TECHNICAL SPECIFICATION
FOR
RUBBER TYRED GANTRY CRANES
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
4-5.1. 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
5-3. 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
6-1.2. 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
7-2.2. 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
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)
Section C. TECHNICAL SPECIFICATION
C (I) Functional Requirement for the Crane
1. General
1-1. Project Description
To carry out the design, construction, delivery, installation, testing and commissioning of Two (2) units of 41 tonnes capacity electrical Rubber Tyred Gantry Cranes. The cranes shall be delivered to Gdynia Container Terminal S.A., Gdynia, Poland in a fully assembled and tested condition.
1-2. Terminal Site
The Cranes shall be delivered and installed on Gdynia Container Terminal on Energetykow 5, Gdynia, Poland (hereinafter referred to as GCT).
1-3. Overriding Requirement of the Purchaser
This Specification forms part of and is subject to the Conditions of Contract. Special attention of the Contractor is drawn to Clause 3. General Requirements of the Conditions of Contract for clarification of position of this Specification in relation to the overall and overriding requirements of the Purchaser.
For the purposes of this Contract (including Clause 3 of the Conditions of Contract and relevant references within the Specification) acceptable routine maintenance shall be within the following general parameters.
(1) For steel structures and related component parts, fittings and fixings, acceptable
routine maintenance shall be limited to the maintaining of the paint system as stated below. Reinforcing, cutting out and/or replacement of any corroded, fatigued or defective steel or its fixings, etc. shall be Defects remedial works and not maintenance.
(2) For the paint system acceptable routine maintenance shall be:
- Preparing and over coating the existing paint system at year 20 after the
issuance of the Commissioning Certificate.
- Removing damaged parts of the paint system back to clean steel and
repainting in isolated areas but not exceeding in aggregate more than 1%, 2% and 3% of the total surface area at years 5, 10 and 15 respectively.
- The removal of the paint system back to steel and replacement of the paint
system in areas aggregating more than the above percentages of the total surface area of the painted part of the Crane shall be Defects remedial works and not maintenance.
(3) For items of electrical and mechanical equipment, controls, systems, components,
maintenance normally carried out on the various parts generally undertaken as establishment practices of the Purchaser.
(4) The foregoing shall apply notwithstanding any inconsistent requirement or
information in any maintenance instructions provided by the Contractor or otherwise put forward by the Contractor and any such inconsistent requirement or information shall not, and shall not be relied on by the Contractor, to relieve, limit or diminish any obligation or liability of the Contractor under the Agreement or otherwise including in relation to Defects.
2. Overall Design Criteria
2-1. Type of Crane
The Crane shall be powered by shore power supply system, electrically driven rubber tyred travelling gantry crane with a self-driven trolley with a cab. The Crane drive and control shall be full AC inverter drive, with fully digitalised controls with PLC. The proposed drive and control system shall be a proven system successfully operating on a similar capacity crane in actual container handling operations.
2-2. Type of Cargo
The type of cargo to be handled by the Crane shall be
1 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
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 the following organisations: -
AWS American Welding Society – Bridges and Dynamically Loaded Structures
BSI British Standards Institute
DIN Deutsche Industrie Normen
FEM Federation European de la Manutention
GB Chinese Standard Institute
IEC International Electro Technical Commission
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 of Utilisation State of Loading Group Classification 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 and moving side guides capable of handling 8’ and 8’ 6” wide containers.
(5) Span (Gantry) 23.470mm (77’) centres of wheels.
(6) Lift above ground 20,750 mm
minimum to the lowest point of spreader (side guides/ lowered end flipper).
Emergency hoist limit at 20,850mm to the lowest point of spreader.
For the lowering, the headblock (spreader removed condition) must be able to be lowered onto the ground.
(7) Overall Crane
Length
Not more than 12,200 (40’).
(8) Speed – Main Hoist 25m/min. minimum with 41 tonne load under
spreader.
60m/min. minimum with empty spreader. Acceleration or deceleration time max. 6.0 s for empty spreader and 3s for rated load.
- Trolley 70m/min. minimum.
Acceleration time max. 4.0 s. Deceleration time max. 3.0 s.
- Gantry 90m/min. minimum.
