TECHNICAL SPECIFICATION FOR RUBBER TYRED GANTRY CRANES

8/20/2019 TECHNICAL SPECIFICATION FOR RUBBER TYRED GANTRY CRANES

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Appendix 1 - Technical Specification Feb 2012

TECHNICAL SPECIFICATION

FOR

RUBBER TYRED GANTRY CRANES

FEBRUARY 2012


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[ GCT - RUBBER TYRED GANTRY CRANES ]

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INDEX

TECHNICAL SPECIFICATION

C (I) Functional requirement for the Crane

1. General ........................................................... ............................................................ ...........................................8 1-1. Project Description ..................................................... ........................................................... ........................8 1-2. Terminal Site .................................................... ........................................................... ..................................8 1-3. Overriding Requirement of the Purchaser .......................................................... ...........................................8

2. Overall Design Criteria..........................................................................................................................................9 2-1. Type of Crane ................................................... ........................................................... ..................................9 2-2. Type of Cargo................................................... ........................................................... ..................................9 2-3. Operating Environment and Design Aim.......................................................................................................9 2-4. Mode of Operation and Performance Target (MMBF)................................................................................10 2-5. Statutory Requirements and Minimum Design Standard.............................................................................10

2-6. Minimum Class of Crane.............................................................................................................................11 2-7. General Design Criteria ........................................................ ........................................................... ............11

2-7.1. Crane Particulars..................................................................................................................................11 2-7.2. Dimensional Restrictions.....................................................................................................................13 2-7.3. Yard Interface ..................................................... ........................................................... ......................13 2-7.4. Electrical Facility Interface (Shore Power)..........................................................................................13 2-7.5. Communication Facility Interface (Radio) .......................................................... ................................15 2-7.6. Climatic Conditions ...................................................... ........................................................... ............15 2-7.7. Wind Conditions..................................................................................................................................15 2-7.8. Lifting Loads and Stability ..................................................... ........................................................... ..15

2-8. NOT USED..................................................................................................................................................16 2-9. Noise Control...............................................................................................................................................17 2-10. Operationally Critical Components ...................................................... ...................................................17

3. Crane Structural Specification.............................................................................................................................17 3-1. General Requirement .................................................. ........................................................... ......................17 3-2. Material........................................................................................................................................................18 3-3. Calculations ...................................................... ........................................................... ................................19 3-4. Loads ...................................................... ............................................................ .........................................19 3-5. Members Subject To Buckling ....................................................... ........................................................... ..20 3-6. Fatigue Design Criteria................................................................................................................................20 3-7. Connection Designs .................................................... ........................................................... ......................20 3-8. Gantry Structure Stiffness............................................................................................................................21 3-9. Camber.........................................................................................................................................................21 3-10. Trolley Rails & Rail Fixing ........................................................ ........................................................... ..21 3-11. Workmanship...........................................................................................................................................21 3-12. Quality Control of Structure Fabrication........................................................ .........................................23

3-13. Temporary Structures ....................................................... ........................................................... ............24 4. Functional Systems Devices & Equipment..........................................................................................................24

4-1. Main Hoist ........................................................ ........................................................... ................................24 4-1.1. Main Hoist Drive .......................................................... ........................................................... ............24 4-1.3. Skew Control ...................................................... ........................................................... ......................26

4-2. Trolley, Trolley Drive..................................................................................................................................26 4-2.1. Trolley Frame ..................................................... ........................................................... ......................26 4-2.2. Trolley Drive ...................................................... ........................................................... ......................27 4-2.3. Sway and Position Control ..................................................... ........................................................... ..27 4-2.4. Power Feeder (Power Chain System) ......................................................... .........................................27

4-3. Gantry Drive ..................................................... ........................................................... ................................28 4-3.1. Gantry Drive ....................................................... ........................................................... ......................28 4-3.2. Steering................................................................................................................................................29 4-3.3. Right Angle & Pivot Turn ...................................................... ........................................................... ..29 4-3.4. Gantry Skew Control .................................................... ........................................................... ............29

4-4. NOT USED..................................................................................................................................................29 4-5. Electrical House, Control Panel, Regenerative E.M.F. Absorbing Resistors..............................................29


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4-5.1. General Construction .................................................... ........................................................... ............29 4-5.2. E-House Temperature Control.............................................................................................................30 4-5.3. Emergency Lights and Fire Control.....................................................................................................30 4-5.4. Back Power Absorbing Resistors.........................................................................................................30 4-5.5. Provision for Future Installation ....................................................... ...................................................30 4-5.6. Control Panel (in the Electrical house) ....................................................... .........................................30

4-6. Operator’s Cab, Checker’s Cab ...................................................... ........................................................... ..30 4-6.1. Construction General .................................................... ........................................................... ............30 4-6.2. Cab Access...........................................................................................................................................31 4-6.3. Window Visibility ........................................................ ........................................................... ............31 4-6.4. Cab Dimension ................................................... ........................................................... ......................31 4-6.5. Cab Fittings..........................................................................................................................................32 4-6.6. Checker’s Cab......................................................................................................................................33

4-7. Personnel Lift ................................................... ........................................................... ................................33 4-8. Headblock....................................................................................................................................................33

4-8.1. Headblock............................................................................................................................................33 4-8.2. Two Wire (Bus) System ......................................................... ........................................................... ..34 4-8.3. Baloney Cable......................................................................................................................................34

4-9.

Spreader, Hook Beam..................................................................................................................................34 4-9.1. Single Lift Telescopic Spreader...........................................................................................................35

4-9.2. Reeve in Spreader ......................................................... ........................................................... ............38 5. Inter-Functional Systems & Components...... ............................................................ .........................................38

5-1. Mechanical System/Components.................................................................................................................38 5-1.1. Bearing, Seals ..................................................... ........................................................... ......................38 5-1.2. Gearing ..................................................... ........................................................... ................................38 5-1.3. Gear Reducers......................................................................................................................................39 5-1.4. Wire Rope Winch Drums ....................................................... ........................................................... ..39 5-1.5. Wire Rope Sheaves..............................................................................................................................40 5-1.6. Wire Ropes ......................................................... ........................................................... ......................41 5-1.7. Shafts, Axles ....................................................... ........................................................... ......................41 5-1.9. Metal Wheels ...................................................... ........................................................... ......................42

5-1.10. Pins, Pin Brackets ..................................................... ........................................................... ............42 5-1.11. Bolts.................................................................................................................................................42 5-1.12. Lubrication.......................................................................................................................................43 5-1.13. Bumper, Buffer ......................................................... ........................................................... ............43 5-1.14. Rubber Tyres .................................................. ........................................................... ......................43

