Technical Specification For Rubber Tyred Gantry Cranes

TECHNICAL SPECIFICATION
FOR
RUBBER TYRED GANTRY CRANES
FEBRUARY 2012
Appendix 1 - Technical Specification Feb 2012
[ GCT - RUBBER TYRED GANTRY CRANES ]

Page: 2
INDEX
C (I)
Functional requirement for the Crane
1.
General ..................................................................................................................................................................8
1-1. Project Description ........................................................................................................................................8
1-2. Terminal Site .................................................................................................................................................8
1-3. Overriding Requirement of the Purchaser .....................................................................................................8
2. Overall Design Criteria..........................................................................................................................................9
2-1. Type of Crane ................................................................................................................................................9
2-2. Type of Cargo ................................................................................................................................................9
2-3. Operating Environment and Design Aim.......................................................................................................9
2-4. Mode of Operation and Performance Target (MMBF)................................................................................10
2-5. Statutory Requirements and Minimum Design Standard.............................................................................10
2-6. Minimum Class of Crane.............................................................................................................................11
2-7. General Design Criteria ...............................................................................................................................11
2-7.1.
Crane Particulars..................................................................................................................................11
2-7.2.
Dimensional Restrictions .....................................................................................................................13
2-7.3.
Yard Interface ......................................................................................................................................13
2-7.4.
Electrical Facility Interface (Shore Power)..........................................................................................13
2-7.5.
Communication Facility Interface (Radio) ..........................................................................................15
2-7.6.
Climatic Conditions .............................................................................................................................15
2-7.7.
Wind Conditions ..................................................................................................................................15
2-7.8.
Lifting Loads and Stability ..................................................................................................................15
2-8. NOT USED..................................................................................................................................................16
2-9. Noise Control...............................................................................................................................................17
2-10.
Operationally Critical Components .........................................................................................................17
3. Crane Structural Specification .............................................................................................................................17
3-1. General Requirement ...................................................................................................................................17
3-2. Material........................................................................................................................................................18
3-3. Calculations .................................................................................................................................................19
3-4. Loads ...........................................................................................................................................................19
3-5. Members Subject To Buckling ....................................................................................................................20
3-6. Fatigue Design Criteria................................................................................................................................20
3-7. Connection Designs .....................................................................................................................................20
3-8. Gantry Structure Stiffness............................................................................................................................21
3-9. Camber.........................................................................................................................................................21
3-10.
Trolley Rails & Rail Fixing .....................................................................................................................21
3-11.
Workmanship...........................................................................................................................................21
3-12.
Quality Control of Structure Fabrication .................................................................................................23
3-13.
Temporary Structures ..............................................................................................................................24
4. Functional Systems Devices & Equipment..........................................................................................................24
4-1. Main Hoist ...................................................................................................................................................24
4-1.1.
Main Hoist Drive .................................................................................................................................24
4-1.3.
Skew Control .......................................................................................................................................26
4-2. Trolley, Trolley Drive..................................................................................................................................26
4-2.1.
Trolley Frame ......................................................................................................................................26
4-2.2.
Trolley Drive .......................................................................................................................................27
4-2.3.
Sway and Position Control ..................................................................................................................27
4-2.4.
Power Feeder (Power Chain System) ..................................................................................................27
4-3. Gantry Drive ................................................................................................................................................28
4-3.1.
Gantry Drive ........................................................................................................................................28
4-3.2.
Steering ................................................................................................................................................29
4-3.3.
Right Angle & Pivot Turn ...................................................................................................................29
4-3.4.
Gantry Skew Control ...........................................................................................................................29
4-4. NOT USED..................................................................................................................................................29
4-5. Electrical House, Control Panel, Regenerative E.M.F. Absorbing Resistors..............................................29

Page: 3
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. Operators Cab, Checkers 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.
Checkers Cab......................................................................................................................................33
4-7. Personnel Lift ..............................................................................................................................................33
4-8. Headblock....................................................................................................................................................33
4-8.1.
Headblock ............................................................................................................................................33
4-8.2.
Two Wire (Bus) System ......................................................................................................................34
4-8.3.
Baloney Cable......................................................................................................................................34
4-9. Spreader, Hook Beam ..................................................................................................................................34
4-9.1.
Single Lift Telescopic Spreader...........................................................................................................35
4-9.2.
Reeve in Spreader ................................................................................................................................38
5. Inter-Functional Systems & Components...........................................................................................................38
5-1. Mechanical System/Components.................................................................................................................38
5-1.1.
Bearing, Seals ......................................................................................................................................38
5-1.2.
Gearing ................................................................................................................................................38
5-1.3.
Gear Reducers......................................................................................................................................39
5-1.4.
Wire Rope Winch Drums ....................................................................................................................39
5-1.5.
Wire Rope Sheaves..............................................................................................................................40
5-1.6.
Wire Ropes ..........................................................................................................................................41
5-1.7.
Shafts, Axles ........................................................................................................................................41
5-1.9.
Metal Wheels .......................................................................................................................................42
5-1.10.
Pins, Pin Brackets ............................................................................................................................42
5-1.11.
Bolts.................................................................................................................................................42
5-1.12.
Lubrication.......................................................................................................................................43
5-1.13.
Bumper, Buffer ................................................................................................................................43
5-1.14.
Rubber Tyres ...................................................................................................................................43
5-2. Hydraulically System/Components .............................................................................................................43
5-2.1.
Standards .............................................................................................................................................43
5-2.2.
Components Sources............................................................................................................................43
5-2.3.
Operating Condition ............................................................................................................................43
5-2.4.
Hydraulic Fluid Reservoir ...................................................................................................................44
5-2.5.
Power Unit ...........................................................................................................................................44
5-2.6.
Valve Mounting ...................................................................................................................................44
5-2.7.
Relief Valve .........................................................................................................................................44
5-2.8.
Flow Control Valve .............................................................................................................................45
5-2.9.
Check valves........................................................................................................................................45
5-2.10.
Servo Valves ....................................................................................................................................45
5-2.11.
Control Valve...................................................................................................................................45
5-2.12.
Solenoid Valves ...............................................................................................................................45
5-2.13.
Piping...............................................................................................................................................46
5-2.14.
Hoses ...............................................................................................................................................46
5-2.15.
Assembly Test .................................................................................................................................46
5-2.16.
Catch Basins ....................................................................................................................................46
5-2.17.
Filters ...............................................................................................................................................46
5-2.18.
Heat Exchangers ..............................................................................................................................47
5-2.19.
Actuator ...........................................................................................................................................47
5-2.20.
Application for Spreader..................................................................................................................47
5-2.21.
Couplings.........................................................................................................................................47
5-2.22.
Gauges .............................................................................................................................................47
5-2.23.
Covers ..............................................................................................................................................47
5-2.24.
Hydraulic Fluid ................................................................................................................................47
5-2.25.
Load Sensing System.......................................................................................................................48

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5-3. Electrical & Electronic System/Components...............................................................................................48
5-3.1.
General.................................................................................................................................................48
5-3.2.
Main Power Supply .............................................................................................................................48
5-3.3.
Power Factor Correction ......................................................................................................................48
5-3.4.
Protection Against Power Surge ..........................................................................................................48
5-3.5.
Protection against voltage dip/loss of power supply............................................................................49
5-3.6.
Wiring ..................................................................................................................................................49
5-3.7.
Marking and Identification ..................................................................................................................50
5-3.8.
Conduit and Cable Tray.......................................................................................................................51
5-3.9.
Electrical Trunking ..............................................................................................................................51
5-3.10.
Motor ...............................................................................................................................................52
5-3.11.
Brakes ..............................................................................................................................................52
5-3.12.
Transformers....................................................................................................................................53
5-3.13.
Resistors...........................................................................................................................................53
5-3.14.
Enclosures........................................................................................................................................53
5-3.15.
Meters, Counters..............................................................................................................................53
5-3.16.
Limit Switches .................................................................................................................................54
5-3.18.
Name Plate.......................................................................................................................................55
5-3.19.
D. C. Power Supply .........................................................................................................................55
5-3.20.
Encoders ..........................................................................................................................................55
5-3.21.
Sensors.............................................................................................................................................55
5-3.22.
Circuit Breakers ...............................................................................................................................55
5-3.23.
Auxiliary Power Socket ...................................................................................................................56
5-4. Crane Motion Controls ................................................................................................................................56
5-4.1.
Control System General.......................................................................................................................56
5-4.2.
Programmable Logical Controllers (PLC) ...........................................................................................57
5-4.3.
Power Supply.......................................................................................................................................58
5-4.4.
Discrete I/O Modules...........................................................................................................................58
5-4.5.
Real Time Clock Module.....................................................................................................................59
5-4.6.
Motion Control Switches in Operators Cab........................................................................................59
5-4.7.
Motion Control Panels .........................................................................................................................61
5-4.8.
Remote Motion Controls .....................................................................................................................61
5-5. Operational Safety Interlocks ......................................................................................................................61
5-5.1.
Main Motions Interlocks......................................................................................................................61
5-5.2.
For Trolley Operation ..........................................................................................................................62
5-5.3.
For Gantry Travel Operation ...............................................................................................................63
5-5.4.
Spreader Functional Interlock..............................................................................................................63
5-5.5.
Cab Entrance Door/Gate Interlock.......................................................................................................64
5-6. Communications ..........................................................................................................................................64
5-6.1.
Intercom System ..................................................................................................................................64
5-6.2.
Radio Communication System ............................................................................................................64
5-6.3.
Data Communication System ..............................................................................................................64
5-6.4.
Public Address System ........................................................................................................................64
5-6.5.
Operation Centre / Maintenance Office Station...................................................................................64
5-7. Crane Condition Monitoring System (CCMS) ............................................................................................65
5-7.1.
General.................................................................................................................................................65
5-7.2.
CCMS Description...............................................................................................................................65
5-7.3.
On-Board Crane Condition Monitoring System (On-Board CCMS)...................................................66
5-7.4.
On-Board CCMS Software Requirements ...........................................................................................66
5-7.5.
On-Board CCMS Hardware Requirements..........................................................................................68
5-7.6.
Condition Monitoring ..........................................................................................................................68
5-7.7.
Fault Diagnosis ....................................................................................................................................72
5-7.8.
Preventive Maintenance.......................................................................................................................73
5-7.9.
Equipment Performance Data and Operation Log ...............................................................................73
5-7.10.
Remote Crane Condition Monitoring System (RCCMS) ................................................................73
5-7.11.
RCCMS Software Requirements .....................................................................................................74
5-7.12.
RCCMS Hardware requirements .....................................................................................................74
5-7.13.
Server(s)...........................................................................................................................................75
5-7.15.
CCMS Data Communication ...........................................................................................................75
6. Common Items ....................................................................................................................................................75
6-1. Walkways, Stairs, Ladders and Platforms ...................................................................................................75
6-1.1.
Applicable Code/Std. ...........................................................................................................................75

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6-1.2.
Stairway Requirements ........................................................................................................................76
6-1.3.
Ladder Requirements...........................................................................................................................76
6-1.4.
Platforms Requirements.......................................................................................................................77
6-1.5.
Walkway Handrail Requirements ........................................................................................................77
6-1.6.
Cab Access Platforms ..........................................................................................................................78
6-1.7.
Walkway Requirements .......................................................................................................................78
6-2. Illumination and Lighting ............................................................................................................................78
6-2.1.
Walkways, Stairs, Ladders, Cab Access ..............................................................................................78
6-2.2.
Work Area Floodlights ........................................................................................................................78
6-2.3.
Floodlights on Trolley .........................................................................................................................79
6-2.4.
Emergency Lighting for Escape Routes...............................................................................................79
6-2.5.
Lighting Control Switches ...................................................................................................................79
6-2.6.
High Pressure Sodium Lamp and Ballast ............................................................................................79
6-2.7.
Fluorescent Lamps...............................................................................................................................80
6-2.8.
Access for Lights Maintenance............................................................................................................80
6-3. Painting and Protective Coating ..................................................................................................................80
6-3.1.
Paint System General...........................................................................................................................80
6-3.2.
Surface Preparation..............................................................................................................................81
6-3.3.
Abrasive Blast Cleaning ......................................................................................................................82
6-3.4.
Painting Generally ...............................................................................................................................83
6-3.5.
Paint Systems.......................................................................................................................................85
6-3.6.
Galvanising ..........................................................................................................................................87
6-3.7.
Reinstatement of Protective Coatings at Site .......................................................................................87
6-3.8.
Inspection and Sample Panels..............................................................................................................88
6-4. Purchasers Logo, Crane Numbers, Signs ...................................................................................................89
6-4.1.
Purchasers Logo .................................................................................................................................89
6-4.2.
Crane Numbers ....................................................................................................................................89
6-4.3.
Crane Capacity Signs...........................................................................................................................89
6-4.4.
Manufacturers Name Plates................................................................................................................90
6-4.5.
Other Signs ..........................................................................................................................................90
6-5. Alarm, Warning Signals ..............................................................................................................................90
6-5.1.
Gantry Travel Warning ........................................................................................................................90
6-5.2.
Main Hoist Overload Warning.............................................................................................................91
6-5.3.
Premature Twistlock Operation Warning ............................................................................................91
6-5.4.
By-Pass Switch Abuse Warning ..........................................................................................................91
6-5.5.
Electrical Control House A/C Warning ...............................................................................................92
6-5.6.
Public Address/Warning ......................................................................................................................92
6-6. Emergency Stop Push Buttons.....................................................................................................................93
6-6.1.
Locations .............................................................................................................................................93
6-6.2.
Type .....................................................................................................................................................93
6-6.3.
Emergency Stop Signs .........................................................................................................................93
6-7. Service Outlets.............................................................................................................................................93
6-7.1.
Location ...............................................................................................................................................93
6-7.2.
Type Model..........................................................................................................................................93
6-8. Fire Extinguishers ........................................................................................................................................94
6-8.1.
Locations .............................................................................................................................................94
6-8.2.
Type-Model .........................................................................................................................................94
6-9. Maintenance Tools and Equipment .............................................................................................................94
6-9.1.
Mechanical Maintenance Tools ...........................................................................................................94
6-9.2.
Electrical/Electronic Maintenance Tools .............................................................................................94
6-9.3.
Hydraulic Maintenance Tools..............................................................................................................94
6-9.4.
Special Tools and Equipment ..............................................................................................................94
6-9.5.
Wear Gauges........................................................................................................................................95
7. Project Q.A. and Administrative Requirements...................................................................................................95
7-1. Document Submission (Project) ..................................................................................................................95
7-1.1.
Project Organisation Chart (Shop & Site)............................................................................................95
7-1.2.
Project Schedule (Shop & Site) ...........................................................................................................95
7-1.3.
Project Progress Report .......................................................................................................................96
7-1.4.
Quality Assurance Programme/ Manuals ............................................................................................96
7-1.5.
Daily Plan and Report (Site Work) .....................................................................................................96
7-2. Document Submission (Technical)..............................................................................................................97
7-2.1.
Submission Schedule ...........................................................................................................................97

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7-2.2.
Conceptual Design...............................................................................................................................97
7-2.3.
Drawings and Calculations for the Purchaser's Review.......................................................................97
7-2.4.
Lubricant List.......................................................................................................................................98
7-2.5.
Crane Delivery Method Statement.......................................................................................................98
7-2.6.
Site Work Method Statement...............................................................................................................98
7-2.7.
Commissioning Test Procedure. ..........................................................................................................99
7-2.8.
Up-Dated Drawings .............................................................................................................................99
7-2.9.
Training Programme ..........................................................................................................................100
7-2.10.
Structural maintenance Program....................................................................................................100
7-2.11.
Operation Manuals.........................................................................................................................101
7-2.12.
Maintenance Manuals ....................................................................................................................101
7-2.13.
As-Built Drawings .........................................................................................................................102
7-3. Shop Inspection & Tests ............................................................................................................................103
7-3.1.
Shop Inspection and Verification.......................................................................................................103
7-3.2.
Pre-Shipment Inspection and Test .....................................................................................................104
7-4. Shipment, Delivery and Site Work ............................................................................................................105
7-4.1.
Clearance for Shipment .....................................................................................................................106
7-4.2.
Notification of ETA Site....................................................................................................................106
7-4.3.
Navigation Requirement ....................................................................................................................106
7-4.4.
Berthing and Roll-off Requirements..................................................................................................106
7-4.5.
Customs Clearance ............................................................................................................................107
7-4.6.
Work Permits .....................................................................................................................................107
7-4.7.
Site Safety and Security.....................................................................................................................107
7-4.8.
Site Erection Area and Access...........................................................................................................107
7-4.9.
Site Office Communication ...............................................................................................................107
7-4.10.
Test Weight....................................................................................................................................108
7-4.11.
Water, Electricity Supply...............................................................................................................108
7-4.12.
Contractors Representatives. ........................................................................................................108
7-5. Site Inspection and Tests, Certification .....................................................................................................108
7-5.1.
Commissioning Tests Application .....................................................................................................108
7-5.2.
Defects List........................................................................................................................................108
7-5.3.
Rectification Report...........................................................................................................................109
7-5.4.
Commissioning Test ..........................................................................................................................109
7-5.5.
Endurance Test. .................................................................................................................................109
7-5.6.
Acceptance Certification....................................................................................................................110
7-5.7.
Access for Remedial Work ................................................................................................................110
7-6. Training .....................................................................................................................................................110
7-6.1.
Training Off-Site. ..............................................................................................................................110
7-6.2.
Training On-Site (Operators).............................................................................................................110
7-6.3.
Training On-Site (Maintenance) ........................................................................................................111
7-6.4.
Special Training on the Operationally Critical Components Maintenance........................................112
7-6.5.
Spare Parts .........................................................................................................................................112
7-6.6.
Ordered Spare Parts ...........................................................................................................................112
7-6.7.
Spare parts for Commissioning Work................................................................................................112
8.
APPENDICES
I.
Structural Limit of the Crane
II.
Inspection Control Sheets
III.
Crane Interface Drawings

1. Container Stack General Layout
2. Typical Cross Sections-Container Stack Blocks and Crane
Runways
IV. Reference Drawings and Data

Page: 7
1.
2.
3.
4.
5.
6.
7.
Crane Numbers at Ground Level

Circuit Diagram for Net Handling House Logic
Control Console Switches Layout
Locations of Floodlights on the Trolley
Operators Cab
GCT Logo, Approved Colours, Warning Signs, Name Plates etc
Type and Model of Labels and Cable Routing for AGSS and
PDS
8. Overview and Configuration of Crane Condition Monitoring
System (CCMS)
V.
List of Drawings / Calculations to be reviewed by the Purchaser

(Minimum Requirements)
VI. List of Operation/ Maintenance Manuals and As Built Drawings

Page: 8
Section C.
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:
(3)
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.
For items of electrical and mechanical equipment, controls, systems, components,

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

Page: 9
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
2
3
4
2-3.
ISO 20ft, 40 ft and 45ft containers including high-cube, half height, flat rack
containers.
Other types of container with ISO corner fittings at 20ft, 40ft, or 45 ft positions.
Containers with overheight cargoes through an overheight cargo container lifting
frame of the Purchaser.
Damaged container with slings and shackles attached to lifting lugs of the spreader.
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 nonhygroscopic, 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/operators cab. The Contractor will provide adequate,
safe and fool-proof protection in and around all equipment and fittings in these areas
of the Crane.
4.
Ease of maintenance and safety of the maintenance staff shall be aimed at

throughout the design to minimise total downtime of the Crane.

Page: 10
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 Purchasers 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 operators
performance.
The MMBF is defined as:
MMBF =
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

Page: 11
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
State of Loading
Group Classification
Impact Factor
Duty Factor
U7
Q2
A7
1.4
0.9
Normal Load Spectrum factor 0.80 of rated capacity.

Mechanisms
Mechanisms
Hoist
Trolley Travel
Gantry Travel
2-7.
Class of
Utilisation
T7
T7
T7
State of
Loading
L3
L3
L3
Group
Classification
M8
M8
M8
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.

Page: 12
(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)
(10)
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.
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
from any operational speed with full

Page: 13
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, 50Hz5%, 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 Purchasers power supply cable and optics fibre cables into the

Page: 14
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

Page: 15
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)
(2)
(3)
(4)
Ambient temperature
-20oC to 40oC
Relative humidity
Max. 100%
Dew point
Max. 3oC
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
45ft - concentric 41 tonnes weight container, in which case a set of main

Page: 16
hoist wire ropes on the landed side is assumed slack and not carrying the
load.
ii)
(2)
(3)
The calculations of the structural and mechanical components shall include

calculation for this criterion.
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.
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)
(6)
2-8.
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.
All other loading conditions forming the design criteria other than specified in this
Specification shall be submitted to the Purchaser for review.
NOT USED

Page: 17
2-9.
Noise Control
The Cranes noise level shall conform to the following requirements: -
2-10.
(1)
The noise level inside the operators 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
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 operators 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)
(2)
(3)
(4)
Gantry drive machineries including 90 degree and an intermediate angle (for spin
turn) steering mechanisms.
Control panels and panel house.
Starting equipment and control panel.
Trolley power feeding system.
3-1.6. The following fittings shall be fitted to the main structure.

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

Page: 18
(2)
(3)
(4)
(5)
(6)
(7)
3-2.
Lighting for operation and for walkway, stairs, ladders and platforms (refer to 6-2)
Intercom telephones (refer to 5-6.1).
Travel warning device (refer to 6-5.1). Speakers and flashing strobe light at each
of 4-corners.
Service outlet (refer to 6-7).
Emergency stop buttons (refer to 6-6).
Four fire extinguishers; 5kg CO2 capacity, 1 at outside of panel house, 1 at
trolley platform and one 2 kg at outside the drivers cab.
Material
3-2.1 The whole of the materials used in the Crane shall be new, of the best quality and suitable
for the duty intended. Mill certificates shall be obtained and records strictly maintained to
match these to the various Crane sections produced during crane manufacture. The steel
materials for all the stress members shall be selected from the materials which specification
includes the notch toughness requirement at or below -20 deg. Celsius.
3-2.2 The steel used for the manufacture of the Crane shall conform as a minimum to one or more
of the following standards most recent issue.
Deutsche Industrie Norman (DIN)
British Standards (BS)
Japanese Industry Standards (JIS)
American Standards (ASTM/API)
Chinese Standard (GB)
3-2.3 Welded Joints
Stresses at weld throats shall be calculated as the vector sum of the individual stresses
applied to the weld throat. For fatigue design when calculating the stress range, the
vector difference of the greatest and least vector sum stress may be used instead of the
algebraic difference.
Welded joint design shall conform to BS 5400: Part 10, BS 7608, and for static loads
only AWS D1.1 - 2000.
3-2.4 Bolted Joints
Bolted joint design shall conform to BS 5400: Part 10, BS 7608, and to the AISC
Specification using 0.9 times AISC allowable values. Prying action due to distortion of
the connection details shall be considered. Bolts subject to fluctuating tensile stress shall
be checked according to BS 7608. Bolts governed by fatigue strength shall comply with
ASTM A325. Structural bolted joints are not allowed unless approved in writing by
Purchaser.
3-2.5 Pin Joint
An effective lubrication system shall be provided for each pin Joint to prevent its seizure
within the life of the structure.
3-2.6 Machinery bases

Page: 19
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
3-3.
(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.
Calculations
3-3.1 Submission to Purchaser
3-4.
(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.
Loads
3-4.1 The design shall incorporate all loads and load combinations pertinent to all in service
and out of service conditions of the crane. The loads due to temperature effects, erection
stresses, and others based on the Contractor's experience shall be included in the analysis
if they cause significant stresses. If rational analysis indicates loads larger than specified,
the larger loads shall be used.
3-4.2 The Contractor shall comply with BS2573: Part 1: 1983, Rules for the Design of Cranes.

