P1-101 Submittal Transmittal Date: Project Name: P1-101 Sludge Dewatering and Odor Control at Plant 1 4/10/13 Orange County Sanitation District To: From: Grant Gourley 10844 Ellis Avenue W.M. Lyles Co. 42142 Roick Drive Temecula, CA 92590 Fountain Valley, CA 92708 Attn: Plant #1 Submittal Group, Division 760 Phone: (951) 973-7393 Drawings or Data are Submitted: For Approval For Information Copies Submittal Number Submittal Title Spec. Section(s) 8 14630.001.A Bridge Crane 14630 1 Electronic Copy of Submittal 14630.001.A Manufacturer / Sub: WML Complete either (a) or (b): (a) (b) Check One Check One This is: We have verified that the material or equipment contained in this submittal meets all the requirements specified or shown (no exceptions). Original Submittal: We have verified that the material or equipment contained in this submittal meets all the requirements specified or shown, except for the following deviations (Listed Below): Resubmittal: Supplemental Submittal: Remarks / Deviations: The specifications require a Brinell Hardness number for the wheels of 375-425, while the supplier submittal calls out a Brinell Hardness number of 304. This was explained by the need for the wheels to be softer than the rail, allowing the wheels to fail before rail. The wheels are less costly and easier to replace. Certification Statement: By this Submittal, I hereby represent that I have determined and verified all field measurements, field construction criteria, materials, dimensions, catalog numbers, and similar data and I have checked and coordinated each item with other applicable approved Shop Drawings and all Contract Requirements. FOR OCSD USE ONLY Contractor's Authorized Signature Date Facilities Engineering 900 E. Orangefair Ln Anaheim, CA 92801 Supplier Specification Evaluation Demag Cranes & Components Overhead Crane Supplier General Information Crane Capacity / Tons Span Voltage Bridge Speed Trolley Speed Hoist Speed CMAA Class Crane Shipping Weight Trolley Weight Maximum Bridge Wheel Load Runway Rail Size - Recommended 20.00 Ton 102 FT 0.000 IN 460/3/60 0-100 VFC FPM 0-65 VFC FPM 24/4 FPM C 54450 LBS 4715 LBS 35350 LBS 60# ASCE CMAA Member ISO 9000 Components Product Liability Insurance Nearest Service Location Nearest Parts Location Factory Service School Single Source Warranty Yes Yes Yes San Bernardino, CA San Bernardino, CA Yes Yes Bridge Girder Information Girder Construction Girder Material Computer Design – Girder Section Girder Steel Certification Welders Certification Compliance Girder to End Truck Connection Connection Type Camber Trolley Rail Type Facilities Engineering Job #100507 Welded Steel Torsion Box A36 Yes Yes Yes Bolted Friction Per CMAA Square Bar, ST52 Page 1 Facilities Engineering 900 E. Orangefair Ln Anaheim, CA 92801 Supplier Specification Evaluation Demag Cranes & Components Overhead Crane Supplier Bridge Component Information Bridge End Truck Manufacturer End Truck Design Number of Wheels / per Crane Wheel Diameter Wheel Material Double Flange Wheels Brinell Hardness Bearing Type Sealed bearings Two Bearings per Wheel L-10 Life Rotating Axle Enclosed Bridge Gearing Crane Rail Sweeps OSHA Approved Bumpers Demag Box 4 12.4 inch Nodular* Cast Iron Yes 304 Bhn Roller Yes Yes 64258 Hours Yes Yes Yes Yes Bridge Motor Manufacturer Motor Type Motor HP x Quantity of Motors Nominal Motor RPM Thermal Overload Protection Brake Type Brake Material Demag Squirrel cage - TEFC 7.1 HP @87Hz HP x 2 1500 Yes DC Disc Asbestos-Free Bridge Gearbox Manufacturer Gearbox Type Gear Type Lubrication AGMA Class Demag Hollow Shaft Helical Oil Bath * Wheels impregnated with Spheroidal Graphite GGG70 Facilities Engineering Job #100507 Page 2 Facilities Engineering 900 E. Orangefair Ln Anaheim, CA 92801 Supplier Specification Evaluation Demag Cranes & Components Overhead Crane Supplier Trolley Information Trolley Manufacturer Number of Wheels Wheel Diameter Wheel Material Brinell Hardness Bearing Type Sealed Bearings Two Bearings per Wheel L-10 Life Rotating Axle Enclosed Trolley Gearing Demag 4 6.3 inch Nodular* Cast Iron 304 Bhn Ball Yes Yes 14495 Hours Yes Yes Trolley Motor Manufacturer Motor Type Motor HP x Quantity of Motors Nominal Motor RPM Thermal Overload Protection Brake Type Brake Material Demag Squirrel Cage -TEFC 4.2 HP @100Hz HP 1500 Yes DC Disc Asbestos-Free Trolley Gearbox Manufacturer Gearbox Type Gear Type Lubrication AGMA Class Demag Hollow Shaft Helical Oil Bath * Wheels Impregnated with Spheroidal Graphite GGG70 Facilities Engineering Job #100507 Page 3 Facilities Engineering 900 E. Orangefair Ln Anaheim, CA 92801 Supplier Specification Evaluation Demag Cranes & Components Overhead Crane Supplier Hoist Information Hoist Manufacturer Capacity / Tons Lift (available on hoist) Model Wire Rope Size Wire Rope Construction Min. Wire Rope Safety Factor Reeving Rope Guide Drum Material Drum Bearing Sheave Material Demag 20.00 TON 44 Feet DRPRO20-20 8/2-10.3 Z-6/1 7/10 inch (18 mm) WRC 8 x 36 Breaking Strength 6.2:1 8 Parts Double Yes QSTE 380 N Roller Hardened Cast Iron Hoist Motor Manufacturer Motor Type Motor HP Nominal Motor RPM Thermal Overload Protection Brake Type Brake Material Mechanical Load Brake Drum Brake (Load Halt Device) Regenerative Braking Demag Squirrel cage - TEFC 5.5/35.0 HP 900/3600 Yes DC DISC Asbestos-Free No Optional Yes Hoist Gearbox Manufacturer Gearbox Type Gear Type Lubrication Drum Bearing Facilities Engineering Job #100507 Demag Offset/Parallel Helical Oil Bath Roller Page 4 Facilities Engineering 900 E. Orangefair Ln Anaheim, CA 92801 Supplier Specification Evaluation Demag Cranes & Components Overhead Crane Supplier Hoist Information - Continued Hook Type Hook Safety Latch Hook Bearing Hook Rotation Geared Operational Limit Switch Geared Emergency Limit Switch Service Time Counter Single Yes Thrust 360 Degrees Optional Yes Yes Electrical Information Enclosure Type (All) Motors Total Enclosed Fan Cooled Motor Insulation Branch and Control Fused Mainline Disconnect Mechanical Disconnect Contactor Manufacturer Contactor Type Festoon System for Hoist/Trolley High Temperature Flat Cable Method of Control Pushbutton Control Manufacturer Quick Disconnect Push Button Ergonomic Push Button Design Facilities Engineering Job #100507 NEMA 12 Yes Class F Yes Yes Yes Telemecanique IEC Yes Yes Pushbutton DEMAG Yes Yes Page 5 Equipment Features CRANE TYPE: Feature: Toprunning double girder crane type ZKKE. These rugged cranes of welded box girder construction are designed for a heavy duty service. A Demag DR or DH wire rope hoist is standard. Benefit: We offer standardized cranes for your specific application. Designs are based on high volume and are tested under the toughest applications. Job # 100507 Capacity: 20.00 T Span: 102'- 0.00" Voltage: 460/3/60 Hoist/Trolley: EZDRPRO20-20 8/2-10.3 Z-6/1 GIRDERS: Feature: Girders for double girder cranes are fabricated plate box sections, with diaphragms, designed to resist all vertical horizontal, and torsional forces. Trolley rails are ST52 rectangular sections welded directly over girder webs, to optimize transmission of loads into the girder structure. Maximum allowable girder deflection is 1/888 of span. Benefit: The girder design insures the optimum strength to weight ratio. This can save building costs in new construction applications. GIRDER CONNECTION: Feature: End trucks are bolted to girder ends to form a rigid connection. Bolts in shear or welded connections are not used. Benefit: The girder connection is precision aligned to insure proper tracking of the crane. Cranes do not have to be field aligned thus saving installation time and cost. END TRUCKS: Feature: End trucks are of box