5-2. Hydraulically System/Components .......................................................... ...................................................43 5-2.1. Standards .................................................. ........................................................... ................................43 5-2.2. Components Sources............................................................................................................................43 5-2.3. Operating Condition ..................................................... ........................................................... ............43 5-2.4. Hydraulic Fluid Reservoir ...................................................... ........................................................... ..44 5-2.5. Power Unit...........................................................................................................................................44 5-2.6. Valve Mounting .................................................. ........................................................... ......................44 5-2.7. Relief Valve ........................................................ ........................................................... ......................44

5-2.8. Flow Control Valve ...................................................... ........................................................... ............45 5-2.9. Check valves........................................................................................................................................45 5-2.10. Servo Valves....................................................................................................................................45 5-2.11. Control Valve...................................................................................................................................45 5-2.12. Solenoid Valves ........................................................ ........................................................... ............45 5-2.13. Piping...............................................................................................................................................46 5-2.14. Hoses .................................................... ........................................................... ................................46 5-2.15. Assembly Test .......................................................... ........................................................... ............46 5-2.16. Catch Basins ................................................... ........................................................... ......................46 5-2.17. Filters .................................................... ........................................................... ................................46 5-2.18. Heat Exchangers ....................................................... ........................................................... ............47 5-2.19. Actuator .......................................................... ........................................................... ......................47 5-2.20. Application for Spreader..................................................................................................................47

5-2.21. Couplings.........................................................................................................................................47 5-2.22. Gauges .................................................. ........................................................... ................................47 5-2.23. Covers..............................................................................................................................................47 5-2.24. Hydraulic Fluid ......................................................... ........................................................... ............47 5-2.25. Load Sensing System.......................................................................................................................48


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5-3. Electrical & Electronic System/Components...............................................................................................48 5-3.1. General.................................................................................................................................................48 5-3.2. Main Power Supply ...................................................... ........................................................... ............48 5-3.3. Power Factor Correction......................................................................................................................48 5-3.4. Protection Against Power Surge ....................................................... ...................................................48 5-3.5. Protection against voltage dip/loss of power supply............................................................................49 5-3.6. Wiring..................................................................................................................................................49 5-3.7. Marking and Identification ..................................................... ........................................................... ..50 5-3.8. Conduit and Cable Tray.......................................................................................................................51 5-3.9. Electrical Trunking ....................................................... ........................................................... ............51 5-3.10. Motor .................................................... ........................................................... ................................52 5-3.11. Brakes ................................................... ........................................................... ................................52 5-3.12. Transformers....................................................................................................................................53 5-3.13. Resistors...........................................................................................................................................53 5-3.14. Enclosures........................................................................................................................................53 5-3.15. Meters, Counters..............................................................................................................................53 5-3.16. Limit Switches .......................................................... ........................................................... ............54 5-3.18. Name Plate.......................................................................................................................................55 5-3.19.

D. C. Power Supply ............................................................ ........................................................... ..55

5-3.20. Encoders ......................................................... ........................................................... ......................55 5-3.21. Sensors.............................................................................................................................................55 5-3.22. Circuit Breakers ........................................................ ........................................................... ............55 5-3.23. Auxiliary Power Socket ...................................................... ........................................................... ..56

5-4. Crane Motion Controls ......................................................... ........................................................... ............56 5-4.1. Control System General.......................................................................................................................56 5-4.2. Programmable Logical Controllers (PLC)...........................................................................................57 5-4.3. Power Supply.......................................................................................................................................58 5-4.4. Discrete I/O Modules...........................................................................................................................58 5-4.5. Real Time Clock Module.....................................................................................................................59 5-4.6. Motion Control Switches in Operator’s Cab........................................................................................59 5-4.7. Motion Control Panels ............................................................ ........................................................... ..61

5-4.8. Remote Motion Controls ........................................................ ........................................................... ..61 5-5. Operational Safety Interlocks ......................................................... ........................................................... ..61 5-5.1. Main Motions Interlocks......................................................................................................................61 5-5.2. For Trolley Operation ................................................... ........................................................... ............62 5-5.3. For Gantry Travel Operation ............................................................ ...................................................63 5-5.4. Spreader Functional Interlock..............................................................................................................63 5-5.5. Cab Entrance Door/Gate Interlock.......................................................................................................64

5-6. Communications..........................................................................................................................................64 5-6.1. Intercom System ........................................................... ........................................................... ............64 5-6.2. Radio Communication System ......................................................... ...................................................64 5-6.3. Data Communication System ........................................................... ...................................................64 5-6.4. Public Address System ........................................................... ........................................................... ..64 5-6.5. Operation Centre / Maintenance Office Station...................................................................................64

5-7. Crane Condition Monitoring System (CCMS) ................................................... .........................................65 5-7.1. General.................................................................................................................................................65 5-7.2. CCMS Description...............................................................................................................................65 5-7.3. On-Board Crane Condition Monitoring System (On-Board CCMS)...................................................66 5-7.4. On-Board CCMS Software Requirements...........................................................................................66 5-7.5. On-Board CCMS Hardware Requirements..........................................................................................68 5-7.6. Condition Monitoring ................................................... ........................................................... ............68 5-7.7. Fault Diagnosis ................................................... ........................................................... ......................72 5-7.8. Preventive Maintenance.......................................................................................................................73 5-7.9. Equipment Performance Data and Operation Log......................................................... ......................73 5-7.10. Remote Crane Condition Monitoring System (RCCMS) .................................................... ............73 5-7.11. RCCMS Software Requirements ............................................................ .........................................74 5-7.12. RCCMS Hardware requirements ............................................................ .........................................74

5-7.13. Server(s)...........................................................................................................................................75 5-7.15. CCMS Data Communication ........................................................ ...................................................75 6. Common Items ......................................................... ........................................................... ................................75

6-1. Walkways, Stairs, Ladders and Platforms .......................................................... .........................................75 6-1.1. Applicable Code/Std. .................................................... ........................................................... ............75


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6-1.2. Stairway Requirements ........................................................... ........................................................... ..76 6-1.3. Ladder Requirements...........................................................................................................................76 6-1.4. Platforms Requirements.......................................................................................................................77 6-1.5. Walkway Handrail Requirements ..................................................... ...................................................77 6-1.6. Cab Access Platforms ................................................... ........................................................... ............78 6-1.7. Walkway Requirements.......................................................................................................................78

6-2. Illumination and Lighting ..................................................... ........................................................... ............78 6-2.1. Walkways, Stairs, Ladders, Cab Access..............................................................................................78 6-2.2. Work Area Floodlights ........................................................... ........................................................... ..78 6-2.3. Floodlights on Trolley ............................................................ ........................................................... ..79 6-2.4. Emergency Lighting for Escape Routes...............................................................................................79 6-2.5. Lighting Control Switches ...................................................... ........................................................... ..79 6-2.6. High Pressure Sodium Lamp and Ballast ................................................... .........................................79 6-2.7. Fluorescent Lamps...............................................................................................................................80 6-2.8. Access for Lights Maintenance............................................................................................................80

6-3. Painting and Protective Coating ..................................................... ........................................................... ..80 6-3.1. Paint System General...........................................................................................................................80 6-3.2. Surface Preparation..............................................................................................................................81 6-3.3.