Page: 20
3-5.
3-6.
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.
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.

Page: 21
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 noncertified welders shall be subject to removal by the Contractor at his own expense.
3-11.4 The Contractors 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.

Page: 22
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 Contractors 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 Purchasers
Representative on site.
3-11.9 The Contractors 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 preheating procedures and welding rod hot boxes is essential and will be closely monitored by
the Purchasers 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)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Hardened washers shall be placed under the both the head and the nut.
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.
The snug tight tension shall be approximately 50 percent of the specified tension
and shall be achieved using a calibrated wrench.
The sequence of bolt tensioning shall be shown on the drawings.
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
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.
The flange contact bearing surfaces shall have at least 75% of the bearing crosssectional 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.

Page: 23
(viii)
Bolt tension may be verified at locations selected by the Purchasers Representative.

Bolt tension verification shall be performed by the Contractor in the present of the
Purchasers 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
All Welds
Full Penetration Butt Welds
(Compression)
Full Penetration Butt Welds
(Tension-as determined by
stress levels due to operating
loads combinations)
Type of Testing/Inspection
100% Visual
100% UT
1 X Exposure 400 mm
per weld
100% UT
10% of length RT or
1 X exposure per weld
length 400 mm which
ever is the greater
100% UT
100% of length RT
Acceptance Criteria
AWS D1.1-latest version
Full Penetration Butt Welds in

Tension Bars (if applicable)
Fillet Welds or Partial
Penetration Welds
On FCM
100% of length MT
On Non-FCM
10% of length MT
(as nominated by the
Purchasers Representative)
Rejection of any portion of a weld inspected on a less than 100% basis shall require
inspection of 100% of that weld.
Ultrasonic testing of tension welds shall be done by or under the direct supervision of ASNT
Certified LEVEL III personnel.
3-12.
Quality Control of Structure Fabrication
3-12.1 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:
-
Inventory of incoming material, consumables components and machinery.

Page: 24
-
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 seafastening structure connection details to crane structures for the Purchasers 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
type.

Page: 25
(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 Purchasers
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 headblock-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
operators cabin. The accuracy of the load cell reading shall be within +/-2%.
4-1.2. (Refer to 2-7. 1. (10))

Page: 26
(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
4-2.
(1)
The Spreader skew motion to be controllable up to its maximum angle of 5 degrees.

Speed degree/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.
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, operators 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 operators 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
all of its components and machineries for maintenance.

Page: 27
(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.

Page: 28
(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.
4-3.
(4)
Access to the energy chain system shall be by a permanent walkway and platform.
Manufacturers 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 Drivers cabin to the Electrical House.
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
wheel. Easily identifiable jacking points shall be provided on the wheel yoke. The

Page: 29
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
4-5.1. General Construction

Page: 30
(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)
4-6.
(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.
Operators Cab, Checkers 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.

Page: 31
(2)
The cab shall be fitted with a drain hole on the floor to drain out water due to rain
ingress or cleaners 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 operators cab shall be bolt mounted to the trolley and fitted with safety dropstop 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 operators 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.

Page: 32
4-6.5. Cab Fittings

The operators cab shall be fitted with the following fittings and shall not in any way
obstruct operators view required for Crane Operation.
(1)
One right-hand and one left-hand control consoles. The consoles together with the
chair shall be ergonomically laid out to minimize fatigue of the operator. For
detailed requirements refer to 5-4.6.
(2)
One upholstered operators chair. The chair height and position forward and
backward shall be adjustable to best suit each operator (oriental size). The
operators console and chair shall be fixed (non-rotatable) and mounted on the same
base. The access to the seat shall be via outside and front of control console.
(3)
Spreader Landing (Amber) and Lock (Red), Unlock (Green) indicating lamps
in a box fitted at lower (middle) front part of the cab.
(4)
Window wipers and washers

Wipers and washers to ensure the view angle required for operation. Wipers and
washers shall be fitted to front and side windows.
(5)
Communication equipment (refer to 5-6).
(6)
Split type air conditioning unit.

Minimum 12,000 BTU Hr. Capacity.
(7)
Service outlet (two 13 amp, 220V, 50Hz with NFB).
(8)
Lights and light switches.
(9)
A foot rests for the operator (position to be adjustable for each operator).
(10)
D. C. outlet for radio communication equipment

See Section 5-3.2 (6), (7) for details of this power supply complete with a battery
relay to cut off battery supply after 300 - 500 seconds.
(11)
3 KW capacity heater (flat type) with manual heat level adjuster (independent of air
conditioning unit).
(12)
Safety bars wherever necessary to prevent accidental fall of the operator or

maintenance staff.
(13)
Siren foot switch (or call for emergency warning sound). For details see 6-5.1(2)
for full description on the common amplifier.

Page: 33
(14)
One (1) - 2 kg CO2 fire extinguisher at outside near the door.
(15)
2 Spare MCBs 220V, 1-phase, 13 Amp capacity.
(16)
Coat hook.
(17)
A foldable chair embedded into the wall at suitable level for use by operator trainer
or a second operator inside the cab. The foldable chair shall be able to swing back
to the wall with a latch when not in use and shall mount flush on the wall surface.
(18)
Spreader height indicator.
(19)
Container load indicator.
(20)
Demisters to lower front and floor windows shall be installed to cover full glass
area.
4-6.6. Checkers Cab

NOT USED
4-7.
Personnel Lift
NOT USED.
4-8.
Headblock
4-8.1. Headblock
The Contractor shall propose a direct reeve-in type spreader, which does not have a separate
headblock frame. (See 4-9.2 below). The headblock shall be designed fully adaptable to the
existing spreaders (Bromma YSX40E) using for operation.
(1)
Fittings
The major fittings on the spreader are as listed below. All components on the
headblock shall be laid out to maximise operators front view. The dimensions,
sizes for all bolts, nuts, couplings etc shall be SI units (metric).
i)
Main hoist sheave blocks. Arrangement to minimize the spreader rocking

motion.
ii)
Baloney cable tub with guide ring.
iii)
Platform with handrails with access openings. Necessary access ladders to

the ladders on the spreader shall be fitted.
iv)
A set of quick release pins and linkage to connect spreader. The pins shall
be positively locked in either Locked or Unlocked position, which will be
clearly indicated on the frame to be seen from outside.

Page: 34
Quick release pins shall be designed as a permanent component, which do

not require replacement due to fatigue for the life of the Crane. The fatigue
loading conditions shall be as specified in 2-7.8.
For quick release pins type, each pin shall be fitted with a limit switch to
detect the completely locked condition. Two triangular type guiding pieces
on both sides of the spreader to match the triangular slots on headblock
shall be used to guide the headblock onto the spreader so that the pins can
go through easily to shorten the time for spreader replacement. Each pin
shall be fitted with a seat and a handle for pushing in and pulling out
operation. A special device to pull down the head block shall be provided
to reduce the time for the spreader replacement process.
v)
An electrical connector for the feeder cable for the spreader. For
standardization purpose, the electrical connector shall be ODU type 310 55
poles.
vi)
Anti-sway or skew devices, if any.
vii)
Limit switches, junction boxes, etc.
(2)
All the fittings shall be securely fitted to the spreader to withstand frequent impact of
landing.
(3)
The design to allow full access to the spreader terminal boxes and spreader control
unit from either front or rear side for manual test operation while the spreader is
engaged to the headblock. An interface shall be provided for remote accessing the
spreader control system and shall enable full simulation and operation of all
functions of the spreader at site during fault diagnostic by using the portal control
panel (Refer to 6-9.4 (1)).
4-8.2. Two Wire (Bus) System

CANOpen type communication system shall be provided for spreader signal communication
between spreader and spreader control panel installed in the operator cabin.
The two wire system shall also be able to communicate with the IFM system using on the
existing spreaders for interchanging.
4-8.3. Baloney Cable
4-9.
(1)
Baloney cable shall have at least 42 nos. 3.5 sq. mm conductor wires.
(2)
All the wire connection shall be designed to withstand frequent impact of landing.
Spreader, Hook Beam

One telescopic spreader shall be provided with the crane. The configuration and rated
capacity of the spreader shall be as referred to in 2-7.1 (4). The spreader connections
electrically and mechanically shall be fully compatible and interchangeable with the
spreaders (Bromma YSX40E) currently operating in the terminal. The Contractor is

Page: 35
required to verify and hence design for the interchange-ability of all spreaders. The spreader
shall have the following general requirements: 4-9.1. Single Lift Telescopic Spreader
(1)
(2)
Spreader Frame
i)
The structural frame shall be designed and constructed to have adequate

safety factors to prevent premature fatigue failure within 2 million load
cycles for which the criteria is set out in 2-7.8. Flared guides shall be
provided at 4 corners of upper surface of the frame if headblock design is
applied. The bottom plate of the twist lock box shall have a hardness of
HS26 or more to reduce wear.
ii)
Access ladders from front and rear side to the platform on top of the head
block shall be fitted to the main frame.
iii)
The spreader frame design to allow 100mm clearance between the lowest
point of spreader frame and top of container when the spreader is landed on a
container.
Spreader Hydraulic Unit

NOT USED.
(3)
Spreader Twist Lock

i)
Twist lock shape to fit ISO corner fitting.
ii)
Twist locks shall be floating type and fitted with sleeve type twist lock
guides. A greasing nipple shall be fitted at a suitable position of the sleeve
guide so that grease can be injected into the sleeve for lubrication between
the sleeve and twist lock shank. Spherical washer and split ring collar (collet
type) load bearing system shall be provided to transmit the twist lock load to
the spreader end beam.
iii)
Twist lock movement from Unlock position to Lock position shall be

prohibited by a mechanical and electrical interlocks unless four twist locks
are confirmed to be fully inserted into corner fittings and the spreader is
landed onto a container.
iv)
Twistlock movement from Lock position to Unlock position shall be

prohibited by a mechanical and electrical interlocks unless complete landing
of the spreader is confirmed. Main hoist motion is to be prohibited unless
physical positions of all of the twist locks match the Lock or Unlock
command switch position on the control console. A method of direct twist
lock sensing is preferred.
v)
For spreader indication lamps in the cab, refer to 4-6.5. (3)

Page: 36
(4)
(5)
vi)
The design life of twist lock main assembly shall be minimum 2 million
cycles.
vii)
NOT USED.
viii)
The hoisting motion shall stop immediately if only one side (2 twist locks)
is locked inside two corner castings and the other side (2 twist locks) is
locked outside the corner casting.
ix)
A twist lock counter shall be provided on the spreader. For function refer to
4-9.1(10).
Spreader Flipper, Side Guides

i)
Four (4) - power operated side guides (easily and quickly be removable)
shall be provided.
ii)
Side guides shall be capable of handling 8-0 wide containers and 8-6 wide
containers with corner fittings at 40 container lifting points. The side guides
must act on corner fittings of the containers. Changeover to 8-0 or 8-6
shall be controlled from the operators cab. Maximum width of side guides
to conform to the dimensional restriction as stated in 2-7.2 (3).
Spreader Telescoping
i)
Telescoping guide shoes or rollers shall be designed to allow easy and quick
access and simple adjustment. Replacement of guide shoes shall be able to
be performed without dismantling main frames.
ii)
Mechanical stoppers shall be fitted for 20 and 40 positions. Such stoppers

shall be automatically engaged following operators command for desired
spreader length.
iii)
Operating time for extension or retraction shall be less than 30 sec for 2040.
The telescopic motion shall allow for approx. 3 seconds slow motion period
after start and before stop of telescopic motion to minimise impact of
start/stop on the driving system.
iv)
(6)
Telescoping mechanism shall be fitted at middle of the 20'-40' spreader

complete with electrical and mechanical equipment. All this equipment
shall be easily accessible for minimum down time.
Spreader Landing Probe

i)
The landing probe shall positively detect the landing of the spreader on the
container.
ii)
The landing probe shall be arranged to detect landing on a flat circular

surface area of 150mm diameter around twist lock hole.

Page: 37
(7)
iii)
The landing probe diameter shall be 40mm minimum.
iv)
The hole for the landing probe on the bottom plate of twist lock box shall be
chamfered to prevent jamming of the probe.
Spreader Lifting Lugs

Lifting lugs for handling a damaged container or an odd shaped cargo with slings
and shackles shall be fitted at four corners near each twist lock and 2 each at about
one third point from each end of the main frame (total 8 lugs on spreader).
(8)
Spreader Protection
i)
All mechanical and electrical components fitted on the spreader shall be

protected from frequent impact and vibration of operation. All related
fasteners shall be anti-loosening type.
ii)
All the electrical cables connected to the moving parts of the spreader shall
be properly protected from damages due to interferences with stationary
parts.
iii)
All the electrical parts including solenoid valve shall be protected from the
weather.
iv)
Mechanical twist lock counter and spreader operating hour meters shall be
fitted on the spreader.
v)
All solenoids (with LED indicators) shall be protected from electrical surge
by use of proper surge absorbers.
vi)
Each individual position sensing proximity switch for twist lock Locked
and Unlocked with LED indicator positioning shall be connected
individually to the I/O unit in order to prevent any mis-indication and unsafe
movement of twist locks caused by short circuit of any proximity switches
failed during operation. Such short circuit status of a failed proximity switch
shall immediately prohibit the main hoist or lower function until a new
replacement proximity switch is in place.
Alternatively the Contractor is allowed to use fail to safe roller lever type
limit switches
vii)
(9)
The Contractor shall consider that the landing probes at the 4 corners of the
spreader can be fitted with 2 limit switches to detect empty spreader
condition, landed condition and loaded condition with a container under the
spreader. The electrical circuit shall be able to identify all 3 conditions as
shown above to avoid lifting a container by one end of the spreader.
Visibility for Spotting

Page: 38
The inner lower edge lines of twist lock boxes of the spreader to be clearly visible by
the operator for spotting the spreader onto the 40 or 45 container.
(10)
Spreader Meters and Indication.

i)
A twistlock counter shall be fitted on the spreader. The counter is required to

record actual number of boxes loaded and unloaded by the crane. As such
the counter shall be designed to register one count when the following
combinations
of
motion
are
detected
locked.
hoisted.trolley.lower.unlock.
ii)
A spreader operating hour meter shall be fitted on the spreader (power on

cumulative hour).
4-9.2. Reeve in Spreader

The Contractor shall propose a direct reeve-in type spreader, which does not have a separate
Headblock frame. In this case the sheave block shall be attached to the spreader through
hand operated quick release pins, which are positively lockable, and the baloney cable shall
be connected near the cable tub with a multi-pin connector of Pile National. Safe and
appropriate platforms and access to operate the quick release pins and the baloney cable
connector shall be provided. The total number of the quick release pins shall be four (4).
These quick release pins shall be designed as a permanent component which does not
require replacement due to fatigue for the life of the Crane under loading conditions
specified in 2-7.8.
5. Inter-Functional Systems & Components

5-1.
Mechanical System/Components
5-1.1. Bearing, Seals

(1)
All the bearing shall be anti-friction bearings except for the shafts or pins with a
limited small angle rotation such as the gantry truck equalizer pins or equalizer
sheaves. For all types of bearings, effective means of lubrication and seal shall be
provided.
Oil less bearing or oil less bush is not allowed.
(2)
The bearing design shall be based on following life as a minimum requirement.

For main hoist system :
For trolley travel system:
For gantry travel system:
(3)
40,000 hours
40,000 hours
40,000 hours
Bearing housing or retainer shall be a split type or bolt-down type to facilitate fast
inspection and replacement work.
5-1.2. Gearing

Page: 39
(1)
The life of main hoist gearing design shall be specifically based on 300,000,000
accumulated number of reducer output shaft revolution.
(2)
Open gears are usually not allowed unless itemised approval is granted from the
Purchaser.
(3)
All open gears, if applied, shall be properly covered or guarded for safety with
covers or guards. The cover or the guard shall be easily removable and have
adequate ports to lubricate and check the gears. Oil or grease tray of a removable
type under each gear shall be provided to receive excess lubricant.
5-1.3. Gear Reducers

(1)
The gear boxes shall be fitted with effective gear inspection windows, weather proof
breathers and oil level gauges. The gear boxes shall be free from oil leakage. Dip
stick type oil level gauge is specifically not allowed.
(2)
The gear boxes shall be designed to allow easy replacement of gear or gear shafts
without removing the whole gear box assembly from its mounting base.
(3)
Drain pipes with shut off valves and end plugs shall be fitted to each gear box. An
appropriate drain receiving space for each drain outlet shall be provided.
(4)
The bearings in each gear reducer shall be from single bearing manufacturer.
5-1.4. Wire Rope Winch Drums

(1)
The main hoist drums shall be of rolled welded steel construction, statically
balanced and complete with machined grooves for single layer winding of wire
ropes.
(2)
The grooves on the drum shall be pitched so that there is clearance between
neighbouring turns of rope on the drum and also clearance between the part of the
rope leading onto, or leaving the drum, and the adjacent coil.
(3)
The bottom of the grooves should have a circular arc over an angle of not less
than 120 degrees and the radius of the groove should not be less than 5% or more
than 7% larger than the nominal radius of the rope.
(4)
The diameter of the drum at the bottom of the groove shall not be less than 30
times the nominal rope diameter.
(5)
The maximum angle of fleet between the rope and a plane perpendicular to the
longitudinal axis of the drum shall not exceed 2 degrees.
(6)
The drum shall be flanged at both ends.
(7)
The wire ropes shall be secured to the drum by a suitable clamping device. The
design of this device will be subject to review by the Purchaser at the design stage.

Page: 40
(8)
The length of the hoist drum and wire ropes shall be such that when the headblock
is at its lowest specified point at least three full turns of rope shall remain on the
drum, and when the load is at its highest possible point at least one empty groove
shall separate two adjacent ropes, depending on the drum configuration.
(9)
Attention should be given to the recommendation in BS.6570 1986.
(10)
Wire rope winch drum shall have machined grooves sufficient to lay wire ropes in
single layer. One extra turn for services and appropriate number of dead turns for
each wire rope end shall be allowed for on the drum.
(11)
The wire rope clamp shall be bolted clamp plate type.
(12)
Oil or grease tray of a removable type adequately segmented for easy removal by
hand shall be provided under each wire drum to receive excess lubricant. Prevention
against overflow of oily water out of trays during rainy operational condition shall
be taken into consideration.
(13)
A removable screw lockable hinged cover over the wire drum shall be provided to
prevent wire lubricant being washed off by rain or melted by the heat of the sun. A
proper support to keep the cover in the opened position (withstanding the wind) shall
be provided.
(14)
4 steel pipe type strong duty wire rope guards shall be fitted at mid level of the wire
rope winch drum to protect the wire ropes from entanglement when spreader is at
its maximum height emergency position.
The clearance between main hoist wire rope and the surface of the guards shall be
equal to half of the wire rope diameter.
5-1.5. Wire Rope Sheaves

(1)
All wire rope sheaves shall be of centrifugally cast or forged steel construction
with smoothly machined grooves. Fabricated or gravity cast sheaves are not
acceptable.
(2)
The bottom of the grooves should have a circular arc over an angle of not less
than 120 degrees, have an included angle of 52 degrees and the radius of the
groove should not be less than 7% or more than 15% larger than the nominal
radius of the rope with 11% being the optimum.
The Contractor is to furnish specific details of the proposed sheave profiles.
(3)
Wire rope sheaves shall have a minimum pitch diameter of 30 times the nominal
rope diameter. Guide rollers (fairleads) shall have a minimum diameter of 5 times
the rope diameter and the diameter of equalising shaves shall not be less than 18
times the rope diameter.
(4)
The maximum angle of fleet between the rope and a plane perpendicular to the
axis of the sheave shall not exceed 2.5 degrees.

Page: 41
(5)
The surface of the groove of the sheave shall have a hardness value of minimum
321 on the Brinell Scale. The depth of the material hardened to this level shall be
at least 3mm. A destructive sample test shall be done to demonstrate the
compliance of hardening process.
(6)
All running sheaves shall be fitted with anti-friction roller bearings with grease
fittings for pressure lubrication. White markings shall be painted on all running
sheaves.
(7)
Minimum designed life of the sheave, specifically the groove and bearing retainer,
shall match the bearing life of 25,000 hoists operating hours.
(8)
The pitch diameter shall be at least 30 times the wire rope diameter. An equalizer
sheaves may have smaller diameter provided that the small radius will not reduce the
safety factor of wire rope below specified value.
(9)
Application of hanger sheave (sheave mounted on swinging hanger) is not favoured

and will only be accepted if it can be shown to be necessary to provided minimum
fleet angles on main hoist ropes.
(10)
All sheaves shall be mounted by shaft and supported at both sides. Single side
support with retainer ring is not allowed. If they form part of the anti-sway system.
(11)
All sheaves shall be designed with easy access and with ample space for
maintenance and repair. The clamp and retainer shall be fitted opposite to the wire
rope pulling force direction. Clamp and retainer bracket shall easily be removed for
sheave replacement.
5-1.6. Wire Ropes

(1)
The factor of safety shall not be less than 6 for all ropes.
(2)
Wire rope lubricant shall be carefully selected to minimize the dripping problems.
(3)
Wire rope dead end splice shall be a mechanical splice (wire rope clips and cotter
socket are specifically not allowed), and the dead end fitting shall be articulated to
allow rope end to move freely in long travel and cross travel directions.
5-1.7. Shafts, Axles

(1)
Shafts shall be designed with due consideration for stress concentration at keyway,
necks or other notches. All splines, gear teeth, or threads shall run out smoothly or
shall be undercut and the surface finish shall be uniformly smooth and free from
defects.
(2)
For any long shaft the torsional deflection shall not affect the coupling or gearing
associated with the shaft.
(3)
Gearing axle brackets shall be a split type or a bolted type for simple removal of axle
and bearing.

