7.1 - Mobile Harbour Crane PDF

Volume III – Specifications Coal handling facility at Berth 11, Mormugao Port, Goa
Section 7 – Mechanical Specifications Bid Package Document

Section 7.1 – Mobile Harbour Crane
Contents
1 SCOPE OF WORK ........................................................................................ 1
1.1 INTRODUCTION ................................................................................................................ 1
1.2 WORK INCLUDED .............................................................................................................. 1
1.3 PACKAGING AND SHIPPING ................................................................................................. 3
1.4 SUPERVISION FOR SITE ERECTION AND START-UP.................................................................... 3
2 SITE CONDITIONS ....................................................................................... 4

2.1 SITE LOCATION ................................................................................................................. 4
2.1.1 Road link ................................................................................................................. 4
2.1.2 Rail link ................................................................................................................... 4
2.1.3 Air Link .................................................................................................................... 4
2.2 METEOROLOGICAL AND OCEANOGRAPHY INFORMATION .......................................................... 4
2.3 MATERIAL CHARACTERISTICS............................................................................................... 4
2.4 SERVICE CONDITIONS ........................................................................................................ 4
2.4.1 Berths...................................................................................................................... 4
2.4.2 Wind ....................................................................................................................... 4
2.4.3 Tidal Data ............................................................................................................... 5
2.4.4 Wave Heights ......................................................................................................... 5
2.4.5 Vessel Sizes ............................................................................................................. 5
2.4.6 Levels ...................................................................................................................... 5
2.5 DUTY AND DESIGN REQUIREMENTS ....................................................................................... 5
2.6 TRAVELLING HOPPER REFERENCE DATA ................................................................................ 5
3 CODES AND STANDARDS ............................................................................ 7

3.1 GENERAL......................................................................................................................... 7
4 DESIGN CRITERIA...................................................................................... 11
5 MECHANICAL DESIGN REQUIREMENTS ..................................................... 12
5.1 GENERAL....................................................................................................................... 12
5.2 MATERIALS.................................................................................................................... 12
5.3 SLEWING SYSTEM ........................................................................................................... 13
5.4 SLEWING SPEED ............................................................................................................. 13
5.5 SLEW BEARING ............................................................................................................... 13
5.6 SLEW DRIVE................................................................................................................... 13
5.7 WINCH AND WIRE ROPE SYSTEMS (IF APPLICABLE) ................................................................ 14
5.8 SHAFTING...................................................................................................................... 16
5.9 BOLTS .......................................................................................................................... 16
5.10 ADJUSTING SCREWS ........................................................................................................ 16
5.11 PLAIN BEARINGS ............................................................................................................. 16
5.12 BEARINGS AND BEARING SEALS ......................................................................................... 17
5.13 SPEED REDUCERS ............................................................................................................ 17
5.14 FLEXIBLE COUPLINGS ....................................................................................................... 18
5.15 RIGID COUPLINGS ........................................................................................................... 18
BMT Consultants India Section 7.1 – Page i

5.16 CHAIN DRIVES ................................................................................................................ 19

5.17 V-BELT DRIVES............................................................................................................... 19
5.18 BRAKES ......................................................................................................................... 19
5.18.1 General Requirements ........................................................................................ 19
5.19 HYDRAULIC LUFFING (IF APPLICABLE) .................................................................................. 20
5.20 HYDRAULIC CYLINDERS .................................................................................................... 20
5.21 HYDRAULIC SYSTEMS ....................................................................................................... 20
5.21.1 General ............................................................................................................... 20
5.21.2 Reservoirs ........................................................................................................... 21
5.21.3 Filtration ............................................................................................................. 21
5.21.4 Pumps ................................................................................................................. 22
5.21.5 Hydraulic Motors ................................................................................................ 23
5.21.6 Cylinders ............................................................................................................. 23
5.21.7 Hydraulic Piping .................................................................................................. 23
5.21.8 Control Valves ..................................................................................................... 24
5.21.9 Enclosures ........................................................................................................... 24
5.22 LUBRICATION SYSTEMS .................................................................................................... 24
5.22.1 General ............................................................................................................... 24
5.22.2 Oil Lubrication Systems....................................................................................... 25
5.22.3 Automatic Grease Lubrication ............................................................................ 25
5.23 MANUAL LUBRICATION .................................................................................................... 26
5.24 GUARDS........................................................................................................................ 26
5.25 VENTILATION AND AIR CONDITIONING ................................................................................ 26
5.26 ANTI-COLLISION SYSTEM .................................................................................................. 27
5.27 GRAB BUCKET ................................................................................................................ 27
6 STRUCTURAL DESIGN REQUIREMENTS ...................................................... 28

6.1 GENERAL....................................................................................................................... 28
6.2 VIBRATION .................................................................................................................... 28
6.3 CRANE SUPPORTS ........................................................................................................... 28
6.4 DESIGN DETAILS ............................................................................................................. 28
6.5 DESIGN LOADS ............................................................................................................... 29
6.5.1 General ................................................................................................................. 29
6.5.2 Seismic Loads ........................................................................................................ 29
6.5.3 Thermal Loads (T) ................................................................................................. 30
6.6 AMENDMENTS TO DESIGN STANDARDS ............................................................................... 30
6.7 FATIGUE DESIGN ............................................................................................................ 30
6.8 MATERIALS.................................................................................................................... 30
6.9 CONNECTIONS................................................................................................................ 31
6.10 BOLTING ....................................................................................................................... 31
6.11 WELDING ...................................................................................................................... 32
6.11.1 Welding Processes .............................................................................................. 32
6.11.2 Additional Welding Requirements ...................................................................... 32
6.12 FINISHING ..................................................................................................................... 33
6.13 TRIAL ASSEMBLY............................................................................................................. 33
7 ELECTRICAL & CONTROL SYSTEM DESIGN REQUIREMENTS ........................ 34
BMT Consultants India Section 7.1 – Page ii

7.1 GENERAL....................................................................................................................... 34
7.2 SYSTEM DESIGN ............................................................................................................. 35
7.2.1 Design Basis .......................................................................................................... 35
7.2.2 Interface ............................................................................................................... 35
7.2.3 Classification ......................................................................................................... 35
7.2.4 General Requirements .......................................................................................... 36
7.3 DRAWINGS .................................................................................................................... 36
7.4 WIRING METHODS ......................................................................................................... 36
7.5 CONDUIT AND FITTINGS ................................................................................................... 37
7.6 GROUNDING .................................................................................................................. 37
7.7 CONDUCTORS AND CABLES ............................................................................................... 37
7.8 MOTORS ....................................................................................................................... 38
7.8.1 General ................................................................................................................. 38
7.8.2 Construction and Installation ............................................................................... 38
7.8.3 Accessories............................................................................................................ 39
7.9 TRANSFORMERS ............................................................................................................. 39
7.9.1 General ................................................................................................................. 39
7.9.2 Construction ......................................................................................................... 39
7.9.3 Insulation, Cooling and Rating.............................................................................. 39
7.10 MOTOR CONTROLS ......................................................................................................... 39
7.10.1 General ............................................................................................................... 39
7.10.2 MV Motor Control and Switchgear..................................................................... 40
7.10.3 415 V Motor Control Centre ............................................................................... 40
7.10.4 Variable Frequency Drives .................................................................................. 41
7.10.4.1 General Description and Construction of VFDs ...................................................... 41
7.10.4.2 VFD Protection........................................................................................................ 42
7.10.4.3 VFD Operator Interface .......................................................................................... 43
7.10.4.4 VFD Controls ........................................................................................................... 43
7.11 POWER DISTRIBUTION PANEL BOARDS................................................................................ 44
7.12 LIGHTING ...................................................................................................................... 44
7.13 MISCELLANEOUS SYSTEMS................................................................................................ 45
7.14 ALARMS, CONTROLS AND CONTROL CRITERIA....................................................................... 45
7.15 CONTROL CONSOLE AND PLC............................................................................................ 47
7.15.1 Control Console................................................................................................... 47
7.15.2 Console Wiring.................................................................................................... 47
7.15.3 Programmable Logic Controller (PLC) ................................................................. 48
7.16 CONTROL DEVICES .......................................................................................................... 48
7.17 CONTROL INFORMATION AND INTERFACE DATA .................................................................... 50
7.18 MAINTENANCE DIAGNOSTICS SUPPLEMENT ......................................................................... 50
7.19 CONTROL CAB ................................................................................................................ 50
7.20 ELECTRICAL HOUSE ......................................................................................................... 51
8 CORROSION PROTECTION ........................................................................ 52

8.1 CORROSION ENVIRONMENT .............................................................................................. 52
8.2 SCOPE OF WORK ............................................................................................................ 52
8.2.1 General ................................................................................................................. 52
8.2.2 Work Included....................................................................................................... 52
BMT Consultants India Section 7.1 – Page iii

8.2.3 Work Not Included ................................................................................................ 53

8.3 DESIGN AND CONSTRUCTION REQUIREMENTS ...................................................................... 53
8.3.1 Bolted Connections ............................................................................................... 53
8.3.2 Dissimilar Metals .................................................................................................. 53
8.4 SURFACE PREPARATION ................................................................................................... 54
8.4.1 Cleaning - General ................................................................................................ 54
8.4.2 Steel - General ...................................................................................................... 54
8.4.3 Steel - Shop Painted .............................................................................................. 54
8.4.4 Steel - Field Painted .............................................................................................. 55
8.4.5 Steel - Galvanized ................................................................................................. 55
8.5 WORKMANSHIP.............................................................................................................. 55
8.5.1 General ................................................................................................................. 55
8.5.2 Inspection ............................................................................................................. 55
8.5.3 Paint Application .................................................................................................. 55
8.5.4 Hot-Dip Galvanizing .............................................................................................. 56
8.5.5 Field Painting ........................................................................................................ 56
8.6 PAINT SYSTEM AND SCHEDULE .......................................................................................... 57
8.6.1 General ................................................................................................................. 57
8.6.2 Painting Materials ................................................................................................ 60
8.7 COLOUR SCHEDULE ......................................................................................................... 60
8.7.1 Primer ................................................................................................................... 60
8.7.2 Intermediate Coat................................................................................................. 60
8.7.3 Topcoat ................................................................................................................. 60
8.8 PROTECTION OF COATED SURFACES.................................................................................... 61
8.8.1 General ................................................................................................................. 61
8.8.2 Lifting .................................................................................................................... 61
8.8.3 Shipping ................................................................................................................ 61
8.8.4 Storage ................................................................................................................. 61
9 DOCUMENTATION.................................................................................... 63
9.1 GENERAL....................................................................................................................... 63
9.2 LAYOUT DRAWINGS......................................................................................................... 63
9.2.1 Structural Drawings .............................................................................................. 63
9.2.2 Mechanical Component Drawings ........................................................................ 63
9.2.3 Electrical Drawings ............................................................................................... 63
9.2.4 Shop Drawings ...................................................................................................... 64
9.2.5 Erection Drawings................................................................................................. 64
9.2.6 As-Built Drawings ................................................................................................. 64
9.3 CALCULATIONS ............................................................................................................... 64
9.4 ERECTION PROCEDURES ................................................................................................... 64
9.5 COMMISSIONING PROCEDURES ......................................................................................... 65
9.6 MANUALS ..................................................................................................................... 65
9.7 QUALITY ASSURANCE....................................................................................................... 66
9.7.1 Quality Assurance Manual.................................................................................... 66
9.7.2 Quality Plan .......................................................................................................... 66
9.7.3 Design Verification................................................................................................ 66
9.7.4 Quality Dossier...................................................................................................... 66
BMT Consultants India Section 7.1 – Page iv

10 LIST OF APPROVED SUB-VENDORS ...................................................... 68

11 ERECTION ,TESTING AND COMMISSIONING ........................................ 70
11.1 SITE ............................................................................................................................. 70
11.2 ERECTION PLAN .............................................................................................................. 70
12 PERFORMANCE REQUIREMENTS ......................................................... 72

12.1 AVAILABILITY AND LIFE OF THE MOBILE HARBOUR CRANE....................................................... 72
12.2 RELIABILITY.................................................................................................................... 72
12.3 PLANNED MAINTENANCE ................................................................................................. 73
12.4 PERFORMANCE TESTING OF MOBILE HARBOUR CRANE ........................................................... 73
12.4.1 General ............................................................................................................... 73
12.4.2 Performance Protocols ....................................................................................... 74
12.4.3 Tests.................................................................................................................... 75
12.4.4 Testing Rate ........................................................................................................ 77
12.5 PERFORMANCE GUARANTEE ............................................................................................. 77
12.6 PRODUCTIVITY ACCEPTANCE CRITERIA ................................................................................ 77
13 ATTACHMENTS ................................................................................... 78
Tables
Table 1: Relevant Drawings ................................................................................................ 1
Table 2: Ship sizes .............................................................................................................. 5
Table 3: Ventilation & Air-conditioning design conditions ................................................. 27
Table 4: Electrical System Voltages Nominal Voltages .................................................... 36
Table 5: Paint Schedule .................................................................................................... 58
Table 6: Approved Sub-vendors - Mechanical .................................................................. 68
Table 7: Approved Sub-vendors - Electrical ...................................................................... 68
BMT Consultants India Section 7.1 – Page v

1 Scope of Work
1.1 Introduction
The Mormugao Port Trust, Goa has awarded the project for “Providing Mechanized
Handling facilities for handling coal at Berth No. 11 at Mormugao Port, Goa” on Design,
Build, Finance, Operate and Transfer (DBOFT) basis to Mormugao Terminal Limited.
The existing berth with mechanized handling system comprises of Mobile Harbour
Cranes, Covered Storage Stockyard with Rail mounted Tripper Conveyors, Train Loading
and Truck loading facilities for import of coal.
The Scope of Work covered by this specification shall include, but not be limited to the
design, supply, manufacture, paint, touch-up paint, pre-assemble, test, disassemble,
matchmark, delivery, site erection supervision, and site commissioning and performance
testing of (2) two fully operable tyre mounted mobile harbour cranes capable of meeting
all requirements of this Technical Specification.
The terms MTL, Owner, Buyer, Buyer’s Representative and the like shall be deemed as
one and the same
The terms Tenderer, Vendor, Supplier, and Manufacturer shall be deemed as one and
the same.
The Tenderer shall design and undertake the full scope of work to provide a facility in
accordance with the highest prevailing standards as would be expected from an
internationally recognised and reputed Tenderer performing equivalent scope of work.
The machine shall be designed and equipped with all necessary accessories and
auxiliaries required to meet the designed parameters for satisfactory operations.
1.2 Work Included