Abrasive Blast Cleaning ......................................................... ........................................................... ..82

6-3.4. Painting Generally ........................................................ ........................................................... ............83 6-3.5. Paint Systems.......................................................................................................................................85 6-3.6. Galvanising......................................................... ........................................................... ......................87 6-3.7. Reinstatement of Protective Coatings at Site....................................................... ................................87 6-3.8. Inspection and Sample Panels..............................................................................................................88

6-4. Purchaser’s Logo, Crane Numbers, Signs .......................................................... .........................................89 6-4.1. Purchaser’s Logo .......................................................... ........................................................... ............89 6-4.2. Crane Numbers ................................................... ........................................................... ......................89 6-4.3. Crane Capacity Signs...........................................................................................................................89 6-4.4. Manufacturer’s Name Plates................................................................................................................90 6-4.5. Other Signs ......................................................... ........................................................... ......................90

6-5. Alarm, Warning Signals ....................................................... ........................................................... ............90

6-5.1. Gantry Travel Warning........................................................................................................................90 6-5.2. Main Hoist Overload Warning.............................................................................................................91 6-5.3. Premature Twistlock Operation Warning ................................................... .........................................91 6-5.4. By-Pass Switch Abuse Warning ....................................................... ...................................................91 6-5.5. Electrical Control House A/C Warning ...................................................... .........................................92 6-5.6. Public Address/Warning......................................................... ........................................................... ..92

6-6. Emergency Stop Push Buttons.....................................................................................................................93 6-6.1. Locations .................................................. ........................................................... ................................93 6-6.2. Type .......................................................... ........................................................... ................................93 6-6.3. Emergency Stop Signs ............................................................ ........................................................... ..93

6-7. Service Outlets.............................................................................................................................................93 6-7.1. Location .................................................... ........................................................... ................................93 6-7.2. Type Model..........................................................................................................................................93

6-8. Fire Extinguishers........................................................................................................................................94 6-8.1. Locations .................................................. ........................................................... ................................94 6-8.2. Type-Model ........................................................ ........................................................... ......................94

6-9. Maintenance Tools and Equipment .......................................................... ...................................................94 6-9.1. Mechanical Maintenance Tools ........................................................ ...................................................94 6-9.2. Electrical/Electronic Maintenance Tools.............................................................................................94 6-9.3. Hydraulic Maintenance Tools..............................................................................................................94 6-9.4. Special Tools and Equipment ........................................................... ...................................................94 6-9.5. Wear Gauges........................................................................................................................................95

7. Project Q.A. and Administrative Requirements...................................................................................................95 7-1. Document Submission (Project) ..................................................... ........................................................... ..95

7-1.1. Project Organisation Chart (Shop & Site)............................................................................................95 7-1.2. Project Schedule (Shop & Site) ........................................................ ...................................................95

7-1.3. Project Progress Report .......................................................... ........................................................... ..96 7-1.4. Quality Assurance Programme/ Manuals ................................................... .........................................96 7-1.5. Daily Plan and Report (Site Work) ............................................................ .........................................96

7-2. Document Submission (Technical)..............................................................................................................97 7-2.1. Submission Schedule .................................................... ........................................................... ............97


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7-2.2. Conceptual Design...............................................................................................................................97 7-2.3. Drawings and Calculations for the Purchaser's Review.......................................................................97 7-2.4. Lubricant List.......................................................................................................................................98 7-2.5. Crane Delivery Method Statement.......................................................................................................98 7-2.6. Site Work Method Statement...............................................................................................................98 7-2.7. Commissioning Test Procedure. ....................................................... ...................................................99 7-2.8. Up-Dated Drawings ...................................................... ........................................................... ............99 7-2.9. Training Programme..................................................... ........................................................... ..........100 7-2.10. Structural maintenance Program....................................................................................................100 7-2.11. Operation Manuals.........................................................................................................................101 7-2.12. Maintenance Manuals ......................................................... ...........................................................101 7-2.13. As-Built Drawings .................................................... ........................................................... ..........102

7-3. Shop Inspection & Tests............................................................................................................................103 7-3.1. Shop Inspection and Verification.......................................................................................................103 7-3.2. Pre-Shipment Inspection and Test .................................................... .................................................104

7-4. Shipment, Delivery and Site Work........................................................... .................................................105 7-4.1. Clearance for Shipment .......................................................... ...........................................................106 7-4.2. Notification of ETA Site....................................................................................................................106 7-4.3.

Navigation Requirement ......................................................... ...........................................................106

7-4.4. Berthing and Roll-off Requirements..................................................................................................106 7-4.5. Customs Clearance ....................................................... ........................................................... ..........107 7-4.6. Work Permits ...................................................... ........................................................... ....................107 7-4.7. Site Safety and Security.....................................................................................................................107 7-4.8. Site Erection Area and Access...........................................................................................................107 7-4.9. Site Office Communication .................................................... ...........................................................107 7-4.10. Test Weight....................................................................................................................................108 7-4.11. Water, Electricity Supply...............................................................................................................108 7-4.12. Contractor’s Representatives. ....................................................... .................................................108

7-5. Site Inspection and Tests, Certification .................................................... .................................................108 7-5.1. Commissioning Tests Application.....................................................................................................108 7-5.2. Defects List........................................................................................................................................108

7-5.3. Rectification Report...........................................................................................................................109 7-5.4. Commissioning Test ..................................................... ........................................................... ..........109 7-5.5. Endurance Test. .................................................. ........................................................... ....................109 7-5.6. Acceptance Certification....................................................................................................................110 7-5.7. Access for Remedial Work ..................................................... ...........................................................110