section type, having a side connection to the bridge girder, with double flanged wheels supported on rotating axles. The axles are supported by dual antifriction bearings having a minimum B-10 life in accordance with the CMAA crane classification specified. Wheels are cast and machined from spheroidal graphite material. Wheels are designed to carry the rated load without undue wear to themselves or the crane runways rails. End trucks are fitted with bumpers capable of decelerating and Facilities Engineering Job #100507 Page 1 Equipment Features stopping the crane within the limits stated by OSHA and CMAA. Benefit: Heavy duty high cycling drives and wheels with low wearing wheels that self-lubricate as they travel, and gearbox that improve lifetime of the travel components. BRIDGE DRIVES: Feature: Horizontal bridge drives are of the CMAA type A-4. Motors are totally enclosed, fan cooled and drive fully enclosed gearing. All gear reduction stages are oil bath lubricated. The gear reducers directly drive the wheel axles through splined shafts. VFC (variable frequency control) combined with Demag cylindrical rotor motors offer smooth acceleration and deceleration to minimize load swing. Motors have Class F insulation and are thermally protected by heat sensors imbedded in the windings. Benefit: Smooth stepless acceleration and deceleration provides the operator with exceptional control. CONTROLS: Feature: VFC bridge control provides smooth accel and decel characteristics for accurate load handling. The bridge inverter drive handles a wide speed range and adds safety by reducing load sway. Enclosures are selected to meet the service requirements of the application. Standard enclosure classification is NEMA 12, water tight and dust resistant. Control voltage is isolated from the main power supply by a transformer and does not exceed 120 volts. The standard control voltage for cranes with type DR hoist is 48 volts. Benefit: State of the art controls for smooth crane operation PUSHBUTTON STATION: Feature: Floor control is provided by an ergonomically designed pushbutton station. Slanted position and alert colors of the light, high-impact resistant fiberglass casing promote safe operation. The P.B. station is suspended from an enclosed track system to enable separation of operator and load. Plug connectors are used on both ends of the pushbutton control cable for a ease of maintenance or replacement. DR Pro hoists come standard with a bar load readout, and will provide a Facilities Engineering Job #100507 Page 2 Equipment Features warning symbol in the event of an overload or if the system requires maintenance. Benefit: Ergonomic pushbutton station provides crane status information to the operator for greater safety. BRIDGE ELECTRIFICATION: Feature: Electrification across bridge for power and control circuits consists of highly flexible neoprene covered flat-section cable suspended from smooth running enclosed track system. Benefit: This provides a cost effective solution to bridge electrification PAINT: Feature: All structural and Component parts are cleaned with solvent and or shot blasted or wire brushed. Prime coat and finish coat are applied. Standard colors are safety-yellow for structural parts and Demag blue for machinery. Benefit: The product has an exceptional appearance due to the painting process. HOIST TYPE: Feature: Demag DR PRO rope hoist meets all the requirements for state-of-the-art hoists for tomorrow’s needs. Besides the space-saving design and particularly long service life, it also offers a higher lifting speed for faster handling rates and a comprehensive list of standard features at an attractive price. Standard features include: (DR Pro hoists) Overload Protection Condition Monitoring Diagonostics for entire crane which are downloadable with laptop or PDA interface Self defense against operator plugging and excessive jogging Low current contactor switching Duty and Load spectrum recording Benefit: The DRPRO Hoist product line offers the most advanced options as standard in the industry. Facilities Engineering Job #100507 Page 3 Equipment Features HOIST DESIGN: Feature: Demag is a member of CMAA and HMI and our wire rope and electric chain hoists are designed in strict conformance to all applicable national and local codes and regulations. Benefiit: You have insurance that cranes and hoists designed meet application requirement. Demag is also an ISO certified company as ISO 9001 and ISO14001 HOIST CONTROLS: Feature: Technology package is onboard and the standard package that offers a wide array of diagnostic tools. Diagnostics available includes service history along with overload protection. The controls also feature the following: 1. Anti-Jogging, Anti-plugging, and Phase monitoring. 2. Brake wear monitoring. 3. Life Cycle calculation shows remaining life. 4. Pulse generator to monitor the hoist motor. 5. Hoist no current contact switching for long contactor life 6. Pushbutton with LCD display readout for crane and hoist update 7. Safety warning horn. Benefits: The advanced standard hoist controls protect the equipment for longer life and safe operation. Resulting in less down time and unnecessary shut downs. The onboard smart controls and constant self-monitoring capability of the standard DRPRO help the equipment achieve this goal. HOIST MOTOR: Feature: Demag designed and manufactured, these motors offer dependable performance with a minimum of maintenance. An optimised motor design for low-vibration, quiet operation 12/2-pole squirrel-cage motor with cylindrical rotor. All motors have Class F insulation and are protected from overheating by thermal protectors imbedded in the windings. Motors are totally enclosed, fan cooled (TEFC). Enclosure is outdoor rated IP 55 with a duty of 60% running time and 360 starts/hour. Facilities Engineering Job #100507 Page 4 Equipment Features Benefits: The hoist motor specifically designed and manufactured by Demag insures to meet the challenges of lifting applications. HOIST BRAKE: Feature: Demags DC disk brake is a fail-safe type, electrically released, spring set for close positioning and motor start-up monitoring, with a minimum brake safety factor of 1.8. The brake is fast acting brake due to integrated electronic modules. The hoist (DR Pro) includes a brake sensor that monitors brake wear and will provide a warning to the operator if a brake adjustment is necessary. The high quality brake is designed for a minimum of 5 years life under single shift operation. Benefit: The hoist has failsafe braking that insures safe lifting, spotting, and positioning of loads. HOIST GEARING: Feature: All gear stages have helical gearing and are case hardened for low noises and smooth running. Each gear and hub connection is designed with a conical bonded press-fit connection. This means high resistance to vibration and insensitivity against load peaks. Gear lubricant is synthetic and does not require replacement for the normal life of the hoist. The standard hoist design is rated for FEM2+ (20% greater duty than FEM2). Benefit: The heavy duty gears are permanently immerse in a high grade synthetic oil that leads to long life. ROPE DRUM: Feature: Drum is of welded steel construction, with machined groove, optimized to a minimum depth of 0.375 times the rope diameter. Supported at each end by sealed anti-friction bearings, the drum is driven by a central splined shaft. To assure positive winding of rope on the drum and to prevent rope overlapping and potentially dangerous groove peak contact, a hoisting rope guide is employed. Benefit: Reduce rope and drum wear and no risk of double wrapping the rope on the drum. Facilities