Page: 42
(4)
Shafts shall be properly covered or guarded for safety.
5-1.8. Couplings
(1)
All main drive couplings shall be supplied by an internationally recognised

manufacturer of couplings.
(2)
Main driving shaft shall be fitted with flexible couplings. All coupling bolts shall be
locked with a proper anti-loosening system such as lock wires. Grease nipples shall
be fitted at OEMs greasing positions.
(3)
Couplings shall be properly covered or guarded for safety. The cover or the guard
shall allow easy access for lubrication of the coupling without removing entire cover
or guard.
(4)
For any spline coupling a wear indicator with visible wear limit mark shall be
provided. The grease nipple for the spline coupling shall be extended to the edge of
the main hoist winch drum to facilitate easy maintenance.
(5)
A proper label in Polish shall be fitted at a conspicuous place to remind the greaser
to carry out greasing in accordance with the maintenance plan.
5-1.9. Metal Wheels

(1)
Trolley wheels shall be double flanged type, forged steel wheel with hardened tread.
Minimum designed life shall be 40,000 trolley operating hours. If guide rollers are
required, the guide rollers shall be designed to have a minimum operating life of
25,000 trolley operating hours. Prevention of falling down of guide rollers when
failed shall be taken into design consideration. In normal operating condition, the
guide rollers shall not cause any damages to the rail or associated fixtures.
(2)
Gantry tyre wheels shall be for tubeless pneumatic tyres to fit for tyres of
international size. The wheels and rims shall be designed for the whole life of the
Crane; the internal surfaces of the wheel, i.e. the area that will be within and
covered by the tyre when fitted shall receive an anti-corrosion treatment in
accordance with the following clauses:
-
blasting 6-3.3
painting 6-3.4 and 6-3.5
5-1.10. Pins, Pin Brackets

(1)
For the pins which require jacking or pulling for dismantling, adequate space for a
jack or a puller shall be provided.
5-1.11. Bolts
(1)
All bolts are to be manufactured to ISO-metric standard.
(2)
Tightening torque for all fitting bolts shall be clarified by the Contractor in a form of
a bolt list clearly indicating bolt location, size, materials and quantities.

Page: 43
5-1.12. Lubrication
(1)
All the moving parts shall be effectively lubricated.
(2)
All the lubricant specified by the Contractor shall be locally available. The
lubricants initially filled in manufacturers shops shall be pre-approved by the
Purchaser for their compatibilities with those lubricants used by the Purchaser.
(3)
Any excess lubricant shall be trapped in removable trays or receivers.
(4)
All greasing nipples shall be stainless steel.
(5)
Compressed air pipes shall be installed from the ground to the girder. Two (2) air
inlets shall be provided at ground level for connection to air compressor. Two air
outlets shall be provided on the girder.
5-1.13. Bumper, Buffer

Trolley buffers shall be fitted above the trolley platform at the four corners of the trolley
frame. The buffers shall be capable of absorbing and dissipating the impact of collision at
full speed with rated load. The buffer shall be of sufficient stroke so as to decelerate the
trolley at no more than 4.90m/sec sq. (0.5G) at 50% rated trolley speed.
5-1.14. Rubber Tyres
Gantry tyre wheels shall be for tubeless pneumatic tyres to fit for tyres of international size.
Wheels dimensions should be 18.00-25 or 21.00-25.
5-2.
Hydraulically System/Components
5-2.1. Standards
Hydraulic systems shall be designed in accordance with relevant international Standards. As
a minimum all components must be capable of operating continuously i.e. pumps, valves etc.
All hydraulic components shall be manufactured to ISOmetric standard.
5-2.2. Components Sources
All components shall be sourced from internationally approved suppliers and the hydraulic
systems shall use components, which are readily available in Poland and the European
Community.
5-2.3. Operating Condition
Under conditions of continuous operation, the pump inlet temperature of the fluid must not
exceed 65 degrees C. The equipment shall operate efficiently in an ambient temperature
range of minus 20 degrees C. to plus 35 degrees C. The system shall incorporate fluid over
temperature protection which shall operate to indicate the fault and stop the operation of the
pump.

Page: 44
5-2.4. Hydraulic Fluid Reservoir

The type of hydraulic fluid for the initial fill by the Contractor must be pre-approved by the
Purchaser.
All Hydraulic reservoirs/storage tanks shall be provided with adequate drainage facilities to
permit the draining of the hydraulic fluid into waste oil receptacles through shut-off valves
which can be easily accessed. Space shall be provided around and below the drain valve to
allow this essential maintenance work without spillage.
(1)
The capacity of the fluid reservoir shall be sufficient to contain all the fluid that can
flow from the system into the reservoir. The fluid level shall be maintained at a safe
working height to prevent cavitations in the pump during the operating cycle.
(2)
Reservoirs shall be equipped with clearly viewed flush mounted or protected fluid
level indicators. They must be provided with markings indicating high level when
pumps are stopped and low level when the pumps are in operation.
Reservoirs shall be constructed to prevent entry of foreign matter, including fluid
contamination and moisture.
(3)
Both fluid intake and return points shall terminate sufficiently below the minimum
fluid level to prevent aeration.
5-2.5. Power Unit

(1)
Positive displacement pumps and motors are preferred.
(2)
Means and good access shall be provided for filling and draining pump and motor
casings in accordance with the manufacturers specifications.
5-2.6. Valve Mounting

Wherever possible, valves shall be mounted so that their removal and replacement can be
made without disconnecting pipe fittings. Adjustable valves shall be such that their settings,
when made, will be maintained against vibration.
5-2.7. Relief Valve
A pressure relief valve capable of relieving the maximum flow at the outlet of the pump
shall be provided on the delivery side of the pump and there shall be no other valve between
the pump and the relief valve.
Relief valves shall reseat within 3% maximum of cracking pressure, and shall have a
rated working pressure of not less than 150% of operating pressure. Relief valves subject
to changeable back pressure shall be externally drained. Wherever possible, relief valve
shall be used as safety reliefs and shall be set a minimum of 10% higher than maximum
operating pressure. Solenoid operated directional valves shall have oil immersed or wet
pin solenoids. Each solenoid shall have means for external mechanical actuation for
testing. If internally drained, tank ports will not be subjected to more than 1,000 psi or

Page: 45
maximum pressure allowed by manufacturer, whichever is less. External drain lines shall
be designed to minimize pressure surges and reduce backpressure. Four-way valves shall
spring center or spring offset to a failsafe position upon electrical failure.
5-2.8. Flow Control Valve
Variable flow control valves shall show the direction of operation for increase and decrease
of throughput.
Flow control valves shall be pressure and temperature compensated over the full range of
flow for which the valve is rated. Flow setting shall be adjustable and shall have
facilities for locking when proper flow setting is reached. Flow control valves must be
adjustable to zero flow.
5-2.9. Check valves
Check valves may be either ball type or piston type. Swing checks shall not be used.
Check valves shall be spring loaded closed and have zero reverse flow.
5-2.10. Servo Valves
Servo valves shall be rated for maximum operating flow with a maximum pressure drop
of 400 psi across both ports combined. Servo valves shall have non-bypass type 3 micron
absolute full flow filters on their supply lines. Each servo valve shall have externally
adjustable null.
5-2.11. Control Valve
All control valves shall be subplate mounted or cartridge type. Shut off valves, check
valves and needle valves may be line mounted. Maximum flow rates and pressures
through valves shall not exceed manufacturers rated flow and pressure.
5-2.12. Solenoid Valves
(1)
All solenoid valves shall be 220VAC 50 cycles and shall be replaceable without
disassembling the valve or removing it from the subplate or manifold.
(2)
All solenoid valves shall be protected from weather.
(3)
Valves including specifically solenoid valves shall be readily accessible to allow

for any adjustment, operational check, or manual operation in an emergency.
(4)
Solenoids shall have continuous rating and be equipped with an LED indicator for
indicating fault.
(5)
All solenoids shall be fitted with an independent surge absorber to absorb high
voltage spike due to close and open of highly inductive load = solenoid.
(6)
Solenoid valves shall be equipped to provide remote signals to operators cab /

computer control and to central data collecting point.

Page: 46
5-2.13. Piping
(1)
Welded joints in hydraulic pipe work shall not be allowed.
(2)
All rigid piping shall be securely supported to minimize vibration or movement.

The length and method of supporting flexible piping shall be such as to avoid sharp
flexing and straining, particularly at the end fittings. The spacing between adjacent
rigid pipes and between rigid pipes and the surrounding steelwork etc. shall be
sufficient to allow the pipe couplings to be secured with ease and without damage to
adjacent pipes or couplings.
All the piping shall be securely fixed to the structure and shall withstand internal and
external vibration and impact.
(3)
Piping between actuating and control devices shall be as short as possible and pipes
must be removable without dismantling equipment, components or adjacent piping.
5-2.14. Hoses
(1)
Flexible hoses and couplings shall be in accordance with the requirements of the
relevant international Standards and shall be of an approved type and manufacturer.
All dimensions shall be in accordance to SI units (metric).
(2)
Flexible hose shall be protected from mechanical damages due to interference with
structure, equipment, or any moving parts.
(3)
Where the pressure adjustment is critical, a pressure gauge port with shut off valve
shall be provided in the line so that the pressure can be checked without
disconnecting the lines.
(4)
Hoses shall be designed for burst pressures of 70 Mpa and shall be tested at 35 Mpa.
5-2.15. Assembly Test

After assembly, the system shall be hydrostatically tested to 150% maximum pressure.
5-2.16. Catch Basins
(1)
All hydraulic power units will have catch basins to collect leakage for the power
unit and its components. The basin shall be sized to a minimum of 10% of the
reservoirs volume.
(2)
Catch basins shall be fitted with a manual valve equipped with drains. The drains
shall either be accessible from crane walkways, machinery decks, the wharf, or
from the trolley. Space shall be provided for a container to accept the drained
fluid. Where the catch basin is compartmentalized, the various compartments
shall be piped together to form a single drain point.
5-2.17. Filters

Page: 47
(1)
Filters shall be full-flow, non-bypass type complete with visual condition monitoring.
The filter may generally be fitted either in the intake, pressure, or return lines and
shall have a 10 micron nominal filtration rating. When the filter is installed in the
pressure or return lines the pump intake shall be fitted with a wire mesh screen (100
mesh or finer).
(2)
The filter shall be easily accessible for element replacement purposes without having
to drain the reservoir and/or system.
(3)
A suitable magnet should also be fitted in the bottom of the reservoir between the
return side of the reservoir and the suction strainers. Magnets shall be easily
removable for cleaning.
5-2.18. Heat Exchangers

Heat exchangers shall be installed and shall be air/ oil type sized to limit the maximum
reservoir oil temperature to 48 deg c. All heat exchangers shall be provided with bypass
valves to limit maximum operating pressure to 100 psi or less.
5-2.19. Actuator
All actuators shall be laid out to allow easy removal and reinstallation.
5-2.20. Application for Spreader
NOT USED.
5-2.21. Couplings
(1)
Quick release couplings shall be provided and ample space provided between
couplings for coupling and uncoupling of hoses.
(2)
The quick release couplings shall be match marked with ferrules on the connecting
ends.
5-2.22. Gauges
(1)
A delivery pressure gauge shall be provided. The gauge shall be connected via a
fail to-safe valve and damping loops, and rigidly mounted on a structure. It can
only be read by operation of a fail safe valve.
(2)
An oil level gauge on the reservoir shall be provided at a location convenient for
inspection by direct eye-sight.
5-2.23. Covers
Any cover for the hydraulic system must be manufactured in order to allow prompt and
direct access to manually check the solenoid valves. This should be allowed without the
need to remove the whole cover.
5-2.24. Hydraulic Fluid

Page: 48
The type of hydraulic oil for the initial fill by the Contractor shall be pre-approved by the
Purchaser.
5-2.25. Load Sensing System
The load sensing system shall include the installation of 4 No. compression type load cells.
The Contractor shall make use of the load sensing system to measure and record the weight
of each lifted container. The weight of the container shall be registered in the Purchasers
RDS.
5-3.
Electrical & Electronic System/Components
5-3.1. General
Electrical system shall be designed to allow for simultaneous operation of Main Hoist and
Trolley motions, and Gantry and Trolley motions.
5-3.2. Main Power Supply
(1)
Main drives A.C. motor voltage and control power voltage to be proposed by the
Contractor.
(2)
A.C. motors - A.C. 380V 3-phase 50Hz.
(3)
Lighting
(4)
Alarm, intercom and other accessories - A.C. 220V 1-phase 50 Hz.
(5)
Window wiper and washer - D. C. 24V.
(6)
Radio communication equipment D.C. 24 V (5 Amp) and D.C. 12V (10 Amp)
- A.C. 220V 1 - phase 50 Hz.
5-3.3. Power Factor Correction

The power factor of the entire system under normal working condition shall be not less than
0.9.
5-3.4. Protection Against Power Surge
All electrical and electronic equipment shall be protected by transient surge suppressor
installed as close as possible to each equipment, which requires protection from the surge
in power and control circuit. The transient surge of the power supply shall be recorded as a
permanent record for information to the maintenance personnel that there has been a surge
in the line at specific time of such occurrence. Any electrical apparatus or device on the
Crane or device on the Crane which may introduce a surge shall be properly designed to
suppress surge within its own environment and shall not cause any interference to other
equipment or control functions of the Crane. The followings are, but not limited to,
particular areas which require special attention in terms of the transient surge suppression.
i)
The incoming circuit shall be protected by suitable surge absorbers on A.C. three
phase power supply lines to stabilize the incoming power in case of any surge in the

Page: 49
A.C. circuit.
ii)
All rectifiers from A.C. to D.C. shall be protected by surge absorber on the A.C.
side as well as the D.C. side to have a clean D. C. output and with a suitable zener
diode to maintain the voltage at optimum level.
iii)
All A.C. contactors, D.C. contactors and relays shall be connected in parallel with
suitable surge absorber to absorb transient surge due to make and break of coils
contact and minimize the disturbance of voltage to the sensitive areas within the
Crane.
iv)
All hydraulic solenoids shall be connected with surge absorber to be protected from
any induced voltage which may cause burn off of the solenoid during operation.
v)
Critical items such as Programmable Logic Controllers, computers and I/O modules
shall be protected from external transient surge by independent surge absorber on
their power supply line.
vi)
Any other items considered vulnerable to any transient surge must be properly
protected from transient surge to minimise interruption of Crane operation.
vii)
All brake coils shall be protected with an arrestor over voltage protection.
5-3.5. Protection against voltage dip/loss of power supply

(i)
The power supply electrical circuit of the Crane shall be properly designed to
minimise Crane recovery time in case of power supply failure in form of short
duration voltage dip or a complete loss of power supply.
(ii)
The inverter drive for the Crane shall be designed so that in case of power supply
voltage dip, it shall always trip the under voltage relay before burning the
protection fuses and/or transistors. The electrical circuit shall be designed to
allow simple and quick reset of the system by a push button fitted on the inverter
drive control unit assembly.
(iii)
The A.C. line low voltage power supply beyond the transformer shall be
connected in series with a properly designed A.C. current limiting reactor to
reduce the short circuit current between the transformer and the Converter in case
of a short circuit at the output circuit.
5-3.6. Wiring
(1)
A minimum wire size shall be 3.5 sq mm, except for factory wired panels which
may include smaller size wires.
The Contractor shall ensure that all heavy current low voltage power cables are
sized to include suitable derating for the temperature and space factor. All heavy
current power wires shall be separated. (One group for each motor or electric
device) The mixing of control wires and power wires shall not be acceptable and
will be rejected by the Purchaser.

Page: 50
The Contractor shall submit all calculations on sizing of cables for review by the
Purchaser.
(2)
Wire shall be connected only at the terminal blocks in panels, control box, joint box,
or at the terminal for electrical equipment. Wire shall not be joined other than at
proper terminals.
All conductor wires of 4 sq. mm or smaller shall be terminated at terminal strips and
at components having screw type terminals with spade or ring tongue crimped
solderless lugs.
All wire end terminations shall be checked and where necessary retightened prior to
the Commissioning Test.
(3)
All the wires shall be run in trunking or conduit. Cables shall be laid in orderly
manner and according to the requirements of the IEE regulations. It is preferable
that all the wires are so designed and installed inside the interior of the Structural
System. All the wire run through holes and openings of structure shall be protected
from insulation damages due to mechanical contact with structures. Control and
signal wires shall be separated from power wires to avoid any interference causing
false signals. Mufti-core cables may be run on cable trays or raceways with
adequate cable clamps, and covered with sun-shield and mechanical protection
covers.
(4)
At least 10% of control wires as spare wires shall be installed on all routes and
specifically labelled as such.
(5)
Vertical long distance wiring shall be designed to prevent wire breakage due to
suspension of self weight of wires or cables.
(6)
Wiring on the trolley, headblock and spreader shall be designed to withstand

continuous vibration and impact.
(7)
Each wire shall be fitted with terminal lugs and marked at both ends with ferrule
with number corresponding to the number in schematic diagram.
(8)
Additional cables and terminal boxes shall also be installed for intelligent
identification system.
5-3.7. Marking and Identification

(1)
All conductors (internal and external to panels) shall be suitably labelled at both
ends with hot foil printed, plastic tubing wire markers in accordance with electrical
drawings and wire schedules. All terminal blocks shall be properly marked as to
block number and terminal number per drawings.
(2)
All terminal blocks shall be properly marked with the block number and terminal
number as shown on the drawings.
(3)
Groups of cables entering junction boxes, cabinets, panels and pull boxes shall be
tagged as to location of the other end.

Page: 51
(4)
All panels, boxes and cabinets shall be marked on the outside using engraved
plastic name tags fastened with stainless steel screws containing unit number and
general function, name or description.
(5)
Individual control devices in cabinets shall be labelled by number description in

accordance with the drawings using durable, heat resistant labels with permanent
markings, and fixed in a manner designed to combat extreme hot and cold
conditions over long periods.
(6)
Major control cabinets shall be labelled with engraved plastic description tags
fastened with stainless steel screws.
(7)
The method securing cables within the control panels shall utilise a proper and
correct method of attachment. The use of self adhesive pads to secure the cables to
the panel walls shall not be acceptable.
5-3.8. Conduit and Cable Tray

(1)
Conduit (rigid and flexible), with pull boxes at appropriate locations, shall be water
proof and continuous. Inside of the conduit must be smooth, and inner edges of both
ends must be rounded smooth.
(2)
Flexible conduit (Kopex heavy duty or equal approved type) with proper fittings
shall be used between rigid conduit and pull boxes or terminal boxes of motors,
brakes, limit switches and all other independently installed electrical equipment
which require adjustment, realignment or removal for maintenance or are subject to
vibration.
(3)
Rigid conduits shall be rigidly fastened to the crane structures.
(4)
All conduits shall be contained within the protection of the crane structures.
(5)
No conduit is to be installed across walkways or working platforms or in any way

that could be considered to impede access, safety operation, etc.
(6)
For conduit runs of more than 6 metres a pull wire shall be left in place.
(7)
A drain hole shall be provided at the lowest point in each junction box.
(8)
Ladder type open electrical cable tray shall be hot dipped galvanised finished and
fixed to the structure using stainless steel bolts and nuts. The type and fixing of the
cable tray shall be reviewed by the Purchaser.
Any cut edges on the hot dip galvanised cable tray or ladders shall have the sharp
edges removed by grinding or filing and the raw surface area protected by a zinc rich
primer immediately after suitable cleaning with clean solvent and prior to any
degradation by rust.
5-3.9. Electrical Trunking

Page: 52
(1)
Electrical trunking and trunking covers shall be free from sharp edges or sharp
corners to protect the wires.
(2)
Trunking shall have appropriate partitions to separate power and control wires, and
clamps to prevent excessive wire movement in the duct.
(3)
Trunking shall be designed to prevent water ingress. Nevertheless the trunking shall
not trap any water in case of water ingress.
5-3.10. Motor
(1)
The construction of all motors shall meet the requirements of BS 4999. The motors
shall be sized according to FEM 3rd edition, booklet 4 Selection of Motors. The
minimum rating and duty of the motors, designated according to IEC 34-1 standard,
shall be as follows:
Motors
Main Hoist motors
Trolley travel motors
Gantry travel motors
Minimum Ratings required

Continuous rating, duty type S1.
Continuous rating, duty type S1.
S2 duty type, 60 minutes rating.
All AC motors shall be totally enclosed non-ventilated (TENV) type of IP 55

protection. All exposed moving parts of motors shall be adequately guarded.
Motors for hoist and trolley shall be mounted horizontally.
(2)
Motor terminal box shall be fitted facing an open space for maintenance.
(3)
All the main motors shall be fitted with space heaters.
(4)
Ample space shall be provided for inspection of AC Induction motor itself.
(5)
The main hoist motor and brakes shall be fitted inside an 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.
(6)
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.
(7)
All motors shall be connected with an earthing wire from the motor body to the
nearest support metal structure to provide a proper earthing connection.
5-3.11. Brakes
(1)
Ample space shall be provided around brakes for inspection and maintenance works.
(2)
Brake disc shall be dynamically balanced.

Page: 53
(3)
Brakes disc shall not sustain damages due to an emergency stop operation.
(4)
Main hoist and trolley brakes shall be a peak impact damping type approved by the
Purchaser. The deceleration shall be accompanied electrically and regenerative with
the brakes applied only when the motion has slowed down to essentially stopped
condition
(5)
Brake linings to be of non-asbestos material.
(6)
The main hoist brake shall be protected from ingress of grease from external
rotating machinery.
(7)
If used, the main hoist thruster disc brakes shall be supplied from an internationally
recognised supplier of brake systems The thruster brake, excluding consumable
parts, shall have a life same as the crane
(8)
The main hoist thruster brakes and trolley brakes shall be fitted with limit switch to
ensure brake close or open according to the command from the operator through
electrical control at the PLC.
5-3.12. Transformers
(1)
Transformer shall be dry type.
(2)
The location of transformers shall be selected not to raise panel temperature.
(3)
All transformers shall be connected with an earthing wire from the transformer
body to the nearest support metal structure to provide a proper earthing connection.
5-3.13. Resistors
(1)
Regenerated back E.M.F. absorption resistor bank shall be installed independent of

electrical control house (panel house) in a position where it will not raise the
temperature of control panels.
(2)
Resistor banks shall be protected from weather and properly shielded or fenced off
to avoid accidental contact by operational and maintenance staff.
(3)
The Contractor shall ensure that the resistor banks have correctly designed
removable louver covers in order to provide adequate cooling inside the resistor
box. The design of the louver covers shall not allow the ingress of water under
any circumstances.
5-3.14. Enclosures
All external components mounted inside outdoor enclosures must be designed to allow for
wind driven rain and conform to minimum class of IP55.
5-3.15. Meters, Counters

Page: 54
(1)
All the meters shall be installed at the height not exceeding 1.7m from the floor level,
but not below 1.2m from the floor level. All counters and meters shall be
mechanical type unless specified by the Purchaser.
(2)
The following individual meters and counters shall be installed in addition to

ordinary meters on the control panels.
On the control panel house wall, protected from weather, facing outside in a position
to be easily read by operators or engineers without entering the house.
i)
Operation hour meters for main hoist, trolley travel and gantry travel.
ii)
Twist lock counter (count 1 for [Locked followed by Hoist Lowered

followed by Unlocked])
iii)
Main hoist revolution counter shall be incorporated in the PLC for

300,000,000 hoist wire drum revolutions.
iv)
Net handling hour meter showing hours [main hoist + trolley - (overlap of
hoist & trolley)].
The connection of this meter shall be by parallel connection of hoist brake
(Normally open) contact with the trolley brake (Normally open) contact
then connect the meter in series with the above two contacts to an AC
source.
5-3.16. Limit Switches

(1)
All the limit switches shall easily and quickly be accessible for adjustment and
maintenance. All limit switches shall be adjustable in X, Y, and Z directions.
(2)
Application of proximity switch shall be fail-to-safe application. Short circuit

status created within the switch at the time of its failure must prevent further motion
which is controlled by the switch, and such short circuit fault must be registered for
tracing.
(3)
Special attention is drawn to the twist lock Locked and Unlocked signals from
the proximity switches, which are not fail-to-safe. In order to avoid damage to the
spreader and the container by lifting one end only, the proximity switches for
Locked and Unlocked signal shall be individually connected to the PLC through
an I/O module. The PLC when detected a short circuited proximity switch on
Locked or Unlocked will immediately cut off the hoisting motion. Further
motion will be restricted to lowering only
(4)
The Contractor can propose an alternative system of design incorporating roller

lever type switches for the Purchasers review.
5-3.17. Space Heater

(1)
Space heaters shall be fitted to the following locations

Page: 55
i)
ii)
iii)
(2)
All AC motors for main hoist, trolley and gantry travel.