7-6. Training .................................................. ............................................................ .......................................110 7-6.1. Training Off-Site. ......................................................... ........................................................... ..........110 7-6.2. Training On-Site (Operators).............................................................................................................110 7-6.3. Training On-Site (Maintenance) ....................................................... .................................................111 7-6.4. Special Training on the Operationally Critical Components Maintenance........................................112 7-6.5. Spare Parts .......................................................... ........................................................... ....................112 7-6.6. Ordered Spare Parts ...................................................... ........................................................... ..........112 7-6.7. Spare parts for Commissioning Work................................................................................................112

8. APPENDICES

I. Structural Limit of the Crane

II. Inspection Control Sheets

III. Crane Interface Drawings

1. Container Stack General Layout

2. Typical Cross Sections-Container Stack Blocks and Crane

Runways

IV. Reference Drawings and Data


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1. Crane Numbers at Ground Level

2. Circuit Diagram for Net Handling House Logic

3. Control Console Switches Layout

4. Locations of Floodlights on the Trolley

5. Operator’s Cab

6. GCT Logo, Approved Colours, Warning Signs, Name Plates etc

7. Type and Model of Labels and Cable Routing for AGSS and

PDS

8. Overview and Configuration of Crane Condition Monitoring

System (CCMS)

V. List of Drawings / Calculations to be reviewed by the Purchaser

(Minimum Requirements)

VI. List of Operation/ Maintenance Manuals and As Built Drawings


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Section C. TECHNICAL SPECIFICATION

C (I) Functional Requirement for the Crane

1. General

1-1. Project Description

To carry out the design, construction, delivery, installation, testing and commissioning of

Two (2) units of 41 tonnes capacity electrical Rubber Tyred Gantry Cranes. The cranes

shall be delivered to Gdynia Container Terminal S.A., Gdynia, Poland in a fully

assembled and tested condition.

1-2. Terminal Site

The Cranes shall be delivered and installed on Gdynia Container Terminal onEnergetykow 5, Gdynia, Poland (hereinafter referred to as GCT).

1-3. Overriding Requirement of the Purchaser

This Specification forms part of and is subject to the Conditions of Contract. Special

attention of the Contractor is drawn to Clause 3. General Requirements of the Conditions of

Contract for clarification of position of this Specification in relation to the overall and

overriding requirements of the Purchaser.

For the purposes of this Contract (including Clause 3 of the Conditions of Contract and

relevant references within the Specification) acceptable routine maintenance shall bewithin the following general parameters.

(1) For steel structures and related component parts, fittings and fixings, acceptableroutine maintenance shall be limited to the maintaining of the paint system as

stated below. Reinforcing, cutting out and/or replacement of any corroded,

fatigued or defective steel or its fixings, etc. shall be Defects remedial works and

not maintenance.

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

- Preparing and over coating the existing paint system at year 20 after theissuance of the Commissioning Certificate.

- Removing damaged parts of the paint system back to clean steel and

repainting in isolated areas but not exceeding in aggregate more than 1%,

2% and 3% of the total surface area at years 5, 10 and 15 respectively.

- The removal of the paint system back to steel and replacement of the paint

system in areas aggregating more than the above percentages of the total

surface area of the painted part of the Crane shall be Defects remedial

works and not maintenance.

(3) For items of electrical and mechanical equipment, controls, systems, components,

fittings and fixings, acceptable maintenance shall be the periodic and routine


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maintenance normally carried out on the various parts generally undertaken as

establishment practices of the Purchaser.

(4) The foregoing shall apply notwithstanding any inconsistent requirement or

information in any maintenance instructions provided by the Contractor or

otherwise put forward by the Contractor and any such inconsistent requirement or

information shall not, and shall not be relied on by the Contractor, to relieve, limit

or diminish any obligation or liability of the Contractor under the Agreement or

otherwise including in relation to Defects.

2. Overall Design Criteria

2-1. Type of Crane

The Crane shall be powered by shore power supply system, electrically driven rubber tyred

travelling gantry crane with a self-driven trolley with a cab. The Crane drive and controlshall be full AC inverter drive, with fully digitalised controls with PLC. The proposed drive

and control system shall be a proven system successfully operating on a similar capacity

crane in actual container handling operations.

2-2. Type of Cargo

The type of cargo to be handled by the Crane shall be

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

containers.

2 Other types of container with ISO corner fittings at 20ft, 40ft, or 45 ft positions.3 Containers with overheight cargoes through an overheight cargo container lifting

frame of the Purchaser.

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

2-3. Operating Environment and Design Aim

1. The Crane shall be operated and maintained on 24 hours per day basis in all weather

conditions. All electrical, electronic, and mechanical equipment shall be non-

hygroscopic, non-corroding suitable for use in conditions stated in 2-7.6, 2-7.7, 5-4

of this Specification.

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

2. Special considerations shall be given in all aspects of the design for achieving

accurate load spotting ability with quick sway/yaw damping, and ensuring full

operational capability and safety for round the clock operations, including operation

under heavy rain and/or falling snow.

3. The Crane shall be exposed to non-technical personnel specifically at the ground

level and in access to trolley/operator’s cab. The Contractor will provide adequate,

safe and fool-proof protection in and around all equipment and fittings in these areas

of the Crane.

4. Ease of maintenance and safety of the maintenance staff shall be aimed at

throughout the design to minimise total downtime of the Crane.


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2-4. Mode of Operation and Performance Target (MMBF)

The Crane shall be manually controlled; all functions on the Crane shall be controlled fully

by the operator from the operators cab position.

The MMBF of the Crane will be ascertained by the Purchaser after its Commissioning. For

the purpose of ascertaining MMBF the Crane will be put into operation under such

conditions and circumstances as may exist or be required by the Purchaser from time to time

including if the Purchaser elects operation for the purpose of the Purchaser’s business and/or

for the specific purpose of ascertaining MMBF. No credit or allowance shall be given for

the benefit of the Contractor in respect of conditions, circumstances, and operator’s

performance.

The MMBF is defined as:

Twist Lock Count (TLC) for one week

Number of Breakdowns of a Crane for one week

TLC = One TLC is defined as the operation of twist lock + hoisting + trolley + lowering +

unlock.

The actual MMBF shall be recorded on a weekly basis. Following completion of the Initial

Trial Period, the Intermediate Trial Period and the Final Trial Period for a Crane the MMBF

shall be calculated by dividing the total number of twist lock counts recorded during the

final four-weeks by the total number of breakdowns in the same period.