Engineering Job #100507 Page 5 Equipment Features WIRE ROPE: Feature: The hoisting wire rope is of proper design and construction for hoist service. The rated capacity load divided by the number of parts of rope does not exceed 20% of the breaking strength of the rope. Benefit: long service life of the wire rope. BOTTOM BLOCK: Feature: Bottom block has a totally enclosed housing fabricated of steel. The rope sheaves are supported on anti-friction bearings and the hook is forged alloy-steel and supported on an anti-friction thrust bearing. Hook is equipped with a heavy spring safety latch. A handle recess makes it easier to be gripped and handled. Moving plastic elements close the opening where the rope enters and leaves the bottom block thus preventing the hands from getting caught and jammed. Benefit: Safe handling by keeping operator hands in handle and away from the load. LIMIT SWITCH: Feature: Hoist is equipped with a 4 position geared upper and lower limit switch. This switch is easily adjusted to set the extreme upper and lower limits of hook travel. The limit switch is equipped with a digital drum revolution counter for use in evaluating service conditions and maintenance intervals. Benefit: Hoist slows than stops at the bottom and the upper limit positions. TROLLEY: Feature: The EZDR low headroom trolley supports the hoist on one side of the beam allowing an excellent high-hook dimension. The precision machined and welded steel trolley frame includes side guide rollers for precise tracking, and an under flange pressure roller for consistant horizontal drive traction and anti-kick-up. Lifting lugs are provided for simple transport and installation and the compact design allows for minimum hook approach dimensions. Benefit: Excellent approach height with low headroom dimensions with excellent tracking characteristic. Facilities Engineering Job #100507 Page 6 Equipment Features TROLLEY DRIVE: Feature: Motorized trolleys are powered by a Demag cylindrical rotor motor with DC brake. A frequency inverter provides true variable speed travel motions for smooth safe positioning, low-sway travel motions and exact positioning. Motors have Class F winding insulation and are totally enclosed. Motors are protected from overheating by thermal protectors imbedded in the windings. Benefiit: Smooth stepless trolley travel with low load sway and excellent operator control. AUDIBLE WARNING DEVICE: Feature: A warning horn is provided as a standard feature on DR Pro wire rope hoists. The horn is mounted on the hoist electrical enclosure. The horn is activated by a 2 position horn button from either a DSE pushbutton station or a DRC radio transmitter. The horn button first position will result in a constant sound from the horn. The second position will result in a pulsating sound. The horn DB rating is 95 db (+/- 3db). The warning horn will also sound if a control system error is detected. Other optional AUDIBLE WARNING DEVICES are available. Benefit: Warning device to warn other poeple that the crane is moving in a work area. DR DIAGNOSTICS: Feature: The diagnostics tool will help eliminate un-necessary down time and remove the guessing game with maintenance requirements. The performance and safety status of your installation are kept under surveillance by the monitoring system. The LED display within the pendant control shows the operator or maintenance engineer the relevant status information and any unusual operating status, if applicable. Two way communication is possible via PC/PDA communication with hoist via IRDA (infrared) or through Laptop comport cables. Benefit: Condition monitoring data can be downloaded and used to schedule preventative maintenance. Facilities Engineering Job #100507 Page 7 DUCT-O-BAR Figure 8 Electrical Conductor Systems For Overhead Cranes, Trolleys, Monorails, Hoists, Conveyors, Automatic Stacker-Retrieval Systems. . . any Application that Requires a Reliable, Safe, and Economical Moving Power System. • 90 AMP • 110 AMP • 160 AMP • 250 AMP • 350 AMP • 500 AMP Basic Figure 8 Systems Heated Conductor Systems Rolled Galvanized Steel Rolled Galvanized Steel Rolled Stainless Steel — Copper Laminated Rolled Copper — Steel Laminated Rolled Electrolytic Copper Extruded Electrolytic Copper Side Contact Systems Totally Enclosed Systems 8-Bar Systems V-Bar Systems CAUTION MAKE CERTAIN POWER SUPPLY IS DISCONNECTED BEFORE INSTALLING, REPAIRING, OR WORKING IN THE PROXIMITY OF ANY ELECTRICAL SYSTEM. ONLY QUALIFIED ELECTRICAL PERSONNEL SHOULD INSTALL OR REPAIR THESE PRODUCTS. www.duct-o-wire.com P.O. Box 519 1351 W. Second Street 379 Davis Road, Unit #3 Corona, California 92878-0519 Oconomowoc, Wisconsin 53066 Oakville, Ontario, Canada L6J 2X2 Phone: 909-735-8220; 800-543-3885; 800-735-1922 Phone: 262-567-2288 Phone: 905-844-1791; 800-361-9473 Fax: 909-735-2372; 800-752-6001; 800-735-0857 Fax: 262-567-0857 Fax: 905-844-2533; 800-663-0933 UL LISTED Conductor Bar Selection ® File # E29805 Contr. 678L Approved in Canada Determining Ampere Load The conductor selected must be large enough to carry the necessary ampere load safely without undue heating. To compute the ampere load, proceed as follows: 1. List the horsepower of all motors used in the application. 2. Determine the voltage and type of current that will feed the conductor. For example: 230v dc 2 wire; 460v ac 3 phase; etc. 3. Refer to the Horsepower Conversion Table on page 3 and convert the horsepower to amperes. 4. Prepare the ampere load figure that will be used to size the conductors as follows: List the full load ampere rating of each motor used on the crane or monorail unit. Determine the duty cycle from the following paragraphs and apply the corresponding factor. Light Duty — Class A and B Crane Service Standby or infrequent use. Up to two motors started at a time. Two to five lifts per hour. Use a factor of 90% of the calculated ampere load. Average Duty — Class C Crane Service Moderate use during the work day. Five to ten lifts per hour. Not over 50% of the lift at rated capacity. Use a factor of 100% of the calculated ampere load. Heavy Duty — Class D Crane Service Used continually during the work day and usually for more than one shift. Loads of 50% of rated capacity or more handled constantly during the work period. Use a factor of 110% of the calculated ampere load. Severe Duty — Class E and F Crane Service Used continually for two or more work shifts a day for loads approaching 100% of capacity. Use a factor of 120% of the calculated ampere load. Due to the mechanical considerations on severe duty use, contact the factory engineering group when selecting the conductor system for this application. 