SPECIFICATIONS Top-Running Cranes With serial built Wire Rope Hoists

Transcription

1 SPECIFICATIONS Top-Running Cranes With serial built Wire Rope Hoists 1 of 11

2 DISCLAIMER These SPECIFICATIONS ARE INTENDED AS GENERAL GUIDELINES ONLY for technical procedure. Questions concerning exact specifications must be referred to Demag Cranes & Components Corporation on a job by job basis. DCC expressly DISCLAIMS all liability of any kind under any theory of law including, but not limited to, liability sounding in contract and tort (including negligence and strict liability) for improper use of these specifications. In the event of improper use such user agrees to indemnify DCC against any demands, claims, losses, damages, liabilities, whether joint or several, and expenses of any kind including, but not limited to, attorneys fees which result from or are connected with such improper use. 2 of 11

3 TABLE OF CONTENTS Section 1: Specification for Top Running Cranes Pages of 11

4 SPECIFICATION For TOP RUNNING Electric Overhead Crane INDEX 1. APPLICABLE PUBLICATIONS AND SPECIFICATIONS, Page 4 2. GENERAL, Page 5 3. SUBMITTALS, Page 6 4. CRANE SPECIFICATIONS, Pages MISCELLANEOUS, Page APPLICABLE PUBLICATIONS AND SPECIFICATIONS The latest issues of the following publications form a part of this specification to the extent indicated by the references thereto: CRANE MANUFACTURERS ASSOCIATION OF AMERICA CMAA Specification No.70 For Electric Overhead Traveling Cranes CMAA Specification No.74 For Top running and Under running Single Girder Electric Overhead Traveling Cranes AMERICAN NATIONAL STANDARD ANSI B Overhead & Gantry Cranes ANSI B Overhead Hoists ANSI B Single Girder Top running Cranes OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) 29 CFR Par Overhead & Gantry Cranes NATIONAL ELECTRIC CODE NEC (Article 610 Cranes and Hoists) 4 of 11

5 2.0 GENERAL 2.1 The Crane Manufacturer shall be in business for at least seven years, having successfully designed and built several installations of similar scope and shall be an active member of the Crane Manufacturers Association of America (CMAA). Manufacturer shall carry at least $1,000,000 of product liability / completed operations insurance. Manufacturer shall be responsible for providing equipment of the highest quality and workmanship, which will perform specified functions reliably and safely and shall permit required maintenance procedures with minimum interference of service or degradation of reliability. 2.2 SCOPE The work required under this request for quotation shall include but not necessarily be limited to designing, manufacturing and shipping of the crane(s) and other related equipment. It may also include installation and testing of equipment, if so required. 2.3 CRANE DESCRIPTION, The following specific data shall be provided in your quote/drawing: Quantity of Cranes Capacity of Crane(s) Type of Crane(s) (building design is based on this design) Span of Crane(s) Classification of crane(s) is listed in the Technical specifications based on CMAA/FEM calculations. Your quote is to be based on a crane utilization study to verify the class. If necessary the technical specifications will give frequency of use for each size load within a certain time frame so the Crane Manufacturer can perform and submit a crane utilization study to accurately determine the duty classification. Speeds of hoist, trolley and crane Hook approaches for each crane (Hook height and lift, approach towards runways, approach towards walls at end of runway) Building dimensions as part of your drawing submittals. Operating Environment that your quote is based on. 2.4 RUNWAY ELECTRIFICATION The runway conductor system shall be sized per the manufacturer's recommendations and installed in accordance with all applicable codes and specifications A runway conductor system shall be supplied for each crane runway, utilizing totally enclosed, insulated conductors for three phases with one extra conductor used for grounding the equipment. The conductors shall have sufficient ampacity to carry the required current to the crane (or cranes), when operated at rated load and speed. To prevent excessive voltage drop a sufficient number of feed points to the runway electrification shall be installed to satisfy the crane manufacturers requirements The fused mainline disconnect switch and electrical power feed shall be according to requirements of the National Electric Code and will be provided by an electrical contractor. 5 of 11