The following drawing forms an integral part of this Technical Specification:
Table 1: Relevant Drawings
Drawing Title Drawing Number
Master Plan BMTI – 1211 – Gammon – ME – D – 101
Flowsheet BMTI – 1211 – Gammon – ME – D - 201
Belt Conveyor SBC-01 – General Arrangement BMTI – 1211 – Gammon – ME – D – 301

BMTI – 1211 – Gammon – ME – D – 302
The Work shall include, but not be limited to the following:
• Design and supply of steel structures for the Cranes including machine and electrical
equipment platforms, stairs, ladders, walkways and handrails.
• Design and supply of the fixed support pedestal complete with platforms and
stairways.
BMT Consultants India Section 7.1 – Page 1

• Slewing/swing machinery.
• Boom, boom arm, and boom luffing machinery.
• Hydraulic or rope type grab bucket.
• Counterweight.
• Operator’s cabin.
• Centralized automatic lubrication system to provide continuous lubrication to all points

on the superstructure. Grab lubrication will be by manual methods.
• All electrical equipment and wiring, cable trays, junction boxes, controls, etc,
including, but not limited to:
- On board electrical room;

- Transformer(s) for transforming incoming 3.3 kV supply to Crane required
voltage;
- Switchgear, MCCs, VFDs, PLCs

- Crane lighting;
- Protective devices including limit switches, overload protection
- All power and control cables on the Crane;
• Shop and factory painting systems including all labour, supervision, tools, equipment,
cleaning and paint materials and all other materials required to provide an effective
corrosion protection system, as specified in this Technical Specification.
• All fasteners and accessories required for field erection. Note: Metric size fasteners
only will be accepted.
• Match marking and labelling of all components.
• Recommended spare parts list for field erection and start-up.
• Recommended spare parts list for two years of operation c/w pricing.
• Special tools required for field erection and maintenance.
• Weights of all major components for field erection purposes.
• The Contractor shall provide loads and anchor bolt template for the pedestal structure
to concrete foundations (foundations by others).
• All documentation as listed in this Technical Specification.
• First fill of lubricants.
• Production and commissioning schedule.
• Ocean freight, inland freight, brokerage, duties and insurance to site.
• Site erection supervision.
• Testing and commissioning of the complete Crane system.

• Training of maintenance personnel.
1.3 Packaging and Shipping

It is the responsibility of the Contractor to prepare and load the equipment supplied in
such a way that it is not damaged in transit. Where required, temporary bracing, supports
and protective covers or enclosures shall be installed and marked as such. Small loose
items shall be shipped in wooden boxes with weather-resistant labels identifying
purchase order number and their contents. Each part shall have a mark number as
shown on the assembly and erection drawings.
Provision of all necessary transportation documentation, including Material Safety Data

Sheets, is the responsibility of the Contractor.
The Contractor shall provide detailed storage requirements at site for all components for
a period of 6 months.
1.4 Supervision for Site Erection and Start-Up

The Contractor shall provide a competent site engineer to:
• Supervise the unloading, erection, installation, testing and commissioning of the

Cranes. The Contractor shall define work, engineering and labour support hours and
equipment, etc. included in the basic proposal provisional amount included in the
supply scope.
• Instruct the Buyer's operating personnel in operations and maintenance procedures

for starting, operating, shutting down, lubricating, maintaining and periodically
inspecting the Cranes.
• Calibrate the Cranes to meet guaranteed performance and to optimize operation.
Manufacturer’s representatives (the Contractor’s subcontractors) shall be available, as

required, for trouble shooting, commissioning and testing of sophisticated equipment such
as hydraulics, etc.

2 Site Conditions
2.1 Site Location

Refer section 1.1.1.1 of “Volume I – Employer’s Requirement”.
2.1.1 Road link
Refer section 1.1.1.3.2 of “Volume I – Employer’s Requirement”.
2.1.2 Rail link
2.1.3 Air Link
The nearest airport is at Goa which is about 7.4 km away by road.
2.2 Meteorological and Oceanography Information

For meteorological and oceanography information, refer section 1.1.1.5 and 1.1.1.6
respectively of “Volume I – Employer’s Requirement”.
2.3 Material Characteristics

Material Coal
Size minus 150 mm
Bulk Density 0.8 t/m3 for volume, 1.0 t/m3 for structural design.
Angle of repose (stockpiling) 37°
Angle of surcharge 20° on conveyor
Moisture content 45 % approx.
2.4 Service Conditions
2.4.1 Berths
Berth 11 is located on the eastern most end of the harbour. It is 275 m long and 25 m
wide. The water depth available at the berth is -13.1 m (CD).
2.4.2 Wind
The Wind loads on structure shall be considered as per IS 875: Part 3.
Refer section 1.1.1.5 and 1.1.1.6 respectively of “Volume I – Employer’s Requirement”.

2.4.3 Tidal Data
2.4.4 Wave Heights
2.4.5 Vessel Sizes
Table 2: Ship sizes
Vessel For Berths 1, 2 & 3 For Berths 1 & 2
Smallest Bulk Largest Bulk carrier Regular Bulk carrier Largest Bulk carrier
Carrier
Displacement Tonnage,DT 13333 106667 150000 187200
DWT 10000 80000 125000 160000
Overall Length (m) 140 259 300 300
Length between the 130 249 - -

perpendicular (m)
Breadth (m) 18.5 36.6 48 45
Depth (m) 10.5 19.8 - -
Draught (Laden) (m 7.9 13.2 14.5 16.5
Approach Velocity (m/sec) 0.15 0.15 0.10 0.10
2.4.6 Levels
Refer section 1.3.5 of “Volume I – Employer’s Requirement”.
2.5 Duty and design requirements

Equipment shall be designed for 24 hours per day continuous operation. The Mobile
harbour crane shall be of heavy-duty design and suitable for operating in a hot, humid,
and dusty port environment.
Unloading shall be out of oceangoing vessels with capacities of up to 60,000 DWT.
2.6 Travelling Hopper Reference Data

Design parameters shall be as under:
Volume 125 m3
Top opening 9mx9m
Bottom opening 4.5 m x 1.8m
Height 6.3 m

Valley Angle 50 degree minimum
Rail Centres 7.5 m
Rail Size CR80
Travel Length 151.7 m approx
Cable Reeling Drum Motorised Type
Mounting On structure as indicated in the drawing
Air cannons shall be provided for assisting flow of coal.

3 Codes and Standards
3.1 General
The supply of all equipment, materials and services and the design and construction of
the mobile harbour crane shall comply with this Technical Specification including the
requirements of applicable Codes and Standards.
City, State and Country rules and Safety Standards shall take precedence over these
specifications in case of conflict. In case of conflict between Codes, Standards and this
Technical Specification, the most stringent requirements shall apply, unless otherwise
approved by the Owner.
All reference to Codes, Standards and/or material specifications shall be to the latest
revision, including all effective supplements or addenda thereto.
The mobile harbour crane shall be designed, manufactured, installed and tested in
accordance with a complete and consistent set of internationally accepted standards that
are available in English. International (ISO), Indian (IS), German (DIN), European
(F.E.M.), British (BS) or North American standards are acceptable.
The equipment shall be designed and selected keeping in view the facility for inspection,
cleaning, replacement and repair and for use where continuity of operation and safety are
first considerations.
The equipment shall conform to the latest Indian Electricity Rules and Regulations
as regards safety requirements, earthing and other essential provisions specified
therein. They shall also comply with the statutory requirements.
The design, manufacture, testing as well as performance of the equipment covered

in this specification shall comply with the latest editions of the following standards and
safety codes.
In the event the requirements of this specification exceed the requirement stipulated in
the corresponding standards, regulation, safety code, the specification shall govern.
In the event of conflict between the standard, regulations and codes, the most
stringent one shall govern and the decision of the Purchaser shall be final.
Mechanical
IS: 14418 1996 Ship loader – Rail Mounted – Design, Manufacture and Erection
IS: 10643 Part 2 Glossary of terms for Bulk Handling Equipment Part 2 Ship
loading, Loading and Reclaiming Equipment
IS: 11592 1985 Code of practice for selection and design of belt conveyors.
(Reaffirmed 1990)
IS: 4776(Part I) 1977 Specification for Troughed belt conveyors.

(Reaffirmed 1991)
IS: 1891(Part I) Specification for Rubber Conveyor and Elevator Belting

1994
IS: 7403 1974 Code of practice for selection of standard worm and (Reaffirmed
1991) helical gear boxes.
IS: 8531 1986 Specification for pulleys for Belt Conveyors.

(Reaffirmed 1993)
IS: 9295 1983 Specification for Steel Tubes for Belt Conveyors. Idlers
(Reaffirmed 1990)
IS: 1570 1961 Specification for schedules for wrought steels for general.
engineering purposes
IS: 8598 1987 Specification for Idlers and Idler sets for belt conveyors.
(Reaffirmed 1993)
IS: 2266 1989 Specification for steel wire ropes for general engineering purposes.
IS: 2365 1977 Specification for steel wire suspension ropes for lifts,
(Reaffirmed 1991) elevators and hoists.
IS: 3459 1977 Specification for small wire ropes.

(Reaffirmed 1991)
IS: 210 1993 Specification for gray iron castings.
IS:1030 1989 Specification for carbon steel castings for general engineering
purposes.
IS:2062 1992 Wieldable structural steel
IS:7155 1986 Code of practice for conveyor safety
IS:3443 1980 Specification for rails
IS:8535 1987 Specification for Flat Counter Sunk Nib Bolts
IS:7423 1974 Dimensions for Apron Conveyors
IS:5895 1985 Specification for steel roller conveyors
Electrical
IS: 8623 1993 Specification for factory built assemblies for switchgear and control
gear for voltages up to and including 1000V A.C. and 1200 V D.C.
IS:4237 1982 General requirement of switch gears and control gears for
voltages not exceeding 1000 volts.

IS: 13947 (Part I) Degree of protection provided by enclosures of LV switch

1993 gears.
IS: 5082 1981 Specification for wrought aluminum and aluminum alloy bars, rods,
tube and sections for electrical purposes.
IS: 5578 1985 Marking and arrangement for switchgear busbars, main
connection and auxiliary wiring.
IS:13118 1991 Specification for alternating current circuit breakers.
IS:13947 1993 Specification for heavy duty air break switches and composite
unit of air break switches and fuses for voltage up to 1000 volts.
IS: 9224 1979 Specification for HRC cartridge fuse links up to 650 volts.
IS: 2705 I, II, III Specification of current transformers.

1992
IS: 4772 1983 Rotating electrical machines.
IS: 2551 1982 Danger notice plates.
IS: 3043 1987 Code of practice for earthing.
IS:4160 1967 Interlocking switch socket outlet
IS: 4051 1991 Code of practice for installation and maintenance of electrical
equipment in mines.
IS: 1889 1982 Codes of practice for installation and maintenance of

transformers.
IS: 3639 1991 Specification for fittings and accessories for power transformers.
IS: 335 1993 Specification for insulating oil for transformers and switchgear.
IS: 3429 1966 Specification for metal enclosed switchgear and control gear for
voltages above 1000 volts but not exceeding 11, 000 volts.
IS: 1777 1978 Specification for industrial lighting fittings with metal reflectors.
IS:3528 1966 Specification for water proof electric light fittings.
IS:3646 1966 Code of practice for interior illumination.
IS:1554 (Part I) PVC insulated heavy duty 1988 electric cables for working
voltages up to and including 1100 volts.
IS: 8130 1984 Conductors for insulated electrical cables and flexible cords.
IS: 6415 1984 Elastomeric insulation and sheath of electric cables.

IS: 9968(Par I) Rubber insulated cables with copper 1988 conductors.

4 Design Criteria
• Type: Pedestal
• Boom Type : Lattice type
• Lifting Capacity and Working Radius:
• Working Height
• Lifting Height/Depth
• Speed
• Hook
• Luff
• Slew
• Off/Side Lead

5 Mechanical Design Requirements
5.1 General
Mechanical components shall be designed for continuous heavy duty operation in a coal
dust laden environment and with due regard to impact, possible overloads, cycles of
stress application, physical properties of the material (especially in regard to ductility and
endurance limit) and the geometric shape of components to reduce stress concentration.
Where possible, motors, gear reducers, shafts, bearings and all other components
requiring periodic maintenance shall be standardized to minimize spare parts and
components inventory.
Drives shall be designed in modular form to eliminate the need for field alignments. Easily
maintainable drives that are designed for the environment in which they will be working
are essential.
Operating noise levels shall not exceed 85 dBA one meter from any drive, combination of
drives in a single area, or moving component.
Any subsection contained in these mechanical design requirements shall not be read
without consideration for all other applicable subsections.
5.2 Materials
All materials used in constructing the Cranes shall be as specified herein or the best
suitable for the specified service, and shall be subject to acceptance by the Buyer.
The Contractor shall indicate the ASTM or other material designation on the drawings
submitted.
Cast steel shall be of a grade equal or superior to ASTM A148, Grade 80-40.
Cast ductile iron shall conform to grades specified by ASTM A536 except as otherwise
approved by the Buyer. Grey cast iron shall not be used except with the prior approval of
the Buyer.
Mill certificates or material test reports providing chemical composition and physical
properties shall be obtained by the Contractor for all structural steel, mechanical shafting,
drive gears, pinions and other critical components. Copies of mill certificates or test
reports shall be furnished to the Buyer upon request.
Copies of heat treatment procedures, records and test reports shall be provided to the
Buyer for all critical components made from harden steel subject to quenching and
tempering heat treatment process.
Coating materials shall conform to the requirements given in this Technical Specification.

5.3 Slewing System

General
The slew bearing shall support the rotating structure including boom, boom arm,
counterweight, superstructure, etc.
Jacking pads shall be provided integral with the structure to permit replacement of the
slew bearings. Access shall be provided to the jacking points.
The slewing range shall be 4000 capable of unloading the coal to covered storage.
5.4 Slewing Speed

The slew speed shall be continuously variable in either direction.
5.5 Slew Bearing

The slew bearing shall be equipped with wear measurement blocks, protection against
spillage, grease collection tray and secured with high tensile bolts tightened with a
hydraulic tensioning device. Sufficient space shall be provided for using this device,
inspecting, removing, and installing the bolts without disassembly, cutting or slotting.
The hydraulic bolt tensioning device shall be turned over to the Owner upon completion of
the project.
5.6 Slew Drive

Two diametrically opposed slewing drives shall be provided. The drive pinion shall be
mounted to the output shaft of the drive to simplify alignments.
Adjustment of the gear mesh and backlash between the ring gear and pinion shall utilize
an eccentric drive mounting plate/bushing.
The motor shall be VFD speed controlled.
An overload protection device shall be incorporated to protect the drive elements in the
event the boom encounters an obstruction when slewing.
The brake shall normally act as a holding brake. Only during emergency stopping will
mechanical braking apply.
Adequate safety against drifting (excluding all inherent resistance forces) shall be
included.
There shall be no external cooling fans on the slewing drive gearbox.