5. If the conductors are to be located where the ambient air temperature is unusually high, the current carrying capacity of the conductor is reduced. Multiply the current capacity of the selected conductor by the derating factor in the following table. Temperature Derating Table Ambient Air Temperature Derating Factor 100°F 95% 130°F 75% 160°F* 50% * At this ambient temperature it will be neccessary to use the higher rated conductor cover, XHT rated at 280°F. Determining Voltage Drop According to CMAA, the voltage drop to the unit motors shall not be more than 3% from the power taps to the load at the farthest point on the conductor run. To determine the voltage drop use the appropriate formula in the following table. Current Type Formula AC 3 phase 60 cycle V = L x I x Z x 1.73 AC 1 or 2 phase 60 cycle V=LxIxZx2 DC 2 wire system V=LxIxRx2 V = Voltage drop L = Distance from power feed to end of conductor I = Total amperes drawn as calculated from conversion charts Z = ac impedance R = dc resistance 2 See Conductor Engineering Data Table on page 4 for values of Z and R. Divide voltage drop by system voltage to get the percent of voltage drop. Maximum voltage drops that are 3% of various supply voltages are as follows: Supply Voltage 460v ac 230v ac or dc 575v ac Voltage Drop (V) 13.8 6.9 17.2 Volts lost that are equal to or less than the above values when using the formulas above will help in selecting the correct conductor. Conductor Selection Example Given a 300 foot runway, power fed at the center, using 460 volt, 3 phase, 60 cycle power supplied to a bridge crane — there is a 40 h.p. hoist motor, a 20 h.p. bridge motor, and a 5 h.p. trolley motor. The operation is Average Duty. Ambient temperature varies from 50°F in winter to 90°F in summer on this Indoor installation. Step 1 — Determining Ampere Load See National Electric Code article 610-14(e) for determining motor loads where there are multiple motors on a single crane. Then from the Horse Power Conversion Table 460v column (right): 40 h.p. hoist motor — 52 amps @ 100% = 52 amps 20 h.p. bridge motor — 27 amps @ 50% = 13.5 amps 5 h.p. trolley motor — 7.6 amps @ 50% = 3.8 amps The total current load is 69.3 amperes. With Average Duty cycle, the current load is factored at 100%. Normal ambient conditions of 50°F to 90°F require no temperature derating. Selecting a 90 amp conductor caused a voltage drop of 4.3% using the formula. Since this is unsatisfactory, use a 110 amp conductor (FE-908) for Step 2. Step 2 — Determining Voltage Drop Use the AC 3 phase formula on page two. V = L x I x Z x 1.73 where: L = 150 ft. (Distance to the end of the runway from the center power feed.) I = 69.3 amperes Z = .0008 for 110 amp conductor (From the Conductor Engineering Data Table, page 4.) 1.73 = 3 phase constant V = 150 x 69.3 x .0008 x 1.73 = 14.4 volts 14.4/460 = 3.1% Since this voltage drop only occurs at the farthest end when two or more motors are started simultaneously, exceeding the 3% voltage drop goal by only 0.1% will not cause a problem. Horsepower Conversion Table 3 Phase AC — 60 Cycle Amperes H.P. 230v 460v 1/2 2 1 3/4 2.8 1 Direct Current Amperes 575v 230v .8 2.7 1.4 1.1 3.8 3.6 1.8 1.4 4.7 1-1/2 5.2 2.6 2.1 6.6 2 6.8 3.4 2.7 8.5 3 9.6 4.8 3.9 12.2 5 15.2 7.6 6.1 20 7-1/2 22 11 9 29 10 28 14 11 38 15 42 21 17 55 20 54 27 22 72 25 68 34 27 89 30 80 40 32 106 40 104 52 41 140 50 130 65 52 173 60 154 77 62 206 75 192 96 77 255 100 248 124 99 341 125 312 156 125 425 150 360 180 144 506 200 480 240 192 675 Ampere Load Calculations for Multiple Units For information about sizing ampere loads for multiple cranes on the same runway, see Article 610-14 (e) of the National Electrical Code for the demand factors. This article also covers additional loads on the bridge cranes other than motor loads. full-load current varying with speed. In these cases, use the higher nameplate current rating. Induction Type Squirrel Cage and Wound Rotor Motors The Horsepower Conversion Table is taken from the 1996 NEC Article 430. The values are for motors running at usual speeds with normal torque characteristics. Motors built for especially low speeds or high torques may require more running current, and multi-speed motors will have For motors that are wound for single or double phase operation, use the nameplate rating. For older slip ring motors or models that have secondary windings be sure to obtain both primary and secondary current ratings. Secondary windings may also need separate conductors or cables when updating the electrification. The voltages listed are rated motor voltages. The current listed shall be permitted for system voltage ranges of 110 to 120, 220 to 240, 440 to 480, and 550 to 600 volts. Motors rated at 208v ac should increase the 230 volt column figures by 10%. 3 Conductor Engineering Data Table Conductor Bar No. Description Weight per Ampere Rating Coefficient of 10' section Linear Expansion lbs. Continuous Intermittent* per °F Resistance Factor AC (z) DC (R) ohms/ft. ohms/ft. Circular Mills FE-758 Galvanized Steel 4.5 90 135 .000007 .0011 .00072 130,000 FE-908 Galvanized Steel 6.5 110 165 .000007 .0008 .0005 189,000 FE-1608 Stainless/Copper Laminate 6.5 160 240 .000008 .000144 .0001 188,000 FE-2008 Copper/Steel Laminate 6.25 250 350 .000008 .000142 .0001 189,000 FE-3008 Rolled Copper 6.75 350 530 .000009 .000085 .000058 188,000 FE-5008 Extruded Copper 500 750 .000009 .000065 .000033 315,000 11.5 * Intermittent Service Rating is determined for one minute on, one minute off operation. Miscellaneous Applications Curves Duct-O-Bars, except the Totally Enclosed System, can be bent to form curved sections without damaging the insulating cover or conductor. Bends with a five-foot radius or greater can be done in the field by using a fly wheel, monorail beam, or similar object to bend the conductor to approximately the necessary radius. Hangers used on curved sections must be placed at intervals of 2-1/2 feet maximium — and closer if required. Use B-100 cross bolt clamp type hangers and P-Series collectors. Discontinuous Circuits On discontinuous circuits a pickup guide assembly must be installed to ensure that the self-centering type collectors engage and disengage the conductor bar. The pickup guide (FE-2JNN3 is illustrated) must have its own support point. The minimum spacing between conductors on curves is three inches. For curves of five-foot radius or more, use five-inch collector shoes. For curves of less than five-foot radius use three-inch collector shoes; also consult the factory for additional information. 10" Support Point 5' Max. Pickup Guide Assembly DUCT-O-BAR 3" 3-1/2" Transfer Cap Self-Centering Collector Other Special Applications Consult the factory for recommendations on applications such as de-icing systems, totally enclosed systems, and other systems not covered here. 4 Support Bracket Support Bracket 2-1/2" Interlocks, Switches, or Fixed Gaps The maximum fixed gap occurring at interlocks is one-inch when using 100 amp P-Series collectors and 1/2 inch when using 40 amp collectors. Use transfer caps as shown to ensure that the collector brushes transfer evenly and smoothly. Also round both ends of the contact brushes to facilitate the transfer. Use clamp type hangers only. When both interlocks and curves of less than a four-foot radius are encountered, the tandem 40 amp collector is recommended. Transfer Cap 1" Max. Gap — 100 AMP Collectors 1/2" Max. Gap — 40 AMP Collectors Expansion Gaps Expansion gaps should be placed at intervals determined by 1) the expansion rate of the metal in the conductor selected, and 2) the variation in temperature that will occur at the conductor location over a full year of operation. 1. Steel Conductor Systems Given that steel conductors expand 1" for every 150' of runway with a temperature change of 100°F over a full year of operation, put the length of the runway and the maximum temperature change for the system to be used into the following formula: Total Steel Expansion (inches) = X/150' x Y/100°F where X is the runway length and Y is the 12 month temperature variation. Example: A 450' long steel conductor (X) installed in a building with an indoor temperature change of 40°F (Y). Total Expansion = 450'/150' x 40°F/100°F = 1.2". (See Section 3.) 2. Copper Conductor Systems Given that copper conductors expand 1" for every 100' of runway over a 100°F temperature change at the conductor over a full year of operation, put the length of the runway and the maximum temperature change for the system to be used into the following formula: Total Copper Expansion (inches) = X/100' x Y/100°F. Example: A 300' long copper conductor system (X) installed outdoors with an anticipated temperature fluctuation of 80°F (Y). Total Expansion = 300'/100' x 80°F/100°F = 2.4". (See Section 3.) 