6 Electrical power conduit feed(s) shall be run to within a 3-ft. distance from the designated crane runway feed point. 2.5 WORK NOT INCLUDED Unless specified otherwise, the runway rails and crane end stops will be supplied and installed by others according the CMAA tolerances (see also 5.2) 3. SUBMITTALS 3.1 Manufacturers drawings shall be submitted for approval in at least two copies. Drawings shall include the following information: a. Outline and clearance dimensions b. Crane data c. Overall arrangement, maximum wheel load and shipping weight d. Specified side and orientation for the runway conductor system 3.2 At time of crane shipment, 2 sets of operation instructions, maintenance manuals and recommended spare parts information shall be furnished. 6 of 11

7 4. CRANE SPECIFICATION 4.1 Crane Bridge Girder Crane girders shall be made from structural shapes or box sections fabricated from steel plate. Box girders shall be diaphragmed box sections designed to resist vertical, horizontal and torsional forces. Girders may be of symmetrical or unsymmetrical design (different plate thickness for top, bottom and web plates. Trolley rail sections may be located directly over inside web.) For double girder cranes, the maximum vertical deflection of the girders produced by the weight of the hoist, trolley and the rated load shall not exceed 1/888 th of span. Vertical inertia forces shall not be considered in determining deflection. Box girders shall be fabricated using high penetration continuous welding and should be factory cambered as required by CMAA. Trolley rails on double girder cranes may be ASCE rails or high strength steel bars designed to carry trolley wheel loads with a minimum of wear. On single girder cranes with a box girder, the bottom plate should be of ASTM 572 steel designed to carry the wheel loads with a minimum of wear. Except as indicated above, girders shall be fabricated of A36 steel plate as a minimum. The maximum vertical deflection of uncambered girders produced by the dead load, the weight of hoist, trolley and the rated load shall not exceed 1/600 th of the span. The maximum vertical deflection of cambered girders produced by the weight of the hoist, trolley and the rated load shall not exceed 1/888 th of the span. Vertical inertia forces shall not be considered in determining deflection End Trucks End trucks shall be of box type construction having double flanged wheels supported on rotating axles. Design of End truck shall allow easy wheel removal and exchange. The anti-friction bearings supporting the axle shall have a minimum L-10 bearing life in accordance with the classification specified (see par. 2.3). Wheels shall be cast nodular iron, or, rolled or forged steel. Wheels shall be designed to carry the wheel loads without undue wear. End trucks shall be fitted with shock absorbing bumpers capable of decelerating and stopping the crane within the limits stated by OSHA and CMAA Girder End truck Connection End trucks shall be bolted to girder ends to form a rigid connection. Bolts in shear shall not be permitted Crane Drives Horizontal bridge drives shall be one of the arrangements as detailed by CMAA (A-1 through A-6). Totally enclosed motor and fully enclosed gearing shall be directly connected to the rotating axle. If hollow shaft, individual drives are employed, gearbox and axle shall be mated by use of a fully splined shaft for uniform rotational force distribution. All gears shall be heat-treated and shall run on anti-friction bearings with constant oil bath lubrication. Acceleration and deceleration rate must be as constant as possible and shall not be significantly affected by variations of the live load, or, by the location of the live load on the bridge span. 7 of 11