5.7 Winch and Wire Rope Systems (if applicable)

The Contractor shall supply socketed wire rope on all winches and wire rope systems
used.
Each winch shall be suspended from or mounted on a rigid steel frame capable of
supporting all external and internal forces that may occur.
Drums shall be grooved and have ample capacity to spool the required rope in a single
layer. Multiple layer winding is not permitted.
Winches shall operate such that there will never be less than three full turns of rope on
the drum.
Upper and lower end-of-travel (EOT) and over-travel (OT) limit switches shall be
provided. Over-travel limit switches shall be hardwired.
Winches shall have rope anchorages suitable for reverse winding. Fleet angles on drums
and sheaves shall not exceed the values defined in the appropriate standards.
Rope speed shall not exceed 3 meters per second unless otherwise approved. Hoists
shall be provided with an overspeed detection device and a slack rope detection device,
interlocked to stop the motion and apply the hoist brakes. Rope systems shall be reeved
in such a manner as to minimize reverse bends in the rope.
The rope assemblies shall be of proven well-established design and manufacture, having
achieved a high standard of reliability in service.
Wire ropes shall be regular-lay, steel core and shall have a safety factor of at least 6:1
against breaking when the maximum load is acting.
Materials shall be free from all defects and imperfections that may affect the performance.
Wire ropes shall have no wires "out-of-lay" along their lengths.
The dual rope systems shall originate from one production length where lays are
identical. The two systems shall be terminated in a single balance beam that will
compensate for normal irregularities between the two systems. A limit switch shall be
provided to alarm an out of balance system.
Wire rope shall terminate in zinc sockets, designed for the particular strand or rope, or
other approved terminations rated to at least 100% of the breaking strength of the ropes.
Drum anchorages shall develop at least 100% of rope breaking strength.
The sockets shall be of the open or closed type to suit the application with a sufficient
basket length to develop and exceed the full breaking strength of the size of strand or
rope to which they are intended to be connected. Socket assemblies, including pins,
shall have ultimate strengths in excess of the breaking strength of the strand or rope to
which they are connected.

Open sockets shall be supplied with pins. Closed sockets shall be supplied without pins.
The bearing surface against which the pin acts shall have a machined or drilled 250
micron or better finish prior to galvanizing.
Drip trays shall be provided under winches to prevent rope lubricant and general
lubricating oil being carried onto walkways, etc. A removable drip proof cover shall be
provided over winch machinery.
Provision for lubrication and cleaning shall be made.
Sheaves shall be standard size to facilitate replacement. All sheaves shall have suitably
sealed, greaseable anti-friction bearings. Rope guides shall be provided to prevent slack
rope from leaving sheave groove.
Access shall be provided to all sheaves for inspection, servicing and replacement.
Lubrication points shall be piped to the nearest access to permit safe lubrication.
Sheave supports shall be designed for easy removal. Removal of sheave shafts in order
to remove the sheave in the field is not acceptable.
The materials shall be of the best quality used for the purpose in commercial practice.
The galvanized wire rope shall be manufactured in accordance with the following
standard, or equivalent, approved by the Buyer:
• ASTM Standard A475-89 Zinc-coated Steel Wire Strand.
• ASTM standard A506-93 Steel Sheet and Strip, Alloy, Hot Rolled and Cold Rolled,
Regular Quality and Structural Quality.
The galvanized rope sockets shall be manufactured in accordance with the following
standards:
• ASTM standard A148-93a (Grade 80-50) High Strength Steel Castings for Structural
Purposes.
• British Standard B.S. 463, Part 2, 1970 Open Socket Specification (metric) for Steel
Wire Ropes, 8 mm to 56 mm diameter.
The socket pins shall be manufactured from ASTM A-148 Grade 80-50 or better, with a
minimum specified yield strength of 360 MPa.
The sockets shall be sweated onto the ropes and strands in a manner offering least
damage to the ropes and guaranteed to ensure that either the rope or the socket will fail
before the rope or strand pulls out of the socket.
The material used for fixing the ropes to the sockets shall be 99.95% pure zinc ingot
(Reference ASTM B6-70 (E40-11) High Grade or equal) and a copy of the test analysis of
this material shall be forwarded to the Buyer’s Engineer. Care shall be taken to ensure
that the zinc is not contaminated during the speltering process.

5.8 Shafting
Shafting shall be designed for a life in excess of the economic life of the Crane.
Shafts shall be sized and selected for maximum interchangeability. Stress concentrations
at turned down shaft ends shall be considered in the design of shafts.
All keyways shall be in-line and square. Keys shall be supplied with shafts, shop fitted
and taped in place for shipping. Keyed shaft ends and keyways shall be in accordance
with only one of ISO or ANSI standards.
Shafting less than 100 mm in diameter shall be ductile bright shafting AISI Type C 1018
or better. Shafting over 100 mm in diameter and shafts in critical areas shall have their
metallurgical composition and heat treatment procedures specified by the Contractor for
review by the Buyer. Only materials having guaranteed notch toughness values greater
than 27 J at 0°C shall be used for safety critical shafts.
All commercial sized shafting shall be cold rolled steel (CRS). Shafts 150 mm in diameter
and larger shall be forged and ultrasonically tested before machining. Shaft ends shall be
chamfered.
Turned down shaft ends shall have a finish of 0.8 mm or better. Turndown radii shall
have a finish of 1.6 mm or better and shall be at least 25% of the minor shaft diameter.
Undercut at radius shall not be permitted.
Repairs that involve welding shall not be carried out on shafts.
5.9 Bolts
Bolting requirements are summarized in Section 6.10.
5.10 Adjusting Screws

All adjusting screws shall be stainless steel and Metric sizes.
5.11 Plain Bearings

Use of plain bearings shall be minimized.
Where plain bearings are to be used, they shall be either proprietary hardened steel
spherical bushing units or bronze bushing shall be utilized, as the application dictates.
Bronze material shall be either a suitable SAE or British Standard leaded bronze, or a
hard bronze. If two bearings are used, one shall be fixed and the other floating, with
adequate adjustment allowance.
Plain bearings shall only be used on slow speed bearing applications.
Suitable grease passages shall be provided and shall be connected to the lubrication
system.

All plain bearings shall be adequately sealed for dusty and corrosive environment.
5.12 Bearings and Bearing Seals

The basis for the selection of anti-friction bearings will vary with the duty of the
mechanical component.
Each shaft shall have one fixed and one floating type bearing, the fixed bearing being on
the drive end of any driven shaft.
Seals shall be taconite, grease purged, radial design, replaceable triple labyrinth type or
accepted equal. Where a shaft terminates at a bearing, the shaft shall terminate within
the bearing housing and the housing shall be equipped with a dust-tight end disc. Seals
shall be designed taking account of fabrication and running alignment tolerance.
All pillow blocks for 50 mm shaft diameter and larger shall have cast ductile iron, cast
steel, or fabricated steel split housing. All pillow blocks shall be arranged such that the
line of force acting through the pillow block shall be perpendicular to the pillow block
supports. Pillow blocks larger than 89 mm diameter shall be furnished with four bolt-
bases. Grey cast iron shall only be used where approved by the Buyer’s Engineer.
Preferred mounting of pillow blocks shall be on the top surface of supporting steel for
ease of removal and adjustment, however, mounting orientation shall be near
perpendicular to the line of force. Suitable adjusting screws with locknuts and lugs shall
be welded to supporting steel to facilitate alignment of components. Maximum angular
misalignment between shaft and housing shall be 0.25°.
Hydraulic grease fittings shall be installed on all bearing housings. Housings shall be
filled with grease before shipping.
Minimum L10 life of all bearings shall be 60,000 hours taking into account all service
factors.
5.13 Speed Reducers

General Requirements
All speed reducers shall be of the manufacturer’s standard design and shall comply with
AGMA standards.
Expected service life for gears (G1: 1% expected failure rate) and bearings (L10) shall not
be less than 60,000 hours. An application factor evaluated and identified by the
Contractor shall be included in the calculation of gear capacity. This factor shall not be
less than 1.5 (i.e. the mechanical rating of all reducers shall be at least 1.5 x the motor
nameplate horsepower).
Reducers shall be rated in accordance with AGMA Standard 6010-F97, latest edition, for
gear capacity, bearing capacity and strength of other components such as shafts, keys
and bolting except where a higher requirement is specified elsewhere in this Technical
Specification.

The thermal rating shall be at least for the motor nameplate horsepower, ignoring the
overload factor, as calculated by the method of AGMA Standard 6010-F97, latest edition.
Maximum sump oil temperature shall not exceed 80°C. Gear case design shall be such
that no external heat exchanger is required to achieve this temperature limitation. The
use of an external cooling fan mounted to the input shaft of the gearbox is acceptable.
Resistance Temperature Detectors (RTDs) or thermocouples complete with a 4–20 mA

signal shall provide a temperature signal to the onboard control system. As an option,
temperature switches may be provided. Two sets of contacts shall be provided for every
type of sensor; for example, one to provide a high temperature alarm and a second to
provide a high-high temperature trip.
Evaluation of speed reducer noise emission shall be measured by the methods of AGMA
6025 C90 or by DIN equivalent, DIN45635.
All speed reducers shall be free from critical vibrations in the operating speed range.
Speed reducer casings shall be of cast iron, fabricated steel, or cast steel. The
Contractor shall submit any deviation from the above specified materials for approval by
the Buyer. All reducers shall be fitted with lifting lugs.
Input and output shafts shall be equipped with triple labyrinth seals with grease fittings
and oil retention system.
All speed reducers shall be fitted with dip stick type oil level indicators, oil filler cap at
least 150 mm high, oil sample point above the drain port, and an adequately sized drain
with drain tap and screwed plug at discharge, suitably arranged for draining the lubricant
into a drain pan. Oil filler caps shall be removable without using tools.
All speed reducers shall be suitable for lubrication with Standard AGMA EP petroleum-
based oils. Except in cases where reducers are subject to movement during operation
that may result in oil starvation due to either position or centrifugal forces, the lubrication
system shall be of the splash type. Where pumped oil circulation is required, it shall meet
the requirements of this specification. All external lubrication piping shall be neatly
mounted and protected to avoid damage during handling and servicing.
Each reducer shall be equipped with cartridge type breather. Any standpipes shall be at
least 150 mm high.
All reducers shall have dams across bearings to eliminate dry starts.
5.14 Flexible Couplings

Flexible power transmission high speed couplings shall be gear type; all others steel grid
type and shall be designed and constructed with a service factor of not less than 1.5
based on the nameplate motor power.
5.15 Rigid Couplings

Rigid couplings shall be designed using a service factor of 1.5 on all applied loads
including bending moment.

A spigot shall be provided in order to locate the coupling halves and center them on their
respective shafts.
A key, perpendicular to the shaft, located between the coupling halves is the preferred
method of transferring torque.
The coupling shall be laid out so that removal of bolts is possible without removing the
coupling or any of the adjacent drive components.
Bolt holes shall have a 1 mm clearance to their corresponding bolts.
5.16 Chain Drives

Chain drives shall be avoided where practical. Use of chain drives must be approved by
the Buyer. If approved, they shall be totally enclosed oil bath type, with oil pump and filter
in larger sizes. Holes and covers shall be provided for insertion of a hand held
tachometer.
5.17 V-Belt Drives

V-belt drives shall be used only for small ancillary drives such as compressors. Use of V-
Belt drives must be approved by the Buyer.
5.18 Brakes
5.18.1 General Requirements
Brakes shall be disc type.
All brakes and their support structure shall be rated at a minimum of 150% of full load
motor torques unless otherwise specified. Electro hydraulic thrusters can be used.
Brakes shall be actuated by compression springs and released by hydraulic and/or

electromagnetic means such that brakes are applied when power fails.
Brake pads shall be self-aligning, nonbinding and easily replaceable.
Each brake shall be provided with an engraved stainless steel plate, which provides data
on:
• The required coefficient of friction between the lining material and the disc;
• The design torque output of the brake;
• The required pad pressure and the corresponding spring compression required.
Where possible, the brake callipers shall be electrically released with a switch to sense
when the brakes have been released and provide a permissive for operation.