3. Determine the Number of Expansion Gap Assemblies After calculating the actual expansion of the runway conductor system, use the following rule of thumb to pick the number of expansion gap assemblies: a. Under 1" of expansion, use no expansion assemblies. Install one anchor clamp set at the center of the conductor run. b. From 1" to 2" of expansion, use one expansion assembly in the center of the conductor run. c. From 2" to 4" of expansion, use two expansion assemblies. Locate them at 1/3 of the runway length in from each end. d. For systems with more than 4" of expansion, use one expansion gap assembly for each 2" of expansion. 4. Anchors Anchor clamps are required at midpoint on all systems without expansion gaps and halfway between gaps and from gaps to the end of systems with multiple gaps. See the Figure 8 Installation Instructions on anchor locations. The maximum gap opening for all ten foot Figure 8 expansion gap assemblies is 1-3/4 inches. Expansion assemblies are also required at building expansion joints. Conductor Assembly Selection Duct-O-Wire Figure 8 Conductor Bars are furnished as assemblies consisting of a ten-foot long conductor bar rated at 600 volts, an insulating cover, splice cover, and connector pins or joint clamps as applicable. The insulating cover must be appropriate for the environment — indoor, outdoor, or high temperature — in which the conductor is to operate. Indoor systems are for use in ambient temperatures up to 160°F. They have an Orange PVC Insulating Cover. They are not recommended for outdoor use in direct sunlight. Outdoor systems are for use in direct sunlight and ambient temperatures up to 160°F. They have a Gray PVC Insulating Cover with an ultraviolet additive. High temperature systems are for use in ambient temperatures up to 280°F. They have a Yellow Lexan Insulating Cover. From the table to the right, you can select the basic (FE) conductor assembly with the appropriate bar and insulating cover for your application. For information on other conductor assemblies, see page 12. Basic Figure 8 (FE) Conductor Assemblies 10 ft. Lengths Conductor Weight Bar No. Pounds Assembly Catalog No. Indoor Use Outdoor Use High Temp. Use FE-758 4.5 FE-758-2 FE-758-2-SC FE-908 6.5 FE-908-2 FE-908-2-SC FE-908-2XHT FE-1608 6.5 FE-1608-2 FE-1608-2-SC FE-1608-2XHT FE-2008 6.25 FE-2008-2 FE-2008-2-SC FE-2008-2XHT FE-3008-2 FE-3008-2-SC FE-3008-2XHT FE-5008-2 FE-5008-2-SC FE-5008-2XHT FE-3008 FE-5008 6.75 11.5 FE-758-2XHT Cross-sectional drawing of Basic Figure 8 (FE) Conductor Assembly 5 Typical Conductor Mounting Note: S indicates minimum conductor spacing. Standard Vertical Mounted Conductors Lateral Mounted Conductors 3-Phase System • Bottom Contact • 5 Ft. Maximum Support Spacing 4 Ft. Maximum Support Spacing. Use only Lateral (L) Model Collectors. NOTE: we will supply Standard Vertical Mount with (4) Conductors S S 1-1/2" — Single Collectors – Staggered 3" — Collectors Adjacent or when pickup guides are used Use Metal Hangers Only on Lateral Systems Monorail Application Install two conductors on one side of the beam and one conductor on the opposite side to balance the collector spring forces, particularly on light weight hoists. 2-1/2" 2-1/2" 1-1/2" — Single Collectors — Staggered 3" — Collectors Adjacent or when pickup guides are used S 1-1/2" — Single Collectors – Staggered 3" — Collectors Adjacent or when pickup guides are used Duct-O-Bar Figure 8 (FE) Components Catalog Number Weight Pounds Description Angle Brackets for Web Mounting Brackets are galvanized 12 gage rolled steel channel. Hangers are priced separately, but will be factory installed at no charge when hanger locations are shown on sketch. 6 B-100-BR1A 1.0 Bracket — 11-1/4" long. B-100-BR7A 1.12 Bracket — 15-3/4" long. B-100-BR7B 1.18 Bracket with gusset support — 15-3/4" long. B-100-BR13A 1.5 Bracket — 20-1/4" long. B-100-BR13B 1.57 Bracket with gusset support — 20-1/4" long. Catalog Number Weight Pounds Description Straight Brackets for Top Flange Mounting Hole Spacing: 1-1/2 " Typical Hole Dia.: 7/16" Capped I-Beam B-100-BR3A B-100-BR4A 1.25 1.82 B-100-BR5A B-100-BR6A 1.32 2.01 B-100-BR9A B-100-BR10A 1.60 2.19 B-100-BR B-100-TMC-U 8.0 .31 B-100-BR4A-J 1.75 B-100-BR6A-J 1.94 B-100-BR10A-J 2.12 “J” Bolts: 3/8-16 x 4” Brackets are galvanized 12 gage rolled steel channel. Hangers are priced separately, but will be factory installed at no charge when hanger locations are shown on sketch. Bracket — 18" long. Bracket with two Mounting Clamps and hardware — 18" long. Bracket — 21" long. Bracket with two Mounting Clamps and hardware — 21" long. Bracket — 24" long. Bracket with two Mounting Clamps and hardware — 24" long. Channel — 10 feet long. Universal Mounting Clamps with hardware. For 5/8" to 1-5/16" thick Beam Flanges. Capped I-Beam Bracket with hardware. 18" long. Capped I-Beam Bracket with hardware. 21" long. Capped I-Beam Bracket with hardware. 24" long. Hole Spacing: 1-1/2 " Typical Hole Dia.: 7/16" Straight Brackets w/ Mounting Plate for Web Mounting Mounting Plate Hole Spacing: 3-3/8" Mounting Bolts: 1/2-13 x 2" Brackets are primed 12 gage rolled steel channel with mounting plate and hardware. Hangers are priced separately, but will be factory installed at no charge when hanger locations are shown on sketch. Bracket — 2 holes — 3-3/4" long. Bracket — 3 holes — 5-1/4" long. Bracket — 4 holes — 6-3/4" long. Bracket — 5 holes — 8-1/4" long. Bracket — 6 holes — 9-3/4" long. Bracket — 7 holes — 11-1/4" long. Bracket — 8 holes — 12-3/4" long. Bracket — 9 holes — 14-1/4" long. Bracket — 10 holes — 15-3/4" long. Bracket — 11 holes — 17-1/4" long. Bracket — 12 holes — 18-3/4" long. B-100-BRCT1 B-100-BRCT2 B-100-BRCT3 B-100-BRCT4 B-100-BRCT5 B-100-BRCT6 B-100-BRCT7 B-100-BRCT8 B-100-BRCT9 B-100-BRCT10 B-100-BRCT11 1.2 1.3 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 Typical Hole Dia.: 7/16" Bolts: 3/8-16 x 1-1/2" Z-Brackets for Lateral Mounted Conductors B-100-BRZ1 1.0 B-100-BRZ2 1.2 B-100-BRZ3 1.64 B-100-BRZ4 1.8 B-100-BRZ5 2.3 Mounting Holes Hanger Holes 3" Brackets are red primed 10 gage steel. Hangers are priced separately, but will be factory installed at no charge when hanger locations are shown on sketch. Z-Bracket — 1-1/2" hanger spacing, 3" mounting hole spacing. O.A.L. — 4-1/2" Z-Bracket with hardware — 1-1/2" hanger spacing, 3" mounting hole spacing. O.A.L. — 4-1/2" Z-Bracket — 3" hanger spacing, 6" mounting hole spacing. O.A.L. — 7-1/2". Z-Bracket with hardware — 3" hanger spacing, 6" mounting hole spacing. O.A.L. — 7-1/2". Z-Bracket — 3" hanger spacing, 9" mounting hole spacing. O.A.L. — 10-1/2". 