Acceleration/Deceleration time max. 8.0s.
The above speeds must be achieved for crane operation under a sustained 20 meter/sec. wind condition.
(9) Skew adjustment (*) ±5 degrees
Speed: 0.5 degree/second minimum
(*) Note 1 Skew adjustment systems shall be capable of
changing attitude of a 41 Te container with 1.6 meter eccentricity.
(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 the yawing motion following the trolley stopping
deceleration, or after the end of the skew motion command. The system shall meet the above criteria measured at the spreader end beams expanded to the 45’ position between 3.0 meters above the ground level and the maximum lift.
(11) Number of gantry wheels Eight (8) (Two in line per corner).
(12) Gantry Wheels Steering A hydraulic wheel jack up system shall be
installed between each pair of wheels to allow free turning of the wheel pairs through 90 degrees. The complete cycle from activation of the wheel jack system, turning of the wheels through 90 degrees to raising the jacks shall be no more than 70 seconds.
The gantry system shall also be designed to allow the wheels to adopt intermediate turning angles to allow pivot turning of the Crane. See 4-3.3.
2-7.2. Dimensional Restrictions
(1) The Crane profile shall be within the structures limit as defined in the drawing no.
GCT-RTG-01 in Appendix I, to ensure safe operation of the Crane at any lane.
(2) The spreader width must be kept within 2800mm when handling 8’-0” wide
containers, and 2900mm when handling 8’-6” wide containers. 2-7.3. Yard Interface
(1) The Crane runway path is part of the reinforced concrete terminal pavement.
Typical layout of runways is shown on the attached drawing in Appendix. III. The design should allow for cranes to safely pass other Cranes operating on adjacent runways, taking into account 1% cross grades and certain amount of drift of the Cranes.
(2) NOT USED
2-7.4. Electrical Facility Interface (Shore Power)
(1) A shore power supply system shall be installed on the crane through H.V. cable reel
system that shall permit the normal container operation. The power supply to the crane shall be 15 KV (±15%) 3 phase, 50Hz±5%, a suitable transformer shall be provided to convert the in-coming HV power supply down to match the crane electrical system circuitry.
(2) The high tension trailing cable connection on the yard shall be terminated into
specially designed HV junction boxes. Termination of the cable conductors and fibre waveguide in the plugs at the junction box shall be done by the Contractor. Termination of the Purchaser’s power supply cable and optics fibre cables into the
socket shall also be the scope of the Contractor. The high tension cable shall be supplied by contractor with a suitable cable reeling device. A sufficient length of cable to cover minimum 200 meters gantry travel range from the junction box shall be provided by the Contractor. The Contractor shall bring the Crane trailing cable end to the junction box and shall complete the cable connecting work with an approved cable joint kit. The supply and installation of the H.V. junction box shall be by others. The cable joints made at Site and high tension wiring shall be subject to the inspection requirements of the local power supply authority
(3) The high tension trailing cable shall be 15 KV ethylene propylene rubber insulated
polychloroprene jacketed round type flexible power cable based on IECA Pub. S68 - 516 or the equivalent approved by the Purchaser.
The conductor shall be stranded flexible conductor consisting of tinned annealed copper wires. The cable shall also carry the fibre- optic cable for the remote CCMS (refer to 5-7).
(4) The HV cable reel shall be installed opposite to the operator cabin, the transformer
on the electrical house side. The cable reel shall be installed within the restricted dimensions as set out in 2-7. The drive control system of the cable reel shall be designed to minimise abrupt starting, braking and excessive slack / tension in the cable when the Crane passes the cable feed point. Sensors to detect the above conditions shall be provided.
(5) Cable guide wheels shall be installed near the gantry trucks to keep the high tension
cable close to the ground level. The cable shall be laid inside the cable slot within a total wheel base of gantry trucks in one corner.
(6) The system especially the high tension slip ring components shall be well protected
from weather, having an IP rating of not less than 55.
(7) The cable reel drive machinery and slip ring area shall be isolated by fencing or other means and to permit to access of authorised persons only. High tension warning signs shall be provided and fitted to the entrance of the fenced area.