5.19 Hydraulic Luffing (if applicable)

General
• The Crane boom luffing system shall be designed to position and hold the boom at
any desired angle within the full operating angle range specified herein. A dual
cylinder system shall be provided, one for each side of the structure, with each
cylinder having sufficient capacity to support an empty or fully loaded grab bucket in
the event of a failure in the other cylinder.
5.20 Hydraulic Cylinders

The cylinders shall be provided as a minimum with the following features:
• Sufficient stroke shall be provided to avoid shock loads within the operating range.
• Heavy duty mill type with flanged ends.
• Protection against boom travel in case of a broken line (i.e., use of pilot operated dual
counterbalance valves).
• Cylinders shall have expansion boots on the rod ends for piston rod protection.
• Cylinders shall be fitted with hardened steel scrapers.
• Induction hardened, double chrome plated and/or ceramic coated piston rods may be
used.
• Components which are required to carry a sustained load shall be of zero-leak design
and shall be fitted with cylinder mounted, manually operated, emergency shut-off
valves.
• In general, flow control valves together with cylinder mounted speed fuses are the
preferred method of control of maximum cylinder speed to 120% of design full speed.
Hydraulic shock, resulting when speed fuses close, shall be considered in the design.
5.21 Hydraulic Systems
5.21.1 General
Hydraulic systems shall be designed to operate year around on an anti-wear type

premium hydraulic oil that is readily available in Indonesia.
Maximum operating pressure shall be limited to 25 MPa. All components in the system
subject to operating pressure shall be rated for continuous operation at 35 MPa.
The use of oil coolers and oil heaters shall be avoided wherever possible. Maximum oil
temperature shall be limited to 60°C.
The hydraulic system and components thereof shall conform to the latest applicable
standards as listed in Section Error! Reference source not found..
The system diagram and component setting data shall be engraved on a corrosion

The system diagram and component setting data shall be engraved on a corrosion
resisting metal plate mounted in an accessible place on the power unit.
5.21.2 Reservoirs
Reservoir storage capacity shall be greater than or equal to three minutes of maximum
pump flow.
Reservoirs shall be arranged so as to provide a positive inlet head to all pump suction
lines. Minimum fluid level shall be 450 mm above pump inlets.
There shall be no shutoff valve on the pump suction line.
All return lines shall be equipped with down-pipes to within 75 mm of reservoir bottom.
Reservoirs shall be constructed from clean, pickled steel plate, adequately braced and of
sufficient thickness to prevent distortion. All interior surfaces shall be clean, free of scale
or weld spatter and adequately protected against rusting by use of G.E. 'Glyptal' or similar
suitable paint.
Reservoirs shall be equipped with internal baffles to separate the return oil flow from the
intake flow, and shall have a suitably sloped bottom surface with a drain port, equipped
with a shut-off valve and valve plug, at the lowest point.
Clean out access shall be provided using an adequately sized, sealed cover plate
employing a neoprene or Buna N gasket seal. Sealing compound shall not be used for
gasketting.
All reservoirs shall be provided with:
• ‘Pronal' flexible separators or ‘Greer Kleen’ (preferred) vent breathers or approved

equal closed circuit air bag breathing systems;
• Visual type fluid level indicators, designed to be easily readable with clear fluid;
• Combined low level/high fluid temperature warning switches; each switch shall
provide a warning and a shutdown of the system. For example, low level warning and
a low-low level shut down; high temperature warning, high-high temperature shut
down;
• Dial type accurate fluid temperature visual indicators.
5.21.3 Filtration
In-tank type suction strainers are not permitted.
Continuous filtration of the fluid to the strictest requirements of the component

manufacturers shall be provided. Filters shall be located in pressure, return or auxiliary
circulation lines as necessary to achieve a 16/13 cleanliness level (ISO 4406, NFPA/JIC
T2.24.1 - 1990) during normal equipment operation.

All return flows with the exception of casing drain flows shall be filtered through filter
elements rated at better than 98.7% multipass performance efficiency (ISO 4572, B10 >
75).
Provision shall be made for reservoir filling via return oil filters.
Filter location must be convenient for routine servicing. Shut-off valves shall be provided,
where required, to minimize fluid spillage during servicing.
Filters shall be sized to provide a minimum of 800 hours operation under normal system
operation.
All filter assemblies shall include replaceable elements of the 'throw away' type and visual
type element condition indicators.
Filter assemblies whose elements cannot withstand full system differential pressure
without damage shall be equipped with bypass valves. The bypass valve opening
differential pressure shall be at least 20% higher than the differential pressure required to
actuate the element condition indicator.
Piping connections to the fluid power filter assembly(s) shall be such as to eliminate
external leakage. Taper pipe threads or connection mechanisms, which require the use
of a non-integral sealing compound, shall not be used.
5.21.4 Pumps
Hydraulic pumps shall be direct driven through flexible couplings. Parallel keyed drive
shafts are preferred.
Where possible, pumps shall be face mounted to NEMA 'C' or equivalent face type
electric motors using suitable mounting adapters to maintain alignment and contain the
flexible coupling.
Where suction lines are used, these shall be sized and the pump located such that pump
cavitation cannot occur.
Pump outlets shall be equipped with pressure gauges fitted with 'push-to-read' gauge
isolators.
Gauges shall be securely mounted and isolated from vibration to extend their life.
Gauge tap points (at least four) shall be provided at strategic circuit locations to assist in
troubleshooting. Plug-in type fittings are preferred to allow easy air bleeding procedures
or facilitate the connection of test gauges.
A solenoid operated dump valve shall be incorporated into hydraulic power units to
unload the pump of fixed volume delivery systems when the pump must run, but working
pressure is not required.

5.21.5 Hydraulic Motors
Side loads on motor shafts shall be taken into account in the assessment of allowable
working pressure across the motor.
5.21.6 Cylinders
Tie-rod construction may only be used for small cylinders. They shall be arranged with
Standard NFPA mounting dimensions. Induction hardened, chrome plated and/or
ceramic coated piston rods may be used.
Components which are required to carry a sustained load shall be of zero-leak design
and shall be fitted with cylinder mounted, manually operated, emergency shut-off valves.
In general, flow control valves together with cylinder mounted speed fuses are the
preferred method of control of maximum cylinder speed to 120% of design full speed.
Hydraulic shock, resulting when speed fuses close, shall be considered in the design.
Cylinders shall be fitted with zero-leak seals with hardened steel scrapers. Bellows shall
be provided.
5.21.7 Hydraulic Piping
Inlet piping may be via approved suction type hose and fittings. All hard piping shall be
minimum schedule 80 pipe with internal bore thoroughly cleaned by blast cleaning and
flushing or by acid pickling, neutralizing and flushing. Use of tapered pipe threads shall
be avoided. SAE 'O' ring type fittings (threaded or flange type) or socket weld fittings
shall be used on all pressure piping.
Pressure piping 1” bore size shall be fabricated from cold drawn seamless mechanical
steel tubing. Socket weld SAE 'O' ring flanges shall be used for interconnections and for
transition to flexible hose lines.
Hydraulic supply lines under 1” bore size shall be fabricated from S.S.316 finished
hydraulic steel tube using J.I.C. 37° flared fittings.
Flexible hoses shall be Caterpillar XT-3 (20 MPa, i.e., 3,000 psi rated), XT-5 (35 MPa,
i.e., 5,000 psi rated) or approved equivalent non-skive type. Use of hose shall be kept to
a minimum. Re-useable fittings are not permitted. Threaded fittings in pressure lines
shall be SAE 'O' ring type only.
Teflon tape shall not be used for thread sealing.
Piping shall be sized so that maximum oil velocity under normal operating conditions shall
not exceed the following rates:
In suction lines 1 m/sec (sized to eliminate risk of cavitation)
In return lines 3 m/sec
In pressure lines 4.5 m/sec

Minimum bursting pressure rating for all pressure piping and hoses shall be at least four
times the maximum system operating pressure.
Piping shall be adequately supported using hydraulic piping clamps - "Hydra-Zorb",

"Multi-Clamp" or equivalent, spaced per manufacturer's specifications.
Air bleeding points shall be located at the top of all loops in the system and shall be
readily accessible. The bleeding sequence shall be given in the start-up instructions.
5.21.8 Control Valves
All manually operated hydraulic control valves shall be of the deadman type, such that the
action is stopped when the control is released.
All solenoid valves shall be equipped with manual override operators.
5.21.9 Enclosures
Major hydraulic power units shall be located in a robust, walk-in machine room enclosure
or enclosures of similar construction to the electrical room. There shall be adequate area
and lighting around power units for maintenance. Power units shall be adequately
protected and mounted to prevent damage by vibration and shock.
5.22 Lubrication Systems
5.22.1 General
Lubrication lines shall be fabricated in stainless steel SS 316 and located to permit
servicing and dismantling of adjacent components.
Ample provision for lubrication shall be made to keep maintenance to a minimum. All
points requiring pressure lubrication shall be provided with easily accessible Alemite, or
equal, hydraulic fittings. Lubrication fittings shall be all of the same make, size and type
(1/4” standard Alemite fittings).
All lubricated parts, and lubricant containing enclosures, shall be thoroughly cleaned
before lubrication.
Initial lubrication, including that required for adjustment and testing shall be by the
Contractor.
All lubrication points shall be accessible from, or piped out for ready access from
walkways, platforms, or stairs with extension tubing of rust resisting material.
Tubing between distribution blocks and the delivery point shall be fabricated in stainless
steel (SS.316).
Brass or copper tubes shall not be used.
Flexible lines, where required shall be minimum 6.4 mm (1/4 inch) I.D. wire braid, grease
resistant, rubber covered non-skive type hose.

5.22.2 Oil Lubrication Systems
The following minimum design criteria shall apply for self-contained systems on
gearboxes requiring forced lubrication:
Gear type pumps driven by an independent drive shall be used.
The design pumping capacity at the lowest oil temperature shall be 1.25 times the oil
requirement for all bearings and gears lubricated by the system.
In-tank type suction strainers are not permitted.
All pumps shall have flooded suction.
The pump shall discharge through a full-flow 100-Micron filter with replaceable cartridge
element. Filter system shall have dual filters with a manual changeover. Flow and/or
pressure switches shall be provided downstream of the filter and shall have two contacts,
low warning and low-low shutdown. These pressure switches shall prevent start-up or
continued operation when oil pressure is inadequate.
Clean steel piping shall be used for suction and pressure lines. Brass or copper tubing
shall not be used.
Unions shall be provided at all bearings.
In case of split housing, unions shall be provided on all piping close to, or in line with, the
split to facilitate removal of gearbox cover.
Inspection holes with covers shall be provided for inspection of all spray points.
Screw joints or pipefittings shall not be used inside gearboxes.
Troughs shall be used instead of piping in zero pressure oil flows inside gear cases.
All piping shall be securely supported.
5.22.3 Automatic Grease Lubrication
A centralized, automatic lubrication system shall be provided as standard equipment to

provide continuous lubrication to all points on the superstructure, which require pressure
lubrication. Pumps shall be electric powered.
Dual line system shall be provided.
The system shall have a high pressure/low pressure alarm indicating such conditions as
plugged lines, broken lines, etc. The system shall also have an indicator, preferably
mechanical, signifying which line is the problem line.
Critical lube points shall have lubrication feedback monitoring and adjustment of lube
supply rates at the point of lubrication. The flow shall be monitored by a micro-switch
installed at the end of each critical lube point. Critical lube points shall include, but are not

limited to, the pivot bearing and the end of long feed lines. The Contractor shall identify
each of these points.
Flow rates to individual points shall be manually adjusted at the distribution metering
blocks. Lubrication cycle time shall be adjusted at the pump where it will vary the
frequency of lubrication to all points connected to that particular system. Individual grease
quantities at each point will be setup during commissioning.
Distribution lines shall be stainless steel SS 316 and all metering blocks mounted in
cabinets.
All lubrication reservoir fill points will be remotely located to facilitate filling from ground
level.
Tank size for lubrication shall be sized to minimize frequency of refilling.
Tank level full indication will be visible or audible from the ground level refilling point (e.g.,
flashing light).
5.23 Manual Lubrication

Manual lubrication will be applied for grease points on the Grab.
All manually serviced grease lines shall be grouped together to central distribution.
Hydraulic Buffers
Buffers shall be of the self-resetting, re-usable type. They shall preferably be of a proven
concept.
The buffers shall be designed for stopping the machine under normal operating
conditions without exceeding Crane design deceleration limits.
5.24 Guards
All revolving parts such as drives, couplings, and exposed shafts shall be adequately
guarded in accordance with MSHA, OSHA and local requirements. Non-lubricated drives
shall have guards of flattened expanded mesh for visual inspection. All guards shall be
fabricated and mounted with provision for rapid and easy removal without tools and by
one person. Handles shall be provided on all guards and guard panels. Lubrication
capability, without requiring removing of guard, shall be maintained in all cases.
Guards shall be failsafe so that should the securing system fail or come loose, the guard
will not fall off. All guards shall be painted safety yellow.
5.25 Ventilation and Air Conditioning

The electrical and hydraulic rooms and control cab shall be air conditioned, and
pressurized with filtered, outside air.
Design shall be based on ASHRAE Handbook – Fundamentals.

Design conditions shall be as per table 3.
Table 3: Ventilation & Air-conditioning design conditions
Area Maximum Temperature Minimum Ventilation Rates
Control Cab 26°C 42 m3/h

50 Pa pressurization
Electrical Room 32°C slight pressurization
Hydraulic Room 32°C slight pressurization
Air conditioning units shall be heavy duty industrial grade direct expansion (DX) type,
using ozone friendly type refrigerant, single or multizone package units complete with
electric heating coils, air-cooled condensers, compressors, evaporators, fans and filters.
Filters shall consist of prefilter (rough-in filters) and high efficiency, disposable dry type
cartridge filters. Pressure differential indicating switches shall be provided for the HVAC
units to indicate and alarm dirty filter conditions.
5.26 Anti-Collision System

The Barge Unloading Crane shall be designed so that all operations and functions of the
Crane are protected by the anti-collision system.
Anti-collision system shall prevent collision with:
• The other Barge Unloading Crane
• Coal Barge
• Stockpiles
The Crane shall be fitted with a device that shall provide indication of its swing position
relative to the stockpile datum to an accuracy of ±50 mm with ground calibration at
regular intervals along the stockpile. There shall also be provided a device to determine
the vertical and horizontal position of the boom end to an accuracy of ±100 mm. Signals
from these devices shall be transmitted to the Crane PLCs for processing and via the
wireless Ethernet to the yard-based PLC for information.
Minimum clearance between Crane extremities when unloading from the same barge
shall be one (1) meter.
5.27 Grab Bucket

The Grab Bucket manufacturer shall be either Peiner or Nemag.

6 Structural Design Requirements
6.1 General
The machine structure shall be of heavy duty construction and of adequate strength,
stiffness and rigidity. It shall be sufficiently braced and stiffened so that it will withstand all
loads to which it will be subjected without excessive vibration and deflection.
The structural system of the Crane shall, to the greatest extent possible, remain stable
and intact in the event of unforeseen failure of major individual structural or mechanical
components. Failure scenarios for the major structural and mechanical systems shall be
identified and their effects considered in the design.
6.2 Vibration
In order to safeguard against resonant frequency problems which may result from
imposed periodic loads (such as boom bounce and vibration), as part of the design
process, the natural frequencies of susceptible structural components of the machine
shall be calculated and compared with the frequencies of imposed periodic loads and
wind, and the design modified as required to eliminate the potential resonance.
6.3 Crane Supports

The Crane will be supported by a fixed pedestal at the rear end which shall be designed
to carry all vertical and horizontal loads.
6.4 Design Details

Where practical, the member and connection details shall be designed to avoid
accumulation and retention of coal and coal dust or water during normal operation.
Remaining areas which would otherwise be subject to accumulation of coal fines shall be
provided with shedding plates so arranged as to not impede access to the structure or
equipment for inspection or maintenance. Where pockets or depressions cannot be
avoided, ample drain holes of minimum 25 mm diameter (or equivalent area for non-
circular holes) shall be provided at low points in each pocket or depression.
Closed metal sections shall be used where possible to assist in preventing build up.
Closed sections shall be sealed to prevent ingress of moisture. Large closed sections
shall be provided with a watertight means of access for inspection and maintenance. End
cover plates of minimum 6 mm thickness shall be installed by welding all-around on all
open ends of all hollow structural section and structural pipe members, including
handrails.
All access holes and inspection ports into box structures and hollow sections shall be
provided with bolted cover plates of minimum 10 mm thickness. Access holes and
inspection ports shall be sealed against the ingress of dust and moisture. These sections
shall be corrosion protected on the inside.