7 Catalog Number Weight Pounds Description Threads: 3/8-16 Snap-In Type Hanger Assemblies FE-908-2PF FE-908-2PF FE-908-2PFS .10 .10 FE-908-2SF FE-908-2SFE FE-908-2SFS .11 .11 .11 FE-908-2SF These hangers are not recommended for curves, switches or short runs unless separate anchors are used. Refer to the Figure 8 Installation Instructions. Nylon Insulating Hanger. Nylon Insulating Hanger with Stainless Steel Hardware. DO NOT USE nylon hangers in temperatures higher than 230°F. DO NOT exceed 4 lb. per foot torque when tightening nut on mounting bolt. Zinc Plated Steel Hanger. Epoxy Coated Steel Hanger. Stainless Steel Hanger with Stainless Steel Hardware. Snap-In Type Spring Hanger and Insulator Assemblies for Outdoor, Wet and Dirty Applications Threads: 3/8-16 FE-908-2SFG FE-908-2SFFG FE-908-2SFSG .20 .20 .20 Zinc Plated Steel Hanger with Insulator. Epoxy Coated Steel Hanger with Insulator. Stainless Steel Hanger with Insulator and Stainless Steel Hardware. Clamp Type Hanger Assemblies for All Conductor Systems Threads: 3/8-16 B-100-2FF B-100-2FFE .19 .19 B-100-2FFS .19 Zinc Plated Steel Hanger. Epoxy Coated Steel Hanger. For special environments. Stainless Steel Hanger with Stainless Steel Hardware. For special environments. Clamp Type Hanger and Insulator Assemblies for Outdoor, Wet and Dirty Applications. Threads: 3/8-16 B-100-2FG B-100-2FFG B-100-2FSG .30 .30 .30 Zinc Plated Steel Hanger with Insulator. Epoxy Coated Steel Hanger with Insulator. Stainless Steel Hanger with Stainless Steel Hardware. B-100-2F2 .40 B-100-2F3 .59 FE-908-2PF3 FE-908-2SF3 FE-908-2SF4 FE-908-2SF5 .50 .53 .72 .93 Plastic Triple Hanger Assembly. Zinc Plated Steel Triple Hanger Assembly. Zinc Plated Steel Four-Gang Hanger Assembly. Zinc Plated Steel Five-Gang Hanger Assembly. B-100-1G .12 30% Glass-filled Nylon — 400°F rated. Suitable for chemical or oil-laden atmospheres. Clamp Type Special Hanger Assemblies Threads: 3/8-16 Zinc Plated Steel Twin Hanger Assembly. 1-1/2" centers. For indoor applications. Staggered Collectors. Zinc Plated Steel Triple Hanger Assembly. 1-1/2" centers. For indoor dry applications only. Staggered Collectors. Snap-In Type Special Hanger Assemblies Threads: 3/8-16 Centers: 1-1/2 " FE-908-2SF3 Threads: 3/8-16 Mushroom Insulators with Hardware 8 Catalog Number Weight Pounds Description Power Feeds with Insulating Case FE-908-2CP .25 FE-1158-2CP .26 FE-2008-2CP .63 FE-3008-2CP 1.10 FE-758-GCTP .14 FE-908-GCTP .14 90 Amp Rated — Steel. For FE-758-2 systems. Will accept up to # 4 AWG cable. 110 Amp Rated — Copper. For FE-908-2 systems. Will accept up to # 2 AWG cable. 250 Amp Rated — Bronze. For FE-1608-2 and FE-2008-2 systems. Will accept up to # 1/0 AWG cable. 350 Amp Rated — Cast Bronze. For FE-3008-2 systems. Will accept up to # 3/0 cable. End Power Feeds 40 Amp Rated. For all systems with FE-758 conductor bar. 40 Amp Rated. For all systems with FE-908, FE-1608, FE-2008, and FE-3008 conductor bar. Expansion Gap Assemblies Anchor sets and connector pins are included with the hardware package. FE-758-2H10 FE-758-2H10-SC FE-758-2H10XT FE-908-2H10 FE-908-2H10-SC FE-908-2H10XT FE-1608-2H10 FE-1608-2H10-SC FE-1608-2H10XT FE-2008-2H10 FE-2008-2H10-SC FE-2008-2H10XT FE-3008-2H10 FE-3008-2H10-SC FE-3008-2H10XT FE-5008-2H10 FE-5008-2H10-SC FE-5008-2H10XT 7.0 7.0 7.0 9.0 9.0 9.0 10.5 10.5 10.5 10.0 10.0 10.0 12.5 12.5 12.5 16.5 16.5 16.5 Each assembly consists of a ten-foot conductor bar, insulating cover, connector pins for one end, guide assembly, two power feeds with a jumper cable and hanger set. Refer to the Figure 8 Installation Instructions. For Indoor System FE-758-2. For Outdoor System FE-758-2-SC. For High Temperature System FE-758-2XHT. For Indoor System FE-908-2. For Outdoor System FE-908-2-SC. For High Temperature System FE-908-2XHT. For Indoor System FE-1608-2. For Outdoor System FE-1608-2-SC. For High Temperature System FE-1608-2XHT. For Indoor System FE-2008-2. For Outdoor System FE-2008-2-SC. For High Temperature System FE-2008-2XHT. For Indoor System FE-3008-2. For Outdoor System FE-3008-2-SC. For High Temperature System FE-3008-2XHT. For Indoor System FE-5008-2. For Outdoor System FE-5008-2-SC. For High Temperature System FE-5008-2XHT. Special Application Components FE-2JNN3 3.75 FE-2JNN4 4.50 Pickup Guide Assembly — 3" wide. Includes clamps and two foot section of system conductor. Specify conductor system. Pickup Guide Assembly — 4" wide. Includes clamps and two foot section of system conductor. Specify conductor system. 9 Catalog Number Weight Pounds Description Special Application Components (cont.) FE-758-GCT FE-908-IP FE-758-GCT FE-758-GCTL .08 .08 FE-758-GCTR .08 FE-908-GCT .08 FE-908-GCTL .08 FE-908-GCTR .08 FE-908-IP .02 FE-908-IS .19 B-100-TG 1.81 B-100-TGE 1.81 FE-908-IS B-100-TG Maximum O.A.L.: 12-1/4" Transfer Cap. For FE-758 Bar only. Transfer Cap. For FE-758 Bar only. Cut at 45° for left hand curves. Transfer Cap. For FE-758 Bar only. Cut at 45° for right hand curves. Transfer Cap. For FE-908, FE-1608, FE-2008, and FE-3008 Bar. Transfer Cap. For FE-908, FE-1608, FE-2008, and FE-3008 Bar. Cut at 45° for left hand curves. Transfer Cap. For FE-908, FE-1608, FE-2008, and FE-3008 Bar. Cut at 45° for right hand curves. Isolating Piece — 1" long. For all bars except FE-758 and FE-5008. Isolating Piece — 8" long. For all bars except FE-758 and FE-5008. Steel Transfer Guide Assembly. For use with isolating pieces. Epoxy Coated Transfer Guide Assembly. For use with isolating pieces. C-Series Collector Assemblies C-40-V3 C-40-L3 1.5 2.75 C-100-V5 1.80 C-100-L5 3.13 FC-TB1 3.25 C-100-V5 C-Series Collectors are used on short continuous run systems. They feature steel pivot points for good tracking capability. 40 Amp Collector — single shoe. Vertical mount. 40 Amp Collector — single shoe. Lateral mount with steel counter weight. O.A.L. — 15" 100 Amp Collector — single shoe. Vertical mount. 100 Amp Collector — single shoe. Lateral mount with steel counter weights. O.A.L. — 16" Collector Mounting Post Bolts: 3/8 - 16 x 1-1/2" Mounting Post with Hardware — 18" long. Mounting plate is 4" square with 3" hole spacing for C-Series and P-Series Collectors. (Contact factory for special lengths or finishes.) P-Series Collector Assemblies Maximum O.A.L.: 15-1/4" P-40-V3 P-40-L3 P-40-S3 P-100-V5 P-100-L5 P-100-S5 P-100-V5 10 2.19 2.50 2.25 2.44 2.55 2.60 P-Series Collectors are used on straight and curved runs and transfers. The pantograph design provides virtually constant spring pressure for the entire stroke range. Lateral Mount Collectors are provided with spring balance. Conductor Bars must be spaced at least 3 inches apart. To order bronze collectors with stainless steel hardware, add “BR” to the catalog number. Call factory for prices. 40 Amp Collector — single shoe. Vertical mount. 40 Amp Collector — single shoe. Lateral mount. 40 Amp Collector — single shoe. Self-centering. 100 Amp Collector — single shoe. Vertical mount. 100 Amp Collector — single shoe. Lateral mount. 100 Amp Collector — single shoe. Self-centering. Catalog Number Weight Pounds Description Maximum O.A.L.: 28" P-Series Collector Assemblies (cont.) P-80-VT3 4.34 80 Amp Collector — double shoe. Vertical mount. P-80-LT3 4.35 80 Amp Collector — double shoe. Lateral mount. P-80-ST3 4.5 80 Amp Collector — double shoe. Self-centering. P-200-VT5 5.0 200 Amp Collector — double shoe. Vertical mount. P-200-LT5 4.63 200 Amp Collector — double shoe. Lateral mount. P-200-ST5 4.6 200 Amp Collector — double shoe. Selfcentering. P-200-VT5 Additional Components B-100-2L .03 Spring Cover Clip — Zinc Plated Steel. Used only to ensure alignment of the cover on laterally mounted systems. Placed midway between hangers. B-100-2FEA .30 Clamp Hanger Set — 2 pieces. Clamps both sides of hanger. FE-1GC .04 Flexible PVC End Cap. For all Figure 8 conductor bars. FE-908-A .02 Nylon Anchor Pin. For drilled anchoring. Two required at each hanger. FE-1GC B-100-2L FE-2ER-EX FE-908-1M FE-908-1M 2.88 Connector Tool. One tool usually ordered for each new system. Used to pull two sections of bar together. FE-908-1MB .10 Connector Tool Pins — Pair. FE-2ER-EX .05 Splice Cover — Standard black. Use this part number when ordering extra splice covers. B-100-2FEA Conductor Bar Cleaning Accessories Contact the factory for application. C-100-VCT 1.80 Complete C-Series Collector with cleaning head. Vertical mount. P-100-VCT 2.19 Complete P-Series Collector with cleaning head. Vertical mount. C-100-2ACT .50 Cleaning Head only for C-Series or B-Series Collectors. P-100-2ACT .57 Cleaning Head only for P-Series Collector. B-40-2B3-CI .17 Cast Iron Cleaning Shoe — 3" long x 1/4" wide. B-100-2B5-CI .26 Cast Iron Cleaning Shoe — 5" long x 1/4" wide. C-100-CT .14 Cleaning Brush — Stainless Steel. B-100-TT .08 Micro Hone — 1/4" x 4". 