(8) A suitably sized space heater shall be provided for the slip ring enclosure. An
indicator light indicating functioning or malfunction of the space heater shall be installed near the cable reel machinery and shall clearly visible from ground level. The slip ring enclosure shall have hinged, sealed and lockable access panels on both sides to provide for easy access for servicing and maintenance.
(9) Limit switches to control gantry motion near the travelling limit (limited by cable length) shall be provided.
(10) An override switch shall be provided to allow operation of the cable reel drive. This
switch shall be enclosed in a lockable and weatherproof box mounted at ground level in the proximity of the cable plough arrangement.
(11) The composite HT trailing cable shall incorporate not less than eight (8) numbers of
low loss silica glass optical fibre waveguides. The cable reel mechanisms shall incorporate low loss connecting devices that allow the use of all waveguide
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 40oC
(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 this Specification.
2-7.7. Wind Conditions
The entire Crane structure with all of its machineries, components, fittings, or accessories, and all tie-down equipment shall be designed and constructed to withstand following wind loading conditions.
(1) Allow for wind loading of sustained wind speed of 25m/sec. for safe load handling
operation of the Crane.
(2) For the stowed condition of the Crane:
A wind loading of wind speed up to 43m/sec. shall be allowed for the condition that the Crane is out of service and stationary without any gantry tie downs, but trolley anchored.
2-7.8. Lifting Loads and Stability
(1) One side landing
i) A normal operating condition shall include the case of one side landing of a
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 to
completely eliminate the possibility of lifting one end of a container by two twistlocks. The design shall incorporate a system to immediately detect this condition and to render the hoist motion inoperable. The spreader which stops with one end locked inside a container shall allow lowering only with attendance of maintenance personnel.
(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 and hoisting position.
(ii) The Crane shall be stable and shall not sustain any damage in the case when
emergency push button is pressed during gantry travel with a rated speed with a 41 tonnes rated load suspended at the maximum lift height position in an operational gantry gradient of not more than two percent.
(6) All other loading conditions forming the design criteria other than specified in this
Specification shall be submitted to the Purchaser for review.
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 maintenance
and inspection of operationally critical components (i.e. those components and structural joints where failure could have catastrophic consequences).
3. Crane Structural Specification
3-1. General Requirement
3-1.1. Deflection or oscillation of the structure shall not affect the Crane capacity and operating efficiency (particularly spreader positioning ability).
3-1.2. The main structure shall be designed so as not to sustain damage in the event of puncture of any one tyre.
3-1.3. The girder shall be designed to allow operator to escape from the operator’s cab to the walkway of the girder at any point of trolley travel range, in an emergency.
The walkways along the full length of the girder members shall be mounted off the side of the girder members and not less than 800mm below the top flange of the girder. The “Power Chain” may also be mounted between the side of the girder and the walkway to afford protection against falling from the walkway to the inside of the crane.
3-1.4. Trolley rails shall comprise a standard rail section and be fitted to the girder through rail clips and a proven fastening system. The rail joints shall be welded and ground smooth. 3-1.5. The following equipment/machinery shall be fitted to the main structure.
(1) 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.
(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.
All main drive machinery bases (Motors, brakes, gearboxes, bearing housings/pedestals, etc.) shall be machined; after all adjacent welding has been completed.
All machinery mounts shall have adjustable locking screws for horizontal adjustment (forward and backwards, side to side) for the purposes of the equipment alignment.
3-2.7 Edge Finish
All edges of structures shall be free from sharp edges or burrs. 3-2.8 Surface Finish
(1) All welding spatters shall be removed from structure surfaces.
(2) The metal surfaces shall be cleaned and touched up with primer immediately after
cooling down to prevent oxidation and the formation of rust. 3-2.9 Draining and Inspection Manhole
(1) All the structure shall be designed to drain water effectively. Any draining water shall not affect safety of operations or maintenance work under heavy rain. No water trap shall be allowed in any part of the crane structure. Adequate numbers of inspection manholes shall also be installed.
(3) Appropriately, sized manholes shall be provided in all unsealed members to provide
for internal inspection. The manholes shall be positioned such to allow access from each end of any unsealed member and particular attention for safety shall be given to those areas where manholes directly access onto or from vertical ladders.
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.
3-5. 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.
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.
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.