8 Motors shall have Class F insulation and shall be thermally protected by heat sensors embedded in the windings with variable speed (VFC control). Variable (speed) drives shall use AC squirrel cage motors designed and insulated for VFC with a 100% duty rating. Variable speed drives shall provide stepless speed changing with a top speed of at least 130 ft/min. Fully proportional control systems are preferred over systems utilizing two-step pushbuttons. Acceleration and deceleration rates shall be adjustable. Motors and drives shall be sized to allow acceleration and deceleration rates in the range of 0.2 to 0.8 feet/second 2. Travel speeds higher than 175 FPM shall be cab or remote controlled. 4.2 HOIST Serial Built Hoist motor and braking system Hoist motor shall develop sufficient power to lift the rated load at the specified speed. Motor windings shall have Class F insulation. Motor shall be rated for the number of starts per hour expected in the application and for the duty cycle (on-time vs. off-time). Ratings such as 30 minute or 60 minute shall not be accepted, as they do not represent the testing criterion that simulates hoisting service. A control system equipped with a phase monitoring system to insure the proper phasing of the power connection is preferred. Motor shall not be mounted inside the hoist drum except in ANSI B30.16 H1 applications due to insufficient heat dissipation and difficulty of maintenance. If the application requires a slow spotting speed in addition to the normal lifting and lowering speed, a two winding, squirrel cage motor shall be used to achieve a 3:1, 4:1 or 6:1 ratio. Pole changing motors for hoist applications shall be used for Class C or lower duty cycles with exceptions based upon the Crane manufacturer's duty cycle calculations. For applications of CMAA Class D duty or greater, a motor with a minimum rating of 360 starts/hour shall be used. Variable Frequency Control (VFC) may be specified. Refer to the Technical Specifications. All motors shall be protected from overheating by thermal protectors imbedded in the windings. All motors shall be totally enclosed, fan cooled. The hoist holding brake shall be an electrically opened and mechanically closed unit. It may be of the shoe brake, disc brake or conical brake type having a minimum torque rating of 150% of motor full load torque. Control braking means may be mechanical or electrical and shall be capable of maintaining controlled lowering speed within +20% of rated lifting speed. For lifts greater than 25 feet or for higher duty classifications than ANSI B30.16 H3, electrical lowering control is required. Brake material shall not contain asbestos. A brake monitoring system to insure safe braking operation and to monitor brake wear is preferred Gearing Motor torque shall be transmitted to the reduction gear through a flexible coupling to dampen load peaks. All gears shall be ground and hardened and shall operate in an oil bath. Gear reducers for serial built hoists shall be of the helical type for balanced load distribution, with a helical first stage. Gear lubricant shall be synthetic and shall not require replacement for the normal life of the hoist. Gear box shall have a minimum design rating of 1600 full load hours (FEM 2M) full load hours is preferred. The hoist motor and gear box shall provide a minimum lifting speed of 24 FPM for 3 and 5 ton hoists and 20 FPM for 10 ton. Above 10 tons, the speed should be based on the application. 8 of 11

9 4.2.3 Rope Drum Rope drum shall be of welded construction and machine grooved to a minimum depth of times the rope diameter. Drum shall be supported at each end by sealed, antifriction bearings. Drum shall be driven by a central, splined shaft Rope & Drum Guide The hoisting rope shall be of proper design and construction for hoist service. The rated capacity load divided by the number of parts of rope shall not exceed 20% of the breaking strength of the rope. Hoist reeving shall be single or double as appropriate to the application. Double reeving ( true vertical lift ) shall not be required except in applications where lateral hook travel must be less than 0.1 inch per foot of vertical hook travel. To assure positive winding of rope on the drum and to prevent rope overlapping and potentially dangerous groove peak contact, a hoisting rope guide shall be employed. Double wrapping of rope shall not be permitted Bottom Block Bottom block shall have a totally enclosed housing fabricated of steel. The rope sheaves shall be supported on anti-friction bearings. The hook shall be forged of steel and supported on an anti-friction thrust bearing. The hook shall be equipped with a heavy spring safety latch. Bottom lock to be equipped with a safety grab point that allows operator to move the bottom block without the danger of grabbing the hook or wire rope. The bottom block shall also be equipped with a safety protection cover to eliminate pinch points at the rope entry into the sheaves. 4.3 TROLLEY Limit Switch Hoist shall be equipped with a four position, geared upper and lower limit switch. This switch shall be adjustable to set the extreme upper and lower limits of hook travel. The setting shall be used for the high-speed slow-down and operational limit stop in both the lifting and lowering motions Single Girder Trolley Trolley wheels shall be cast and machined from spheroidal graphite nodular material for best wear characteristics. To minimize beam and wheel wear, the wheels shall be shaped to match the running surface. Trolley motors shall have Class F insulation and shall be thermally protected by heat sensors embedded in the windings with variable speed (VFC control). Variable speed drives shall use AC squirrel cage motors designed and insulated for VFC with a 100% duty rating. Variable speed drives shall provide stepless speed changing with a top speed of at least 130 ft/min. Fully proportional control systems are preferred over systems utilizing two-step pushbuttons. Acceleration and deceleration rates shall be adjustable. Motors and drives shall be sized to allow acceleration and deceleration rates in the range of 0.2 to 0.8 feet/second 2. 9 of 11