11 DUCT-O-BAR Special Application Conductors All Duct-O-Wire Figure 8 conductor systems can be sized electrically by using the general and technical information contained in this brochure. For applications with special mechanical or environmental considerations, refer to the table below for the proper Duct-O-Bar System to use. Conductor System Heated (HFE) Side Contact (SFE) Totally Enclosed (EFE) 8-Bar (8-BAR) V-Bar (VFE) Application or Usage Price List Technical or Installation Bulletin To prevent ice build-up problems such as outdoor yard cranes or indoor frozen food storage. HFE-994 FE-01INST and HFE Supplement Monorails and some underhung units which require special mounting hanger brackets to fit the manufacturer’s tracks. Not recommended for outdoor use. SFE-9911 SFE-97INST Prevents airborn contaminants from collecting on conductor surfaces. EFE-9911 EFE-95INST 8-9911 8-95INST VFE-961 VFE-95INST When contour cover shape is specified or requested. For V-tracking or side contact applications requiring insulated hangers. Not recommended for outdoor use. Duct-O-Wire representatives and distributors are located throughout the U.S. and Canada. Call the factory for the representative or distributor closest to you. Brochure FE-01 Replaces FE-98 © 2001 (DW-24) Printed in U.S.A. Section 14630 BRIDGE CRANES PART 1 - GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall furnish and install an electrically operated bridge crane system complete, in accordance with the requirements of the Contract Documents. The bridge crane shall be of the low headroom type, equipped for electric lift and travel in both directions and it shall be mounted on standard I-beams, or specially fabricated sections. 1.2 RELATED WORK SPECIFIED ELSEWHERE A. The requirements of the following Sections and divisions apply to the Work of this section. Other Sections and divisions of the Specifications, not referenced below, shall also apply to the extent required for proper performance of this Work. 1. Division 01, Additional General Requirements 2. Section 14600, Hoists and Cranes, General 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. All Work specified herein shall conform to or exceed the applicable requirements of the referenced portions of the following publications to the extent that the provisions thereof are not in conflict with other provisions of these Specifications. B. Comply with the applicable editions of the following codes, regulations and standards. 1. Industry Standards: AISC Specifications for the Design, Fabrication, and Erection of Structural Steel for Buildings ANSI/ASME B30.11 Overhead and Underhung Cranes - Safety Standard for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings ANSI/ASME B30.16 Overhead Hoists (Underhung) - Safety Standard for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings ASTM A 36 Standard Specification for Carbon Structural Steel 2. Other Standards: AGMA American Gear Manufacturers Association AISC American Institute of Steel Construction Sludge Dewatering and Odor Control at Plant 1 Project No. P1-101 CONFORMED BRIDGE CRANES 14630-1 ASME American Society of Mechanical Engineers CMAA Crane Manufacturers Association of America NEMA National Electrical Manufacturers Association UL Underwriters Laboratories C. Comply with the applicable reference Specifications as directed in the General Requirements and Additional General Requirements. 1.4 CONTRACTOR SUBMITTALS A. Submittals shall be made in accordance with the General Requirements, Additional General Requirements and as specified herein. 1.5 QUALITY ASSURANCE A. General: 1. Comply with the requirements specified herein and the applicable reference Specifications of the General Requirements and Additional General Requirements. 2. Comply with the requirements of Section 14600, Hoists and Cranes, General. PART 2 - PRODUCTS 2.1 GENERAL A. Requirement: The bridge crane system shall be controlled from a pendant pushbutton station and be furnished complete with all required safety devices and overload protection. The power supply shall be from enclosed, UL-approved conductor bar systems. The rails shall be standard I-beams, or specially fabricated steel sections, firmly anchored to the structure, as shown. The track deflection shall not exceed 1/800 of the span, or 1-1/4 inches, whichever is less. The completed crane system, except the tracks, shall be the product of one crane manufacturer regularly engaged in the manufacture of such equipment as indicated in Section 14600, Hoists and Cranes, General. B. Site Conditions: Equipment No.: 15LCRN017 Location: Thickening and Dewatering Facility Atmosphere: Indoors C. Design Criteria: The bridge crane system shall have the following capacities and dimensions: Equipment No.: 15LCRN017 Type of Crane: Top Running Type of Bridge: Double Girder BRIDGE CRANES 14630-2 Sludge Dewatering and Odor Control at Plant 1 Project No. P1-101 CONFORMED 2.2 Capacity (tons): 20-Ton Maximum lift (feet): 35 feet Length of track (feet): 250 feet Length of bridge (feet): 102 feet Span between tracks (feet): 100 feet Speed Control: Multiple Speed Lifting Speed (fpm): 16/2.6 ft/min 2-Speed Trolley Speed (fpm): 65 ft/min Stepless Bridge Speed (fpm): 100 ft/min Stepless Hoist Motor (hp): 25 Trolley Motor (hp): 2-1 Bridge Motor (hp): 2-3 Power Supply: 480 V, 3-phase, 60 Hz FABRICATION A. Hook and Wire Rope: The lifting hook shall be of drop-forged, heat-treated steel with a 360-degree swivel on a shielded roller-thrust bearing with safety spring latch. The wire ropes shall be improved plow steel with steel center complete with swaged fittings. B. Hoist and Drive: The hoisting drum shall be a large diameter, deep grooved and flanged drum with at least two full turns of rope to remain on the drum at the lowest hook position, with heavy-duty, pre-lubricated sealed bearings. The drum shall be driven by a helical gear reducer with external spur drum gear enclosed in an oil-tight housing. The housing motor shall be a standard, 30-minute-duty-cycle motor, 1,750 rpm, with suitable NEMA type shaft extension. The hoisting mechanism shall be provided with dc magnetactuated disc motor brake with hook drift. The motor shall be rated with minimum of 150 percent of full load torque, with gravity type upper and lower hook limit switch, and an overload cut off switch to interrupt the raising circuit. C. Trolley Assembly: The trolley assembly shall be a top-running type, as specified, framed by a structural shape welded into a stable assembly for proper wheel and bearing alignment. The trolley assembly shall be supported by trolley wheels of tread surfaces hardened to 375 to 425 Brinell. The tread shall be tapered to provide suitable running alignment for trolley. Each wheel shall be supported on tapered roller bearings suitable to take radial and thrust loads. The wheel mounting shall be designed so that axles and wheels can be removed without disturbing other truck elements of their alignment. The wheel tread shall be smooth, true, and uniform within 0.010 inch tread diameter on all wheels. Sludge Dewatering and Odor Control at Plant 1 Project No. P1-101 CONFORMED BRIDGE CRANES 14630-3 D. The trolley shall be driven by a 30-minute-duty-cycle rated motor, through an oil-tight gear reducer conforming to NEMA Specifications. The motor shall be provided with cushion start and controller for smooth travel and load control. The driver shall provide synchronous drive from gear reducer to both drive wheels. The trolley drive shall be provided