(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
AWS D1.1-latest version
Full Penetration Butt Welds in Tension Bars (if applicable)
100% UT
100% of length RT
AWS D1.1-latest version
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)
AWS D1.1-latest version
Rejection of any portion of a weld inspected on a less than 100% basis shall require inspection of 100% of that weld.
Ultrasonic testing of tension welds shall be done by or under the direct supervision of ASNT Certified LEVEL III personnel.
3-12. Quality Control of Structure Fabrication
3-12.1 Quality Control shall be the responsibility of the Contractor. The Contractor must implement a written quality control programme and this programme shall be submitted to the Purchaser within 1 month of the date of the Agreement for comment.
3-12.2 The quality control programme shall follow the applicable requirements laid out in 7-1.4. For the structure fabrication this shall include but not be limited to the following:
- Traceability procedures for materials together with traceability identification codes, which shall be serial and indexed to the controlled manufacturing procedures.
- Cutting, fit up, welding, forming and dimensions of structural components.
- Welding and inspection procedures identifying clearly the type and extent of NDT
inspection carried out on the cranes structure.
- Welding and inspection personnel qualification and certification (see 3-11).
- Welding, machining, measuring and inspection equipment maintenance and
calibration.
- Machining, finish surfaces, bolting tensioning procedures.
- Procedures for non-conformance (NCR) and Punch List (PL) reporting and
rectification of defects.
- Design and manufacturing drawing control and procedures for revisions, updates
and reissue of drawings
- Procedures for material cleaning, preparation blasting and painting.
A copy of a company standard QA manual prepared for the manufacture of similar cranes shall be submitted with the tender for examination as part of the tender assessment.
3-13. Temporary Structures
3-13.1 Temporary Structures
Connections details of temporary structures (such as lifting lugs, etc) fitted onto Operationally Critical Components must be reviewed by the Purchaser.
3-13.2 Sea-Fastening
At least three months before the intended shipment, the Contractor shall submit sea-fastening structure connection details to crane structures for the Purchaser’s review, consideration and acceptance or otherwise. The submission shall also provide details of the proposed methods for removal of the temporary bracings and fixings. The Purchaser prefers a system that minimizes any “Hot Work” at the site to minimize the risk of damage to paintwork and the need for extensive paint system repairs.
4. Functional Systems Devices & Equipment
4-1. Main Hoist
4-1.1. Main Hoist Drive
(1) The main hoist drive reduction gearbox shall be totally enclosed, oil bath lubricated
(2) Two AC servo operated disc brakes shall be fitted on the high speed pinion shaft. Each brake shall be rated at 150% full load motor torque and shall be capable of stopping and holding the maximum rated load from full rated speed. Final adjustment of brake torque shall be carried out during commissioning using appropriate calibration equipment.
(3) Overspeed switches shall be fitted to the main hoist drums to shut down the drive and set the brakes if the load exceeds 115% of rated speed. Geared limit switch unit for the main hoist shall be electromagnetic type.
(4) Pulse generator encoders shall be installed on the main hoist drums.
(5) Acceleration from zero speed to a maximum speed or deceleration to zero speed
shall be smooth and steeples for any load under spreader. (See 2-7. 1 (8) for speed/time requirements.).
(6) There shall be two stages of the upper main hoist slow down to cater for an empty
spreader and a loaded container in order to enhance performance of container handling. In the condition of empty spreader the hoist shall incorporate a lower slow down whilst the loaded spreader condition shall incorporate a higher slow down. Under each condition the emergency limit position shall not be tripped. The Contractor shall propose a method statement with calculations for the Purchaser’s review.
(7) Frequent inching operation and plugging operation shall be catered for in the design.
(8) The main hoist motor and brakes shall be fitted inside weather-proof enclosure. The
enclosure shall be designed to provide for ease of motor and brake maintenance with suitable removable doors. Thermal cycling due to hot and cold climatic changes shall also be considered within the design of the enclosure.
(9) The enclosure shall be equipped with an exhaust fan. Cool air may be drawn from
any opening beneath the main hoist motor housing; however water shall not be drawn into the enclosure under any circumstances.
(10) The main hoist wire ropes to the headblock shall not interfere with the stacked containers when the Crane is working on a single slot between two - five high stacks. Outside wire ropes shall be stationary during hoisting and lowering motion.
