to lift equipment on and off the mezzanine floor. The bridge crane, a Demag type ZKKE, shall be an electric driven top running, double girder with trolley. The proposed KW Annex Sludge Loading Bay facility is located near the Columbia River on the northern part of the Hanford Site.

2.0 PURPOSE

The purpose of this technical specification is to provide the minimum functional, performance, and code requirements allowing the prospective vendor to adequately supply of the required overhead crane system.

3.0 REFERENCE DOCUMENTS

3.1. PRC-STP-00329, KW Basin Modified Annex Design Specification, CH2M Hill, Revision 3

3.2. ASME B30.2, Overhead and Gantry Cranes, Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist

3.3. CMAA Specification No. 70-2004, Specifications for Top Running Bridge and Gantry Type Multiple Girder Electric Overhead Traveling Cranes

3.4. DOE-RL-92-36, Hanford Site Hoisting and Rigging Manual, Rev. 1.

3.5. AFS 44577-M-CALC-020 Rev C, Seismic Restraints for the KW Annex Crane

3.6. AFS 44577-S-CALC-003 Rev B, Crane Runway Beam and Support Design

3.7. DOE, KW Annex, Structural Intermediate Roof Plan, H-1-96805 Rev B

4.0 SCOPE OF SUPPLY

The crane vendor shall furnish the following equipment & services: • Supply of a 10-ton capacity double girder bridge crane as specified herein • Supply of runway rail(s) including rail clips and rail stops, and runway beams for the 10-ton crane above. • Supply of runway electrification as specified herein • Installation of supplied equipment above • Equipment operating and maintenance instructions • Installation drawing with clearance and performance notes such as:

o Travel speeds o Wheel loads o Rail size





o Total Current draw, starting & full load o Component weight list: end truck, girder, trolley with hoist and total assembly

• Recommended spare parts lists • Operation and Load Test support • Signed Certificate of Conformance indicating the design, fabrication, and assembly requirements of ASME

B30.2 [3.1] and CMAA 70 [3.3] have been meet.





5.0 GENERAL PARAMETERS AND SPECIFICATIONS The following table lists general parameters and specifications required for this crane.

Table 5.0 – Crane Parameters and Requirements

General Parameter Specification

Crane Type Top-running double girder crane, Demag type ZKKE

Capacity 10 Ton

Crane Span 23’-4” center to center of crane rail

Hook Height Minimum lift height of 29’-2”

Duty Class Class “C” (Moderate Service)

Hoist Lift Speed 0-41 FPM, variable frequency control

Trolley Travel Speed

0-100 FPM, variable frequency control

Bridge Travel Speed 0-160 FPM, variable frequency control

Operation/Controls

The bridge crane shall be provided with two control types, a radio and pendant control. The default control mode is by radio operation. The pendant control mode is enabled only when manually plugged into the control cabinet located on the bridge. The pendant control is intended for use on the mezzanine level only.

Runway The crane shall be provided with runway support beams (W18 X 76), runway rails, rail clips, and crane runway stops. The runway length and attachment point details are based on the attached reference drawing [3.7].

Runway Electrification

Complete installation of the runway conductor system mounted along the north runway.

Supply Voltage 480/3/60

Control Panel Enclosures

NEMA Type 12

Foot-walk(s)

The crane shall have two separate foot-walkways with railing along the bridge girder length, one on each side of the crane bridge. Access to the foot-walk is by ladder or portable stairs from the mezzanine level provided by others. An access gate is required on each end of the foot-walk to enable safe personnel access.

Fluorescent shop lights

Qty (4) 120VAC X 4 ft fluorescent shop light fixtures with dual T5 type bulbs, rigid mounted under catwalks (two on each catwalk, spaced 3 ft from centerline of the bridge span, oriented parallel with the crane run way). Lights powered continuously, no switch required.





6.0 COMPONENT FEATURES

The following table lists crane component features with corresponding requirements.

Table 6.0 – Crane Component and Specifications

General Parameter Specification

Runway Crane runway girder, runway rails, rail clips, and crane runway stops shall be sized and provided by Demag. Runway support lengths and details are given in the attached reference drawing [3.7].

Bridge Girders

Bridge girders shall be fabricated plate box sections, with diaphragms, designed to resist all vertical, horizontal, and torsional forces. Trolley rails shall be ST52 rectangular sections welded directly over girder webs, to optimize transmission of loads into the girder structure. Maximum allowable girder deflection is 1/888 of span.

Girder Connection End trucks shall be bolted to girder ends to form a rigid connection. Bolts in shear or welded connections are not to be used. The girder connection shall be precision aligned to insure proper tracking of the crane.

End Trucks

End trucks shall be box section type having wheels supported on rotating axles. The axles shall be supported by dual anti-friction bearings having a minimum B-10 life in accordance with the CMAA crane classification specified. Wheels shall be cast and machined from spheroidal graphite material. Wheels to be designed to carry the rated load without undue wear to themselves or the crane runways rails. End trucks shall be fitted with bumpers capable of decelerating and stopping the crane within the limits stated by OSHA and CMAA. Lateral restraint shall be provided by either double flanged wheels or side guide rollers meeting both CMAA and seismic loading requirements.