At all low points in all box structures and all hollow sections whose greatest cross-
sectional dimensions exceed 100 mm, the Contractor shall provide tapped drain holes
closed by threaded plugs to permit periodic inspection for dryness. Tapered pipe thread
of minimum nominal diameter of 1/2 inch shall be used for drain holes and plugs. Plugs
shall be provided with hexagonal head, square head, or hexagonal socket head to permit
removal.
For all box structures which contain internal baffles, diaphragms or stiffeners, the
Contractor shall provide drainage, by means of drain holes of minimum 12 mm diameter
and/or corner copes in internal structural elements to ensure that any moisture which
enters any portion of the box structure will drain to low points equipped with drain holes
and plugs. Stress concentrations arising from the use of internal baffles and diaphragms
shall be considered in the design.
Arrangements and details, which create closed areas that are difficult to reach for welding
and painting, such as back-to-back angles, shall not be used.
Counterweight shall be designed to avoid accumulation of water and dirt.
6.5 Design Loads
6.5.1 General
The design of the Crane shall be adequate for all loads imposed when the machine is
operating or parked.
The Contractor shall assume full responsibility for determination of all design loads in
accordance with FEM 2.131/2.132-97 Rules for the Design of Mobile Equipment for
Continuous Handling of Bulk Materials, as amended by these Technical Specifications.
The design loads, load factors, load combination factors and load combinations which the
Contractor proposes to use shall be submitted to the Buyer’s Engineer as outlined in
Section Error! Reference source not found..
The design of the Crane shall take into account the loads and stresses that will arise from
construction and maintenance activities which are to be kept within design limits.
The anticipated loads from maintenance and erection shall be clearly defined in the
design calculations and the allowable maintenance loads shall be described in the
maintenance manuals.
6.5.2 Seismic Loads
Design for seismic loads shall be according to the Uniform Building Code. The dynamic
lateral force procedures specified in UBC shall be used (spectral acceleration ≤2.5xpeak
ground acceleration), including consideration of the effects of vertical ground motions.
Peak Ground Acceleration (1/100 year return period) 0.09 g
Peak Ground Acceleration (1/500 year return period) 0.21 g

Occupancy Category (Seismic Importance Factor) 1.0
6.5.3 Thermal Loads (T)
The design shall make allowances for changes in temperature and the effect of solar
radiation.
6.6 Amendments to Design Standards

The following amendments shall apply to International Standard ISO 5049/1 Mobile
Continuous Bulk Handling Equipment - Part 1: Rules for the design of structures:
Rule 4.1.6.2 to read:
The inertia forces due to acceleration and deceleration of moving structural parts must be
taken into account acting at their respective centre of gravity locations. Their magnitude
shall be taken as one and one half times the design values of the drive and braking
components.
6.7 Fatigue Design

All structural details in regions of fluctuating stress shall be designed to avoid stress
concentrations likely to result in excessive reduction of the fatigue strength of members
and connections. Any exceptions shall be submitted to the Buyer for review and
approval. Care shall be taken to avoid sudden changes of shape of a member or
thickness of material and sharp re-entrant corners, especially in regions of tensile stress
or local secondary bending.
All structural details in regions of fluctuating stress shall be designed in accordance with
the provisions of AISC Load and Resistance Factor Design Specification for Structural
Steel Buildings, or other standard acceptable to the Buyer’s Engineer. The number of
cycles used in fatigue design shall be determined from the location of the component
under consideration, and the design life and coal tonnages specified elsewhere in these
Technical Specifications. ISO 5049/1, AWS D1.1 and other authoritative documents may
be used for guidance in determining the appropriate number of fatigue cycles to be used
in design of components for which fatigue cycles cannot be directly calculated. Where the
proposed fatigue design cycles cannot be directly calculated, the proposed fatigue design
cycles for such components shall be referred to the Buyer’s Engineer for review prior to
commencement of final design.
6.8 Materials
All material used in construction shall be new and free from defects.
The materials selected shall be stated in the bid documents, noting their qualifications
under ASTM or other acceptable standards and their impact test properties as
established by Charpy V-notch impact testing.
All structural steel and miscellaneous steel shall be ASTM A36 or better. Additionally, all
structural steel plate 50 mm or greater in thickness shall be produced using fine-grain

practice and each heat of such plate shall be subject to Charpy V-notch impact testing at
20oC to provide a minimum acceptable absorbed impact energy of 27J. Mill certificates
or material test reports providing chemical composition and physical properties shall be
obtained by the Contractor for all structural steel. Copies of mill certificates or test reports
shall be furnished to the Buyer’s Engineer upon request.
Unless otherwise agreed in writing by the Buyer’s Engineer, minimum steel thicknesses
for plates and rolled sections shall be:
Flanges and stiffeners 10 mm
Webs of rolled sections 4.5 mm
All other locations 6 mm
All grating shall be heavy duty 3Cr12 or fibre glass material. Walkway and platform
grating shall be free draining.
6.9 Connections
The Contractor shall identify the connections which are critical for the integrity of the
structure, and submit the procedure by which he intends to control their quality.
Wherever practical, connections shall be located away from highly stressed areas.
Work points at the intersection of connection members shall be located and designed so
that no eccentricities will be introduced in the members.
Beam connections combined with bracing connections or subject to lateral or longitudinal

loads from columns, shall be designed for the combined effect of the bracing forces plus
the beam and reaction plus the axial force transmitted through beam to bracing system.
Cross bracing shall be connected at intersection points. Back-to-back sections shall not
be used.
6.10 Bolting
Bolted connections shall use high strength bolts, installed fully tensioned. Exclude
threads from shear planes where possible. Design connections where slippage cannot
be tolerated (including connections subject to fatigue or frequent load reversal) as slip
critical connections.
Bolts of strengths up to and including ISO Grade 8.8 shall be galvanized.
All high strength bolts shall be supplied with raised distinguishing marks.
Direct tension indicators may be employed in all bolted connections of primary structural
components. They shall be compressible washer-type meeting the requirements of ASTM
Standard F-959-85.

Faying surfaces of slip-critical bolted connections shall be coated with inorganic zinc-rich
primer or other surface coating certified to satisfy the requirements of this Specification.
Such surfaces shall not be painted or contaminated in any other way.
All bolted structural connections shall have at least two bolts.
High tensile bolts shall use through-hardened washers.
Minimum size for high strength bolts shall be M20. Metric bolt sizes shall be used
throughout.
6.11 Welding
6.11.1 Welding Processes
Welding methods other than electric arc welding will not be accepted.
All welding shall be carried out in strict accordance with the requirements of AWS
D1.1:2000.
The Contractor shall forward to the Buyer’s Engineer its Welding Specification Manual. It
shall include all the specification sheets for the welds to be used for the fabrication of the
Crane.
6.11.2 Additional Welding Requirements
All welds shall be continuous for the full length of the joint, unless approved otherwise by
the Buyer’s Engineer. Intermittent fillet welds shall not be used.
No welded joint shall be designed in the highest stressed area of any structural member.
For hot-dip galvanized hollow sections, the vent holes, required for the galvanizing
process, shall be sealed by welding after completion of galvanizing. A zinc-rich paint
suitable for repair of galvanized surfaces shall be applied to the vent-hole seal welds after
completion of welding.
Field welded splices in members will not be permitted.
All box structures and hollow sections shall be completely sealed by welding, except for
access holes and inspection ports.
Seal welds shall be used to seal enclosed surfaces other than the faying surfaces of
bolted connections, except where continuous seal welding would contravene the
requirements of the AWS code. In this case, the unwelded corners of the lap joint shall
be sealed using a suitable sealant or caulking material prior to application of topcoat
paint.
Access holes ("mouse-holes") may be employed as required to facilitate sound groove

welds. These access holes shall be no larger than necessary for access, free from sharp
or re-entrant corners, and finished to be free from notches, nicks, gouges, slag and
welding spatter. These access holes need not be filled with weld metal or cover plated,

except as otherwise specifically required by the Buyer’s Engineer. Access holes shall in
any case not be made in highly stressed members.
Critical welds shall be identified in the quality control plan.
6.12 Finishing
Sharp corners and edges on items to be painted shall be rounded by grinding or
machining to a minimum of 1 mm radius, unless otherwise noted. Edges of bolt holes
shall be debarred, but need not be rounded.
On items to be hot-dip galvanized, the Contractor shall debar all sharp edges, corners
and holes and shall break sharp outside corners using a grinder or file.
On items to be painted or galvanized, laps or other irregularities in welds which would

result in poor coating quality shall be blended into the surrounding surface by grinding.
All weld spatter, welding slag and welding wire stubs shall be removed.
6.13 Trial Assembly

All structural components shall be trial-assembled during fabrication to ensure correct fit.

7 Electrical & Control System Design Requirements
7.1 General
This section provides design requirements of the electrical power and control systems
required for normal and emergency operation and control of the Crane in accordance with
these specifications. The electrical system, comprising power, control, lighting, and all
associated Crane electrical equipment and wiring shall be designed, supplied, built, pre-
assembled, tested and delivered by the Contractor.
It is the intent that the Contractor will supply and install all electrical components
associated with the Crane. These shall be shop mounted, wired and tested to ensure full
functional operation.
To avoid damage to electrical components during shipping and erection on site, they shall
be removed, tagged and packaged securely for shipping, complete with all mounting
hardware, connectors, etc. required for remounting on site.
Testing, programming, and commissioning of the entire electrical and control system shall
be the responsibility of the Contractor.
The electrical system includes, but is not limited to:
• 6.6 kV switchgear;
• 6.6 kV/415 V Transformer;
• 415/240 V Transformer;
• Onboard electrical room complete with air conditioning and other building services;
• 6600 V and 415 V MCCs and VFDs;
• Power, control and communication wiring;
• Motors and motor control equipment;
• Programmable Logic Controller (PLC) including PLC software, programming and

documentation;
• Wireless Ethernet communications
• Control power transformers and panel boards;
• Operator's and auxiliary control consoles, including all required operating and control
pushbuttons, switches, indicators and instrumentation;
• Miscellaneous transducers and control devices;
• Lighting fixtures, fittings, transformers and distribution panels;
• Collector rings, flexible power and control cables;
• Cable tray, conduit, flexible conduit and all necessary cable support fittings;

• Junction boxes as required.
The Contractor shall clearly describe and supply one complete set of start up and
commissioning spares as part of the purchase price. This should include an appropriate
number of fuses, lamps, and filters of each type supplied.
The electrical system shall incorporate only new equipment. Workmanship shall be of the
highest quality. The installation shall be neat in appearance and in compliance with all
required local, national and international codes, standards and practices. All equipment
and material supplied shall conform to project standards unless otherwise approved by
the Buyer. Names of acceptable manufacturers will be supplied by the Buyer.
7.2 System Design
7.2.1 Design Basis
All electrical, instrumentation and control systems on the Crane shall be designed to
North American (NEMA) standards.
Electrical distribution power will be available to the Crane at 6600 V, 3 phase, 50 cycle
fed from a land based circuit breaker supplied by the Buyer.
Electrical equipment shall be designed, manufactured and installed in accordance with

the codes and standards as given in Subsection Error! Reference source not found..
In the event of variations in the requirements of the Codes and Regulations the most
stringent shall apply.
7.2.2 Interface
The power and control cables of the Crane shall be terminated in Contractor supplied and
installed pivot tower termination panels at the fixed portion of the Crane pivot tower, one
for controls and one for 6600 V power. The cable support structure from the Crane pivot
tower termination panels to the land based electrical room will be by Others.
Controls, interlocks and other signals with the exception of hardwired signals (i.e.
emergency stops, etc.) shall be transmitted via wireless Ethernet. Hardwired signals shall
be brought to the pivot tower termination panel as required, and terminated on terminal
strips for interconnection by Others.
The installation and termination of the power supply and control cables to the pivot tower
termination panels shall be deemed to be the electrical INTERFACE point between the
Crane and the Buyer's equipment. Complete specification of all other required interface
points shall be the responsibility of the Contractor.
7.2.3 Classification
Electrical equipment shall be classified as per area classifications identified in the NEC.
Class II, Division 1, Group F areas on the Crane are defined as those locations located in
environments exposed to routine coal dust such as on the coal grab. Equipment mounted
within 3 m of these locations shall be classified Class II, Division 2, Group F. Areas

outside of the above situations that are not covered by another NEC requirement, do not
require hazardous classification.
The coal grab, and any external device which would normally be inside the barge’s hold
during unloading, shall be rated Class II, Division 1, Group F.
7.2.4 General Requirements
Equipment mounted inside the Electrical Room and the Control Cab shall have IP54
enclosures.
All nameplates shall be stainless steel or plastic laminate (black lettering on white),
affixed with stainless steel screws. Text shall be in the English language.
Electrical equipment and installations shall be designed and rated for use under the
conditions given in this Technical Specification.
The effect of equatorial solar radiation shall be taken into account in the design and
selection of electrical equipment and installation.
Since the Crane is subject to mechanical shock and vibration, all components and
particularly lamps, shall be selected and mounted to ensure life in these conditions.
Table 4 indicates the voltages and design parameters for various services on the Crane.
Table 4: Electrical System Voltages Nominal Voltages
System Voltage Phase Wire Frequency
Medium Voltage Distribution 6600 3 3 50
Low Voltage Distribution 415 3 3 50
Motors above 200 hp 6600 3 3 50
Motors 0.33 to 200 hp 415 3 3 50
Motors below 0.33 hp 240 1 2 50
Lighting 415/240 3 4 50
Control equipment 240 1 2 50
7.3 Drawings
Drawings, equipment lists, and specifications shall be submitted according to Section 9.
7.4 Wiring Methods

Electrical installations shall be wired using insulated stranded copper conductors installed
in conduit or alternatively in flexible armoured cables mounted in UV resistant, vertically
oriented vinyl ester resin fibre glass cable trays using stainless steel cable straps or black
UV resistant tie wraps. Conductors in wire-ways, control panels and cabinets, etc., shall
be secured with UV resistant tie wraps. Lacing with string or plastic tape will not be
accepted.