(11) The main hoist reeving arrangement shall be such that these are no imbalance in the
horizontal components of the resultant forces in the main hoist ropes, at the head-block-sheave level.
(12) Load cells shall be provided for sensing the weight of the container suspended under
the spreader. Display of the weight of the container shall be installed inside the operator’s cabin. The accuracy of the load cell reading shall be within +/-2%. 4-1.2. (Refer to 2-7. 1. (10))
(1) The Anti-sway/yaw device or sway/yaw damping system shall work effectively for a short distance travel as well as for a stop after full deceleration. The operation of the system shall not alter the elevation of the spreader with or without load at any height.
(2) A simple mechanical anti-sway system which is a proven design and which
preferably shall be based on a main hoist eight (8) single fall rope reeving system. Hydraulic type anti-sway system is not acceptable.
(3) Details of the construction and performance of the mechanical anti-sway system
shall be submitted with the tender document. 4-1.3. Skew Control
(1) The Spreader skew motion to be controllable up to its maximum angle of ±5 degrees.
Speed ½degree/sec.
(2) One push button switch on the control console shall automatically correct the
spreader position to a ‘Zero skew’ position.
(2) “Zero skew” position shall be indicated with a lamp on the panel in cab.
(4) Screw jack mechanism shall be adopted for the skew control.
(5) Limit Switch shall be installed to prevent over travel of the ball screw-jacks.
4-2. Trolley, Trolley Drive
4-2.1. Trolley Frame
(1) The trolley frame shall be fitted with the main hoist machinery, trolley drive
machinery, anti-sway device, skewing device, operator’s cab, and buffers for forward motion and backward motion collision impact. The buffers shall be capable of absorbing and dissipating the impact of collision at full speed with rated load (refer to 5-1.13).
(2) The trolley frame shall be fitted with safety lugs which shall support the trolley in case of wheel shaft failure.
(3) The trolley frame shall have adequate jacking points for trolley wheel replacement
work.
(4) The trolley frame shall provide an emergency access from the operator’s cab to the
walkways of the girder at any point of trolley travel range.
(5) The trolley drive system, and wheel, shaft and bearing system shall be designed to
facilitate fast replacement of components at any point on the girder.
(6) The trolley frame shall be provided within safe maintenance platform and access to
(7) The trolley frame shall be equipped with drop-pin type storm/gale stowage pin device. The stowage pin device shall allow a one-man operation to engage / disengage pins on both sides of the trolley from the girder. The stowage pin device shall allow approx. ±100mm trolley positioning allowance. The girder shall be marked for the operator to spot the storm/gale stowage position. The dropping of the stowage pin shall prohibit the trolley motion.
(8) A mirror of non-breakable material construction shall be provided to assist viewing
the far side of lifted container in a slot underside of the trolley frame.
(9) Four pairs of heavy duty side guide rollers shall be fitted on both sides of the trolley
frame at fore and aft to guide the trolley movement on the rail without running of misaligned trolley wheel due to uneven track way. The roller bearing of the rail side guide shall be heavy duty and design to carry calculated and imposed forces without damage.
4-2.2. Trolley Drive
(1) Trolley shall be driven by conventional “driven-wheel” system.
(2) The gearbox input shaft shall be fitted with an AC servo operated disc brake rated at
150% full load motor torque. The installation of the brakes shall allow all round access for maintenance.
(3) The reduction gears shall be totally enclosed, oil bath lubricated type.
(4) Geared limit switch drive shall be by a proper gear reducer and a flexible coupling.
Chain drive is not allowed.
(5) Frequent inching operation and plugging operation shall be catered for in the design.
(6) The trolley drive system design shall take into account effects of ±2% cross grades
of the runway, and additional grades caused by deflection of the tyre due to moving loads. For the acceleration and deceleration time requirements refer to 2-7.1. (8). 4-2.3. Sway and Position Control
(1) The sway control shall bring the spreader to a stop following full deceleration of
the trolley from full speed with any operational load to within +/- 50mm at any lifting height as measured at the bottom corners of the 40’ container or the twist lock of an empty spreader. It shall be capable of bringing the spreader to a stop to within 2 cycles of sway.