Limit switch enclosures.
All control panels.
An indication light shall be installed external to each space heater location in order
for the maintenance team to easily identify that the space heaters are functioning
correctly.
5-3.18. Name Plate

Electrical equipment shall be supplied with a nameplate immediately adjacent and
symmetrical to the equipment. These nameplates shall contain appropriate inscriptions or
identification markings to convey all relevant information appertaining to the characteristics
of the equipment.
5-3.19. D. C. Power Supply
The DC power supply shall be able to self regulate the output DC voltages to a constant
value against variations in the input AC supply voltage. There shall be sufficient cooling /
heat dissipating ability for the DC power supply.
5-3.20. Encoders
Electronic absolute encoders shall be used for position feedback for main hoist and trolley
travel.
5-3.21. Sensors
All sensors installed on the spreader shall be wired in parallel.
5-3.22. Circuit Breakers
1.
All electrical circuit breakers shall be molded type circuit breaker, except
otherwise specified.
2.
Circuit breakers shall be designed to isolate defective circuits such as over current
or short circuit conditions.
3.
When the molded type circuit breakers are tripped, the lever shall stay at mid
position to show that it is tripped. The lever shall be pushed down once before it
can be switched on again. Mid position of the lever is to show that the outgoing
circuit is faulty.
4.
Earth Leakage Circuit Breakers (ELCB) shall be used to protect the flood light
system in individual branch so that only the affected area will lose the lighting and
not the other healthy circuits.
Circuit breakers shall be fitted indoors only. If fitted outside, it shall be enclosed
inside a waterproof stainless steel box.

Page: 56
5-3.23. Auxiliary Power Socket

The Crane shall be equipped with an emergency power connection socket. This socket shall
be connected to the output side of transformer set (on secondary side, low voltage) in the
electric circuit and equipped with the mechanical selector switch and interlock for the
changing of power supply (shore power through transformer / auxiliary power). The
emergency connection socket shall give the possibility to connect auxiliary power source
supplying to the crane in case of emergency such as damage of the shore cable or cable reel
etc.
The Contractor shall submit the circuit diagram to the Purchaser for review during design
stage.
5-4.
Crane Motion Controls
5-4.1. Control System General

The Crane control system design shall be based on a control system incorporating a
programmable logical controllers (PLC) designed to the latest industrial standards. The
programmable logical controllers are to be installed in the machinery house and operators
cab which is operated in following environment and operating conditions. An external
environment which ranges from +40C and 100% humidity to -20C.
(1)
Environment - The entire system shall be designed to be operated in where

installations are subject to prevailing heavy condensation. Equipment shall also be
protected so as to resist the entry of small insects. All components shall be
tropicalised-treated.
(2)
Degree of Protection - A minimum IP class (IEC 144 and 529) of IP41 is required
for all in house, enclosed installations. Equipment of installations at open, exposed
atmosphere shall have an IP class of IP55 as a minimum degree of protection.
Finger protection against electrical hazard to operators or maintenance personnel
shall be equipped according to the latest industrial standards.
(3)
Ambient Temperature - The system shall be designed to be operated in the

atmospheric conditions surrounding the electrical components may be modified by
systems that are proven and reliable e.g. heaters or air conditioning provided that the
total system is fail safe.
(4)
Relative Humidity - The operating and storage humidity of this system shall have a
range from 8% to 99% (non-condensing).
(5)
Vibration and Shock Resistance - The entire system shall be designed and installed
with an adequate vibration and shock resistance of not less than 16.7 Hz at a 3
dimensional amplitude of minimum 3mm in vibration and 10G in shocks. This
value shall be equivalent to JISO911 IIB - class 3 and JISO912 respectively.

Page: 57
(6)
Operating Voltage - The system shall be designed and operated with a power supply
of 220VAC, single phase with an electrical potential tolerance of 10% and a
frequency of 50Hz with a frequency tolerance of 2%. The Contractor shall install
harmonic filters and power surge absorbers as a standard feature. The system shall
have a minimum isolation resistance between external circuits and internal circuits
of 50M ohm at 500VDC. An isolation voltage of up to 1500VAC for 1 minute is
also required.
(7)
Duty Cycle - The system shall be designed to be operated 24 hours a day for the
whole year round with a mean time between failure (MTBF) at the component level
of not less than 30,000 hours and an operational mean time to repair (MTTR) of not
more than hour per component replacement and module replacement. The
operating availability shall be not less than 99.997% per every continuous duration
or period of 3 months.
(8)
One unit of Uninterrupted Power Supply (UPS) with a minimum of 15 minutes shall
be provided to enable the system to back up all status data for an orderly shutdown
in case of power failure so that all previous status data can be retrieved and safe
operation can be resumed when the power is restored.
The UPS shall support the following equipment during power failure:
(i)
(ii)
(iii)
(iv)
(v)
PLC and discrete I/O modules.

Public address system
Intercom system
Crane computer system and on-board CCMS.
Trunk radio
5-4.2. Programmable Logical Controllers (PLC)

(1)
The PLCs shall be of cartridge-insert type design with a rack that can provide the
installation of power suppliers, I/O modules (as specified in the related clauses), etc.
in a compact and low operating cost environment.
(2)
The PLCs shall be able to intercommunicate with each other through a network
following the Open System Interconnection communication architecture. The PLCs
shall comply with the requirements of IEC 11311 1 and 11311 2.
(3)
The racks shall be industrial type with a capability of expansion via simple
communication interface between and among the racks. It is preferable to have a
racking system of a minimum slot or cartridge-insert space for at least 8 modules
which excludes the slots or cartridge-insert space for the power supply and CPUs.
(4)
The racks shall have a back-plate communication design and back-plate power
supply distribution system. This is to achieve maximum feasibility in module
replacement as well as minimize the mean time to repair when it is required.
(5)
The PLCs shall have multi-tasking, remote communication capabilities and

supporting interrupts. The input interrupts shall be hard wired to the front of the
logic processor module. When triggered, the logical processor immediately halts the

Page: 58
execution of the main control program and executes the interrupt routine associated
with the given input interrupt.
(6)
The PLCs shall have sufficient memory capacity to hold control algorithms for more
than one process plus at least 30% redundant memory capacity. The program shall
be stored in EEPROM and RAM. Facilities shall be incorporated on the PLCs to
enable programming of the EEPROM. There shall be facilities and space provided
for adding memories for future developments.
(7)
The complete cycle time of crane software inclusive of scanning all I/O modules as
well as execution of control modules in one cycle shall not be more than 30
milliseconds.
(8)
The communication cables in between PLCs shall have 100% spare cables.
(9)
All parameters adjustments and internal settings of the Drives shall be available on
the PLC.
5-4.3. Power Supply

(1)
The power supply unit shall be a high efficiency, low loss, cartridge-insert type
design with a fuse protected, surface mount input plug for connecting the main
supply mounted to this power supply unit.
(2)
LED shall be equipped to show the healthy status of the incoming supply and the
outgoing supply. This shall be a standard feature of this power supply unit.
(3)
The rating of the power supply shall be at least 25% more than the total normal
consumption of all the modules that are connected or that are going to be connected
in future.
5-4.4. Discrete I/O Modules

(1)
The discrete I/O modules shall be designed from the latest industrial standards with
cartridge-insert type installation and the modules are expected to be operated under
an environment which is specified in 2-7.6.
(2)
The discrete I/O modules shall be designed to have an I/O points with 8, 16 and 32
in steps. All the I/O points shall be equipped with screw type fixtures, additional
plug-in interfacing plugs or "swing arm" configuration for easy maintenance will be
an advantage. All solid state output points shall be protected with quick-burnt fuse
for system protection. Replacement of the quick-burnt fuse shall require no
dismantle or disassembly of modules and racks. The I/O modules shall be equipped
with LEDS which show the status of the inputs and outputs.
(3)
The maximum signal delay of the 'on' and off' status of the output modules shall not
be larger than 1ms and 9ms respectively. At the same time, the maximum signal
delay of the 'on' and 'off' status of the input modules shall not be greater than 20ms
and 25ms respectively.

Page: 59
(4)
The discrete I/O modules shall be equipped with a removable tab for wiring
identification.
(5)
There shall be at least 20% spare I/O ports. Space in the cubicles or junction boxes
for adding I/O modules shall be provided.
5-4.5. Real Time Clock Module

(1)
The real time clock module shall be industrial type with a cartridge-insert type
design. The real time clock module shall have the following seven date and time
functions:
i)
ii)
iii)
iv)
v)
vi)
vii)
Day of the week

Year
Month
Day of the Month
Hour
Minutes
Seconds
(2)
The real time clock module shall have an accuracy of not more than 60 seconds per
year in temperature range from -20oC - 50oC.
(3)
The module shall have the capability to register the event logs together with the time
clock and then send the logs to the communication module when command is
executed.
5-4.6. Motion Control Switches in Operators Cab

(1)
Main hoist and gantry motion control (right console)

A right-hand control console shall control main hoist and gantry motion with one
joystick controller. The controller shall be spring returned and lockable at zero notch
and released by push button switch incorporated into the controller joysticks. Fore
and aft movement for main hoist lowering and hoisting, left and right movement for
gantry travel. Selection of motions on first-come-first-served basis. Cross interlock
device shall be incorporated to the joystick controller.
(2)
Trolley motion control (Left console)

A left-hand control console shall control trolley motion with one joystick controller.
The controller shall be spring returned and lockable at zero notch and released by
push button switch incorporated into the controller joysticks.
Other motion control switches or control buttons shall be ergonomically laid out on
control consoles.
(3)
Following motion control switches shall be laid out on both consoles similar to
existing cranes (refer to Appendix IV). Telemecanique type motion control switches
are preferred.

Page: 60
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
Twist lock Lock/Unlock changeover switch.

Flipper selector switch for Left side, Right side.
Flipper Raise/Lower changeover switches.
Spreader Extend/Retract control switches.
Spreader Skew/Trim joystick.
One push button switch to automatically correct spreader position to Zero
Skew position.
Window wiper On/Off switches.
Window washer On/Off switches.
Warning siren push button switch. This warning siren push button switch
shall activate the same amplifier speaker as the landing by-pass, twist lock
by-pass alarm sound.
Other control switches necessary for normal operation.
Two emergency stop push buttons on each side console.
-
to cut out main hoist, trolley and gantry power.
to turn off the whole crane.
The button shall be a mushroom type with raised guard to prevent accidental
tripping.
(4)
Following equipment start-stop switches and selectors are less frequently operated
switches shall be installed either on the control consoles, or an independent panel
within operators reach from his seating position.
i)
ii)
iii)
v)
vii)
Viii)
(5)
Spreader power supply On/Off push button switch.

Spreader motor selector switch (if any)
Lighting switch.
Exciter switch.
Gantry wheel 90 degree steering switch..
Gantry wheel intermediate angle steering switch for spin turn.
Indicating lamps on the console

i)
ii)
iii)
iv)
v)
Auxiliary power source On indicator.

Spreader position indicator (20 or 40).
Spreader motor No. 1 or No. 2 (if any).
Spreader Zero Skew position indicator.
Other indicating lamps as necessary to indicate operable condition with the
lamp On.
All indicating lamps on the console shall be LED type.

(6)
Interlock override spring return key switches

Labels shall be provided for each switch and indicator in both English and Polish,
and to be approved by the Purchaser.
(7)
Each console shall be provided with 220V AC outlet.

Page: 61
(8)
All push button control switches shall be LED illuminated.
5-4.7. Motion Control Panels

(1)
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)
Panels with electronic control units shall be designed to maintain the inside air
temperature below 40 C 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 RPM meter, ampere meter and
volt meters which indicate motor current, field current, reference voltage and motor
voltage.
5-4.8. Remote Motion Controls
NOT USED.
5-5.
Operational Safety Interlocks

In addition to all the necessary protection of structural, mechanical and electrical/electronic
system and system components, following interlocks are required.
5-5.1. Main Motions Interlocks

(1)
Main hoist (hoisting or lowering) motion to stop:

i)
At upper and lower hoist limits.
ii)
With brake malfunction.
iii)
With wire rope slack either with or without spreader.
iv)
With over-speed.
v)
With motor field loss (if any)
vi)
With motor over-heat.
vii)
Hoisting with an incomplete lock position of twist lock after the spreader is
landed on a load fitted with corner fittings.
viii)
Hoisting with an incomplete unlock position of twist lock.
ix)
If the physical position of any of the twist locks are different from
Lock/Unlock command switch position.
x)
With loss of lub oil pressure if forced lubrication is applied.

Page: 62
(2)
xi)
Landing limit switch detected as not at its intermediate position (spreader

attached with a container).
xii)
When the operator turns the twist lock switch from unlocked to lock or
from locked to unlock while the spreader is not sat properly on top of a
container. Operator must turn the twist lock switch back to original position
to continue hoisting operation.
xiii)
While the gantry brake is energised.
Main hoist (hoisting or lowering) motion to slow down, or in slow speed:

i)
Two main hoist slow downs shall be provided to cater for empty spreader
and loaded with a container condition on hoisting. The proposed
arrangement for both empty spreader slow down and spreader attached with
a container slow down shall be submitted to the Purchaser for approval.
Both cases shall not hit the emergency stop limit switch striker and
sufficient height to clear the combination of 9 containers.
ii)
Lowering at near the lower hoist limit.
iii)
Hoisting until slack of the wire rope is taken up.
iv)
When Twist-lock or Landing by-pass is being depressed by the operator

to alert people underneath the crane by an audible alarm that it is dangerous
and by-pass of interlock is being used by the operator.
5-5.2. For Trolley Operation

(1)
Trolley motion to stop:

i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
(2)
At travel end limits.

With motor field loss (if any).
With motor overheat.
With the storm stowage pin not in the raised position.
When the operator turns the twist lock switch from unlocked to lock or
from locked to unlock while the spreader is not sat properly on top of a
container. Operator must turn the twist lock switch back to original position
to continue trolley operation.
With the cab access swing door/gate in unlock or open condition.
With spreader landing signal.
Trolley motion to slow down, or in slow speed:

i)
At near the travel limits forwards and backwards with a safety margin for
full deceleration distance before hitting the end stopper.
ii)
When Twist lock or Landing by-pass is being depressed by the operator

to alert people underneath the crane by an audible alarm that an abnormal

Page: 63
operation is being carried out and by-pass of interlock is being used by the
operator.
5-5.3. For Gantry Travel Operation
(1)
Gantry motion to stop:

i)
ii)
iii)
iv)
v)
vi)
viii)
ix)
x)
xi)
xii)
While turning wheels to or from 90 degree or intermediate spin turn angle

steering position.
With motor field loss (if any).
With motor overheat.
While the main hoist brake is energized.
With turning wheels are not at the similar steering position.
With anti-collision signal.
With cable reel limit switch or travel limit.
With cable reel motor over torque.
With cable reel cable snack signal.
With cable reel motor or control system fault.
(2)
Gantry travel warning gong sound and warning lights shall be kept activated while
the gantry control lever is moved to either direction.
(3)
Gantry travel anti-collision device shall be installed on the Cranes to detect the
proximity of another Crane which is likely to cause collision. The device shall have
two settings one to give audio warning signal to the operator and the other to bring
the crane to an emergency stop.
5-5.4. Spreader Functional Interlock

For Spreader Operation
i)
Spreader twist lock movement shall be mechanically and electrically interlocked

with the spreader landing detection so that lock movement is prohibited unless
all the twist locks are confirmed as inserted into the corner fittings. The landing
signal shall allow for a one (1) second time lag (adjustable) to indicate the
completion of landing to the operator and to activate the interlock.
ii)
The premature unlocking movement while suspending the load with twist locks
shall be prohibited by means of electrical interlock on the logic control circuitry.
There shall be no physical movement of the twist locks on the spreader even though
the switch is turned to Unlock position. Audible and visual alarms noticeable at
ground level and at inside the operators cab shall be activated by this premature
turning of the level type twist lock switch and all motions of the crane shall be
deactivated. Both audible and visual alarms shall cease when the twist lock switch
is returned to its original position. Alarm tone shall be approved by the purchaser.
iii)
The twist locks shall remain on its last position after power interruption, i.e. failure
and resumption of electrical power.

Page: 64
5-5.5. Cab Entrance Door/Gate Interlock.

Refer to 5-5.2.
5-6.
Communications
5-6.1. Intercom System

(1)
A communication system which allows selective and partly (simultaneous)

communication among the panel house and operators cab shall be installed. Hand
sets shall be provided at operators cab and control house.
(2)
Signal to tractor drivers

A green flashing light at each corner, of the gantry structure, which will be activated
by Crane Operator in the cab by pressing a push button switch, shall be provided to
draw attention of a tractor driver, who has positioned tractor-trailer under the Crane,
to communicate with the Crane Operator.
5-6.2. Radio Communication System

The radio and UHF set shall be provided by the Contractor as follows:

Radio master unit-Motorola MaxTrac F6 or the equivalent

Power unit: Shunde SD 1732W2 or the equivalent
Amplifier: DSP/MP-300PH
Loudspeaker: DSP/PH10 30W or equivalent
The Contractor shall supply DC outlet for radio communication equipment (refer to 4-6.5
(10) and 5-3.2 (6), (7)).
5-6.3. Data Communication System
This clause is not used.
5-6.4. Public Address System
A public address system consists of an amplifier with a hand free microphone (goose neck
type) shall be installed in the drivers cab. Loud speakers of water-proof construction shall
be installed at the following locations:
i)
ii)
At one of the legs of the enclosure side.

At one of the legs of the electrical panel house side.
5-6.5. Operation Centre / Maintenance Office Station

NOT USED.

Page: 65
5-7.
Crane Condition Monitoring System (CCMS)
5-7.1. General
The Contractor shall supply, deliver, install and commission a Crane Condition
Monitoring System (hereinafter referred to as the CCMS). The design of the CCMS shall
facilitate future expansion in terms of capacity and functional features. The CCMS
hardware and software shall be modular in design and construction to facilitate future
expansion. There shall not be major re-configuration of the hardware and software
modification and development. System expansion shall not be limited by the capacity of
individual On-Board CCMS and PLCs.
The Crane Condition Monitoring System shall be installed in the following locations:
(1)
In the electrical house of each Crane (hereinafter referred to as the On-Board

Crane Condition Monitoring System, On-Board CCMS).
(2)
In the maintenance base at the Engineering office building (hereinafter referred to

as the Remote Crane Condition Monitoring System, RCCMS)
5-7.2. CCMS Description
The On-Board CCMS and RCCMS shall incorporate alarm/fault monitoring and graphics
display, the condition status monitoring with graphics display, the fault diagnostic
functions, Crane operation and shall allow access to the programming logic and software
(all of the above shall be in Polish language). These functions must be able to be
downloaded as a softcopy and printed as a hardcopy. The PLC program must be able to
download/upload from the electrical drives to the CCMS and vice-versa. The CCMS
shall consist of but not be limited to the following elements:
(1)
One (1) set of On-Board CCMS on each crane. This shall consists of a personal
computer with monitor, key boards and CD driver, Licensed Microsoft Windows
and Microsoft Office software, necessary associated peripherals and software. All
hardware and software required for interface to the communication network and
peripheral devices shall be included and approved by the Purchaser.
(2)
One (1) set of RCCMS. This shall consist of a personal computer together with
monitor, key board and necessary associated peripherals and software. All
hardware and software required for interface to the communication network and
peripheral devices shall be included.
(3)
A laser jet printer to be installed in the Engineering office and its associated
peripheral for printing necessary information from the RCCMS.
(4)
One (1) set of RCCMS server and a standby server for providing access to the
cranes under the same drive system.
(5)
The Contractor shall provide free-of-cost technical training for the engineering
staff of the Purchaser. The training program shall be submitted in the tender
proposal. This training shall be conducted by Polish/English speaking personnel
who are duly appointed as the representative of the Contractor.

Page: 66
(6)
The Contractor shall provide 3 sets of soft copies in CD-ROM and 6 sets, cost
free, reproducible maintenance manual, operator manual, recommended spare part
list and spare part manual to the Purchaser.
(7)
The Contractor shall submit a quotation upon practical completion date of the OnBoard CCMS to the Purchaser for a recommended spare part list of the On-Board
CCMS for an operation period of 5 years continuously.
(8)
The Contractor shall also bind to guarantee to have a spare part be supplied after 5
years upon the practical completion of this contract.
(9)
The CCMS shall have proper documentation of circuit diagrams, source codes,
hardware and software with user license, and associated peripherals.
(10)
The design overview of the CCMS is shown in Appendix IV. The Contractor shall
submit within two (2) months after the date of award of contract, the CCMS
system architecture for review by the Purchaser.
5-7.3. On-Board Crane Condition Monitoring System (On-Board CCMS)

General Specification
The On-Board CCMS is located in the electrical room of the Crane. The On-Board
CCMS is designed to provide a diagnostic and condition / status real time monitoring of
the crane control system. The On-Board CCMS shall consist of the necessary sensors and
transducers to be installed on each crane and with in conjunction with the PLCs to
provide continuous monitoring, diagnostics, data collection on the Cranes operating
systems. The system shall also provide crane operational data that is used to determine
crane performance, maintenance scheduling, spare part details and daily/shift reports.
5-7.4. On-Board CCMS Software Requirements
(1)
The On-Board CCMS and RCCMS operating system shall be real time, multitasking, multi-user operating system. The operating system shall allow the OnBoard CCMS and other programs to run simultaneously and allow the user to
access any software without affecting the real time condition monitoring of the
crane control system and the communication link between the On-Board CCMS
and the RCCMS.
(2)
The Contractor shall develop a user interface software to meet the following
requirements:
i)
The software shall be able to run on Window XP operating platform. The

operating platform and user interface software has to be approved by the
Purchaser. All back-up copies of the software shall be stored in the CDROM or USB storage device.
ii)
The software shall incorporate alarm/fault monitoring and graphics display,

the condition status monitoring with graphics display, the fault diagnostic
functions, Crane operation and shall allow access to the programming
logic and software (all of the above shall be in Polish language).