2-5. Statutory Requirements and Minimum Design Standard

1. The Crane and its mechanism shall be designed and manufactured to comply in all

aspects with the requirements of all latest, applicable state or local Polish and

European Community laws, ordinances, rules, orders, or other legal or regulatory

institutes.

2. Where items are not covered by Poland / European Community Statutory

requirements, the Crane and other Goods shall be designed and manufactured to at

least the standards as specified in this Specification. For items which are not

specified above, then to at least to the current applicable recommendations of thefollowing organisations: -

AWS American Welding Society – Bridges and Dynamically Loaded Structures

BSI British Standards Institute

DIN Deutsche Industrie Normen

FEM Federation European de la Manutention

GB Chinese Standard Institute

IEC International Electro Technical Commission

MMBF =


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IEEE Institute of Electrical and Electronic Engineers

ISO International Standards Organisation

JIS Japanese Industrial Standards

UL Underwriters Laboratory

The Contractor shall be required to submit to the Purchaser a full list of applicable

standards used in the design of the Crane.

2-6. Minimum Class of Crane

Structures:

Class of Utilisation U7

State of Loading Q2

Group Classification A7

Impact Factor 1.4

Duty Factor 0.9

Normal Load Spectrum factor 0.80 of rated capacity.

Mechanisms

Mechanisms Class ofUtilisation

State ofLoading

GroupClassification

Hoist T7 L3 M8

Trolley Travel T7 L3 M8

Gantry Travel T7 L3 M8

2-7. General Design Criteria

2-7.1. Crane Particulars

Major dimensions, clearances and performance requirements:

(1) Rated Load

Under Spreader 41 tonnes.

(2) Test load for overload test 51.25 tonnes under spreader.

(3) Container type ISO 20’, 40’, and up to 53’ containers with ISO

corner fittings at 20’, 40’ or 45’ position.

(4) Spreader 20’/40’/45’ telescopic type

with power-operated retractable end flippers andmoving side guides capable of handling 8’ and

8’ 6” wide containers.


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(5) Span (Gantry) 23.470mm (77’) centres of wheels.

(6) Lift above ground 20,750 mmminimum to the lowest point of spreader (side

guides/ lowered end flipper).

Emergency hoist limit at 20,850mm to the

lowest point of spreader.

For the lowering, the headblock (spreader

removed condition) must be able to be lowered

onto the ground.

(7) Overall Crane

Length

Not more than 12,200 (40’).

(8) Speed – Main Hoist 25m/min. minimum with 41 tonne load under

spreader.

60m/min. minimum with empty spreader.

Acceleration or deceleration time max. 6.0 s for

empty spreader and 3s for rated load.

- Trolley 70m/min. minimum.

Acceleration time max. 4.0 s.

Deceleration time max. 3.0 s.

- Gantry 90m/min. minimum.

Acceleration/Deceleration time max. 8.0s.

The above speeds must be achieved for crane operation under a sustained 20

meter/sec. wind condition.

(9) Skew adjustment (*) ±5 degrees

Speed: 0.5 degree/second minimum

(*) Note 1 Skew adjustment systems shall be capable ofchanging attitude of a 41 Te container with 1.6

meter eccentricity.

(10) Anti-sway/yaw The Crane shall be provided with anti-sway

dampening.

The anti-sway system shall be capable of

damping the spreader after the trolley has

stopped with full deceleration at any operational

speed with any operational load, to within

50mm of lateral displacement after 2 cycles of

sway. The same criteria will apply to theyawing motion following the trolley stopping

from any operational speed with full


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deceleration, or after the end of the skew motion

command. The system shall meet the above

criteria measured at the spreader end beams

expanded to the 45’ position between 3.0 meters

above the ground level and the maximum lift.

(11) Number of gantry wheels Eight (8) (Two in line per corner).

(12) Gantry Wheels Steering A hydraulic wheel jack up system shall be

installed between each pair of wheels to allow

free turning of the wheel pairs through 90

degrees. The complete cycle from activation of

the wheel jack system, turning of the wheels

through 90 degrees to raising the jacks shall be

no more than 70 seconds.

The gantry system shall also be designed to

allow the wheels to adopt intermediate turning

angles to allow pivot turning of the Crane. See

4-3.3.

2-7.2. Dimensional Restrictions

(1) The Crane profile shall be within the structures limit as defined in the drawing no.

GCT-RTG-01 in Appendix I, to ensure safe operation of the Crane at any lane.

(2) The spreader width must be kept within 2800mm when handling 8’-0” widecontainers, and 2900mm when handling 8’-6” wide containers.

2-7.3. Yard Interface

(1) The Crane runway path is part of the reinforced concrete terminal pavement.

Typical layout of runways is shown on the attached drawing in Appendix. III. The

design should allow for cranes to safely pass other Cranes operating on adjacent

runways, taking into account 1% cross grades and certain amount of drift of the

Cranes.

(2) NOT USED

2-7.4. Electrical Facility Interface (Shore Power)

(1) A shore power supply system shall be installed on the crane through H.V. cable reel

system that shall permit the normal container operation. The power supply to the

crane shall be 15 KV (±15%) 3 phase, 50Hz±5%, a suitable transformer shall be

provided to convert the in-coming HV power supply down to match the crane

electrical system circuitry.

(2) The high tension trailing cable connection on the yard shall be terminated into

specially designed HV junction boxes. Termination of the cable conductors and fibre

waveguide in the plugs at the junction box shall be done by the Contractor.

Termination of the Purchaser’s power supply cable and optics fibre cables into the


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socket shall also be the scope of the Contractor. The high tension cable shall be

supplied by contractor with a suitable cable reeling device. A sufficient length of

cable to cover minimum 200 meters gantry travel range from the junction box shall

be provided by the Contractor. The Contractor shall bring the Crane trailing cable

end to the junction box and shall complete the cable connecting work with an

approved cable joint kit. The supply and installation of the H.V. junction box shall

be by others. The cable joints made at Site and high tension wiring shall be subject

to the inspection requirements of the local power supply authority

(3) The high tension trailing cable shall be 15 KV ethylene propylene rubber insulated

polychloroprene jacketed round type flexible power cable based on IECA Pub. S68 -

516 or the equivalent approved by the Purchaser.

The conductor shall be stranded flexible conductor consisting of tinned annealed

copper wires. The cable shall also carry the fibre- optic cable for the remote CCMS

(refer to 5-7).

(4) The HV cable reel shall be installed opposite to the operator cabin, the transformer

on the electrical house side. The cable reel shall be installed within the restricted

dimensions as set out in 2-7. The drive control system of the cable reel shall be

designed to minimise abrupt starting, braking and excessive slack / tension in the

cable when the Crane passes the cable feed point. Sensors to detect the above

conditions shall be provided.