4-2.4. Power Feeder (Power Chain System)
(1) An approved low noise weatherproof, heavy duty energy chain system design for
rated speed of the trolley shall be proved from the junction boxes at the end of the fixed trolley girder to a similar junction boxes mounted on the moving trolley.
(2) The energy chain shall have extra slots for extra cables (in addition to the specified spare wires) and shall be designed so replacement and cable replacement can be accomplished without dismantling or taking down the carrier assembly.
(3) The chain design shall afford complete segregation of cables for power, control and
data transmission. Cables shall be suitably rated, extra flexible round or flat form adequately sized (minimum wire diameter of 1.5mm square). The installation shall not generate mechanical damage to cables and be such that bend radius specified by the cable manufacturer is not exceeded.
The installation, including junction box(es) terminations shall be EMC compliant. The required quantity of each size and type of conductor shall be provided plus with the exception of AC Motor power cables, 25% of each as spares.
The supplier of the Energy Chain shall also supply the cables and cable glands.
(4) Access to the energy chain system shall be by a permanent walkway and platform.
Manufacturer’s recommendations shall be adhered to strictly for installation detail and tolerances. A platform on the trolley can be used for access to the energy chain providing it provides safe access and hand rails are fitted.
(5) The system design shall not generate water traps internally, between cables and
chain material or externally between chain material or crane structure.
(6) Two (2) spare fiber optical cables (62.5/ 125 multimode) shall be provided and
installed from Driver’s cabin to the Electrical House.
4-3. Gantry Drive
4-3.1. Gantry Drive
(1) Eight (8) - rubber tyred wheels shall be provided for gantry drive. All the tyres shall
be tubeless rubber tyres, minimum 40 ply.
(2) Four (4) gantry motors shall be used for the gantry travel system. It is preferred that
each gantry motor is driven by individual drive. The drives and motors shall be sized to meet the operational requirements for future possible installation of the AGSS.
(3) The gantry drive, motors and brake system shall provide sufficient thermal capacity,
torque and traction for all operating condition.
(4) The gantry motor and brake shall be rated to be able to safely operate the unladen
crane on a slope of ±3% with rated speed. The brake capacity to be sufficient to stop
the Crane whilst not sustaining damages in the event that an emergency stop button is pressed during full-speed gantry travelling with 25 m/s tail wind.
(5) Wheel yoke and equalizer beams shall be designed to allow simple removal of any
Jacking load and position shall be reviewed by the Purchaser to prevent overloading of crane runways.
(6) Wheels, dual chains and gears shall be fitted with safety guards. The guards or covers shall have greasing windows.
(7) Robust tyre guards shall be provided on all wheels.
(8) A sleeve shall be fitted between the gantry equalizer beam and the yoke wheel
assembly enclosing the vertical yoke shaft. This sleeve shall be designed and fitted to all yoke shafts to allow for the bending movement of the gantry motion to be transmitted from the yoke shaft to the sleeve to eliminate shaft breakage. (9) All vertical gantry motor disc brake assemblies shall be fitted with a sealed steel
cover fixed permanently by bolts in order to prevent water ingress. 4-3.2. Steering
(1) Proper manual control steering system for running on crane runways (both
longitudinal and cross travel directions) shall be provided.
(2) The drive and steering system shall be designed taking into account effects of ±1%
cross grades with a rated load at any trolley position. Steering guide bars pointing at the inner edge of pathway of 1,500 mm wide shall be fitted on each wheel close to the ground level. These guide bars must be clearly visible by the operator. 4-3.3. Right Angle & Pivot Turn
(1) Each wheel shall be able to be turned 90 degrees for cross travel, or an intermediate
angle to allow spin turn of the Crane for shifting the crane to another lane. The turning of the wheels shall be controlled by the operator in the cab. Positive locks to keep the wheel in position parallel, at an intermediate angle, or at 90 degrees to the sill beams shall be provided. An audible signal shall be given in the cab when all wheels have fully rotated and locked in the designated position. The maximum time to turn the wheels through 90 degrees shall be 70 seconds. Proximity switches shall be used for installation of the wheel turn and locking mechanism.
(2) The limit switches for the hydraulic wheel jack system shall be “external type”.