Page: 67
iii)
The software shall be commercially available software and it shall serve as

an interface to display on the screen all the captured data from the OnBoard CCMS. The software shall be able to generate but not restricted to
historical trend charts/files, trending, alarm management and fault logging,
crane maintenance and performance report, planned maintenance
information. The Purchaser will release the reporting format and details to
the Contractor and the Contractor shall comply with the same as part of
the Works. The capacity of the memory shall be able to store not less than
500 fault messages together with the related fault records and at least 3
years of historical productivity data / information. The software shall be
able to download or export data files to other commercially available
software such as Microsoft Access, Microsoft Excel, and Microsoft Words
etc. The export data files shall include but not be limited to txt, xle,
doc format.
iii)
The proposed structure for storing the CCMS data and information shall
be Oracle database System.
iv)
The software shall allow engineers to access (read and write) the ladder
diagrams of the PLC, remote PLC and Drives, Boolean logic and other
software codes. Forcing-on and forcing-off of switches, contacts and relays
on the PLC ladder diagram shall be available on the On-Board CCMS.
Parameters adjustments and internal settings of both PLC and Drives shall
be available on the On-Board CCMS. All as built electrical drawings shall
be accessible by the On-Board CCMS. Key switch and password shall be
available to authorized personnel to carry out any modifications as
described above. There shall be three (3) levels of security for accessing to
different levels of CCMS software. The exact details will be released to the
Contractor by the Purchaser and the Contractor shall comply with the same
as part of the Works.
v)
The On-Board CCMS shall be able to copy or upload PLC software

programme to each PLC within 30 minutes. The On-Board CCMS shall be
able to download all data files which shall include all real time
information of the CCMS and time response graphs. This information
shall be able to store in a CD-ROM or any USB storing device for printing
using Microsoft Word / Excel / Access. Time response graphs displaying
different signals simultaneously shall be incorporated in the On-Board
CCMS.
vi)
The RCCMS operating system and software shall be the same as what is
running under the On-Board CCMS.
vii)
The software in the On-Board CCMS shall be made accessible for the
Purchaser to include additional or new monitoring points and to modify
software for presentation, reports for future enhancements.
viii)
Original Licensed software shall be used, these includes the operating

system application software. One original licensed copy of the software
package shall be provided for each computer in the Agreement.

Page: 68
5-7.5. On-Board CCMS Hardware Requirements
(1)
The On-Board CCMS shall be mounted in an environmental controlled, industrial

type cabinet that can withstand vibration.
(2)
The On-Board CCMS shall consist of but not limited to the following items:
i)
Computer
The personal computer shall consist of the following hardwares:
The CPU shall be an Intel Duel Core, or better, processor with a clock
speed of not less than 2.4G, at least 2GB on board memory, 8MB cache,
500GB harddisk with a speed of 7200rpm in SATA format, one unit of
DVD-RW with a speed of 16X, key board, mouse, one unit of 19 monitor,
two (2) parallel COM ports and two (2) USB ports, an Ethernet card. The
heat sink shall be force-ventilated by a fan unit. It is the intention of the
Purchaser to standardize the make and model of the On-Board CCMS
computer. The details will be released to the Contractor.
5-7.6. Condition Monitoring

(1)
The status and condition for the electrical systems, sub-systems and all the
essential components, Electrical, Mechanical and Hydraulic which are critical to
the proper functioning of the crane shall be monitored, during all modes of
operation and status of power supplies.
The Contractor shall provide a UPS, suitably rated for 15 minutes, to afford
access to all information in the event of power failure, either relating to the shore
power.
(2)
The CCMS shall present all information, status, graphics and data in easy to read
window display formats (in Polish language). The Purchasers preferred format for
real time data, being graphical displays rather than numerical presentation of the
relevant data.
(3)
The main screen shall lead the user to separate screens, divided into the following
major application screens (in Polish language).
Example:
MAIN MENU
DATA/CONTROL
SCREEN #1
SCREEN #2
SCREEN #3
SCREEN #4
SCREEN #5
SCREEN #6
HOIST
GANTRY
TROLLEY
SPREADER
Power
Supply
PERFORM
ANCE
(4)
SCREEN #7
Principle functions and components, associated with each application shall be

Page: 69
displayed, in real time mode, on individual screens, such as, but not limited to:
Motor Feedback Signals, i.e. Speed, Current, Voltage, Frequency, Torque
Revolutions, Directions and Temperature.
Reference signals of Controller, Ramp Generator and Acceleration/ Deceleration
Ramps, Encoders, Pulse Generators.
Performance, Operation, Positioning, Current, Voltage and Speeds of Converters,
Inverters, Brake Chopper Units, Brakes, Contactors, Relays and other devices,
applicable to the application.
Hardware status of Limit Switches, Interlocks, Cam Switches, Sensors, Encoders,
Fuses and other Protection devices shall be monitored and displayed in an
approved format.
Data relating to Loads, Component Operational Time and Operational hours of
major devices, i.e. Motors, Converters, Inverters, and Brakes shall be displayed in
an approved format.
Provision shall be made for Status Warning, Alarm Trips and Faults to be
displayed at all times on all screens.
The system shall provide sub-windows, where operational performance of subassemblies can be monitored, such as, but not limited to:
Shore Supply, Hydraulic Motors and Pumps, Wheel Turning operation and
Spreader Functions.
Meters, such as all motors running hour and twistlock count.

Performance includes fault message, summary and statistical data, i.e. MMBF,
number of failure, total downtime & etc.
(5)
The Contractor shall provide easy to access data of Systems, Parameter Settings
of PLC and/or Drives and Components in easy to read formats. These systems and
components shall include, but not limited to the following:
Performance of the Drives (Inverters and Converters) which includes the AC
Supply, AC Motor Control, DC Motor Control (if any), Operator Control, Motion
Interlocks, Safety Interlocks, Sequence Interlocks.
The temperatures for all AC Motors, DC Motors (if any), Gears, Reducers, Rope
Drums for the Main Hoist, Gantry Travel, Trolley Travel.
The operating voltages and currents for all the Converters, Invertors, Braking
Chopper Units, Brakes and Motors.
The status of the high voltage switches, low voltage switches, protections relay.
A real time update of all Positioning / Distance sensors.

Page: 70
Threshold values for warning and shutdown shall be incorporated in the CCMS.
Adjustment of the threshold values shall be made accessible to the Purchaser.
Any abnormality in the Cranes system and components shall be prompted and
immediately displayed on the screen of the On-Board CCMS.
A real time update of all speeds, motions and operations.
All Ramps
Actual Loads
(6)
(7)
(8)
The following, as a minimum, data associated with the Hoist operation shall be
displayed:
i)
Controller Position of Forward, Reverse, Hoist, Lower, Left, Right and

Zero, shall be displayed. Actual proportional position of Controller
reference shall be displayed in an approved graphical format and indicates
to the user actual percentage (%).
ii)
Hoist motion interlocks, Spreader interlocks, Slack Rope, Load Cell

measuring.
iii)
Hoist Inverter status, interlocks, and performance and protection devices.
iv)
Hoist Brake Function, Operation and Brake Proving shall be displayed
v)
Function and Operation of Limit Switches, Cam Switches, Encoders,

Tacho-Generators and Pulse Encoders.
vi)
Hoist Speed, Slowdown, Speed Check, Stop and Positioning.
The following, as a minimum, data associated with the Trolley operation shall be
displayed:
i)

Zero, shall be displayed. Actual proportional position of Controller
ii)
Trolley motion interlocks, Spreader interlocks,
iii)
Trolley Inverter status, interlocks, performance and protection devices.
iv)
Trolley Brake Function, Operation and Brake Proving shall be displayed
v)

vi)
Trolley Speed, Slowdown, Speed Check, Stop and Positioning.
The following, as a minimum, data associated with the Gantry operation shall be

Page: 71
displayed:
(9)
(10)
i)

Zero shall be displayed. Actual proportional position of Controller
ii)
Gantry motion interlocks, Wheel Turning interlocks.
iii)
Gantry Inverter status, interlocks, performance and protection devices.
iv)
Gantry Brake Function, Operation and Brake Proving shall be displayed.
v)

vi)
Gantry Speed, Slowdown, Stop and Positioning.
vii)
Hydraulic Wheel Turning, function, Operation and positioning.
The following, as a minimum, data associated with the Spreader operation shall
be displayed:
i)

Zero shall be displayed. Actual proportional position of Controller
ii)
Spreader motion interlocks, Spreader Retract and Expand interlocks,
iii)
Spreader Motors status, interlocks, performance and protection devices.
iv)
Spreader Flippers, Up and Down.
v)
Function and Operation of Proximity and Limit Switches, Cam Switches,

Encoders, Tacho-Generators and Pulse Encoders.
vi)
Spreader Stop and Positioning.
vii)
Spreader Twistlocks, Lock and Unlock, including indication and By-Pass

status.
viii)
Function clock shall display actual operation time of Expand/Retract,

Twistlock Operation and Flipper Operation.
The following, as a minimum, data associated with the General Crane Control
System shall be displayed.
i)
Emergency Stop operation where the status of individual stations shall be

displayed.

Page: 72
ii)
Main Generated Power Supply, Auxiliary Power Supply, Shore Power

Supply and UPS function, status and performance.
iii)
Function Operation and Status of Circuit Breakers, Fuses, Contactors,

Relays and Protection devices, shall be displayed.
iv)
Operator Mode Selection, Function and Status
5-7.7. Fault Diagnosis

(1)
The faults and status data including historical data shall be stored in the On-Board
CCMS database. All the data in the database shall be translated and stored in a
suitable text file for a standard editor. All data shall be easily downloaded to a CD
ROW or USB storage device. A zip function shall be available in the software for
file compression.
(2)
The objective of the fault diagnosis is to assist Purchasers engineers to remedy

the fault or confirm the exact nature of a fault within a very short time. All faults
shall be coded with a suitable numerical code and the first fault causing an alarm,
trip or crane stoppage shall be highlighted as first fault. Provision shall be
provided that as a minimum the system shall display twenty (20) faults that may
occur at any one time.
This first fault shall be displayed clearly to assist the Purchasers engineers on the
CCMS and remote display units. Faults interrupting crane operation shall be
highlighted, either by flashing or appearing in a Pop-up window, regardless of
screen selected and fault indication shall be only when crane motion or operation
is selected.
(3)
The fault diagnosis shall be able to narrow down the faults to the exact
components; safety interlocks failures, drive faults, PLC controller failures,
remote interface device failure, remote communication failure and system
communication failure.
There shall be details and information on faulty component locations and possible
remedy actions to be taken. There shall be intermediate fault tracing and
measurements checkpoints and these functions shall be made available to
Purchasers qualified personnel to input new parameters for troubleshooting
purposes. The resolution and duration of these measurements are 10ms to 100ms
and 5s to 50s respectively.
(4)
Drawings on electrical circuit, PCB layout, schematic drawing, software ladder

and software device listing of crane control, Drives and PLC shall be made
available in the fault diagnostic mode. Access to the information shall be easily
obtainable on any CCMS screen.
The CCMS shall store all faults in appropriate historic files in daily, weekly,
monthly and yearly log folders, easily accessible and selection of data shall be by
selecting a daily, weekly, monthly or yearly option.

Page: 73
5-7.8. Preventive Maintenance

(1)
The utilization hour of the consumable parts shall be recorded automatically and
compared with the respective pre-set replacement interval. Adjustment of the
replacement interval shall be made available to the Purchaser. The system shall
prompt the user when a part is due for replacement. The system shall have
sufficient capacity, which allows the Purchaser to add new consumable parts. The
consumable parts shall include but not limited to the following:
i)
ii)
iii)
iv)
v)
Brake pads and lining

Brake shoes
Wire ropes
Bearings
Oil and air filters
5-7.9. Equipment Performance Data and Operation Log

(1)
The CCMS shall provide records on equipment performance and operation data.
This data shall include but not limited to the following:
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
(2)
Frequency of breakdowns
Twist Lock Count
Main Hoist, Boom Hoist, Trolley, Gantry Hours and overlapping Main
Hoist / Trolley Hours
Occupied Time
Mean Move Between Failure
Mean Time to Repair
Availability
Breakdown Percentage
Average Cycle Time
Handling Capacity
Number of containers handled according to the size and weight of the
containers.
These data shall be available in trend graphs / charts plotted against time. The
equipment performance and operation report format and the formulas for the
equipment performance parameters shall be discussed and approved by the
Purchaser before implementation. The Purchaser will release the exact details to
the Contractor at design stage. The data shall be stored in the On-Board CCMS.
The data shall be able to download or export data files to other commercially
available software such as Microsoft Access or Excel & etc. All counters in the
CCMS shall be able to be reset by the Purchasers engineering personnel but only
with user-identify recording and the use of passwords.
5-7.10. Remote Crane Condition Monitoring System (RCCMS)

(1)
General Specification

Page: 74
The RCCMS shall allow engineering personnel to perform diagnostic, condition
monitoring of the CCMS in the engineering office remote to the Cranes. The
RCCMS shall be able to perform all the functions of the On-Board CCMS as stated
in Clause 5-7.4 and the following additional requirements:
(i)
All the information and functions on the Cranes On-Board CCMS specified
in this Specification shall be available for the RCCMS.
(ii)
All the alarm and fault messages on the Crane which requires the attention of
engineering personnel shall interrupt the RCCMS. The response time for the
alarm and fault messages shall be less than 5 seconds. After the interrupt has
been acknowledged, the present task shall be able to continue. The fault
messages shall include but not limited to the following:
(a)
(b)
(c)
(d)
(e)
(iii)
Crane ID
Location
Fault code / messages
Part code
Date/time reported
There shall be a server for the CCMS by each drive supplier. The RCCMS
computers shall be able to access to the On-Board CCMS of any Crane via
the respective server and CCMS software.
5-7.11. RCCMS Software Requirements

The RCCMS software shall be able to perform all the On-Board CCMS functions as
defined in clause 5-7.5.
5-7.12. RCCMS Hardware requirements
The RCCMS shall consist of but not limited to the following items:
(i)
Computer
The personal computer shall consist of the following hardware:
The CPU shall be a Intel Duel Core, or better, processor with a clock speed of
not less than 2.4GHz, at least 2GB on board memory, 8MB cache, 300GB
harddisk with a speed of 7200rpm in IDE format, one unit of DVD R/W with a
speed of 16X, key board, mouse, one unit of 19 monitor, two (2) parallel COM
ports and two (2) USB ports, an ethernet controller, fibre optic interface and a
portable harddisk or USB storage device with 300GB memory for connection to
the parallel interface for downloading of data. The heat sink shall be forceventilated by a fan unit.
(ii)
One unit of UPS with a minimum of 15 minutes.
(iii)
One unit of laser jet printer.

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(iv)
One unit of server. Details refer to 5-7.13.
5-7.13. Server(s)
The server shall allow the RCCMS computers to access to the On-Board CCMS
computers including file transfer, crane diagnostic, receive status and alarm message. It
shall also enable the On-Board CCMS computers to send status data and alarms by means
of interrupts to the RCCMS and computers (outside the terminal). The server shall be
modular and upgradeable to enable all the On-Board CCMS to be served.
5-7.14.
CCMS Reporting Format

The CCMS reporting format will be released to the Contractor, shall be reviewed and
5-7.15. CCMS Data Communication

(1)
The data communication between the On-Board CCMS, Server(s) and RCCMS
shall be through a Radio Frequency (RF) link data communication media.
Contractor shall provide all necessary equipment and peripherals for the RF link
data communication between the On-Board CCMS and the RCCMS.
(2)
The Contractor shall provide and install the following hardware and cables on the
Crane for communication among the above servers and computers.
-
Terminating boxes with ST connectors for fibre-optic cables inside the

Operators Cabin.
One set of twelve cores multi-mode fibre-optic cable from the fibre-optic
termination box in the Electrical House to the terminating boxes inside the
Operators Cabin. Size of each core of the fibre-optic cables shall be
62.5/125 microns.
6. Common Items
6-1.
Walkways, Stairs, Ladders and Platforms
6-1.1. Applicable Code/Std.

(1)
Walkways, stairways and platforms shall be designed to avoid tripping, skidding,

ducking or crawling. Clear headroom of 2.1m shall be maintained throughout the
walkways, stairways and platforms. Special non-skidding treatment and snow
accumulation shall be applied for flat structural surface if used as walkways.
(2)
The design of walkways, stairs and ladders shall comply with the requirements of
BS4211, BS5395, BSEN13586 and ISO11660. Design and construction shall be
Modular such that all welding and Hot-work is carried out before the specified
anti-corrosion treatment either blast and paint and/or hot dip galvanising.

Page: 76
6-1.2. Stairway Requirements

(1)
Access to the transformer house, electrical house, trolley platform, operators cab
shall preferably be by stairways with appropriate landings throughout. (See also 61.3 (1).
(2)
Landings shall be provided for stairs at intervals of not more than 8 meters. The
gradient of stairs shall not exceed 50 degrees.
(3)
Stairways shall be designed to avoid tripping, skidding, ducking or crawling. Clear

headroom of 2.1m shall be maintained throughout the stairways.
(4)
The height of kick plate from the stairway tread level shall be minimum 200mm.
The kick plate shall be continuous along stairways, and constructed of minimum
200mm wide steel strip of minimum thickness 4.0mm.
(5)
Stairway treads shall be expanded metal or open grid metal construction, hot dip
galvanized.
(6)
Stairs shall be provided to allow ample and safe access to all sheaves, pins, wheels,
carriers, ropes, machineries, switches and control equipment, etc., where preventive
maintenance is necessary. At least 600mm clear passage around any machinery
shall be provided.
(7)
An emergency vertical ladder with suitable landing platforms and safety hoops shall
be provided. This emergency ladder shall be installed at the opposite side to the
operator cabin access ladder, i.e. from top of main girder down to ground level.
6-1.3. Ladder Requirements

(1)
Approval must be obtained from the Purchaser if vertical ladders are used elsewhere.
Vertical ladders shall have stiles made of steel flat bars with special non-skidding
treatment applied to the flat surface. Vertical or near vertical ladders of over 2
meter length shall be attached with safety hoops. The space within the hoop shall be
sufficient for a man with tools to climb up or down the ladder and shall not be
smaller than 650mm depth x 600mm width. Vertical straps for the hoops shall be
spaced adequately to prevent a human body falling through.
(2)
Landings shall be provided for ladders at intervals of not more than 8 meters. The
gradient of stairs shall not exceed 50 degrees.
(3)
Adequate safety straps or bars shall be provided between safety hoop of a ladder and
handrail for a landing wherever there is a wide clearance which may allow
accidental fall of personnel.
(4)
Access by ladder and/or platforms or landing shall be provided to allow ample and
safe access to all sheaves, pins, wheels, carriers, ropes, machineries, switches and
control equipment, etc., where preventive maintenance is necessary. At least 600mm
clear passage around any machinery shall be provided.

Page: 77
6-1.4. Platforms Requirements

(1)
The inspection and maintenance platforms for the Transformer set shall be a folding
type to minimise total width of Transformer house to create adequate safety
clearances for the operation. When it is extended it may be allowed to project over
the Structure Limit of the Crane.
(2)
Platforms shall be designed to avoid tripping, skidding, ducking, crawling or snow

accumulation. Clear headroom of 2.1m shall be maintained throughout the
platforms.
(3)
Platforms shall be provided to allow ample and safe access to all sheaves, pins,
wheels, carriers, ropes, machineries, switches and control equipment, etc., where
preventive maintenance is necessary. At least 600mm clear passage around any
machinery shall be provided.
(4)
The vertical columns for cables between transformer housing and main girder at
one end, between electric room and main girder at the other end shall be fitted with
vertical ladders inside which shall be used to bind cables being mounted inside the
columns. For binding requirement see 3-3. (2) vi) for details. Cable ladders
external to the structural members may be acceptable subject to the approval of the
purchases representative upon submission of details of mechanical protection
details of the ladders, cable fixing, ease of access (i.e. removal of protection).
(5)
A permanent inspection and maintenance platforms shall be provided under the

trolley for inspection and replacement of wire ropes and sheaves.
6-1.5. Walkway Handrail Requirements

For a level walkway the height of the top handrails shall be 1100mm with two
intermediate rails at heights of 350mm and 685mm. The height shall be increased as
necessary to ensure safety of passage. The handrail shall be constructed with pipe,
all welded joints finished smooth to same diameter as the pipe, and continuous along
walkways platforms and stairways.
The height of kick plate from the walkway tread level shall be 150mm. The kick
plate shall be continuous along walkways, stairways and platforms, and constructed
of steel strip on nominal width of 150mm, of minimum thickness 5.0mm.
Handrails, i.e. the welded assembly of tubular steel and angle stanchions, shall be
modular in construction and fully hot dip galvanised, after all fabrication works is
completed.
These modular sections shall be interconnected at transition points by a continuous
top hand rail connected by galvanised sleeves, retained in position by two grab
screws.
The structural part of a walkway platforms or the side members of a stairway shall
be either hot dip galvanised or blast cleaned and painted in accordance with the
provisions of clause 6-3, but only after all fabrication works is completed.