(5) Cable guide wheels shall be installed near the gantry trucks to keep the high tension

cable close to the ground level. The cable shall be laid inside the cable slot within a

total wheel base of gantry trucks in one corner.

(6) The system especially the high tension slip ring components shall be well protected

from weather, having an IP rating of not less than 55.

(7) The cable reel drive machinery and slip ring area shall be isolated by fencing or

other means and to permit to access of authorised persons only. High tension

warning signs shall be provided and fitted to the entrance of the fenced area.

(8) A suitably sized space heater shall be provided for the slip ring enclosure. An

indicator light indicating functioning or malfunction of the space heater shall be

installed near the cable reel machinery and shall clearly visible from ground level.The slip ring enclosure shall have hinged, sealed and lockable access panels on

both sides to provide for easy access for servicing and maintenance.

(9) Limit switches to control gantry motion near the travelling limit (limited by cable

length) shall be provided.

(10) An override switch shall be provided to allow operation of the cable reel drive. This

switch shall be enclosed in a lockable and weatherproof box mounted at groundlevel in the proximity of the cable plough arrangement.

(11) The composite HT trailing cable shall incorporate not less than eight (8) numbers of

low loss silica glass optical fibre waveguides. The cable reel mechanisms shall

incorporate low loss connecting devices that allow the use of all waveguide


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simultaneously linking the equipment on the crane to external devices. The standard

for the waveguide shall be 60/125 micron.

(12) The optical waveguide shall be terminated with Avaya ST-2 type standard

connectors unless otherwise specified. The composite cable shall be separated into

power and optical fibre cables for termination work in the junction boxes on yard as

well as the cable reel on the Crane.

(13) The source of power supply shall be connected to CMS system (refer to 5-7) and

also indicator in operator cabin.

2-7.5. Communication Facility Interface (Radio)

NOT USED.

2-7.6. Climatic Conditions

The Crane and other Goods shall be designed and constructed to be fully capable of

operating safely and withstanding the following climatic conditions.

(1) Ambient temperature -20oC to 40

oC

(2) Relative humidity Max. 100%

(3) Dew point Max. 3oC

(4) Wind up to 25m/sec. without special warning during operation.

More stringent and specific requirements shall apply for individual crane and other Goods

subsystems and components, which are separately specified in each relevant clause of thisSpecification.

2-7.7. Wind Conditions

The entire Crane structure with all of its machineries, components, fittings, or accessories,

and all tie-down equipment shall be designed and constructed to withstand following wind

loading conditions.

(1) Allow for wind loading of sustained wind speed of 25m/sec. for safe load handling

operation of the Crane.

(2) For the stowed condition of the Crane:

A wind loading of wind speed up to 43m/sec. shall be allowed for the condition that

the Crane is out of service and stationary without any gantry tie downs, but trolley

anchored.

2-7.8. Lifting Loads and Stability

(1) One side landing

i) A normal operating condition shall include the case of one side landing of a

45ft - concentric 41 tonnes weight container, in which case a set of main


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hoist wire ropes on the landed side is assumed slack and not carrying the

load.

ii) The calculations of the structural and mechanical components shall include

calculation for this criterion.

(2) Eccentric container handling

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

be designed to be capable of handling continuously 28 Te gross weight

containers with eccentricity of 1.2m in longitudinal (gantry) direction and

0.25m in transverse (trolley) direction. The eccentricity of container shall

not cause any horizontal drift of the container during hoisting/lowering

motion.

ii) The Contractor shall submit for the Purchasers review, a design method tocompletely eliminate the possibility of lifting one end of a container by two

twistlocks. The design shall incorporate a system to immediately detect this

condition and to render the hoist motion inoperable. The spreader which

stops with one end locked inside a container shall allow lowering only with

attendance of maintenance personnel.

(3) Fatigue condition

All structural fatigue calculations shall include the case of continuous handling of a

28 Te gross weight container with 1.2m eccentricity in longitudinal direction.

Minimum loading cycle to be 2 million cycle.

(4) Dynamic snag load (catch load)

The Crane shall not sustain any damage due to dynamic snag load. The Contractor

shall submit structural calculations to prove that structures are safe under dynamic

snag load.

(5) Stability

(i) The Crane shall be stable with a reasonable safety margin and shall not

sustain damages when a dynamic snag load is applied at any trolley andhoisting position.

(ii) The Crane shall be stable and shall not sustain any damage in the case when

emergency push button is pressed during gantry travel with a rated speed

with a 41 tonnes rated load suspended at the maximum lift height position in

an operational gantry gradient of not more than two percent.

(6) All other loading conditions forming the design criteria other than specified in this

Specification shall be submitted to the Purchaser for review.

2-8. NOT USED


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2-9. Noise Control

The Crane’s noise level shall conform to the following requirements: -

(1) The noise level inside the operator’s cab shall be below 75dB during

operation, with air conditioner on, and doors and windows closed condition.

(2) The noise level measured at a distance of 1 meter from any corner of the

machinery house shall be below 85 dB

2-10. Operationally Critical Components

(1) The Contractor shall submit the inspection and replacement schedule for the

operationally critical components to the Purchaser.

(2) The objective is to assist the Purchaser to establish a standard for maintenanceand inspection of operationally critical components (i.e. those components and

structural joints where failure could have catastrophic consequences).

3. Crane Structural Specification

3-1. General Requirement

3-1.1. Deflection or oscillation of the structure shall not affect the Crane capacity and operating

efficiency (particularly spreader positioning ability).

3-1.2. The main structure shall be designed so as not to sustain damage in the event of puncture ofany one tyre.

3-1.3. The girder shall be designed to allow operator to escape from the operator’s cab to the

walkway of the girder at any point of trolley travel range, in an emergency.

The walkways along the full length of the girder members shall be mounted off the side

of the girder members and not less than 800mm below the top flange of the girder. The

“Power Chain” may also be mounted between the side of the girder and the walkway to

afford protection against falling from the walkway to the inside of the crane.

3-1.4. Trolley rails shall comprise a standard rail section and be fitted to the girder through railclips and a proven fastening system. The rail joints shall be welded and ground smooth.

3-1.5. The following equipment/machinery shall be fitted to the main structure.

(1) Gantry drive machineries including 90 degree and an intermediate angle (for spin

turn) steering mechanisms.

(2) Control panels and panel house.

(3) Starting equipment and control panel.

(4) Trolley power feeding system.