10 4.3.2 Double Girder Trolley Trolley frame shall be a weldment of structural shapes or fabricated box sections, wheels shall resist wear and be mounted on anti-friction bearings having a minimum L-10 bearing life in accordance with the crane classification specified (see Par. 2.3). Trolleys shall be powered by highslip, squirrel cage motor(s) with a brake of sufficient torque capacity. Bridge motors shall have Class F insulation and shall be thermally protected by heat sensors embedded in the windings with variable speed (VFC control). Variable speed drives shall use AC squirrel cage motors designed and insulated for VFC with a 100% duty rating. Variable speed drives shall provide stepless speed changing with a top speed of at least 130 ft/min. Fully proportional control systems are preferred over systems utilizing two-step pushbuttons. Acceleration and deceleration rates shall be adjustable. Motors and drives shall be sized to allow acceleration and deceleration rates in the range of 0.2 to 0.8 feet/second ELECTRIFICATION AND CONTROLS Electrification Electrification across the bridge for power and control to the hoist/trolley, shall consist of a highly flexible type PVC covered flat-section cable system suspended from a smooth running enclosed track system Controls Control of hoist two speed motions shall be by means of magnetic contactors mounted in control enclosures. Controls incorporating anti-plugging and anti-jogging systems are preferred. Enclosures shall be selected to meet the service requirements of the application. Minimum enclosure classification shall be NEMA 12 rated. Control voltage shall be isolated from the main power supply by a transformer and shall not exceed 120 volts. The control system should be equipped with low current contactor switch to improve contactor life Pushbutton Station Floor control of the crane shall be by means of a high impact abrasion-resistant pushbutton station. The push button station should be mounted from a smooth operating track system running along the girder, and should be arranged in close accordance with the applicable paragraphs of CMAA Spec. 70. A pushbutton station that contains a display that provides the number of contactor switching cycles, overload display and signals the operator about event that hoist maintenance is preferred. The pushbutton shall also be equipped with an on/off switch All hoists shall be equipped with an overload protection system that prevents the operator from lifting a load that exceeds the maximum capacity of the hoist by more than 10% Cab Control Cab controlled cranes shall have a cab of the type appropriate for the operation to be performed; open, closed or skeleton-type (dummy). It shall be so located as not to interfere with the hook approach. The cab shall be adequately braced to prevent swaying or vibration, but no so as to interfere with access to the cab or the vision of the operator. Open and closed cabs shall be for full time operation with master switches conveniently arranged before the operator. Multi-directional joysticks are preferred to increase operator s efficiency. Skeleton (dummy) cab control for occasional operation only, shall make use of the remote control unit or standard push button station that can be reached from the cab. 10 of 11

11 Location of cab (whether either end of girder, center of span or trolley mounted) is specified in the technical specifications. (See 2.3) If the environment requires, the cab may be equipped with a heater, fan, or air conditioner, or any other convenience necessary. Access between an open or closed cab and the walkway shall be furnished in compliance with ANSI B Remote (Radio) Control Remote control, if required, is specified in the technical specifications The hoist shall be equipped with retrievable maintenance and service information that provides the number of hoists switching cycles, the load spectrum and the remaining usable service life. 4.6 PAINTING All structural parts shall be cleaned of rust and mill scale. The complete crane shall be given the appropriate number of coats of anti-corrosion paint system to protect the surface from environmental damage. Type of paint and color of final coat shall be according to manufacturer s standard unless otherwise specified. 4.7 LUBRICATION All gear boxes, bearings, etc. shall be properly lubricated prior to shipment from factory. Lifetime lubricated bearings shall be used where possible and appropriate. 5. MISCELLANEOUS 5.1 Shipping Cranes should be assembled as completely as possible. Unloading and installation, unless otherwise specified, shall be by others. 5.2 Runways and Runway Stops Runways and runway stops, unless otherwise specified in this bid request, shall be by others. However, crane supplier may assume runways to be level and within tolerances required by CMAA Spec. 70 and 74. More detailed runway tolerances shall be given with the approval drawing. (Also see par. 2:5.1) 5.3 Spare Parts and Service To properly serve the crane user s need of after sales service and spare parts, the manufacturer shall have local availability of service and spare parts. 11 of 11

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