with integrally mounted spring set and an electrically released drag brake. E. Crane Bridge Assembly: The crane bridge assembly shall be a single beam overriding or top-running double beam, electrically driven, center-drive type. The bridge beam shall be designed in accordance with the latest Specifications of the Crane Manufacturers Association of America. It shall be fabricated of standard structural shape per AISC Specifications. At full load, the beam shall be designed to limit the deflection to 1/600 of the span, but not to exceed 1-1/4-inch maximum deflection. An ASCE rail shall be provided on top of the beam securely fastened in place to maintain center distance. Provision shall be made to prevent creeping of bridge rails by means of positive stops at the ends of the rails. Crane shall be reinforced with outrigger to provide squareness with end truck, adequate lateral stiffness with a minimum lateral moment of inertia of 1/20 that of the vertical beam moment of inertia. Outrigger shall furnish support for squaring shaft and the crane drive motor and gear reducer assembly. F. End Trucks: The end trucks shall be traversed by stable assembly of structural shapes welded together to provide proper wheel and bearing alignment. The end truck wheel base shall be a minimum of 1/7 of the crane span. One wheel of each end truck shall be geared and meshed with the pinion mounted on the crane squaring shaft. The crane and trucks shall contain diaphragm members welded to truck frames to maintain alignment and distribute truck loads on inner and outer truck members. The truck shall be designed so that, in case of a wheel axle or wheel failure, the drop of the load will be limited to 1 inch. The end trucks shall be fastened to the bridge beams with bolts to ensure alignment in assembly. See Remarks on Submittal Cover Sheet G. Crane Wheels: Crane wheels shall have tread surfaces hardened to 375 to 425 Brinell. Treads shall be tapered to provide suitable running alignment for crane. Each wheel shall be supported on tapered roller bearings mounted on stationary axles, suitable to take radial and thrust loads. The wheels shall be lubricated at the factory with a sodium base grease, and provided with a suitable reservoir of lubricant to eliminate the need for field lubrication. Wheel axles shall have mounting nuts for bearing adjustment. Wheel mounting shall be designed so that axles and wheels can be removed without disturbing other truck elements of their alignment. Wheel treads shall be smooth, true, and uniform within 0.01-inch tread diameter on all wheels. H. Crane Drive: The crane drive motor shall be totally enclosed, 30-minute cycle rated. The motor shall be integral with a fully enclosed oil splash lubricated gear reduction. The motor, the drive shaft, and the gear reduction shafts shall be supported by permanently lubricated precision ball or roller bearings. The drive shaft shall provide synchronous drive from the gear reduction to both end trucks. The crane drive shall include integrally mounted spring set electrically released dc rectified disc brake. I. Drive Shaft: The drive shaft of the crane shall be supported on lubricated, precision, ball-bearing pillow blocks based on 10-foot maximum centers. These pillow blocks shall be lubricated through pressure grease fittings. The crane drive shaft shall be steel and designed to limit torsional shaft stress to 6,000 pounds per inch. Maximum torsional twist angle in the drive shaft shall not exceed one degree of the wheel rotation under maximum rated load, regardless of load location. J. Bearing Life: All bearings in the crane wheels, those supporting the drive shafts, and the gear reduction shafts, shall be designed for 5,000 hours B-10 bearing life minimum. BRIDGE CRANES 14630-4 Sludge Dewatering and Odor Control at Plant 1 Project No. P1-101 CONFORMED K. Gearing: All gears shall be cut from solid blanks with 20-degree pressure angle involute shape for high strength and shall comply with AGMA Specifications for load ratings. All gears operating at higher than 20 fpm pitch line speed shall be fully enclosed in oil-tight housings and lubricated by splash principle. All gear teeth shall have ductile cores and be surface hardened to RC40 minimum. The gear shall provide for a minimum service of 4,000 hours, compounded for intermittent operations corresponding to 5 years minimum industrial use. L. Bridge Stops: The bridge shall be provided with bumpers capable of stopping the crane (not including the lifted load) at a rate of deceleration not to exceed 3 fps when traveling in either direction at 20 percent of rated speed. The bumpers shall have sufficient energy absorbing capacity to stop the crane when traveling at a speed of at least 40 percent of the rated load speed. Bridge trucks shall be equipped with sweeps that extend below the top of the rail and project in front of the crane wheel. M. Runway Beams and Rails: The runway beams and rails shall be furnished as specified or shown. The rails shall be an ASCE type securely fastened into the runway beams. The runway beams shall be designed from an ASTM A 36 structural steel shape and shall have a maximum deflection not to exceed 1/800 of the span. The beams shall be equipped with stops on both ends capable of withstanding the impact of the fully loaded crane at 50 percent of rated speed, and shall be field adjustable. All necessary column supports or clamps, hanger rods, bolts, and fittings shall be provided. N. Electrical Controls: Electrical controls shall be single speed or multiple speed as required in each equipment Specification. Bridge control shall include a mainline magnetic contactor, manually operated fused mainline disconnect with lockout provisions, branch circuit fuses, reversing bridge control, and transformer with fused secondary. Bridge control shall be mounted on bridge in NEMA 12 enclosure actuated from a pendant pushbutton station suspended from movable trolley hoist 4 feet above operating floor. Motors shall be provided with cushion start. O. Conductor and Wiring: The runway shall be provided with enclosed conductor base electrification adequately supported. The bridge shall have a rigid truck festoon type electrification. All other wiring of the crane shall be in rigid or flexible conduit and in accordance with National Electrical Code and complying with Fire Underwriters specifications. When a crane is shipped knocked down, the wiring shall terminate in approved terminal boxes and the wire end shall be provided with permanent marking tags. 2.3 PAINTING A. The entire crane assembly shall be shop coated in accordance with the Section 09800, Protective Coating. PART 3 - EXECUTION 3.1 INSTALLATION A. All bridge crane equipment shall be installed in strict conformance with the manufacturer's published or written instructions. Cranes shall be factory assembled and given a no-load test. All major components of the system shall be marked at the factory to assure prompt and correct field identification. B. After completion of the Work, the CONTRACTOR shall test all hoist and crane equipment in the presence of the manufacturer's field representative, who shall certify, in writing, that the equipment meets all applicable Standards and Specifications. Sludge Dewatering and Odor Control at Plant 1 Project No. P1-101 CONFORMED BRIDGE CRANES 14630-5 3.2 MANUFACTURER’S FIELD SERVICES A. Comply with the requirements of Specification section 14600, Hoists and Cranes, General. B. Comply with the requirements of Specification section 01820, Training of OCSD Personnel. ****** BRIDGE CRANES 14630-6 Sludge Dewatering and Odor Control at Plant 1 Project No. P1-101 CONFORMED