Page: 78
(2)
The Contractor can provide the two walkways attached below the top level of the
Girder. The actual level shall be a design that will not cause any inconvenience to
both the operator and maintenance personnel.
As an alternative, the contractor may elect to supply girder access platforms
generally at the level of the top flange of the girder. In this case, special permanent
rails for the attachment of safety lines shall be provided above inside top edge of
trolley girders to prevent accidental falling of operators or maintenance personnel
who are required to work on the girder. The design shall be approved by the
Purchaser.
6-1.6. Cab Access Platforms

The cab entrance platform or walkway at the access/transfer point shall be provided at the
same level as cab platform, and shall be equipped with pipe frame construction, inward
opening and self-closing (by gravity) hinged doors on trolley side and gantry structure side.
Opening of either of the doors shall prohibit the trolley motion by means of electrical and
mechanical interlock protection. (See also requirement at Clause 4.6.2)
6-1.7. Walkway Requirements
6-2.
(1)
Walkways shall be designed to avoid tripping, skidding, duckling, crawling and

snow accumulation. Clear headroom of 2.1m shall be maintained throughout the
walkways. Special non-skidding treatment and snow accumulation shall be applied
for flat structural surface if used as walkways.
(2)
Walkways shall be provided to allow ample and safe access to all sheaves, pins,
wheels, carriers, ropes, machineries, switches and control equipment, etc., where
preventive maintenance is necessary. At least 600mm clear passage around any
machinery shall be provided.
Illumination and Lighting
6-2.1. Walkways, Stairs, Ladders, Cab Access

A lighting system shall provide adequate illumination for all ladders, platforms, walkways,
and access to transformer house, panel house and operators cab. The minimum
illumination shall not be less than 20 lux in walkways, stairs, ladders and accesses. Energy
saving light bulbs shall be considered and LED lighting appliance is preferable.
Lighting fixtures located at outdoor shall be outdoor type. Incandescent type light bulbs
shall be rough service type of IP55 class of protection.
6-2.2. Work Area Floodlights
(1)
A floodlight system shall provide adequate lighting to all work areas of the Crane
including penetration into bottom of a slot between two 6-high stacks. The
illumination of 50 Lux or more at the ground level measured at 7.5m either side of
the centreline of the Crane along entire trolley travel range, and specifically 80 Lux
under the trolley measured at ground level 7.5 metres either side of the centreline

Page: 79
shall be achieved. Such floodlights shall not cause glare in the operators cab for the
operator or shadows which make it difficult to operate the Crane safely.
(2)
The gantry runways shall be well illuminated for viewing from operator's cab for
gantrying. These lights shall be installed at sufficiently high position to avoid glare
to tractor drivers.
(3)
All floodlights are to be protected with stainless steel wires to prevent from falling
off the structure. The ballast for all the floodlights shall be grouped together,
labelled individually and stored in a water proof stainless steel enclosure.
(4)
The illumination shall not be less than 100lux in operator cabin and electrical house.
(5)
Two working lights with water-proof switch shall be provided for maintenance
works carrying out on trolley platform of illumination 100lux as minimum.
6-2.3. Floodlights on Trolley

Powerful spot lights (4 nos. minimum) shall be mounted at lower sides of the cab to provide
excellent viewing of a ground slot in between two 5 - high stacked containers at night. The
floodlight shall be mounted such that they will not obstruct the view of the driver during
container handling operation. Two (2) rotatable spot lights (rated at 360W) control
individually shall be mounted (locations to be confirmed by Purchaser) to facilitate carrying
out maintenance work by engineering personnel.
6-2.4. Emergency Lighting for Escape Routes
Battery operated lamps shall be provided inside the operators cabin electrical control
enclosure and on the trolley platform.
6-2.5. Lighting Control Switches
Light switches shall be gathered in several convenient locations to allow centralized control.
Two (2) sets of - On-off control switches for all the operational floodlight lights (one group)
and walkway lights (second group) shall be located near the panel house on the route from
ground to the operators cabin and also in the operators cab, to allow switching of both
groups of lights from either locations.
6-2.6. High Pressure Sodium Lamp and Ballast
(1)
The lamp shall be outdoor type and fitted with spring loaded anti-vibration bulb
socket.
(2)
The ballasts shall be high power factor type of not less than 0.85 lagging. All the
ballasts shall be installed inside a protective housing for protection from weather and
concentrated at several conveniently accessible locations for ease of maintenance.
Each ballast shall be match numbered with number of corresponding light. The
ballast for floodlight on the cab shall be installed inside a weather proof box which is
to be positioned outside near the operators cab.

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6-2.7. Fluorescent Lamps

Fluorescent lamps shall be straight tube with minimum 24 inches long, rapid-start type,
waterproof for outdoor application and equipped with steel guard, these lamps are the
preferred type for stairway and platform lights.
Energy saving lighting appliance such as LED lighting is preferable.
6-2.8. Access for Lights Maintenance
All the light fixture shall have safe access for replacement of bulbs.
6-3.
Painting and Protective Coating
6-3.1. Paint System General

(1)
The Contractor shall allow for the preparation, cleaning, painting and protection
against corrosion as specified hereafter, of the whole of the work to be provided
in the Specification.
(2)
Surface not required to be painted, but which are adjacent to steel work which is
to be cleaned and painted, shall be protected by appropriate masking during
cleaning and painting of the adjacent work.
(3)
Special care shall be taken during manufacture to ensure that foreign matter is
excluded from all working parts of the crane.
(4)
All parts of the crane shall be surface treated during manufacture to ensure their
protection from the effects of moisture during storage, transport and erection.
(5)
All bright surface and machined parts, including gear teeth, screws threads, etc.,
shall be protected by a suitable approved rust preventive compound. Particular
care shall be taken with the protection of anti-friction bearings and greasing points,
enclosed gears and shafts.
(6)
All metal surfaces shall be thoroughly cleaned to bare metal, removing rust, loose
scale, dirt, grease, oil, dust and other foreign materials in accordance with 6-3.2
and 6-3.3 hereof.
Particular care shall be used at joints and all other places to which access for
cleaning is difficult.
(7)
Faying surfaces of structural members intended to be clamped together by bolts

shall be shot blast cleaned as specified in Clause 6-3.3(3) hereof and shall be
given one coat of Epoxy zinc rich-primer, 25 microns thick.

Page: 81
(8)
Machined mating surfaces of all ferrous components (other than structural

members) which are to be clamped together by bolts, in final assembly, shall be
protected, as specified in Clause 6-3.1(4) above, after fabrication and just prior to
final assembly shall thoroughly cleaned and smoothly coated with a suitable
protective compound approved by the Purchaser.
(9)
All structural steel plates and sections which shall form sealed internal surfaces
shall be blast cleaned and prime coated using whole of plate blasting and
painting with a suitable high temperature shop primer. Angle or flat sections used
for plate stiffening shall be similarly treated by mechanical (but not manual)
treatment methods.
(10)
Providing damage to such prime coating during fabrication is minimal, in the

opinion of the Purchaser, power brush and cleaning of such pre-primed surfaces
with a suitable approved solvent may be accepted in lieu of a second blast
cleaning.
(11)
For the purposes of this Specification 6-3, the term External Surface shall
include the following areas:
(i)
The exterior surfaces of all structural members.
(ii)
The whole of the surface of any object such as an equalising beam or

bogie.
(iii)
The whole surface of any component part such as a lug or cheek plate.
(iv)
The outside surface of any gearbox, motor, brake, bearing spacer, collar,
track wheel (excluding the actual tread), rope drum (excluding the rope
groove) or other similar mechanical or electrical part which is not
protected from the weather by being enclosed in a cabin or housing.
(v)
The outside surface of any guard, cabin or housing.
6-3.2. Surface Preparation

(1)
All castings shall be properly fettled and cleaned. All runners, veins, pins, etc.,
shall be carefully chipped off so that no lumps or rough areas are left.
(2)
All welding slag and spatter shall be carefully cleaned off by mechanical cleaning
method such as chipping and power brush and, where necessary, grinding.
(3)
All sharp edges shall be smoothly ground to a radius of not less than 1.6 mm.
(4)
Any areas of surfaces which are to be blast cleaned as specified in 6-3.3 hereof,
and which show any traces of oil or grease, shall be thoroughly degreased prior to
such blast cleaning, using an approved solvent.
(5)
The outside surface of sheet metal components, such as electrical cubicles, shall
be dressed by means of a finishing machine or orbital sander to produce a smooth
finish, free from weld protrusions, spatter, surface blemishes, etc.

Page: 82
All sheet metal components and thin walled section (below 3 mm in wall
thickness) shall be degreased by an approved process in accordance with BS5493
and shall then be pickled, to remove all mill scale, mill bloom, accordance with
BS5493.
After appropriate neutralisation and rinsing, such components, with the exception
of those which are to be galvanised, shall be given an approved chemical or
electro chemical surface passivation and anti-corrosion treatments.
(6)
Particular care shall be taken to ensure that surfaces which have been prepared
and cleaned for painting, other protective coating or treatment, are not recontaminated by handling with bare hands or by exposure to any contaminating
environment.
6-3.3. Abrasive Blast Cleaning

(1)
All unmachined steel and cast iron surfaces, apart from sheet metal components
and thin walled sections (below 3 mm wall thickness) shall be abrasive blast
cleaned, as specified hereunder, after all fabrication and hot work has been
completed.
The use of pre-blast pre-painted workshop primed steel plate which is treated
within three months before used may be accepted, subject to all mechanical and
heat affected areas being suitably reprepared to the equivalent of the Sa2.5 by
either abrasive blast cleaning or other mechanical methods prior to the application
of subsequent coatings. The welding on of lugs, brackets etc after the application
of undercoats or topcoats is considered to be poor construction practice,
comprises the paint system and must therefore is avoided. Only when it can be
shown to be physically impossible to carry out blasting after fabrication will blast
and prime coating prior to fabrication be permitted.
(2)
Contractor shall submit details of the blast cleaning proposed to be used,

including type of equipment, type and grade of abrasive and profile height
expected from use of such abrasive to the Purchaser or their representative at least
30 days before work commencing, for comment.
(3)
External surfaces as defined in 6.3.1(9) shall be dry abrasive blast cleaned to a

white metal finish in accordance with SIS005900 Sa2.5.
(4)
Internal surfaces to be abrasive blast cleaned shall be dry abrasive blast cleaned to
a finish in accordance with SIS005900Sa2.5.
(5)
After blast cleaning, surfaces shall be fibre brushed or blown with clean dry air
(provided adequate driers and oil mist filters are used in air lines) or vacuum
cleaned to remove all blast products and abrasives from the entire surface,
including pockets and corners.
(6)
Blast cleaning shall not be performed on surfaces that may in the opinion of the
Purchasers Representative, become wetted after blasting and before painting, or

Page: 83
other protective coating, nor shall blasting operations be performed on surfaces
the temperature of which is less than 3oC above the dew point of the surrounding
air, or when the wet bulb temperature in the immediate neighbourhood, as
measured by a standard wet and dry bulb thermometer, differs from the dry bulb
temperature by less than seven and one half (7.5) percent of the dry bulb
temperature, nor shall blasting operations be performed when the temperature of
the metal surface is higher than 38oC or lower than 10oC. Contractor shall ensure
that all measuring equipment is available and tested to record the above
conditions.
(7)
Adequate precautions shall be taken to ensure that no damage to or contamination

of partially or entirely completed portions of the work, or to machinery, occurs
from blast cleaning.
(8)
All free oil and moisture shall be effectively removed from the air supply lines of
all blasting equipment, using adequate and approved filters and driers.
(9)
Blast cleaned surfaces shall be kept free of all contamination before painting, etc.,
as required by 6-3.2(5) above.
Operators shall wear fabric gloves of an approved type during cleaning operations
and any area inadvertently touched by bare parts of the body, shall be
immediately solvent cleaned by approved methods.
All items of metal work to be painted shall be so treated not more than two hours
after surface preparation of each item has been completed.
Any unpainted surfaces which have been subjected to conditions which might
induce condensation of water thereon, or which have been left longer than the
above specified two hours after blast cleaning, shall be again blast cleaned before
being painted.
6-3.4. Painting Generally

(1)
All painting and coating operations shall be performed in a neat, thorough

workmanlike manner. All paint and coating materials shall be in a thoroughly
mixed condition at the time of application and shall be thinned only in accordance
with the manufacturers instructions.
(2)
Paint or coating material shall not be applied unless the temperature of the metal
surface and the atmospheric conditions satisfy the requirements specified in 63.3(6) above. The Purchaser may consider granting approval to the application of
paint at temperature less than 10C but this shall be on a case-by-case basis
subject to the use of paint material specially prepared and formulated for this
condition.
The first coating shall be applied as soon as possible after cleaning the surface,
but in any case not longer than 2 hours after cleaning.
(3)
All surfaces to be coated shall be completely free of moisture, foreign surface

matter and abrasive dust at the time of application of each coat.

Page: 84
(4)
Each coat shall be uniform and free from runs, sags and other imperfections.
Limitations on minimum and maximum inter-coat drying periods recommended
by the paint manufacturer shall be strictly followed.
(5)
All paints shall be of approved colours (refer to Appendix IV).

The colour of each coat shall differ from that of the previous coat to a sufficient
extent to enable missed areas and uneven or inadequate covering to be readily
apparent. The final coat shall be the specified colour.
(6)
All paint shall be applied to the thickness as specified, and such paint thickness
shall be gauged by a certified thickness gauge supplied by the Contractor.
Paint shall be applied by approved spray equipment corresponding to the
equipment recommended by the paint manufacturer for the particular type of paint.
It is preferred that as far as practicable, semi-hollow components such as
switchboard cubicles and consoles and any other smaller items where difficulty
could be encountered in obtaining even coverage, be painted by means of
electrostatic spray equipment.
All welds and edges shall be double passed with each coat.
(7)
The Contractor shall, at his own expense, take all precautions and provide all
equipment, including ventilation plant, which may be necessary to obviate health
hazards arising from the use of specified paints and coating materials in confined
spaces or elsewhere.
(8)
All joints, including bolt heads, bolt ends, nuts, washers and attachments, shall be
painted, after the connection has been made, to complete the protection in the
same system as that specified for the adjacent steel work.
(9)
The Contractor shall submit full technical, application and service details from the
manufacturer of the paints they propose to use to the Purchaser or their
representative at least 30 days before work commencing, for comment.
(10)
Proprietary Equipment
The external surfaces of all mechanical and electrical equipment shall be
protected by paint systems having durability comparable with that of the systems
specified herein for other steel work in similar environment.
Wherever possible special paint treatment of approved quality shall be specified
in the ordering of proprietary items.
Any equipment having external surfaces of materials which are subject to
corrosion and which shall be exposed to the weather shall be protected by an
approved paint system equivalent in durability to that used on the main structures.

Page: 85
(11)
Alternative Paint Systems

Contractor may offer alternative paint systems to those specified, but such will
only be considered if evidence is submitted to support claims that the systems
offered are of at least equivalent durability to that of the system specified.
Refer also to 6-3.5(1) hereafter.
6-3.5. Paint Systems

(1)
External Steel Work

After preparation and cleaning in accordance with 6-3.2 and 6-3.3 above all
external steel surfaces with the exception of (a) galvanised surface and (b)
machined surfaces referred to in Clauses 6-3.1(4) and 6-3.1(8) shall be given the
following protective treatment:
First Coat:
Apply one (1) coat of epoxy zinc rich primer, to a minimum dry film thickness of
75 microns.
Second Coat:
Apply one (1) coat of epoxy micaceous iron oxide primer / under coat, to a
minimum dry film thickness of 100 microns.
Third Coat:
Apply one (1) coat of a high performance anti corrosive barrier coating based on
polyurethane enamel, to a minimum dry film thickness of 50 microns.
N.B. Total Dry Film Thickness of system to be not less than 225 microns.
(2)
Internal Unsealed Surfaces

After preparation and cleaning in accordance with 6-3.2 and 6-3.3 above, all
internal surfaces with the exception of (a) galvanised and non-ferrous surfaces (b)
machined surfaces referred to in 6-3.1(4) and 6-3.1(8) hereof shall be given the
following protective treatment:
First Coat:
Apply one (1) coat of epoxy zinc rich primer, to a minimum dry film thickness of
50 microns.
Second Coat:
Apply one coat of epoxy micaceous iron oxide primer / undercoat to a dry film
thickness of 100 microns minimum.
N.B. Total Dry Film Thickness of system to be not less than 150 microns.

Page: 86
(3)
Galvanised and Non-Ferrous Surface, both Internal and External

Galvanised and non-ferrous components shall, after appropriate cleaning by an
approved method, be given the following protective treatment:
Galvanised and Non-Ferrous Surfaces, both Internal and External
Surface Preparation:
Ensure that all surfaces are free from all grease, oil or other contaminants by
application of a degreasing solution formulated from a blend of solvent and
emulsifier. Apply Degreaser liberally ensuring that material does not spill on
existing paintwork, working well into the surface to be degreased. Allow 5-10
minutes for the solvent to take place. Flush with clean fresh water and allow drying
thoroughly prior to application of the primer coating.
First Coat:
Apply one (1) coat of micaceous iron oxide primer / undercoat to a minimum dry
film thickness of 100 microns.
Top Coat:
Apply one (1) coat of a high performance anti corrosive barrier coating based on
polyurethane enamel, to a minimum dry film thickness of 50 microns.
N.B. Total Dry Film Thickness of paint system to be not less than 150 microns.
(4)
Motor, Gearboxes, etc.

The external surfaces of all machinery such as motors, rope drums, gearboxes,
couplings, etc. in exposed locations shall be given protective treatment as specified
for external steel work, galvanised and non-ferrous surfaces in 6-3.5(1) and 6-3.5(3)
above.
The external surface of such machinery enclosed in housings or enclosures shall be
given the protective treatment specified for internal steel work, galvanised and nonferrous surfaces in 6-3.5(2) and 6-3.5(3) above.
After preparation and cleaning in accordance with 6-3.2 and 6-3.3 above, all
external surfaces of such machinery shall receive the following protective treatment:
First Coat:
Apply one (1) coat of an epoxy zinc rich primer, to a dry film thickness of 75
microns.
Second Coat (Top Coat):
Apply one (1) coat of epoxy based enamel, to a dry film thickness of 50 microns.

Page: 87
Where it can be shown that proprietary items such as electric motors have received
the basic preparation, the Contractor may with the approval of the Purchasers
Representative on submission of technical details, complement such systems with
additional coatings to bring the system up to the standard of the specified system.
The contractor shall remain responsible for ensuring paint system compatibility.
(5)
Horizontal Surfaces of Access Ways, etc.

Area: Horizontal Surfaces of Access Ways
All horizontal surfaces used for pedestrian or traffic surfaces for access to any part
of the crane for normal operation or maintenance procedures, including such
surfaces on structural members, shall be given an approved special paint treatment.
Such special treatment shall provide improved abrasion resistance and non-slip
characteristics while providing protection and having durability not less than that of
the top coating specified for each relevant environment, i.e. external or internal.
Non Skid Powder shall be applied to second last coat while still tacky and allowed
to set prior to application of final coating.
6-3.6. Galvanising
(1)
General
Components or surfaces required to be galvanised shall be prepared generally as
specified in 6-3.2 hereof and shall than be either acid pickled in accordance with
BS5493 or abrasive blast cleaned in accordance with Clause 6-3.3 hereof. Abrasive
blast cleaning shall only be permitted on components or surfaces where there is no
likelihood of distortion due to such cleaning method.
After such cleaning, all components or surfaces so required by this specification
shall be given a hot dipped galvanised coating conforming to the requirements of
BS5493.
Notwithstanding the requirements of BS5493, the minimum thickness of coating at
any point shall be not less than 200 microns.
Galvanising of any component or surface shall only be carried out after completion
of all fabrication work on such component or surface. No welding on any pregalvanised component or surface will be tolerated unless the component or surface
is to be subsequently regalvanized.
6-3.7. Reinstatement of Protective Coatings at Site

(1)
Care shall be taken at all times to ensure that the protective coatings and treatment
shall not suffer any damage during handling, transport and erection.

Page: 88
(2)
After the components have been transported to the Site, assembled and welded
where necessary, all protective coatings shall be carefully inspected and any areas
where protective coatings have been damaged or found defective shall be clearly
marked with orange-coloured spray paint or paint-stick or chalk, for ready
identification and remedial treatment.
All weld slag and spatter or heat affected coatings on surfaces that have not been
adequately protected during field welding, shall be completely removed and any
high points on field welds shall be ground smooth.
All such areas together with field welds, weld margins and burn marks shall be
abrasive blast cleaned as specified in Clause 6.3.3 hereof, with due care of other
areas of the coating to avoid further damage.
All site abrasive blast cleaning shall be affected with approval closed cycle vacuum
blasting equipment.
(3)
Within two hours of cleaning as specified in 6-3.7(2) above, and before any
contamination or discoloration can take place, the blast cleaned areas shall be
recoated with the priming coat and to the thickness specified in 6-3.5 hereof for the
relevant type of surface and location.
Undercoats and top coats of the type and thickness, as specified in Clause 6-3.5
hereof, for the relevant type of surface and location shall subsequently be applied,
with suitable feathering of coats to avoid ledging.
Manufacturers
recommendations regarding application and drying or intercoat intervals shall be
strictly followed.
(4)
Damage to paint coatings such as scratches or abrasions which, in the opinion of the
Purchasers Representative, do not penetrate the total paint system may, at the
discretion of the Purchasers Representative, be reinstated by cleaning with a
suitable solvent and then touch up painting with the relevant primer(s), intermediate
and top coats as directed by the Purchasers Representative.
(5)
For all repair painting, the final coating shall comprise paint from the same batch as
that originally used on the particular surface.
(6)
Cleaning and repair painting of the crane or its equipment shall be carried out only
when the conditions specified for the original cleaning and painting in 6-3.3(6) and
6-3.4(2) hereof, are satisfied.
Painting shall not be permitted if there is dust being deposited on the surface to be
painted or conditions are not in accordance with Clause 6-3.3(6).
6-3.8. Inspection and Sample Panels

(1)
Attention is drawn to Inspection Control Sheets in Appendix II of this Specification.

Inspection shall take place before and after preparation and coating and also on site.

Page: 89
(2)
Before any surface treatment is carried out, the Contractor shall supply to the
Purchasers Representative, free of charge;
a)
Samples of each type and colour of paint approved for use on the crane for
testing. The Purchaser reserves the right to call for further random samples
during the entire painting operation. Should the tests prove unsatisfactory,
the entire batch shall be rejected and the Contractor shall take corrective
action to re-blast and re-paint all sections painted using the rejected batch to
the satisfaction of the Purchasers Representative.
b)
Two sample blast cleaned panels one panel cleaned in accordance with 63.3(3) and the other cleaned in accordance with 6-3.3(4) hereof, each panel
measuring not less than 150mm x 150mm x 6mm, and adequately protected
after cleaning by sealed clean polythene wrapping.
If approved, the sample shall then be retained by the Purchasers
Representative for comparison with the prepared steel work.
c)
Two steel panels for each painting system, at the commencement of

painting operations, cleaned and painted in accordance with the relevant
requirements of this specification with the exception of any site coat.
One of each pair of panels is to be stepped to show the successive build
up of the paint treatment and will be used as a standard of acceptance
throughout the painting operations.
6-4.
Purchasers Logo, Crane Numbers, Signs
6-4.1. Purchasers Logo

Purchasers logo shall be painted on outer sides of the main girders. (For Purchasers logo
refer to the Appendix IV). The size shall be decided by the Purchaser.
6-4.2. Crane Numbers
Crane number shall be painted on outer sides of the main girders and on ends of gantry
equalizers. (For general location and size refer to the appendix IV). Colour to be white
letter on Blue background.
6-4.3. Crane Capacity Signs
(1)
Capacity signs showing the safe working load of the Crane shall be fitted to both
sides of the gantry structure where clearly legible from the ground level.
(2)
Capacity signs showing the safe working load of the spreader and spreader number
which will be designated by the Purchaser during drawing approval process shall be
fitted or painted on both sides of the spreader.
(3)
Capacity of each lifting lug on the spreader shall be indicated near each lug.
(4)
All capacity signs shall be in metric units = Tonnes or in abbreviation Te.