Seismic Restraints

The bridge crane shall include seismic restraints which provide lateral restraint during a seismic event. The seismic restraint design can exist as either: rigid brackets attached to the bridge girder that would contact the upper flange edge of the crane runway during a seismic event, or alternately, sufficiently sized side guide rollers mounted on the end trucks that contact the sides of the runway rail. The lateral seismic restraint load is: 4,784 lbs [3.5]. The recommended allowable stress for restraint design is 20% of the average ultimate strength of the material utilized. The seismic restraint design shall be submitted for review and approval prior to manufacture of the crane. Vertical seismic restraint is not required.

Bridge Drive

Horizontal bridge drives shall be CMAA type A-4. Motors are totally enclosed, fan cooled and drive fully enclosed gearing. All gear reduction stages shall be oil bath lubricated. Gear reducers directly drive the wheel axles through splined shafts. The use of VFC (Variable Frequency Control) combined with Demag cylindrical rotor motors are encouraged to ensure smooth acceleration and deceleration to minimize load swing. Motors shall be Class F insulation and are thermally protected by heat sensors imbedded in the windings.





Motor Controls

Standard enclosure classification shall be NEMA 12, water tight and dust resistant. Control voltage shall be isolated from the main power supply by a transformer and shall not exceed 120 volts. The standard control voltage for cranes with type DR hoist shall be 48 volts.

Pendant Control Station

Ergonomically designed push button pendent control shall be provided for optional use. The pendant control shall normally be unplugged from the control panel. The P.B. station is suspended from an enclosed track system to enable separation of operator and load. Plug connectors shall be used on both ends of the pushbutton control cable for ease of maintenance or replacement. DR Pro hoists come standard with a bar load readout, and will provide a warning symbol in the event of an overload or if the system requires maintenance. The bottom of the P.B. control should hang no lower than 84” from the crane runway “top of rail”.

Bridge Electrification Electrification across bridge for power and control circuits shall consist of highly flexible neoprene covered flat-section cable suspended from smooth running enclosed track system.

Travel Limit Switches Limit switches shall be provided on the bridge and wired into the respective control circuits to stop the driving motors at the extremes of travel.

Paint All structural and component parts shall be cleaned with solvent and or shot blasted or wire brushed. A prime coat and finish coat shall be applied. Standard colors shall be safety-yellow for structural parts and Demag blue for machinery.

Hoist Type

Standard features shall include: (DR Pro hoists) o Over-Capacity Protection o Condition Monitoring o Diagnostics for entire crane , downloadable with laptop or PDA interface o Self defense against operator plugging and jogging o Low current contactor switching o Duty and Load spectrum recording

Hoist Design Designed in conformance to CMAA, HMI and applicable national and local codes and regulations.

Hoist Controls

Diagnostics shall include service history along with overload protection. Controls shall include the following additional features: • Anti-Jogging, Anti-plugging, and Phase monitoring • Brake wear monitoring • Life Cycle calculation shows remaining life • Pulse generator to monitor the hoist motor • Hoist no current contact switching for long contactor life • Pushbutton with LCD display readout for crane and hoist update • Safety warning horn

Hoist Motor

Hoist motor shall be variable frequency hoist control with an optimized motor design for low-vibration and quiet operation 4-pole squirrel-cage motor with cylindrical rotor. All motors shall have Class F insulation and shall be protected from overheating by thermal protectors imbedded in the windings. Motors shall be totally enclosed, fan cooled (TEFC). Enclosure is outdoor rated IP 55 with a duty of 60% running time





and 360-starts/hour.

Hoist Brake

Demag DC disk brake shall be a fail-safe type, electrically released, spring set for close positioning and motor start-up monitoring, with a minimum brake safety factor of 1.8. The brake shall be a fast acting brake. The hoist (DR Pro) shall include a brake sensor that monitors brake wear and provides a warning to the operator if a brake adjustment is necessary. The high quality brake shall be designed for a minimum of 5 years life under single shift operation.

Hoist Gearing

All gear stages shall have helical gearing and be case hardened for low noises and smooth running. Each gear and hub connection shall be designed with a conical bonded press-fit connection. Gear lubricant shall be synthetic and should not require replacement for the normal life of the hoist. The standard hoist design shall be rated for FEM2+ (20% greater duty than FEM2).

Rope Drum

Drum shall be of welded steel construction, with machined groove, optimized to a minimum depth of 0.375 times the rope diameter. Drum shall be supported at each end by sealed anti-friction bearings, the drum shall be driven by a central splined shaft. To assure positive winding of rope on the drum and to prevent rope overlapping and potentially dangerous groove peak contact, a hoisting rope guide shall be employed.