4-3.4. Gantry Skew Control
To enable better gantry skew control, each gantry motor shall be driven by individual drive for the gantry travel system.
4-4. NOT USED
4-5. Electrical House, Control Panel, Regenerative E.M.F. Absorbing Resistors
(1) The electrical control panels shall be housed in a walk-in type dust and weather proof panel house which is installed on top of cab end sill beam.
(2) Special consideration shall be given for corrosion protection of the panel house and
weather protection of resistor banks. 4-5.2. E-House Temperature Control
The inside temperature of the panel house shall be maintained below 240C. Air intakes to
the house or panels shall be filtered by non-corrosion washable mechanical filters. Over/under temperature protection with control interlock shall be provided.
4-5.3. Emergency Lights and Fire Control
(1) The panel house shall be equipped with ample lightings for maintenance work, and
also battery operated emergency lights with door switch for unexpected shut off. The emergency lights should be last for at least 1.5 hours.
(2) One (1) - 5 Kg portable C02 fire extinguishers shall be provided outside the panel
house in a wall mounted cabinet. 4-5.4. Back Power Absorbing Resistors
Regenerated back E.M.F. absorbing resistors shall be installed outside the panel house to avoid affecting the inside temperature of the panel house.
4-5.5. Provision for Future Installation NOT USED.
4-5.6. Control Panel (in the Electrical house)
(1) The control panels shall be of steel construction hinged door lockable type with full
access from the front. Each panel shall be equipped with lights to facilitate maintenance work.
(2) The panels with electronic control units shall be designed to maintain the inside air temperature below 40 0C at all times. Any air inlet for cooling air shall be equipped with air filters.
(3) Each motion control panel shall be fitted with motor frequency meter, motor RPM
meter, ampere meter and volt meters which indicate operating frequency, motor revolution, motor current, reference voltage and motor voltage.
4-6. Operator’s Cab, Checker’s Cab
4-6.1. Construction General
(1) The cabs shall be constructed of zinc plated mild steel, double bottom, double
ceiling and double wall, fire proof, fully air conditioned and heated. The cab shall be water tight as operated in the conditions as specified in previous clauses.
(2) The cab shall be fitted with a drain hole on the floor to drain out water due to rain ingress or cleaner’s hose water. A handy plug shall be fitted into the drain hole to avoid dropping of small materials and it shall be almost flush on surface of the floor.
(3) The design of the cab to allow the operator to clean outside of all the glasses safely.
(4) The cab connection to the trolley shall include anti-vibration mounts to reduce
impact and vibration to the operator.
(5) Shields shall be fitted above the windscreen to prevent wire rope lubricants from splashing onto the glass.
(6) The operator’s cab shall be bolt mounted to the trolley and fitted with safety
drop-stop lugs, which shall prevent the cab from dropping off the trolley in case of supporting failure.
(7) Sun visor shall be installed on all the window. The type of sun visor shall be approved by the Purchaser.
4-6.2. Cab Access
Cab access shall be from a hinged door on one side of the cab. The door shall be self closing, with a latch to keep the door in open position. Electrical and mechanical interlock shall be provided to prohibit the trolley movement when the function is triggered. The access gates shall also be locked (closed) when the trolley is not at the trolley access platform.
4-6.3. Window Visibility
Cab windows to provide as much views as possible including lower rear view. The rear side of the cab shall have a full height window. It shall protect the operator from the glare of the sun with fine screen type roll up sun shade on upper front, side and rear windows which have characteristics to allow vision through it. Window glass shall be non-glare and scratch resistant that meets the requirements of BS 857 safety glass with their both surfaces being flat, parallel and fine polished, giving clear undistorted vision. Full direct vision of a ground slot between two - 6 high stacks immediately below the front bottom window shall be ensured without supplemental devices, from the normal seating position of the operator. The front and bottom window shall be laid out symmetrical about the Crane centreline in left and right direction. The design of operator’s cab shall allow replacement of window glass to be carried out inside the cab. Protection shall be installed to prevent the window glass from falling off or out.
4-6.4. Cab Dimension
Minimum inside floor width of the cab shall to be 2,500mm and length (fore and aft) 2,000mm excluding bottom glass frame.