Page: 90
6-4.4. Manufacturers Name Plates

(1)
Manufacturers name plate could be placed on the girder structure only. The size
and location must be approved by the Purchaser.
(2)
A plate showing year and place of manufacturing, mfg. no., principal dimensions,
speeds and capacity of the Crane shall be fitted in the operators cab.
(3) Manufacturers name plate shall be fitted on each major electrical and mechanical
component showing type, capacity, serial number, manufacturers number
manufacturing date etc, for future reference.
6-4.5. Other Signs
6-5.
(1)
A plate indicating lift height of the Crane shall be fitted at upper front wall of the
operators cab (in Polish and English, size 75mm x 900mm). Wording shall be
provided by the Purchaser in design stage.
(2)
Each element of machinery shall be properly labelled for its direction of motion or
operation and for any precautions to be taken before operation or maintenance.
(3)
Labels and caution plates shall be in Polish and English. Other signs shall be subject
to the approval of the Purchaser in English.
throughout the painting operations.
Alarm, Warning Signals
6-5.1. Gantry Travel Warning

(1)
Four (4)-flashing electronic type strobe warning lights shall be installed at four
corners of the crane. These lights shall be activated automatically by gantry motion.
The type must be approved by the Purchaser.
(2)
One common amplifier for travel alarm sound and emergency warning sound shall
be installed inside the panel house, and the alarm and warning sound shall be
emitted through four (4) speakers installed at four corners of the crane. The gantry
travel alarm sound shall be automatically activated and sustained during gantry
motion. The alarm tone shall consist of an intermittent signal, sounding at 1 second
for duration of 0.5 second. The emergency warning sound shall be activated by the
operator by pressing down the foot switch on the floor of operations cab, and it shall
override the travel alarm sound when pressed during gantry motion. The type of
both travel alarm and emergency warning sounds to be approved by the Purchaser.
(3)
The alarm sounder speakers shall be located at a maximum height of 2.5m above
ground level. The generated signal level shall not be less than 95dB at 1 KHz at the
point 1m forward of each speaker measured at a height of 1.5m above ground level.
The signal shall not exceed the above limit by 3dB.

Page: 91
(4)
The volume of the warning sounds to be adjustable at the amplifier for travel alarm
sound and the emergency warning sound independently.
6-5.2. Main Hoist Overload Warning

(1)
Main hoist system shall include overload warning and tripping system to satisfy
statutory requirement.
i)
80% load for over 3 second: Intermittent warning signal.
ii)
100% load for over 3 seconds: Continuous warning signal.
iii)
110% overload for over 3 seconds: Trip hoist motion. Allow lowering
motion in slow speed only.
6-5.3. Premature Twistlock Operation Warning

(1)
Spreader twist lock movement shall be mechanically and electrically interlocked

with spreader landing detection so that lock movement is prohibited unless all the
twist locks are confirmed to be inserted into the corner fittings. The landing signal
shall allow a one (1) second time lag to indicate the completion of landing to the
operator and to trigger interlock so that momentary landing completion signal do not
activate interlock.
(2)
The premature locking movement before the spreader is landed on a container or

hatch cover shall be prohibited by means of electrical interlock on the logic control
circuitry and mechanical interlock. There shall be no physical movement of the
twist locks on the spreader even though the switch is turned to Lock position
before landing is completed as described in 6-5.3(1) above. Audible and visual
alarms noticeable at ground level and at inside the operators cab shall be activated
by this premature turning of the lever type twist lock switch and all motions of the
crane shall be deactivated. Both audible and visual alarms shall cease when the
twist lock switch is returned to its original position. The alarm tone shall be
(3)
The premature unlocking movement while suspending the load with twist locks
shall be prohibited by means of electrical interlock on the logic control circuitry and
mechanical interlock. There shall be no physical movement of the twist locks on the
spreader even though the switch is turned to Unlock position while the load is
suspended with twist locks. Audible and visual alarms noticeable at ground level
and at inside the operators cab shall be activated by this premature turning of the
lever type twist lock switch and all motions of the crane shall be deactivated. Both
audible and visual alarms shall cease when the twist lock switch is returned to its
original position. The alarm tone shall be approved by the Purchaser.
(4)
The twist locks shall remain on its last position after power interruption, i.e. failure
and resumption of electrical power.
6-5.4. By-Pass Switch Abuse Warning

Page: 92
(1)
For difficult situation during operation when encountered by the operator to handle
containers, an interlock override spring return key switch shall be installed on the
console or near the console apart from normal operational control switch group to
overcome difficult situations that may be encountered during container handling
operations. The key switch shall be spring return type key switch.
(2)
Twist lock interlock bypass spring return key type switch - When this is turned to
handle a difficult situation in order to carry out hoisting or lowering function, an
alarm sound shall be broadcasted by an independent amplifier through a speaker
located outside the operators cab and face downward. The hoisting speed and the
trolley speed shall be at slow down mode since this is a difficult condition and safety
is required.
(3)
Landing bypass spring turn key switch - When this spring return key switch is
turned to allow the twist locks to turn in case of difficult condition, such as deformed
containers, an alarm sound shall be broadcasted by an independent amplifier (same
as the one for twist lock interlock bypass spring return key switch) through a speaker
located outside the operators cab and face downward. The hoisting speed and
trolley speed shall be at slow down mode since it is an abnormal condition and
safety is required.
(4)
Labels shall be provided for each switch and indicator in both Polish and English.
6-5.5. Electrical Control House A/C Warning

Control house shall be well insulated to keep the inside temperature below 25 deg. C all the
time (Ref. to 4-5.2. (1)). The air conditioning system failure shall be indicated at outside of
the room or indication of warning in the CMS, and a warning buzzer in the operators cab
shall be activated in case inside temperature of the panel room rises over 40 degree C. The
air conditioner main circuit shall be activated when the power supply is turned on and
deactivated when the power supply is cut off. Duplicate air conditioning units shall be
provided to ensure that the failure of one unit does not stop the crane operation. Each unit
shall be rated to maintain the set conditions independently of the other.
6-5.6. Public Address/Warning
(1)
An independent public address amplifier shall be installed inside the operators cab
and protected against interference by a key-locked cover door.
(2)
The public address amplifier shall be activated in case of premature locking and
premature unlocking of the twist lock lever type switch with an alarm sound
through a speaker outside the drivers cab. The alarm shall be deactivated when the
lever type twist lock switch is returned to its proper position.
(3)
The public address amplifier shall be activated in case of turning the twist lock bypass or landing by-pass key type spring return switch to On position with an alarm
sound through the speaker same as above (2). The alarm shall be deactivated when
the spring return key switch is released and to the off position.

Page: 93
6-6.
Emergency Stop Push Buttons

The emergency stops shall be hard wired independent circuit that will stop all motions and
isolate power to all drives. PLC shall be configured to monitor E-stop circuit for isolation
and CCMS purposes.
6-6.1. Locations
Total eight (8) emergency stop push buttons shall be installed on the Crane.
1
Near Main Hoist motor.
Near Trolley Travel motor.
In Operators Cab (1 for motion stop).
Two each at panel side and cable reel side sill beams or other Purchasers approved
position, at ground level facing outside and inside of the Crane to be readily reached
by ground operation personnel.
6-6.2. Type
Mushroom head emergency stop pushbutton (self latch) switches shall be provided. All
emergency stop buttons shall be recessed to prevent it from being actuated accidentally.
6-6.3. Emergency Stop Signs
Adequate signs shall be provided in Polish and English to enable easy identification of their
locations to ground level personnel. The size of the sign board shall be 300mm x 300mm
minimum.
6-7.
Service Outlets
6-7.1. Location
(1)
Two independent service outlets (one pair) which conform to BS1363 and AS3122
standard respectively, with ground, 220V, 1-phase, 13 Amp. capacity shall be
provided and mounted adjacent to each other as a combination at following locations:
i)
ii)
iii)
One pair in the Operator's cab.

One pair in the control panel house on the wall.
One pair at ground level, one each under cabe reel side and panel side sill
beam, facing inside of the Crane.
6-7.2. Type Model

Page: 94
Matching plug of industrial type for each outlet (one plug per outlet) shall be supplied by the
Contractor.
6-8.
Fire Extinguishers
All fire extinguishers shall be placed on a properly designed holder so that they are firmly
secured and easily accessible. The lower part of the holder shall have a cylindrical wall of
at least 150mm in height and 3mm in thickness. Drain hole shall be provided at the lower
part to release water. A fast releasing type clip or fastener shall be installed at the upper
part of the holder so that the fire extinguisher could be released quickly. This holder shall
be fixed permanently to a permanent structural member of the Crane.
6-8.1. Locations
(1)
(2)
(3)
(4)
Outside panel house one (1) of 5kg capacity.

Outside transformer house one (1) of 5kg capacity.
Outside drivers cab one (1) of 2kg capacity
Trolley frame one (1) of 5kg capacity
6-8.2. Type-Model
All the fire extinguishers shall be CO2 type of local Government approved model, and shall
be locally refillable by a government approved contractors.
6-9.
Maintenance Tools and Equipment
6-9.1. Mechanical Maintenance Tools

i)
One (1) piece of torque wrench with socket sets (for adjustment of rail bolts).
6-9.2. Electrical/Electronic Maintenance Tools

(i)
(ii)
Two (2) computer notebooks shall be provided.

Five (5) units of digital multi-meter equivalent to Fluke 87 model.
6-9.3. Hydraulic Maintenance Tools

NOT USED.
6-9.4. Special Tools and Equipment
(1)
One unit of portable control panel for operating and testing spreaders in the
workshop and at site for maintenance and fault diagnostic. The panel shall
incorporate functions of push button switches, selector switches, indicator lamps,
PLC, input / output devices, spreader multi-pin connector, cables and all parts and

Page: 95
software necessary for operating and confirming all the functions and safety features
of the spreader. Power supply cable and plug shall be provided if necessary.
(2)
Special tools and jigs necessary for mechanical, electrical and electronic
maintenance works shall be supplied with the Crane, and stored in appropriate
locations of the Crane.
6-9.5. Wear Gauges

i)
2 - complete sets of wear gauges which can indicate the amount of wear, made of
steel plate, shall be supplied with the Crane stored in an appropriate storage box
fitted on the Crane for,
a.
b.
c.
ii)
All the sheave grooves.

All the gears for main hoist, trolley travel (including rack and pinion) and
gantry travel.
Trolley wheels.
Each wear gauge shall be clearly marked with component name to be gauged.
7. Project Q.A. and Administrative Requirements

7-1.
Document Submission (Project)
7-1.1. Project Organisation Chart (Shop & Site)

(1)
The Contractor shall submit to the Purchaser a project organisation chart within one
(1) month after the date of the Agreement.
(2)
The schedule shall show the organisation of the Contractors resources, which he
intends to employ in the total project from shop manufacturing through to the site
commissioning phases. This will clearly identify the departments involved, the
people responsible for each and the number of personnel directly involved in
administering the project.
7-1.2. Project Schedule (Shop & Site)

(1)
The Contractor shall submit to the Purchaser a project schedule within one (1)
month after the date of the Agreement.
(2)
The project schedule shall be presented in the form of a timed schedule covering all
activities appertaining to the manufacture of the Crane(s). The contents shall include
but not be limited to the following: i)
ii)
iii)
iv)
v)
vi)
Contract start date.

Engineering Design Period.
Submission of Drawing/Design Calculations.
Procurement of Materials and Components.
Manufacturing Periods for the main Structural Sections.
Erection in the Contractors Facility.

Page: 96
vii)
viii)
ix)
x)
(3)
Shop Test and Commissioning.

Transportation Period.
Site Commissioning.
Completion Date(s)
The project schedule will be provided in a format approved by the Purchaser and
shall be presented in a way that clearly shows each activity connected in a logical
programme sequence. Each activity shall show the duration, early start and early
finish and shall identify the critical path of the project.
7-1.3. Project Progress Report

(1)
The project schedule shall subsequently be updated and submitted to the Purchaser
at intervals of no more than 1 month throughout the course of the project.
(2)
The monthly update will show actual progress against the original baseline so that
effect of any slip or improvement in progress can be easily identified.
7-1.4. Quality Assurance Programme/ Manuals

(1)
Contractor shall submit to the Purchaser a quality assurance programme for review
within one (1) month after the date of the Agreement.
(2)
The programme shall consist of General Quality Assurance Program, which states
Contractor's general practice and organisation to assure quality during design,
procurement, fabrication and erection periods, and a Specific Quality Assurance
Programme.
(3)
The Specific Quality Assurance Programme is particularly for the Cranes and
Related Equipment in this Contract, which shall include drawings / data submittal
schedule for review of drawings by the Purchaser and key inspection and test items
during fabrication and delivery up to hand over of the Crane or other Goods to the
Purchaser with proposed timing and locations of conducting such inspection and test.
This Programme must cover all the inspection and review items as set out in
Appendix II "Inspection Control Sheet" and Appendix V "Minimum Requirement
for Drawings / Calculations / Data Submission".
An organisation chart with names of the quality assurance team personnel for the
Agreement for each major stage of fabrication, delivery, commissioning and Defects
Liability Period shall be included in this Programme.
7-1.5. Daily Plan and Report (Site Work)

.
For the duration of the period of site work at the Purchasers premises, the Contractor shall
submit, at daily intervals in a form approved by the Purchaser, his progress of activities and
tests carried out. This daily plan shall also indicate weather conditions, number of
Contractors personnel and sub-contractors engaged at site together with the activities
planned for the next day.

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

The Contractor shall submit technical information at the times outlined below for the
Purchasers review.
7-2.2. Conceptual Design
The Contractor shall, submit to the Purchaser a conceptual design, within 1 month from the
date of the Agreement which outlines his proposal for the Crane and other Goods. The
design shall show clearly by drawings and description the following details: -
General arrangement of the Crane

Trolley and operators cab
Rope reeving arrangement
Transformer and Electrical House
Shore power supply system
Lower Crane structure
Gantry equalisers, bogies and wheel arrangement.
7-2.3. Drawings and Calculations for the Purchaser's Review

Following review and acceptance of the conceptual design and prior to the fabrication or
ordering of components, the Contractor shall submit detailed drawings and calculations for
review to the Purchaser. This information shall include but not be limited to the following: (1)
Three (3) sets of structural, mechanical and electrical calculations on all aspects of
the Crane design, for example
-
(2)
Stability and wheel load calculations

Crane structure stress calculations
Fatigue analysis for all stress carrying structural members.
Load combinations for various design criteria.
Design calculations for the hoist, trolley, and gantry
Crane electrical load calculations.
Lighting calculations.
Skew and anti-sway system
Three (3) sets of general arrangement and design drawings showing all elements,
sub elements, component parts, layouts, structure details, connections of the Crane.
The drawings shall include but not be limited to those items listed in the List
contained in Appendix V.
(3)
General arrangement drawings, calculations and drawings other than listed in above
list, which clarifies further details, shall be submitted from time to time at the request
of the Purchaser for review.

Page: 98
(4)
Three (3) -copies each shall be submitted for the review.

Contractor shall submit any other documents as requested from time to time by the
Purchaser.
The Purchaser's comments on the drawings or submittals shall not waive
Contractor's duties or obligations to achieve satisfactory performance of the Crane
and all other Goods as set out in the Conditions of Contract, specifically Clause 3
and to otherwise comply with the Contract. The Purchaser undertakes no duty to the
Contractor to neither identify nor notify to the Contractor any errors or omissions in
the Contractor's design.
One month before the shipment of the first Crane(s), the Contractor shall submit to
the Purchaser four (4) sets of all drawings reviewed and if necessary revised
according to the Purchaser comments or for other agreed reasons
7-2.4. Lubricant List

(1)
The Contractor shall supply a complete list of oil and lubricants to be used on the
Crane three (3) months prior to the test of the Crane in Contractor's shop for the
Purchaser's approval.
(2)
All the oil and lubricant used for the crane shall be Shell lubricating oils.
7-2.5. Crane Delivery Method Statement

(1)
No later than three (3) months before the arrival of the first Crane(s), the Contractor
shall submit a method statement for the Purchasers approval for the roll-off or
lift-off of the Crane(s) and other Goods to the Purchasers quay deck. The method
statement shall include: (i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(2)
The total area required for the roll-off operation.

Full details of the transportation vessel and the stowage of the Crane(s)
Orientation of the vessel when offloading
Number and position of bollards and moor lines,
Length and position of sea anchors. (if applicable)
System of transferring the Crane to the quay deck
All skid beams and skid beam centres. (If applicable)
All positions and magnitude of loadings applied to the quay deck during the
offloading operation.
The proposal shall also show a period of occupancy and the length of the Purchaser's
berth required for roll-off or lift-off operation
7-2.6. Site Work Method Statement

(1)
No later than three (3) months before the arrival of the first Crane(s), the Contractor
shall submit to the Purchaser a site work method statement for the Purchasers
approval showing all activities from arrival of the Crane(s) through to acceptance.
The method statement shall include:

Page: 99
i)
ii)
iii)
iv)
v)
vi)
vii)
The total area required to commission the crane(s) and to store the loose
items and spare parts. (This will be strictly subject to the Purchasers approval)
Roll-off or Lift-off scheme and date of performance.
Key activities of the commissioning and duration.
Number of days required from the date the Crane is ready for starting up and
load testing.
Date the Crane will be Commissioned and handed over to the Purchaser.
Date the Crane will be finally handed over to the Purchaser.
Other key dates of significance.
7-2.7. Commissioning Test Procedure.

(1)
No later than four (4) months before the arrival of the first Crane(s), The Contractor
shall submit to the Purchaser for his approval a Commissioning Test Procedure.
(2)
The Commissioning Test Procedure shall be in a form of a document and shall

contain detailed field and function check procedure to fully demonstrate that the
Crane and other Goods meet the requirements of the Agreement including suitability
of the Crane for container handling operations. The procedure shall describe the
tests to be performed, the indications to be measured and the method by which they
are measured. It shall contain the design or acceptable values of each measurement
along with blanks in which the tester can enter the measured values.
(3)
Provision shall be made within the procedure for the tester and the Purchasers
Representative to initial and date each separate test.
(4)
The Commissioning Test Procedure shall be duly completed by the Contractor

following each individual test or each series of tests conducted at the Contractors
facility or at site. Where necessary the Purchasers Representative shall verify the
results.
(5)
The Contractor shall submit the completed Commissioning Test Procedure no later
than one (1) month after the notification of successful completion of the
Commissioning Test for the Goods in question.
7-2.8. Up-Dated Drawings

(1)
No later than one (1) month after the date of the Agreement, the Contractor shall
submit to the Purchaser full details of the Contractors system of drawing
management, which shall be maintained throughout the project.
(2)
The Contractor shall demonstrate to the Purchaser that a logical system of drawing
administration exists. And the system shall clearly establish to the Purchaser, the
procedures and current practices in place which deal with alterations, modifications
and re-issue of drawings from the design stage through to the as built drawings.
Such system shall, as a minimum, provide for two (2) copies of each and every
drawing amended relating to this contract and which is during the course of the
contract, to be forwarded to the Purchaser for their remain and approval if

Page: 100
appropriate. A system of issuing internal change without notice to the Purchaser is
not acceptable.
7-2.9. Training Programme
(1)
No later than three (3) months before the arrival of the Cranes, the Contractor shall
provide a comprehensive training programme to cover the theoretical and practical
training requirements for the Ports Crane operators, electrical and mechanical
tradesmen and electronic technicians. The programme shall be aimed at all aspects
of the Crane in the respective disciplines in order to provide the trainees with a
sound basic knowledge of the Crane(s) and their systems
(2)
The Contractor shall use the training personnel from the sub-contracted suppliers
where possible and shall not rely upon untrained trainers or site commissioning
personnel.
(3)
The scope of training to be conducted for the disciplines shall be generally as

outlined in 7-5
(4)
The language used for the training shall be Polish/English.
7-2.10. Structural maintenance Program

(1)
The contractor shall submit a Structural Maintenance Program for review. The program
shall be based on the principles of fracture mechanics. This program shall include:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Inspection intervals
Locations to be inspected
NDT procedures to be used
Reporting procedures
Repair procedures
Documentation showing the parameters used to determine the inspection intervals in
accordance with the criteria specified below.
(2)
The first structural inspection will be made during the defect liability period, but later than
after 200,000 moves, in accordance with the Structural maintenance Program. The
inspection results will be given to the Contractor. Within 30 days, the Contractor shall
submit a plan to repair any defects found. Upon Purchasers approval of the Contractors
plan, the Contractor shall repair the defects at their expense.
(3)
Later inspections will be made according to the recommended inspection interval, which
shall be included in the Structural Maintenance Program. The inspection interval shall be
determined according to the following table Inspection Interval Criteria. Locations where
the cumulative damage ratio is less than the minimum 24 year values do not need to be
included in the Structural Maintenance Program. The first inspection period will begin after
completion of the first inspection during Defect Liability Period.
(4)
The inspection method shall be selected to detect fatigue cracks. Only the critical locations
need to be inspected by NDT. The critical locations on all members are those locations
where fatigue cracks, if any, would be expected to initiate. The inspected region shall extend

Page: 101
a reasonable distance beyond the critical point. MT shall be used at the critical locations of
fillet welds and UT shall be used at the critical locations of butt welds. VT shall be used at
all locations of potential fatigue cracks.
(5)
The Contractor shall provide permanent access ladders and platform at all inspection
locations, with inspection interval of 12 years or less. Access shall meet applicable safety
laws and regulations.
INSPECTION INTERVAL VS. CUMULATIVE DAMAGE RATIO D = L/K1 OR 2

DETAIL
24 YEARS
12 YEARS
6 YEARS
NFCM
FCM
NFCM
FCM
NFCM
FCM
B
0.21
0.41
0.19-0.38
0.39-0.64
0.70-1.00
0.65-1.00
C
0.18-0.36
0.17-0.33
0.37-0.62
0.34-0.57
0.63-1.00
0.58-1.00
D
0.18-0.35
0.16-0.33
0.36-0.61
0.34-0.56
0.62-1.00
0.57-1.00
E
0.15-0.29
0.13-0.26
0.30-0.50
0.27-0.45
0.51-1.00
0.46-1.00
G
0.17-0.34
0.16-0.31
0.35-0.58
0.32-0.53
0.59-1.00
0.54-1.00
F2
0.16-0.32
0.15-0.29
0.33-0.56
0.30-0.51
0.57-1.00
0.52-1.00
G
0.21-0.41
Not
0.42-0.70
Not
0.71-1.00
Not
allowed
allowed
allowed
W
0.20-0.40
0.19-0.37
0.41-0.69
0.38-0.64
0.70-1.00
0.65-1.00
TUBULAR 0.20-0.35
0.15-0.30
0.36-0.64
0.31-0.50
0.65-1.00
0.51-1.00
Inspection Interval Criteria
7-2.11. Operation Manuals
(1)
The Contractor shall provide operating instruction manuals (in Polish and English)
to the Purchaser two (2) months before the date of the first Crane departure from the
Contractor's assembly yard.
(2)
The operating instruction manual shall clearly state the start up procedure of every
device on the Crane including all bought-in equipment, and all the points to be
observed or checked during the start up.
(3)
Corrections shall be made by the Contractor to the Manuals for any changes made in
the instructions during the commissioning period, and the revised instruction
manuals shall be submitted one (1) month after the notification of successful
completion of the Commissioning Test of the first Crane(s)
(4)
Two sets of above instructions shall be submitted in a CD ROM format.
(5)
Please refer to Appendix VI for the list and quantity of operation manuals.
7-2.12. Maintenance Manuals

(1)
The Contractor shall provide maintenance manuals (in Polish and English) to the
Purchaser two (2) months before the date of the first Crane departure from the
Contractor's assembly yard.