3-1.6. The following fittings shall be fitted to the main structure.

(1) Walkway, stairs, ladders and platforms (refer to 6-1).


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(2) Lighting for operation and for walkway, stairs, ladders and platforms (refer to 6-2)

(3) Intercom telephones (refer to 5-6.1).

(4) Travel warning device (refer to 6-5.1). Speakers and flashing strobe light at each

of 4-corners.

(5) Service outlet (refer to 6-7).

(6) Emergency stop buttons (refer to 6-6).

(7) Four fire extinguishers; 5kg CO2 capacity, 1 at outside of panel house, 1 at

trolley platform and one 2 kg at outside the driver’s cab.

3-2. Material

3-2.1 The whole of the materials used in the Crane shall be new, of the best quality and suitable

for the duty intended. Mill certificates shall be obtained and records strictly maintained to

match these to the various Crane sections produced during crane manufacture. The steel

materials for all the stress members shall be selected from the materials which specification

includes the notch toughness requirement at or below -20 deg. Celsius.

3-2.2 The steel used for the manufacture of the Crane shall conform as a minimum to one or more

of the following standards most recent issue.

Deutsche Industrie Norman (DIN)

British Standards (BS)

Japanese Industry Standards (JIS)

American Standards (ASTM/API)

Chinese Standard (GB)

3-2.3 Welded Joints

Stresses at weld throats shall be calculated as the vector sum of the individual stresses

applied to the weld throat. For fatigue design when calculating the stress range, the

vector difference of the greatest and least vector sum stress may be used instead of the

algebraic difference.

Welded joint design shall conform to BS 5400: Part 10, BS 7608, and for static loads

only AWS D1.1 - 2000.

3-2.4 Bolted Joints

Bolted joint design shall conform to BS 5400: Part 10, BS 7608, and to the AISC

Specification using 0.9 times AISC allowable values. Prying action due to distortion of

the connection details shall be considered. Bolts subject to fluctuating tensile stress shall

be checked according to BS 7608. Bolts governed by fatigue strength shall comply with

ASTM A325. Structural bolted joints are not allowed unless approved in writing by

Purchaser.

3-2.5 Pin Joint

An effective lubrication system shall be provided for each pin Joint to prevent its seizure

within the life of the structure.

3-2.6 Machinery bases


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All main drive machinery bases (Motors, brakes, gearboxes, bearing housings/pedestals, etc.)

shall be machined; after all adjacent welding has been completed.

All machinery mounts shall have adjustable locking screws for horizontal adjustment

(forward and backwards, side to side) for the purposes of the equipment alignment.

3-2.7 Edge Finish

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

3-2.8 Surface Finish

(1) All welding spatters shall be removed from structure surfaces.

(2) The metal surfaces shall be cleaned and touched up with primer immediately aftercooling down to prevent oxidation and the formation of rust.

3-2.9 Draining and Inspection Manhole

(1) All the structure shall be designed to drain water effectively. Any draining water

shall not affect safety of operations or maintenance work under heavy rain. No

water trap shall be allowed in any part of the crane structure. Adequate numbers of

inspection manholes shall also be installed.

(3) Appropriately, sized manholes shall be provided in all unsealed members to provide

for internal inspection. The manholes shall be positioned such to allow access fromeach end of any unsealed member and particular attention for safety shall be given to

those areas where manholes directly access onto or from vertical ladders.

3-3. Calculations

3-3.1 Submission to Purchaser

(1) Wheel loads, stability calculations, braking capacity and distance calculations for all

motions, and peak power consumption calculations shall be submitted for

Purchaser's review prior to commencement of detailed design.

(2) Other data or design calculations at various stages of design shall be submitted from

time to time as requested by the Purchaser as part of review process.

3-4. Loads

3-4.1 The design shall incorporate all loads and load combinations pertinent to all in service

and out of service conditions of the crane. The loads due to temperature effects, erection

stresses, and others based on the Contractor's experience shall be included in the analysis

if they cause significant stresses. If rational analysis indicates loads larger than specified,

the larger loads shall be used.

3-4.2 The Contractor shall comply with BS2573: Part 1: 1983, Rules for the Design of Cranes.


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3-5. Members Subject To Buckling

(1) The design of columns, beam columns, frames and beams subject to lateral buckling

shall be in accordance with the AISC Specification. The design of flat plates, curved

plates, and plate stiffeners shall be in accordance with a recognized method that

considers the combined effect of shear, compression and flexure. The effects of

biaxial stresses shall be included. Criteria given in FEM are acceptable.

(2) For all structural plates, the ratio of the minimum clear dimension, b, to thickness, t,

shall not exceed 60, i.e. 60 ≥ b/t.

(3) The local buckling criteria given in the AISC and AISE standards are unacceptable

because biaxial and combined stress effects are ignored. The choice of a practical

method of calculation is left to the Contractor who shall state the origin of the

method chosen.

(4) Tension field action may be included for evaluating pure shear resistance during

overload and stowed conditions, provided the tension field shear panels are designed

for a factor of safety against collapse of at least 1.25. Tension field panels shall be

assumed to have zero capacity to resist bending, bearing or axial stress.

3-6. Fatigue Design Criteria

3-6.1 Fatigue design shall generally conform to the requirements of BS 5400: Part 10 1980,

except as modified in this section. Modifications to BS 5400 pertain primarily to the

deletion of provisions that apply to bridges only, insertion of design load spectra

applicable to container cranes and the addition of provisions for tubular joints.

3-6.2 When not specified in BS 5400, the requirements and recommendations in BS 7608 shall

be followed.

3-7. Connection Designs

(1) Connections shall be designed to resist artificial local loads imposed by a stress

equal to the average of the allowable and the calculated stress, but they shall be

designed for not less than 75% of the allowable strength of the member. Notice

that whenever the calculated stresses are less than 50% of the allowable stress, the

75% requirement applies.

(2) Stresses at weld throats shall be calculated as the vector sum of the individual

stresses applied to the weld throat. For fatigue design when calculating the stress

range, the vector difference of the greatest and least vector sum stress may be

used instead of the algebraic difference.

(3) Welded joint design shall conform to BS 5400: Part 10, BS 7608, and AWS D1.1,

Section 9, except for Sections 9.2.1, 9.3, 9.4, 9.5 and 9.6 which contain

information that is covered elsewhere in these Specifications.

(4) Bolted joint design shall conform to BS5400: Part 10, BS 7608. Prying action

due to distortion of the connection details shall be considered. Bolts subject to

fluctuating tensile stress shall be checked according to BS 7608.