Electric motor leads and power connections shall be made using compression type
crimped lugs on the wire ends. The lugs shall be bolted to the motor terminal strip or
alternatively tightly bolted together using cadmium plated bolts and adequately insulated
with several layers of rubber splicing compound and a minimum of two layers of electrical
tape.
Insulated type wire lugs, correctly sized for the conductor and stud size, shall be used.
Other equipment connections shall be made using crimp type pressure connectors.
All conductors shall be clearly identified at both ends with the wire numbers used on the
approved drawings using vinyl sleeve type markers.
All electrical connections and terminals shall be checked for tightness.
7.5 Conduit and Fittings

The Contractor shall advise the Buyer of any conduit requirements and together with the
Buyer’s Engineer shall determine the appropriate type of conduit and fittings for the
application.
Where required, such as at field switches, motors, etc. subject to vibration, flexible
conduit may be used. Such conduit shall be liquid tight and utilize correct liquid tight
connectors.
The installation shall contain no damaged, crushed or deformed conduit.
7.6 Grounding
Exposed, noncurrent carrying electrical equipment metal parts shall be solidly bonded to
the Crane frame using a minimum of #4/0 AWG, soft drawn, stranded, insulated-copper
grounding conductor.
Grounding connections shall be accessible such that the integrity of the grounding
connection can be readily observed. Equipment that is permanently welded to the
structure shall not require additional bonding.
Unless permanently fitted, approved, enclosure grounding terminals are provided,

electrical machines shall be bonded using a grounding conductor connected to the
machine by means of a stud bolt, screwed into a drilled and tapped hole in the frame.
Grounding shall be continuous through the 360° slew range of the Crane.
7.7 Conductors and Cables
Conductors generally shall be stranded copper conductors, 90°C insulated, type XLPE,
THWN or THHW and conforming to NEC specifications. The smallest conductor shall be
#12 AWG (4mm2) for power and lighting circuits and #14 AWG (2.5 mm2) for
instruments, alarms and controls, and #16 (1.5 mm2) for instrument signals.

Cable/conductor insulation for 6600 V service shall be rated at 5 kV. Power distribution
and motor cables/conductors shall have insulation rated at 1 kV. Other 415/240 V service
shall have insulation rated at 600 V. For services at 120 V and below, insulation shall be
rated at 300 V.
Cable conductors shall be rated in accordance with IPCEA standards (IEEE S-135/IPCEA
Publications P-46-426) and the requirements of applicable codes, whichever is most
stringent.
7.8 Motors
7.8.1 General
All electrically driven equipment shall be supplied complete with drive motor.
All motors shall be horizontally mounted. Vertically mounted motors shall be provided with
an adequately sized peaked cover to prevent dust and material from collecting on and in
the fan.
All motors shall be high efficiency, AC squirrel cage, induction type motors of NEMA B
design and suitable for operation from a 50 Hz power supply as detailed in Table 6.2.1.
Motors shall have Class F insulation and be rated with a Class B temperature rise at full
load current. Motors shall have a 1.15 service factor, copper windings, and shall be rated
for extra severe duty.
If variable frequency drives are used, the motors shall be specifically rated for this
service.
7.8.2 Construction and Installation
As a minimum, motors shall be totally enclosed, fan cooled (TEFC), NEMA frame, and
must be rated for the area classification where they will be installed.
Breather drains shall be provided to enable moisture to be drained from the motor
enclosure.
Motors weighing more than 25 kg shall be equipped with suitable lifting lugs.
Motors shall be equipped with cast iron waterproof terminal boxes suitable for terminating
the incoming cable or conduits. Cable entry shall be from below or from the side.
Adequate space shall be provided within the terminal box for the correct termination of
the cables. Adequate space shall be provided around the terminal box to permit the
correct installation of the power supply cable or conduits.
A grounding lug shall be provided inside the motor terminal box.
Motor bearings and seals shall be as specified in Subsection 5.12.

7.8.3 Accessories
Motors rated at 200 hp and larger shall have anti-condensation heaters. Heaters shall be
de-energized when the motor is energized. Heater power supply shall be 240 V, single
phase, 50 Hz. The anti-condensation heater shall be pre-wired to its own termination box
on the motor.
Motors rated at 250 hp and larger shall be provided with winding (2 per phase) and
bearing (1 per bearing), 100 ohm platinum resistance temperature detectors (RTDs) pre-
wired to a single RTD termination box on the motor.
7.9 Transformers
7.9.1 General
Power distribution, lighting, and control distribution transformers shall be supplied as

required to convert the Buyer supplied 6600 V, 3 phase, 50 Hz supply to the voltages
required by the Crane.
7.9.2 Construction
Transformers shall be dry type units.
Each transformer shall have its own ventilated metal enclosure and mounted on its own
structural steel base. Lifting lugs shall be provided on each unit and arranged with
sufficient strength to withstand without distortion, all stresses imposed during shipping,
handling, installation and operation. Anti-vibration mounts shall be provided.
Transformers shall include four full capacity taps arranged at +5%, +2.5%, -2.5% and -5%
of the nominal voltage (2 FCAN and 2 FCBN taps).
7.9.3 Insulation, Cooling and Rating
Transformers shall be naturally ventilated, air cooled ANN type.
Insulation shall be Class H. Temperature rise shall be in accordance with Class F

requirements.
7.10 Motor Controls
7.10.1 General
All motors rated 0.33 hp and above shall be supplied from the MCCs located in the Crane
electrical room.
Motors rated below 0.33 hp may be supplied from the electrical room power distribution
panel by separately mounted, individual motor starter units having enclosures suitable for
the area of location.

A/C units, vent fans and other non-process loads may also be supplied from the electrical
room power distribution panels.
Standard manufactured heavy-duty industrial MCCs with with drawable type starter units
shall be provided.
7.10.2 MV Motor Control and Switchgear
All 6600 V switchgear shall consist of the following, but not be limited to:
• A main fused load break switch with 250 MVA short circuit withstand capacity,
• Transformer feeder breaker,
• 3.3 kV motor controllers complete with fuses, overload relays, ground sensors,
overcurrent protection, open phase-phase reversal protection, ammeters and control
transformers.
Motor protection shall be provided using an electronic, programmable, multifunction,

motor protection relay, including RTD temperature protection, such as a GE Multilin 369
Motor Management Relay or equivalent.
7.10.3 415 V Motor Control Centre
The motor control centers shall be NEMA type 12 with gasketted starter/feeder doors,
suitable for Crane service. The individual starters and feeders shall be withdrawable type
units.
The minimum interrupting capacity for the MCCs shall be 65 kA.
Motor starters shall be fully wired and connected to the various motor drive and control
systems. Combination type, circuit breaker, contactor, motor starters shall be used
incorporating short-circuit protection and adjustable, manually reset overload protection
devices. Contactors shall be magnetically operated and powered from 240 V, single
phase control supplies derived from a transformer within the starter unit. The minimum
size starter shall be NEMA Size 1.
Each starter and feeder breaker/fused switch shall be provided with a disconnect switch
operable from the closed starter/feeder door and shall be lockable in the “Off” position.
All starters shall be provided with two N.O. and two N.C. unassigned auxiliary contacts,
and two push to test pilot lights mounted on the starter door with a green light for Ready
and a red light for Running.
Feeder circuit compartments shall be equipped with molded case, three pole, thermal
magnetic circuit breakers.
Starters size 3 and above shall be furnished with ground fault protection devices.
Busbars shall be copper and continuously rated for the full load capacity of the circuits
supplied including any spare circuits.

Fused disconnect switches shall be provided for all 415 V services, including welding
receptacles, lighting panels, control and lighting transformers, and HVAC.
All motor control centre doors shall have lamicoid nameplates with black lettering on
white, indicating the service supplied, the equipment number and the hp/kW rating.
7.10.4 Variable Frequency Drives
Modular type VFDs using Pulse Width Modulated technology shall be supplied as
required for the Crane.
In general each motor requiring a VFD shall be fed from its own stand alone VFD.
7.10.4.1 General Description and Construction of VFDs
Each VFD shall convert the input AC mains power to an adjustable frequency and voltage
as defined in the following sections:
• The input power section shall utilize a full wave bridge design incorporating diode
rectifiers. The diode rectifiers shall convert fixed voltage and frequency, AC line
power, to fixed DC voltage. This power section shall be insensitive to phase rotation
of the AC line.
• The output power section shall change fixed DC voltage to adjustable frequency AC
voltage. This section shall utilize insulated gate bipolar transistors (IGBTs).
Certain drives can create standing waves on outputs depending on distance to the motor,
thereby exposing the motor to excessive voltages. Each drive shall include all necessary
equipment to reduce voltage to safe operational limits for the motor. Data shall be
supplied by the Contractor on the maximum voltage to which the motor can be exposed,
irrespective of motor distance. The techniques to obtain these voltage stress reductions
shall be submitted by the Contractor. Motor termination snubber modules shall be
provided with the VFDs and installed in the field at the motors.
The VFDs shall be mounted in dust tight enclosures, rated NEMA 12, or equivalent, with
external flange mounted safety disconnect devices. VFDs shall be installed in stand-
alone cabinets suitable for wall or floor mounting in the Crane electrical room with space
on either side to allow for air flow.
VFD cabinet internal components shall be constructed of a modular nature such that drive
maintenance and replacement of parts can be done in the field with front access only and
without any required removal or rear access to the main cabinets.
A mechanical interlock shall prevent an operator from opening any VFD door when the
safety disconnect is in the ON position. Another mechanical interlock shall prevent an
operator from placing the safety disconnect switch in the ON position while a VFD door is
open. It shall be possible for authorized personnel to mechanically defeat these
interlocks.
Provisions shall be made for locking all VFD disconnects in the OFF position with up to
three padlocks. Provisions shall also be made for accepting a padlock to lock the VFD
enclosures’ doors.

Current limiting fuses shall be installed and wired to the VFD’s inputs.
The speed range shall be from a minimum speed of 0.5 Hz to a maximum speed of 100
Hz.
The drives shall be able to slow down a motor operating in reverse and start the same
motor in correct rotation.
Overcurrent capacity shall be 150% for 1 minute.
Operating carrier frequency shall be maximum 10 kHz.
VFDs shall be able to develop no less than 200% of rated motor torque at .5 Hz (60 Hz
base) in a Sensorless Flux Vector mode using a standard squirrel cage induction motor
without an encoder feedback signal.
7.10.4.2 VFD Protection
Upon power-up the VFDs shall automatically test for valid operation of memory, option
modules, loss of analog reference inputs, loss of communication, dynamic brake failures,
DC to DC power supplies, control power and the pre-charge circuits.
The Power Converters shall be protected against short circuits, between output phases
and ground; and the logic and analog outputs.
The VFDs shall have a minimum AC undervoltage power loss ride-through of 200
milliseconds. The VFDs shall have the user defined option of frequency fold-back to allow
motor torque production to continue to increase the duration of the power loss ride-
through.
The VFDs shall have a selectable ride through function which will allow the logic to
maintain control for a minimum of one second without faulting.
For fault conditions other than ground fault, short circuit or internal fault, an auto restart
function shall provide up to 5 programmable restart attempts. The programmable time
delay before restart attempts shall range from 1 second to 600 seconds.
The deceleration mode of the VFDs shall be programmable for normal and fault
conditions. The stop modes shall include free-wheel stop, fast stop and DC injection
braking.
Upon loss of the process follower reference signal, the VFDs shall fault and/or operate at
a user defined speed set between software programmed low speed and high speed
settings.
The VFDs shall have solid-state I2t protection that is UL Listed and meets UL 508 C as a
Class 10 overload protection and meets IEC 947. The minimum adjustment range shall
be from 0.45 to 1.05% of the current output of the VFD.
The VFDs shall have a thermal switch with a user selectable pre-alarm that will provide a
minimum of 60 seconds delay before over-temperature fault.

The VFDs shall have a programmable fold-back function that will anticipate a controller
overload condition and fold back the frequency to avoid a fault condition.
The VFDs shall include Metal Oxide Varistors (MOVs) wired to the incoming AC mains for
surge protection.
The VFDs shall include line reactors wired to the incoming AC Mains for harmonic current
mitigation measures. Size of reactors shall be designed by the Manufacturer to result in
minimal harmonic impact on the power supply system feeding the VFDs.
Isolation/Bypass contactors are not required on this project.
7.10.4.3 VFD Operator Interface
The operator interface terminal shall offer the modification of VFD adjustments via a
touch keypad that is mounted on each VFD cabinet door. The displays shall be
alphanumeric offering Stop, Start, Parameter setting, Speed Control, Forward/Reverse
selection, Fault Indication, and alarm messages.
Start and Stop pushbuttons shall command normal starting and stopping as programmed
when the VFDs are in keypad control mode. The STOP pushbuttons must be active in all
control modes.
Each VFD shall have three LEDs mounted on the front panel to indicate functional status.
A green LED will verify that the VFD power supply is on, but the drive is not running. A
red LED indicator will indicate the VFD is running. A yellow LED indicator will designate a
fault condition (trouble alarm).
The Keypad and all door-mounted controls shall be NEMA 12 rated or equivalent.
7.10.4.4 VFD Controls
External devices shall be able to be connected to terminal strips within the VFDs for
starting/stopping, speed control, and displaying operating status. All control inputs and
outputs shall be software assignable.
For each drive there shall be two software assignable, optically isolated analog inputs.
The analog inputs shall be software selectable from +/- 10VDC or 4-20 mA. There shall
be four optically isolated logic inputs or outputs that can be selected and assigned in the
software. There shall also be 3 dedicated binary control inputs for 24 VDC control along
with 2 addressable serial interface ports.
VFD control power shall be from internal control transformers within the drive cabinets.
Transformers shall be sized by the VFD manufacturer and have a spare capacity of
minimum 25% above the minimum size required to operate the complete drive, its
controls and accessories. Transformers shall be provided complete with primary power
fuses on both phases and a secondary fuse. Control voltage within the drive shall
generally be 240 VAC.
Space heater control contactors shall be provided in the VFD cabinets if the motor rating
is higher than 200 hp as specified in 7.8.3. Contacts shall open when the VFD is
operating and close when the VFD stops operating motors. External motor anti-

condensation heater power wiring shall be installed to these relays. VFD cabinet doors
shall include red lamicoid warning labels with white lettering indicating “WARNING -
POWER FROM MORE THAN ONE SOURCE”.
7.11 Power Distribution Panel Boards

Lighting shall be supplied from 415/240 V, three phase panel boards.
Miscellaneous small power and convenience receptacles shall be supplied from 240 V, 1
phase panel boards.
Miscellaneous control and instrumentation devices shall be supplied from 240 V, single
phase panel boards. These shall each be powered from independent constant voltage
transformers, feeders and MCC circuit breakers, and shall be protected by Transient
Voltage Surge Suppressors (TVSS), GE Tranquell type or equivalent.
7.12 Lighting
A complete lighting installation shall be provided. All materials handling areas, activity
areas, machinery platforms, walkways and stairways, enclosed rooms and operating
areas on the Crane shall be fully illuminated in accordance with required regulatory
standards.
Areas considered by the Buyer as inadequately lit for the operation shall be provided with
additional lighting. As a guide, the following minimum illumination levels shall be
required:
Passageways stairways and ladders 100 lux
Control Ca 1000 lux
Electrical rooms 500 lux
Lighting on the Operator's control cab shall be separately switched and provided with
means of dimming.
Floodlights shall be provided to illuminate the area around the grab. Control of floodlights
shall be from the operator’s control cabin. This lighting shall be sufficient to illuminate the
interior of the barge’s hold to a level of 30 lux.
Inside the e-house lighting shall be fluorescent using fixtures approved for their area of
location. Outside lighting shall be high pressure sodium controlled by contactors and
photocells, with Hand-Off-Auto switch override and lighting panel breaker shut off. All
fixtures shall be equipped with lenses and guards where subject to damage.
Location of lighting fixtures and the design of lighting supports shall enable maintenance
and servicing without the use of ladders or manlifts. Inside the e-house is an exception to
this requirement.
Lighting shall be divided into sub-circuits around the Crane such that loss of one circuit
will not cause all lighting to be lost around access ways.