Page: 102
(2)
The maintenance manual shall include a complete list of wearing parts showing the
allowable limit of wear for each part.
(3)
The manual shall include maintenance intervals and procedures for all the bought-in
equipment, and also calibration instructions and standards for meters, gauges and
any components which require periodical calibration to allow calibration by the
Purchaser's maintenance staff.
(4)
The relevant parts of manuals shall be revised and resubmitted as soon as practicable
by the Contractor for any changes in system or component design.
(5)
Two sets of manual in CD ROM shall be submitted.
(6)
Please refer to Appendix VI for the list and quantity of maintenance manuals.
7-2.13. As-Built Drawings

The Contractor shall submit to the Purchaser 3-full size copies and three sets in CD ROM
(in Polish/English version, Auto-Cad or Acrobat format) of the following as-built drawings
within 30 days after the date of Commissioning Certificate for the first Crane(s) to achieve
Commissioning. Please refer to Appendix VI for the list and quantity of as built drawings.
(1)
All drawings that were previously submitted for the Purchaser's review and revised
as built as at the shipment date.
(2)
Detailed drawings for wearing parts showing machining tolerances, wherever

applicable, and wear limits:
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
Brake drums (or discs)

Brake shoes
Wheels
Sheaves
Anti-friction bearings
Bushes
Bearing plates
Oil seals and O-rings
Wire rope drum
Wire rope drum coupling
Rail
Gears
Rack and pinion
Table for consumable parts of electrical machineries
All other wearing parts
(3)
Detailed electrical control circuit drawings, control logic programs, and wiring
diagrams.
(4)
Full details of all bought-in equipment, drawings instructions, etc.

Page: 103
(5)
List of structural connection bolts and machinery fitting bolts with tightening torque
value for each location/size.
The Contractor shall revise and resubmit drawings for replacement in case any
modification or revision is made on the Works after the initial submission.
7-3.
Shop Inspection & Tests
7-3.1. Shop Inspection and Verification

(1)
Inspection and testing of the Crane shall be performed by the Contractor to verify or
demonstrate the Crane's conformance to this Specification and the other Contract
Documents, following the approved Specific Quality Assurance Programme as
stated in 7-1.4.(3).
(2)
Without limitation to the Purchaser's rights under the Agreement, the Contractor and
the Purchaser shall agree to the content, nature and extent of the review, inspection
and tests to be carried out to any of the Goods at each of the following stages:
i)
ii)
iii)
iv)
v)
vi)
Design.
Fabrication and assembly;
Pre-shipment;
Upon Delivery;
Tests pursuant to Clause 13 of the Conditions of Contract, which, if
successful will lead to the issue of a Commissioning Certificate.
Such further tests as otherwise may be required that in the opinion of the
Purchaser is pursuant to Clause 9 of the Conditions of Contract.
(3)
The Contractor shall notify the Purchaser of the date and place of each key
inspection or test, at least three (3) weeks prior to the date when the key inspection
or test is to be made.
(4)
Inspection and test items shall generally include (but not limited to) the following
fundamental items.
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
Materials and components sources and identification of standards applied.

Workmanship overall.
Painting
Inspection of Operational and Maintenance Safety, Test of all safety
equipment and safety devices.
Inspection of Operational Efficiency, Functional Test of all components
equipped for operation.
Inspection of Maintenance Efficiency, Functional Test and inspection of all
equipment for maintainability.
Rated Load Tests, 1/2 Loads Tests, 1/4 Load Tests and No Load Tests
including Anti-sway Function Test and Measurement of Speeds and
accelerations.
Overload Tests including Stability Test and Measurement of Structural
Deflection.

Page: 104
ix)
x)
xi)
xii)
Accessories and Spare Parts Inventory.

Operating Instruction and Maintenance Manual Review.
Weight verification as necessary.
Statutory inspection and tests.
(5)
The Purchaser reserves the right for itself or any party authorised by the Purchaser to
inspect the Crane or other Goods at any time including during fabrication and
delivery.
(6)
Any inspection or test results verified by the Purchaser shall not waive Contractor's
duties or obligations to achieve satisfactory performance of the Crane in actual
operation as set out in Clause 3 of the Conditions of Contract or any other obligation
or liability of the Contractor.
(7)
The Contractor shall submit to the Purchaser a list of designed weights of the
moving loads, namely, the trolley, operator cab and spreader, and any other moving
loads, when the design of these components are completed.
(8)
At the same time, Contractor shall submit a list of calculated maximum structural
stresses at critical points of the Crane structure.
(9)
The Contractor shall verify the calculated stress level by actually weighing these
moving weights after the fabrication and assembly are completed.
(10)
The weight of trolley assembly, operator cab assembly and spreader assembly shall
be weighed by a third party, who will issue an authorised certificate. The Certificate
shall be submitted to the Purchaser.
(11)
The Contractor shall be responsible for maintaining the calculated stress level within
allowable limits. If there are differences between the designed weights and the actual
measured weights, the Contractor shall re-submit calculations of all stress levels
based on the true weights to show that the levels are maintained within requirements.
Any stress levels over the allowable limit will require a redesign to be carried out by
the Contractor.
(12)
The recalculation and if necessary the redesign plan shall be submitted to the
Purchaser for review no later than commencement of the pre-shipment Crane
assembly load test.
7-3.2. Pre-Shipment Inspection and Test

(1)
The Crane is to be fully erected in the Contractors facility and tested prior to
shipment.
(2)
The Contractor shall prepare a shop assembly and Crane erection programme
including all tests and dimensions to verify the proper installation and assembly of
the Cranes components. The drawings shall include assembly procedures, drawings,
dimensional acceptance criteria, structural member dimensional checks, structural
frame alignment dimensions, structural pin and bore fits, structural bolt torques and
machinery alignments.

Page: 105
7-4.
(3)
The Contractor shall inspect the assembly of components and Crane erection
throughout the process to verify and to be satisfied that the requirements of the
Specification are being fully complied with in all respects.
(4)
The Crane shall be fully lubricated in accordance with the manufacturers

recommendation prior to any shop testing. A lubrication checklist shall be included
in the test documentation.
(5)
The assembled Crane shall be inspected and tested at the Contractors assembly
facility. All installations and functions shall be verified for compliance to the
Specification. The Crane testing shall as a minimum include the following: (i)
Verify main hoist, trolley and gantry speed, acceleration according to

Specification (See 2-7.1)
(ii)
Verify power supply according to Specification (See 2-7.4)
(iii)
The sway control and anti-sway system shall be set up and tuned under a
range of load conditions. Verify the sway control and the effectiveness of
the mechanical anti-sway.
(iv)
Skew motions.
(v)
Interlocks and limit switch settings, and software.
(vi)
Brake dynamic torque values shall be verified for each drive by driving
through each brake and calculating the braking torque from the current draw.
Thermal capacity of the brakes shall be verified in the same manner with
torque, time and brake revolutions recorded. All brakes shall have their
linings properly burnished or seated to the manufacturer's recommendations
prior to conducting these tests.
(vii)
Wheel turning.
(viii)
Spreader functions.
(ix)
Check structural alignment and integrity.
(x)
Inspect and demonstrate that all electrical wiring and wiring components are
installed and properly marked.
(xi)
Emergency stop and all safety protections.
(xii)
On-Board CCMS
(xiii)
Endurance Test (See Clause 7-5.5)
Shipment, Delivery and Site Work

The crane(s) shall be delivered by self-propelling transportation vessel.

Page: 106
7-4.1. Clearance for Shipment

The Crane(s) shall be totally assembled in the Contractor's yard and tested for functions of
all the devices before shipment. The Load test is essential to be performed in the
Contractor's yard. Heat run tests and operational check of interlocks and safety devices shall
be performed through the permanent control gear and components installed on the crane in
the Contractor's yard.
7-4.2. Notification of ETA Site.
(1)
The Crane shall be in fully assembled condition when delivered to the quayside of
the Port.
(2)
The Contractor shall notify the Purchaser of the estimated time of arrival of the
marine transport vessel ("ETA") which is carrying the Goods (or any part of the
Goods) at least 14 days prior to such ETA. Upon receiving such notice, the
Purchaser shall tentatively allocate a berth at Site for delivery and unloading of the
Goods. The Contractor shall confirm to the Purchaser the date of actual departure of
the vessel from the loading port and thereafter the daily Noon position of the vessel
together with an up-dated ETA by daily facsimile transmission to the Purchaser.
The exact berthing time and berthing position for the vessel shall be agreed and
fixed at least one day prior to the ETA between the Purchaser and the Contractor
based on the Contractor's daily position and ETA report.
(3)
The Crane shall be rolled off or lifted off from a vessel onto the designated position
of the quay, then shifted to a designated test position by the Contractor. Such
operations shall in no way over-stress any part of the piled quay deck or the yard.
Specifically any loads on the quay apron waterside of the waterside crane rail beam
(overhung slab) are prohibited.
7-4.3. Navigation Requirement

(1)
The Contractor shall be responsible for following all necessary procedures to ensure
the safe passages of vessels whilst navigating in the Port. The Contractor shall
maintain close contacts with the relevant Poland Maritime Authorities and Port
Authority.
7-4.4. Berthing and Roll-off Requirements

(1)
In order to minimize the occupation of the Purchasers facilities, the contractor

shall finish all necessary preparation before berthing to Purchasers terminal.The
time allowed for the vessel to stay at the Purchaser's berth for the delivery and
unloading of the Goods shall be as provided for in the Conditions of Contract
calculated from the agreed time of berthing as set out in 7-4.2 (2) above
notwithstanding the actual time of the berthing of the vessel.

Page: 107
(2)
The vessel must leave the berth as soon as practicable after completion of the
unloading even if this occurs before the expiry of the time allowed as referred to in
Clause 7-4.4. time limit. The Contractor shall inform to the Purchaser the estimated
time of departure (ETD) of the vessel at least four (4) hours before such ETD.
(3)
All the necessary calculations, design, engineering, preparation works and clean up
works for the roll-off and shifting the Crane to a designated test position and testing
at the Site shall be the responsibility of the Contractor. The preparation works shall
include obtaining necessary technical information of the quay and the Port generally
from outside consulting engineers and elsewhere as necessary, and obtaining
necessary clearance or permit for the works from government offices and all other
competent authorities concerned.
(4)
The Contractor shall have obtained all necessary approval, clearance, permits etc
required for the site works prior to the vessel departing from the Contractors facility
7-4.5. Customs Clearance

The consignee for shipment of all the Goods shall be the Contractor. Import declaration and
cost thereof shall be the responsibility of the Contractor.
7-4.6. Work Permits
All engineer/supervisors dispatched for start-up, testing and training shall obtain proper
working visas for Poland which must be valid for entire estimated and, if longer, actual
period of stay.
7-4.7. Site Safety and Security
(1)
The Contractor shall comply with the Purchaser's security requirements for making
entry or exit to and from the Port, and inside the Port.
(2)
The Contractor and its subcontractors shall be responsible for protecting their own
plants, tools, temporary site offices and other belongings from weather, fire or theft.
The Crane and other Goods shall be protected by the Contractor from typhoon, fire,
collision and any other possible risks until the Crane or other Goods is
Commissioned and handed out to the Purchaser.
7-4.8. Site Erection Area and Access

NOT USED.
7-4.9. Site Office Communication
The Contractor shall at his own cost provide for the installation of a telephone line for
outside call and facsimile purposes.

Page: 108
7-4.10. Test Weight

The load test weights shall be provided by the Contractor for the load testing and adjustment
of the Crane.
7-4.11. Water, Electricity Supply
The Contractor shall at his own cost provide for the installation of suitable metering
equipment, supply fix and dismantle after use all pipework, valves, meters, cables,
switchgear etc and shall pay for the cost of supply of water, diesel and electricity that he
may require for any purpose.
7-4.12. Contractors Representatives.
7-5.
(1)
One Polish/English speaking principal site engineer shall be dispatched prior to

arrival of the Crane(s) to plan and coordinate the work and to communicate with and
report to the Purchaser. He shall stay in the Purchasers locality for the entire period
from delivery to Commissioning, Final Acceptance of the Crane to the Purchaser.
(2)
A sufficient number of qualified start-up engineers and training engineers shall be

dispatched to the Port to handover the Cranes in an expeditious manner.
Site Inspection and Tests, Certification
7-5.1. Commissioning Tests Application

(1)
The Crane or other Goods shall be verified at Site as operational and safe under any
load conditions prior to the Commissioning Tests. Only minor items pertaining to
maintainability which do not affect the safety of operations or maintenance work
may be allowed by the Purchaser as a pending item for correction at the time of the
Commissioning Certificate. These items shall form part of the Defects List. Refer to
7-6.
(2)
The Commissioning Tests which will be as defined in the agreed Commissioning

Test Procedure. (See Clause 7-2.8) The Contractor shall show the Purchaser by
documentation or by physical demonstration (in either case as determined by the
Purchaser) that all functions of the Crane or other Goods are safe and conform to the
Agreement. The Contractor shall correct or modify whatever aspect is found unsafe.
The Crane(s) and shall pass the statutory tests, which will be carried out and
witnessed by the Purchasers Representative.
(3)
Application for inspection for the Commissioning Tests must be submitted to the
Purchaser's in writing at least 2 days prior to the intended inspection date.
7-5.2. Defects List

(1)
The Purchaser or his representative shall be allowed to gain access to any part of the
Crane(s) or other Goods during their assembly at the Contractors facility and at any
other time for the purposes of inspecting part or completed works. If in their opinion

Page: 109
certain parts of the works does not meet with the requirements of the Agreement, or
is deemed as bad practice or poor workmanship, then these shall be noted as a defect
and informed to the Contractor in a list.
(2)
The compilation and provision of this list by the Purchaser or his representative will
in no way relieve the Contractor from his obligation to provide defect free Crane(s)
or other Goods.
7-5.3. Rectification Report

The rectification of defects in the defects list shall be carried out in a thorough and
workmanlike manner. The Contractor shall prepare and submit to the Purchaser a
rectification report that confirms defect completion together with a description of the action
taken.
7-5.4. Commissioning Test

The Contractor shall carry out a series of tests as outlined and defined in the Commissioning
Test Procedure in order to prove that all requirements and functions of the Crane(s) or other
Goods meets with the Agreement. The Crane(s) or other Goods will be required to undergo
inspection and test and performance trials in order to achieve a Commissioning Certificate.
The contractor shall submit a commissioning test programme to the purchaser at least 30
days before commencing for comment.
7-5.5. Endurance Test.
(1)
The Endurance Test forms part of the Commissioning Test. The Crane(s) shall be
required to undergo a test to demonstrate the combined operation of all Crane
systems and the reliability of the components. The endurance test shall consist of
repetitive cycling as follows whilst handling the Cranes rated load
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
Pick up the container from roadway (3 meters from leg centre).

Hoist 15 metres.
Trolley forward 10 metres.
Lower 15 metres.
Wait 5 seconds.
Hoist 15 metres.
Trolley backward 10 metres.
Lower 15 metres.
Unlatch and hoist 1 meter.
Lower 1 meter and latch.
Repeat
After each 30 minutes operation the Crane(s) shall be gantried for a
minimum of 125 metres at full speed to a transfer position, the wheel rotated
through 90 degree, wait for 1 minute, wheels rotated through 90 degree and
the Crane gantried back to the original test position.

Page: 110
This cycle is a preliminary proposal and the final test cycle shall be determined by
the Crane configuration and in agreement with the Purchaser.
(2)
The cycling test shall be continued for a period of 24 hours and in the event of a
malfunction shall be continued until 24 hours of trouble free operation has been
logged. The rate of the endurance test shall not be less than 20 cycles per hour
through the testing period.
(3)
Throughout the period of testing the current, voltage, speed, main drive mechanism
temperature, noise and vibration shall be recorded at intervals of 30 minutes. Any
malfunctions or problems and any remedial action taken during the test shall be
recorded.
7-5.6. Acceptance Certification

(1)
The Commissioning Certificate will be issued on successful completion of the

Commissioning Test, training as defined in Clause 7-5 and issuing of Inspection
Certificate from the Local Labour Bureau.
(2)
The Final Acceptance Certificate will be issued on successful completion of the

Initial Trial Period as defined in Clause 2-4
7-5.7. Access for Remedial Work

Following the issue of the Commissioning Certificate, the Contractor shall be allowed
access to the Crane(s) for remedial work only with the approval of the Purchaser.
7-6.
Training
7-6.1. Training Off-Site.

The Contractor shall conduct training at his works for the Purchaser's operation and
maintenance personnel (total 4 persons) for a minimum period of 2 weeks. This training
shall be at the Contractor's account, including air-fare, transportation and boarding. The
Overseas Training shall be conducted in Polish/English.
7-6.2. Training On-Site (Operators)
The Contractor shall carry out the operator feminization training of the Purchaser's staff
during the on-site commissioning period and for a period of seven (7) days following the
Commissioning Test of the Crane or other Goods. The training shall be conducted by
suitable Contractor trainers in Polish/English. The training shall cater for approximately
eight (8) groups of operators and the content shall include but not be limited to the following:
(1)
Instruction and hands-on training of the cranes start-up procedure.

Page: 111
(2)
Instruction on lighting control.
(3)
Instruction and hands-on training of normal container handling operation in the cab.
(4)
Instruction and hands-on training of normal shutdown procedure.
(5)
Instruction on the use of equipment for emergency.

Emergency stop buttons
Escape route
Fire fighting equipment
Communication
7-6.3. Training On-Site (Maintenance)

The Contractor shall carry out the maintenance training of the Purchaser's staff during the
commissioning period and for a period of seven (7) days following the Commissioning Test
of the Crane or other Goods. The training shall be conducted by suitable Contractor and
Crane or other Goods component supplier trainers. The training shall cater for a group of
approximately five (5) electrical maintenance staff, and a similar group of mechanical
maintenance staff and the content of the training shall include but not be limited to the
following: (1)
Instruction and hands-on training of starting and shutdown procedure.
(2)
Instruction and explanation of all the devices on the Crane (separately for electrical
and mechanical staff).
(3)
Instruction of Start-stop procedure and checking points of all the devices or systems
on the Crane.
(4)
Lectures on electrical/electronic control systems of the Crane and adjustment

method/standards both in a classroom and on the Crane.
(5)
Lectures on mechanical/hydraulic systems of the Crane and adjustment

method/standard both in a classroom and on the Crane.
(6)
Lectures on Condition Monitoring System on the Crane and in a classroom.
(7)
Inspection and Maintenance of Operationally Critical Components.
(8)
Instruction on trouble shooting and repair.

Instruction on emergency equipment.
Emergency stop buttons

Page: 112
Escape route
Fire fighting equipment
Communication
(9)
Instruction on routine maintenance of devices and preventive maintenance plan,

including explanation of special tools, gauges or jigs.
(10)
The Contractor shall provide 6 sets, cost free, reproducible maintenance manual,
operator manual, recommended spare part list and spare part manual to the
Purchaser.
7-6.4. Special Training on the Operationally Critical Components Maintenance.

The operationally critical components (see 2-10) shall be presented and the Contractor shall
therefore prepare and present the training this subject separately.
7-6.5. Spare Parts
7-6.6. Ordered Spare Parts
The Contractor shall warrant in writing its capability for providing spare parts, spare
components, and repair and/or replacement services for a period of 20 years after the Final
Acceptance of the Crane.
7-6.7. Spare parts for Commissioning Work
(1)
The spare parts for the commissioning work shall be provided by the Contractor in
addition to the Ordered Spare Parts and Additional Spare Parts.
(2)
The Contractor shall indemnify the Purchaser against any cost, loss or damage if the
operational Crane(s) suffers stoppage due to the unavailability of an Ordered Spare
Part which has been consumed by the Contractor during the commissioning period
and not replaced before the issue of the Commissioning Certificate.
-End-

Technical Specification For Rubber Tyred Gantry Cranes

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TECHNICAL SPECIFICATION

RUBBER TYRED GANTRY CRANES

Appendix 1 - Technical Specification Feb 2012

[ GCT - RUBBER TYRED GANTRY CRANES ]

Functional requirement for the Crane

[ GCT - RUBBER TYRED GANTRY CRANES ]

[ GCT - RUBBER TYRED GANTRY CRANES ]

[ GCT - RUBBER TYRED GANTRY CRANES ]

[ GCT - RUBBER TYRED GANTRY CRANES ]

Structural Limit of the Crane

Inspection Control Sheets

Crane Interface Drawings

IV. Reference Drawings and Data

Appendix 1 - Technical Specification Feb 2012

[ GCT - RUBBER TYRED GANTRY CRANES ]

Crane Numbers at Ground Level

List of Drawings / Calculations to be reviewed by the Purchaser

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

Appendix 1 - Technical Specification Feb 2012

[ GCT - RUBBER TYRED GANTRY CRANES ]

Functional Requirement for the Crane

Overriding Requirement of the Purchaser

For the paint system acceptable routine maintenance shall be:

For items of electrical and mechanical equipment, controls, systems, components,

Appendix 1 - Technical Specification Feb 2012

[ GCT - RUBBER TYRED GANTRY CRANES ]

The foregoing shall apply notwithstanding any inconsistent requirement or

2. Overall Design Criteria

Operating Environment and Design Aim

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

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

Appendix 1 - Technical Specification Feb 2012

[ GCT - RUBBER TYRED GANTRY CRANES ]

Mode of Operation and Performance Target (MMBF)

Twist Lock Count (TLC) for one week

Statutory Requirements and Minimum Design Standard

Where items are not covered by Poland / European Community Statutory

British Standards Institute

Deutsche Industrie Normen

FEM Federation European de la Manutention

Chinese Standard Institute

International Electro Technical Commission

Appendix 1 - Technical Specification Feb 2012

[ GCT - RUBBER TYRED GANTRY CRANES ]

IEEE Institute of Electrical and Electronic Engineers

International Standards Organisation

Japanese Industrial Standards

Minimum Class of Crane

Normal Load Spectrum factor 0.80 of rated capacity.

General Design Criteria

2-7.1. Crane Particulars

Test load for overload test

51.25 tonnes under spreader.

ISO 20, 40, and up to 53 containers with ISO

20/40/45 telescopic type

Appendix 1 - Technical Specification Feb 2012

[ GCT - RUBBER TYRED GANTRY CRANES ]

23.470mm (77) centres of wheels.

Lift above ground

Not more than 12,200 (40).

Speed Main Hoist

25m/min. minimum with 41 tonne load under

Skew adjustment (*)