Wire Rope The hoisting wire rope shall be of proper design and construction for hoist service. The rated capacity load divided by the number of parts of rope shall not exceed 20% of the breaking strength of the rope.

Bottom Block

Bottom block shall have a totally enclosed housing fabricated of steel. The rope sheaves shall be supported on anti-friction bearings and the hook shall be forged alloy-steel and supported on an anti-friction thrust bearing. The hook shall be equipped with a heavy spring safety latch. A handle recess shall be included to make it easier to be gripped and handled.

Limit Switch

Hoist shall be equipped with a 4 position geared upper and lower limit switch. This switch shall be easily adjusted to set the extreme upper and lower limits of hook travel. The limit switch shall be equipped with a digital drum revolution counter for use in evaluating service conditions and maintenance intervals.

Trolley

A low headroom trolley shall support the hoist on one side of the beam allowing an high-hook dimension. The steel trolley frame shall include side guide rollers for precise tracking, and an under flange pressure roller for consistent horizontal drive traction and anti-kickup. Lifting lugs shall be provided for simple transport and installation. The design shall be compact to allow for minimum hook approach dimensions.

Trolley Drive

Motorized trolleys shall be powered by a Demag cylindrical rotor motor with DC brake. A frequency inverter shall provide a true variable speed travel motions for smooth safe positioning, low-sway travel motions and exact positioning. Motors shall have Class F winding insulation and shall be totally enclosed. Motors shall be protected from overheating by thermal protectors imbedded in the windings.

Travel Limit Switches Limit switches shall be provided on the trolley and wired into the respective control circuits to stop the driving motors at the extremes of travel.

Audible Warning A warning horn shall be provided as a standard feature on DR Pro wire rope hoists.



Document No: 445577-SPEC-M-001 Rev. No: D Page 10 o f 12


Device The horn shall be mounted on the hoist electrical enclosure. The horn shall be activated by a 2 position horn button from either a DSE pushbutton station or a DRC radio transmitter. The horn button first position should result in a constant sound from the horn. The second position should result in a pulsating sound. The horn DB rating shall be 95 db (+/- 3db). The warning horn should also sound if a control system error is detected.

DR Diagnostics

A diagnostics tool should be included for maintenance requirements. The performance and safety status of your installation shall be kept under surveillance by the monitoring system. A LED display within the pendant control should show the operator or maintenance engineer the relevant status information and any unusual operating status, if applicable. Two way communication shall be included via PC/PDA communication with hoist via IRDA (infrared) or through Laptop comport cables.

Crane Walkway(s)

Full length walkway is required and shall be fabricated from steel checkered safety plate with 4 inch high toe guards on all sides. The steel handrails shall be fabricated from 1 1/2 inch square tubing and shall be 42 inches high. A walkway shall be provided on each side of the crane bridge with a gate to enable access via ladder or portable stairs. Handrails and toe guards shall be painted safety yellow.

Radio Control Radio control shall be the default mode of operation. Demag DRC-10 D2 Handheld Radio is the preferred controller.

Control System with Signal Horns

The Control System shall include a handheld transmitter, receiver, audible warning device (in hoist enclosure), batteries, and battery charger. • 6 infinite-action pushbuttons, horn/limit switch test pushbutton, stop pushbutton,

& 2 pushbuttons for special functions • Weight including battery: 500 g (18 oz) • IP55 protection • Temperature range -20 to +50°C

Runway Conductors A four (minimum)-bar, enclosed type conductor system, shall be provided along the full length of the runway.

Lubrication

Grease fittings for lubrication shall not be permitted. Exposed external gears requiring oil or grease lubrication shall not be permitted. All lubrication of bearings, gears, bushings, shafts, slide plates with lubrication requirements shall be of a permanently lubed and sealed type.

Inspection

Inspection by the building contractor during crane structural fabrication shall be permitted by the vendor. These inspections shall be performed to determine the general adherence to these specifications and, in particular, to determine the quality of welding and painting provided.

Testing

Final acceptance testing shall be performed after installation has been completed. Final acceptance testing shall include operational testing at 100% rated capacity and also load testing specific components at 125% rated capacity. All tests of the crane shall be made by the purchaser and vendor representative at a mutually agreeable scheduled time.

Guarantee Vendor shall guarantee materials and workmanship of equipment installed under





these specifications for a period of one year after installation.

Required Vendor Information Upon Receipt of Order

• Outline drawing indicating required clearances, end approaches, horsepower, and full load current rating of all motors and wheel loading.

• Manufacturer’s name and catalog number of any equipment to be furnished not manufactured by vendor.

• Any exception or difference of any equipment to be furnished from that specified and reason for the substitution for approval.

• Name and address of manufacturer’s representative nearest plant site maintaining 24-hour service facilities and complete stock of spare parts.





APPENDIX A:

Documents

AREVA Federal Services LLC - feandc.com Crane runway girder, runway rails, rail clips, and crane runway stops shall be sized and provided by Demag. ... AREVA Federal Services LLC