Emergency lighting units shall be provided to illuminate all stairways, exits and danger
zones where failure of normal electric lighting may create a danger to life. The units shall
have rechargeable batteries and a built-in automatic trickle charger to maintain the
charge, and a built-in fast-charger to quickly restore the battery after an emergency. The
units shall also provide potential source of power for one or more additional extension
lights.
The Buyer reserves the right to specify fixtures to standardize with the existing
installations.
7.13 Miscellaneous Systems

A 415 V, 3 phase, 60 A welding outlet shall be provided on the main platform. The outlet
shall be mounted at least 1 meter above the finished floor level, and shall be provided
with a local fused disconnect switch.
Duplex weatherproof type electrical receptacles shall be provided on the main platform
and other areas of the Crane as required. Locations shall be agreed between the Buyer
and Crane Supplier.
Control power for the PLC system and field instruments shall be provided from a
continuous power system including a separate MCC feeder, a constant voltage regulating
transformer, a 30 minute rated uninterruptable power supply (UPS) and a control power
distribution panel.
An anemometer system shall be provided mounted at the top of the Crane mast. Wind
speed indication shall be provided at the Operator’s control cabin and shall be a 4-20 mA
signal to the PLC and shall be relayed to the Port’s control system via the Ethernet
network. Wind speed range shall be 0 – 60 m/s with an accuracy of +5%.
Wind speed warning and shutdown circuits shall be provided with an adjustable (1-15)
second time delay to prevent actuation from short gusts of wind.
Inclinometers shall be provided complete with a 4-20 mA output. They shall be located for
the boom and the control cabin.
Lightning protection shall be provided as air terminal(s).
7.14 Alarms, Controls and Control Criteria

Control systems shall be real time.
Control systems shall be designed to provide optimum safety, reliability, performance and
low maintenance of motors, starters and driven loads.
Safety devices such as emergency stop pushbuttons, Crane overload, anti-collision

system, over-travel limits, etc. shall in addition be “hard wired” directly to the respective
drive control circuit with indication to the PLC.

Maintainability of the Crane shall be assisted by proactive alarming wherever practical.

This requires alarms that warn of faults before the process is stopped. For example, a
“high temp. alarm” and a “high-high temp. trip”.
The control system shall allow for input from positioning encoders on the Crane slew and
boom angle.
The Crane shall have its own PLC on board. The PLC shall have racks located in the e-
house and the control cabin. The PLC must be able to communicate with the Buyer’s
existing system via Ethernet.
Control, sequencing, interlocking, monitoring of Crane operation, alarming, indication and

acceptance of operator commands from on the Crane shall be done by the PLC interface.
The Crane will normally be controlled manually by an Operator located at the Operator’s
Control Cab.
The control cabin shall incorporate a chair mounted control panel which all Crane drives
and auxiliary systems can be initiated (general lighting, HPU power, etc.).
PLCs shall be used to perform or monitor all logic and interlocking functions, e.g.
sequential start up and shutdown control. PLCs shall collect all monitoring, alarming and
control data and transmit required information to the Buyer’s system via the wireless
Ethernet network.
In the event of a power interruption, brakes shall set, all motions shall be arrested and
equipment maintained in the "prefailure" position.
Component failure or power supply failure shall not leave any control system in an unsafe
condition
Drives shall be equipped with a local “Local-Remote” selector switch and local
“Start/Stop” pushbuttons. When the selector switch is in the Local position, the Start
pushbutton shall act as a jog pushbutton. When the selector switch is in the Remote
position (as during normal operation), control shall be transferred to the Crane operator's
control console and the local Stop button will then function as an emergency stop.
Local emergency stops shall be located at all drives and at the entrances to all moving
stairways. Emergency shutdown pushbuttons (maintained contact) shall be located on
the operator’s control console, at the slew bearing platform and in the hydraulic room, and
shall be arranged to stop all drives.
Warning horns shall be provided as required.
In the event of actuating an over-travel limit switch, a keyed switch on the Operator’s
console must be activated before the drive may be reversed and ‘backed’ away from the
over-travel position.
Limit switches shall be used to indicate when the brakes are fully engaged and lifted.
All auxiliary machinery required for Crane operation such as the coal grab, lubrication
equipment, hydraulic power unit(s), lifting gear, etc., shall be supplied complete with all

necessary control equipment, interlocks, indications and alarms to enable both local
operation and remote operation, plus control and monitoring from the slew bearing
platform control console. Interlocks designed to shutdown equipment shall be fully
integrated through the PLC with the Crane motion to ensure a safe and correct shutdown
procedure. A boom load monitor shall be provided.
An operator shall not be able to back out of a hardwired safety trip without first identifying
the cause for tripping the backup safety limit. An electrician would be required to reset
the limit to permit further operation once the problem has been identified and repaired.
All devices (limit switches, level switches, etc.) shall be mounted so as to be accessible
for maintenance/replacement without the need of ladders, scaffolds or temporary
platforms.
7.15 Control Console and PLC
7.15.1 Control Console
The operator’s control console shall be ergonomically designed with respect to equipment
arrangement, the operator's position and operator sight lines.
Control devices located on the operator’s chair armrest control console shall include, but
shall not be limited to:
• Start/Stop for Crane.
• Joystick control of direction and speed for swing/slewing drives.
• Joystick control of direction and speed of boom and boom arm luffing.
• Controls for grab
• Emergency shutdown pushbutton.
• Alarm reset pushbutton.
• Various alarm/status indication lights.
All joystick type motion controls shall be lever type spring centered.
The console shall be integral with the operator’s chair and manufactured from #12 gauge
stainless steel. Metal edges shall be blunt and free from burrs. Surfaces shall be smooth
and without pits and hollows. Adequate free access shall be provided front, top, sides
and rear. Auxiliary equipment shall be accessibly mounted behind hinged, flange formed
doors. Supports shall be provided to secure doors and panels in their open position.
Wiring shall be neatly trunked and supported at frequent intervals.
7.15.2 Console Wiring
All devices shall be wired to terminal blocks. Terminal blocks shall use tubular type
terminals and incorporate at least 20% spare terminals. No more than two wires shall be
connected to the same terminal block. Terminal blocks shall be identified with numbers
as marked on the drawings.

The minimum wire size permitted shall be #16 AWG (1.5 mm2). Each end of each wire
shall be identified with an approved wire marker, in accordance with the wire numbers
indicated on the drawings. Wiring crossing hinges or doors shall be adequately protected
to prevent straining when the door is opened and chaffing across the hinge or door.
Each device located on the control console shall be clearly identified as to its purpose
and function using permanently affixed screwed lamicoid nameplates engraved with black
lettering on a white background.
No components shall be mounted using adhesives.
7.15.3 Programmable Logic Controller (PLC)
The PLC system shall be supplied complete with PLC cabinet, hardware and
interconnecting cables, Ethernet communication equipment and cabling, wireless
Ethernet modem, Ethernet switches, programming terminal, and software. The Contractor
shall provide complete system design and programming.
The PLC system and components shall include, but not be limited to the following:
• CPU (non-redundant) and I/O.
• Minimum 10 slot rack
• Local PLC Panel Operator interface in Control Cabin.
• PLC Programming software.
• Ethernet Network.
• I/O chassis –as required.
• Power supplies (non-redundant) – as required.
• I/O Modules - as required.
• Spare I/O capacity of 20%.
• Spare module space of 20%.
Temperature sensors connected to the PLC shall be provided in the PLC cubicle to detect
over temperature in the cabinet.
7.16 Control Devices

Instruments and meters shall be provided to adequately indicate the functioning of the
equipment.
Ammeters shall be furnished on all starter panels for motors 100 hp and greater. Where
the above is available from the electronic motor protection unit, separate meters are not
required. An ammeter, together with phase selector switch, shall also be provided on the
3.3 kV incoming switchgear to indicate total current input to the Crane.

Voltmeters, with three phase voltmeter switches, shall be furnished to indicate primary
and secondary voltage for the transformer switchgear. Voltmeters, with three phase
voltmeter switches, shall be furnished on all switchgear incoming sections. Where the
above is available from the electronic motor protection unit, separate meters are not
required.
Current transformers shall have sufficient thermal and mechanical ratings to withstand
currents equal to the maximum interrupting and momentary current ratings of the
protective equipment.
Instruments, panel-mounted relays and meters shall be semi-flush. All instruments,

gauges, charts, etc. shall have units in the metric system of measurement.
In general, all panel-mounted relays shall be of the switchboard draw out type, with built-
in testing facilities, and shall be fitted with targets as required to indicate operation.
Field mounted instruments requiring routine inspection or calibration shall be provided

with rain/sun shields. Field instruments shall be rated as per the area classification of the
NEC as outlined in Section 7.2.3.
Field instruments shall have standard 4-20 mA output signals, isolated where possible.
Pushbuttons, selector switches, pilot lights, and joysticks shall be rated for the area
classification and shall be heavy duty type. Contacts shall be rated for 240 V, 10 A,
continuous operation. In outdoor enclosures, pushbuttons shall use flexible boots.
Pilot lights shall be transformer type AC and resistor type for DC. Colors of indicating
lights shall be as follows:
Red Equipment Running
Green Equipment Ready/Stopped
Amber Equipment Trip or in Alarm
White Position Indication
Blue Level Indication
Control relays shall be of magnetic type, having a coil suitable for operation on 85 to
110% of the normal control voltage. Contacts to be rated for 240 V, 10 A continuous
operation. Relays shall be Allen-Bradley Type 700 or equal with four convertible
contacts.
Timing relays shall be avoided if possible with all time functions being performed in the
PLC. However, if a timing relay must be supplied it shall be of the plug-in solid-state type
with adjustable time delay period. Contacts to be rated for 240 V, 10 A, for continuous
operation.
Position switches shall be heavy duty, rated for the area classification, hermetically
sealed, magnet operated, GO proximity type switches or equivalent.

Where not already specified, the Buyer reserves the right to specify control devices to
standardize with the existing installation.
7.17 Control Information and Interface Data

As a minimum, the following information shall be transmitted to the Buyer’s system:
• Crane “ready”;
• Status of Crane overload protection/limit switches
• High wind lockout;
• Crane emergency stop;
• Crane fire;
• Wind speed;
• All alarms.
As a minimum the following information shall be transmitted from the Buyer to the Crane:
• System emergency stop;
• Onshore Fire Alarm Trouble and Alarm.
The following controls shall also be hardwired to the pivot tower termination panel:
• Crane emergency stop;
• Crane fire.
7.18 Maintenance Diagnostics Supplement

In general, the Contractor shall maximize the use of PLC status inputs to help diagnostics
and maintenance practices.
The Contractor shall:
• Make available all field control and instrumentation device signals for fail-safe
connections to the local PLC.
• Ensure third party suppliers provide fail-safe contacts for connections to the local PLC
for status, control and diagnostics.
7.19 Control Cab

The operator’s cab shall be completely assembled and wired in the shop. All electrical
terminals (with the exception of the I/O rack) to field connections shall be attached to
terminal strips and shall be clearly and permanently labeled.
A full electrical test of the operator’s cab shall be performed in the factory prior to
shipment. The Buyer’s Engineer and Inspection Authority shall be given two weeks
notice of testing.

The operator’s cab shall be fitted with a sunshield on the roof with a minimum clearance
above the roof of 150mm.
The Operator’s Cabin shall be painted as per the Buyer’s specification.
7.20 Electrical House

All electrical equipment and wiring in the electrical house shall be preinstalled, terminated
and tested in the Supplier’s shop prior to shipment.
The electrical house shall be fitted with a sun shield on the roof with a minimum clearance
above the roof of 150 mm. The e-house shall be painted as per the Buyer’s specification.
The electrical house shall be pressurized with filtered air to prevent ingress of dust.
The electrical house shall be fully insulated. Faults on the A/C unit shall be alarmed in
the PLC.
The electrical house shall utilize a false floor design so that all cabling runs will be
between the two floors.
Access covers to equipment shall be limited to manageable sizes and be fitted with lift-off
hinges. Where access covers are provided in the top of equipment there shall be 600
mm or greater clearance above the covers when in place.
Clearance between the opening arcs of all opposing equipment and personnel doors
inside the electrical house shall be not less than 600 mm, irrespective of the location of
personnel doors, door opening direction or expected door usage.
The main entrance to the electrical house shall utilize a double door, air lock type
arrangement to prevent dust from entering the electrical house. E-house room doors shall
open outwards from the room and shall be equipped with panic hardware to open the
door without the use of hands.