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3-8. Gantry Structure Stiffness

3-8.1. Deflection or oscillation of the structure shall not affect the Crane capacity and operating

efficiency (particularly spreader positioning ability).

3-8.2 The horizontal displacement at the girder level due to full acceleration or deceleration of

trolley with a rated load, or full acceleration or deceleration of trolley while suspending a

rated load at the maximum upper limit position, shall not exceed 30mm.

3-8.3 The main structure shall be designed so as not to sustain damage in the event of puncture of

any one tyre.

3-9. Camber

The camber of the two main girders should make due allowance for deflection under load.

3-10. Trolley Rails & Rail Fixing

Trolley rails shall comprise a standard rail section and be fitted to the girder through rail

clips and a proven fastening system. The trolley rails shall be supported by the girders with

Gantrex type rail pads and steel plate to reduce vibration of trolley. The rail joints shall be

welded and ground smooth.

3-11. Workmanship

3-11.1 The whole of the structural fabrication and assembly shall be done in a through,workmanlike manner and shall follow the best modern practices in the manufacture of

high-grade structures. The work shall be performed by workmen suitably skilled in their

particular trades.

3-11.2 Welders, welding operators and tackers shall be certified, for the material, processes and

type of welding being performed, by an independent testing laboratory within 6 months

prior to performing such work. The certifying laboratory will be approved by the Purchaser.

3-11.3 Certification of the qualifications of each individual welder shall be submitted by the

Contractor. Welds installed using unqualified procedures or welding performed by non-

certified welders shall be subject to removal by the Contractor at his own expense.

3-11.4 The Contractor’s Quality Assurance team shall be required to keep an accurate log of the

qualified welders on the job. This log will be subjected to examination at any time by the

Purchaser or their site representative.

3-11.5 Welding procedures may be AWS prequalified or they shall be qualified in accordance

with AWS by the approved testing laboratory.

3-11.6 Written procedures for all welded joints shall be submitted to the Purchaser. Procedures

shall identify required inspections that may be critical to the specific welds. Procedures

shall be identified on the drawings and shall be made available to all appropriate shop

personnel. Procedures shall be prepared in a manner such that shop personnel can

understand and use them without referencing the applicable codes.


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3-11.7 These requirements shall apply to all welding, burning, cutting and grinding on the crane

structure. This includes welds for erection attachment, whether or not they are removed,

and electrical clips and conduit supports.

3-11.8 The Contractor’s Quality Assurance team will ensure that all correct welding procedures

are strictly followed by the welding personnel. Any welding work being seen to not meet

accepted procedures shall be stopped immediately and logged as a non-conformance report.

Continuation of this welding will then be subject to approval by the Purchaser’s

Representative on site.

3-11.9 The Contractor’s Quality Assurance team will ensure that all welding during low

temperatures is carried out under an appropriated welding procedure, as far as practicable,

within an enclosed canopy to provide a controlled environment. The use of correct pre-

heating procedures and welding rod hot boxes is essential and will be closely monitored by

the Purchaser’s Representative.

3-11.10 To facilitate removal / replacement or regular maintenance, all unpainted metal surfaces

shall be treated with an appropriate approved anti-corrosion treatment.

i) Structural Pins-“Copper Kote”, “Copper-slip”, “Moly-slip”, or “Molybonum di

sulphide”

ii) Bearings, housings-grease

iii) Tapped holes-“Never-Seize”

iv) Bolts-“Never-Seize”

3-11.11 A325 and A490 bolts that are 7/8” (22mm) in diameter or less may be tightened to the

required tension by any standard method. A325 and A490 bolts greater than 7/8” (22mm)diameter shall be tightened to the required tension by the calibrated wrench method only.

The following supplemental requirements shall apply in addition to the requirements of the

Specifications to structural joints using ASTM A325 or A490 bolts.

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

(ii) The contractor shall notify the Engineer if the highest and lowest torques measured

during wrench calibration varies by more than 10 percent of the lowest torque, so

they may develop the appropriate solution. If the range exceeds this tolerance, filed

tightening may be erratic.

(iii) The “snug tight” tension shall be approximately 50 percent of the specified tension

and shall be achieved using a calibrated wrench.(iv) The sequence of bolt tensioning shall be shown on the drawings.

(v) After the snug tight condition is achieved, an initial tension of 75 percent of the final

tension shall be developed in all the bolts. Only then shall the final tension be

developed

(vi) The final tension shall be verified by testing 10 percent of the bolts after all the bolts

are tensioned. If the verification indicates loss of tension in some bolts, the

Contractor shall notify the Purchaser. The Purchaser and the Contractor will develop

the appropriate action.(vii) The flange contact bearing surfaces shall have at least 75% of the bearing cross-

sectional areas in contact. The outer surface of the flanges shall fit within 0.010in.

(0.25mm) for 75% of the length of the edge and not more than 1/32in. (1mm) for the

remaining 25% of the length.


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(viii) Bolt tension may be verified at locations selected by the Purchaser’s Representative.

Bolt tension verification shall be performed by the Contractor in the present of the

Purchaser’s Representative and in such a manner that the torque can be wrench gage

read during verification.

3-11.12 Weld Testing and Inspection

All welds shall be subjected to inspection by methods and extent, reflecting the critical

nature of the welded connection.

Welds shall meet the requirements for cyclically loaded structures of AWS D1.1-latest

version. The specific method of weld inspections shall be shown on the drawings. Weld

inspection procedures shall be submitted to the Purchaser.

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

Weld Type of Testing/Inspection Acceptance Criteria

All Welds 100% Visual AWS D1.1-latest version

Full Penetration Butt Welds

(Compression)

100% UT

1 X Exposure ≈ 400 mm

per weld

AWS D1.1-latest version

Full Penetration Butt Welds

(Tension-as determined by

stress levels due to operating

loads combinations)

100% UT

10% of length RT or

1 X exposure per weld

length ≈ 400 mm which

ever is the greater


Full Penetration Butt Welds inTension Bars (if applicable)

100% UT100% of length RT


Fillet Welds or Partial

Penetration Welds

On FCM

On Non-FCM

100% of length MT

10% of length MT

(as nominated by the

Purchaser’s Representative)


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

inspection of 100% of that weld.

Ultrasonic testing of tension welds shall be done by or under the direct supervision of ASNT

Certified LEVEL III personnel.

3-12. Quality Control of Structure Fabrication

3-12.1 Qua

TECHNICAL SPECIFICATION FOR RUBBER TYRED GANTRY CRANES

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