8 Corrosion Protection
8.1 Corrosion Environment

The terminal is located on the sea coast in a tropical climate. All exterior surfaces of the
Crane will be subject to wetting from rain and sea water spray. Therefore, the potential
for rapid corrosion of inadequately protected metal surfaces is considered to be severe.
The Seller shall undertake all reasonable precautions during design, construction and
application of protective coatings to ensure that deterioration from corrosion of Crane
components in service is minimized.
8.2 Scope of Work
8.2.1 General
This Technical Specification covers the supply of all labour, supervision, tools, equipment
and necessary materials to provide an effective corrosion protection system to the Crane.
All cleaning materials, paint and galvanizing materials shall be supplied by the Seller.
All systems shall be completely shop applied except for field fabricated items such as
electrical conduit, field welds and field bolted connections.
8.2.2 Work Included
The work shall include but not be limited to the following:
• Design, fabrication and installation of construction details complying with this

Technical Specification.
• Cleaning and surface preparation of areas to be painted.
• Grit blasting and priming of faying surfaces of splices, and protection from
subsequent paint and contamination.
• Prime and finish painting of the internal and external surfaces of Crane structures.
• Prime and finish painting of the internal and external surfaces of all electrical
enclosures.
• Prime and finish painting of all machinery items, conduit and piping including any
colour-coded identification system as may be required.
• Finish painting of all handrails.
• Field touch-up of damaged paintwork.
• Painting out of erection marks and numbers.
• Painting of all obstruction warnings for limited headroom; only the portion below 2.1 m
level shall be painted as a safety measure.

• Painting of demarcation lines on floors or other surfaces around "Keep Clear" or

"Danger Areas.”
• Painting of caution signs and markings.
• Protection of machined and sliding surfaces.
• Removal of paint from any unintentionally painted area.
• Hot-dip galvanizing of components, materials and hardware, where specified.
• Caulking and sealing.
• Protection during shipment and storage.
8.2.3 Work Not Included
Painting, except where specified otherwise, of galvanized surfaces, aluminium, chrome

and nickel plate, stainless steel, copper, brass, rubber, glass and data plates.
8.3 Design and Construction Requirements

The Seller shall consider and take precautions to mitigate the harmful effects of runoff or
drainage water impinging upon sensitive or critical components such as electrical
enclosures, motors, gear reducers, bearings, shafts, pinions, hydraulic components, etc.
8.3.1 Bolted Connections
After completion and final inspection for bolt tightness of bolted connections, whether
performed in the shop or field, the Seller shall apply a suitable sealant or caulking
material, compatible with the paint system used, to all exposed edges of the mating
surfaces of each bolted connection such that influx of moisture to the mating surfaces is
prevented.
Following completion of bolted connections between painted components, the galvanized

bolt-heads, nuts and washers shall be given one coat of topcoat paint, applied by brush
or spray after pre-treatment of the galvanized fasteners with vinyl/butyryl wash primer
(refer to Table 5 "Paint Schedule"). One coat of topcoat shall also be applied to the
sealant around the edges of each bolted connection.
Galvanized fasteners and edge sealant used at bolted connections between hot-dip
galvanized components shall not be painted.
8.3.2 Dissimilar Metals
The Seller shall take precautions to mitigate or prevent rapid galvanic corrosion arising
from intimate contact between different metals with large differences in electromotive
potential in the galvanic series.
The Seller shall exercise care in the selection of materials and shall avoid contact
between different metals and/or electrically insulate different metals from each other,
wherever possible. In particular, care shall be exercised in the selection and installation

of electrical fixtures, conduit and cable trays. Aluminium and aluminium alloys shall be
avoided wherever possible, except in sheltered locations or within enclosures.
Nameplates mounted on exterior surfaces shall be made from and fixed in place with
austenitic stainless steel or other material with limited potential to cause, or suffer from,
galvanic corrosion. Aluminium, aluminium alloys, copper or copper alloys shall be
avoided except within sealed enclosures, sheltered locations or indoors.
8.4 Surface Preparation
8.4.1 Cleaning - General
All surfaces to be painted shall be cleaned and be free from rust, scale, dirt or other
foreign matter. Grease and oil shall be removed by washing with solvents.
Cleaned surfaces shall be primed immediately. Particular care shall be taken in the
selection of cleaning solvent to prevent damage to the surface and/or surrounding finish.
All surfaces prepared by Others shall be inspected and any defects reported to the Buyer.
The commencement of work will indicate acceptance of the surface by the Seller.
8.4.2 Steel - General
The recommendations outlined in the following standards from the "Steel Structures
Painting Council" (S.S.P.C.) shall be as follows for surface preparation for steel:
S.S.P.C. S.P. No. 1 Solvent Cleaning
S.S.P.C. S.P. No. 2 Hand Cleaning
S.S.P.C. S.P. No. 3 Power Tool Cleaning
S.S.P.C. S.P. No. 6 Commercial Blasting Cleaning
S.S.P.C. S.P. No. 7 Brush-off Blast Cleaning
S.S.P.C. S.P. No. 10 Near White Metal Blast Cleaning
S.S.P.C. S.P. No. 11 Power Tool Cleaning to Bare Metal
Special attention shall be paid to cleaning irregularities such as weld joints, bolts, nuts
and damaged areas.
All weld spatter shall be removed from all weld areas, all weld areas shall be power wire-
brushed (SSPC-SP3) and harmful electrode deposits shall be removed by scrubbing with
a 5% phosphoric acid solution (SSPC-SP1), followed by rinsing with clean water, prior to
cleaning by other methods.
8.4.3 Steel - Shop Painted
Steel surfaces that are to be shop painted, unless specified otherwise, shall be subjected
to "Near White Metal Blast Cleaning" (SSPC-SP10). Except as otherwise recommended

by the paint manufacturer, abrasive blasting shall achieve a 25 to 50 micron anchor

profile as measured by a Keane Tator Surface Profile Comparator or similar device.
8.4.4 Steel - Field Painted
Bare steel surfaces and damaged shop-painted surfaces to be painted on site shall be
cleaned and prepared as specified in Subsection 8.5.5.
8.4.5 Steel - Galvanized
Steel surfaces that are to be galvanized shall first be degreased in a caustic bath, prior to
pickling in inhibited sulphuric acid.
8.5 Workmanship
8.5.1 General
All paint coatings shall be applied in accordance with the manufacturer's published
application instructions. Such instructions are deemed a part of this Technical
Specification.
8.5.2 Inspection
Inspection of surface preparation and coating shall be performed as outlined in this

Technical Specification.
8.5.3 Paint Application
Coating shall take place within eight hours after inspection of surface preparation and
before any visible or detrimental corrosion or contamination occurs.
All equipment shall be maintained in good working condition and shall be comparable to
that described in the printed instructions of the coating manufacturer. All equipment shall
be thoroughly cleaned before use.
Unless otherwise specified in this Technical Specification, coatings shall not be applied
when the surrounding air temperature is below 15oC or above 38oC. Furthermore, the
surface temperature of the steel shall not be below 15oC or above 52oC, and shall not be
less than 2oC above the dew-point temperature. Coating shall not be applied in rain or
when the relative humidity exceeds 85%.
Notwithstanding the above, all coatings or systems shall be applied under controlled
conditions in the fabricator's shop prior to shipment.
Spray painting shall be employed for all paint application, with airless spray preferred,
except for the following:
• Brush application of primer and intermediate paints along welds and edges ("stripe
coating"), performed prior to spray painting with the same materials, may be used to
ensure uniform coverage.

• Brush or roller application may be used to touch-up small areas of damaged or

defective paint.
All air lines shall be equipped with water traps to positively remove condensed moisture.
All paint films shall lie within the specified thickness ranges and shall be free of voids,
shadows, bubbles, pinholes, runs, sags, mud cracks or other signs of improper
application techniques or undesirable shop conditions.
Minimum recoat and curing times, as stated in the printed instructions of the coating
manufacturer, shall be carefully observed. Particular care shall be taken to ensure that
solvent-borne inorganic zinc type paints are completely cured before over coating.
Newly coated surfaces shall be protected from rain, condensation and contamination until
thoroughly dry.
Nameplates on mechanical and electrical equipment shall not be painted.
Faying surfaces of friction-type bolted connections shall be painted only with inorganic
zinc-rich primer. After primer painting, these surfaces shall be masked to keep the
surfaces free from other types of paint. The masked area shall extend 50 mm beyond
faying surface.
8.5.4 Hot-Dip Galvanizing
Hot-dip galvanizing of iron or steel components and hardware shall be performed in

accordance with ASTM A123 or A153, as applicable, and shall employ practices defined
in ASTM A385.
Galvanized components which are subsequently to be painted shall be hot-dip galvanized

using the "dry process" method, shall not be quenched after galvanizing, and shall not
receive a chromate surface passivation treatment.
8.5.5 Field Painting
All structures and equipment shall be delivered to the site complete with shop coating
system already applied; the following conditions shall apply for "touch-up" and any other
miscellaneous field painting required.
The Seller shall be responsible for the supply and application of paint and any other
materials required to repair and complete the paint system in the field.
Materials shall be identical to those applied in the shop.
Field coatings shall be applied as outlined in the Paint System and Schedule, except for
surface preparation.
Painting shall only be carried out when the climatic conditions, as required by Subsection
8.5.30 are being observed.

All surfaces to be painted shall be inspected for surface preparation and approved by the
Owner prior to painting.
All unpainted surfaces and surfaces on which the paint film has been damaged down to
the underlying metal shall be spot blast-cleaned, unless deemed impractical by the
Owner in which case the area shall be prepared by power tool cleaning to bare metal
(SSPC-SP11).
Previously painted surfaces which have been damaged, but where the damage has not
fully penetrated the paint film to the underlying metal, shall be prepared by sanding and
scraping to blend the damage area into the surrounding undamaged paint and to roughen
the surface. One or more coats of paint shall be applied to the damaged area to provide
the Dry Film thickness specified for each coat in the Paint System and Schedule.
Spot blast-cleaning shall be done under cover and shall employ protective screens as
necessary to protect adjacent equipment, structures and personnel.
Following sealing of the edges of friction-type bolted connections as outlined in

Subsection 8.5.30, all exposed portions of these connections which are painted with zinc
primer only shall have intermediate coat (where applicable) and topcoat applied in the
field. Spray application is preferred, but brush or roller application may be used for small
areas.
8.6 Paint System and Schedule
8.6.1 General
All structures and equipment shall be coated as indicated in Table 7.1.
Any deviations from the indicated systems and schedule, including any deviations in the
indicated Dry Film Thickness range of each coat, shall be subject to the Owner's prior
review and approval.
At Seller's option, hot-dip galvanizing may be substituted for painting of non-structural

components (e.g., shrouds, dust covers, etc.), secondary structural members (e.g.,
walkway supports), or other structural components which are subject to predominantly
static or compressive stresses. Hot-dip galvanizing shall not be used for structural
members or components subject to high fatigue loads.

Table 5: Paint Schedule
Surface Coating Material and Dry Film Thickness (DFT) in microns Minimum
AREA Preparation Total
Primer DFT Intermediate DFT Topcoat DFT DFT

(SSPC No.) Coat (Micron)
Exterior Surfaces: Structural and SP-10 Zinc-rich 50 - 75 H.B. Epoxy 100 -150 H.B. Epoxy 100 - 150 275
Miscellaneous Steel Polyamide Polyamide
or
Aliphatic 40 - 70 200
Polyurethane
Interior Surfaces of Unsealed Box Structures SP-10 Inorganic Zinc 60 - 90 (not required) - (not required) - 60
Floor plates and grating, stair treads, Pickling Hot-dip Per ASTM (not required) - (not required) - Per ASTM
optional structural and miscellaneous steel, galvanizing Spec. Spec.
junction boxes and conduit fittings
Handrails, guard plates, ladders and cages, Pickling and Hot-dip Per ASTM Vinyl Butyryl 7 - 12 H.B. Epoxy 100 - 150 107 +
machinery guards, screens and covers, after galvanizing galvanizing Spec. wash primer Polyamide galvanized
danger demarcation areas on galvanized
SP-1 solvent thickness
steel, galvanized structural bolts
wash
Interior Surfaces of Sealed Members None not reqd. - not reqd. - not reqd. - -
Machinery - pre-painted to manufacturer's SP1 Universal 35 - 60 (not required) - Epoxy enamel 30 - 60 70 +initial paint
standard paint system Barrier Primer or 80 +
Aliphatic 40 - 70 initial paint
Polyurethane
Machinery - unpainted SP1, SP3 and Zinc-rich 50 - 75 H.B. Epoxy 100 - 150 Epoxy enamel 30 - 60 190
Phosphate Polyamide or

Surface Coating Material and Dry Film Thickness (DFT) in microns Minimum
AREA Preparation Total
Primer DFT Intermediate DFT Topcoat DFT DFT

(SSPC No.) Coat (Micron)
Treatment Aliphatic 40 - 70 200

or Polyurethane
SP10
Machined surfaces - iron and steel SP1 (not required) - (not required) - Solvent-soluble 25 - 50 25
rust preventative
Electrical enclosures:
Electrical enclosures, outdoor use, outer Phosphate Zinc chromate 50 - 75 Vinyl enamel 25 - 45 Vinyl enamel 25 - 45 110
surface treatment
Electrical enclosures, outdoor use, inner Phosphate Zinc chromate 50 - 75 (not required) - Vinyl enamel 25 - 45 80
surface treatment
Electrical enclosures, indoor use, outer Phosphate Zinc chromate 30 - 60 Vinyl enamel 20 - 35 Vinyl enamel 20 - 35 75
surface treatment
Electrical enclosures, indoor use, inner Phosphate Zinc chromate 30 - 60 (not required) - Vinyl enamel 25 - 45 60
surface treatment

8.6.2 Painting Materials
For each area or major subassembly, all paints shall be from the same manufacturer and
shall be recommended by that manufacturer for use in the paint system indicated in the
Paint Schedule.
Prior to commencement of painting, the Seller shall provide the Owner with copies of the
manufacturer's paint data sheet for each type of paint to be employed.
The term "inorganic zinc" as used in the Paint Schedule refers to a water-borne or
solvent-borne primer paint which cures to form a film of metallic zinc powder in a silicate
matrix. Before painting over solvent-borne varieties of this paint, it is important that the
coating become fully cured which requires that the coating be left exposed to atmosphere
for a period of time, dependent upon humidity, beyond the time it has become dry to the
touch.
The term "zinc-rich" primer as used in the Paint Schedule shall mean either "inorganic
zinc" primer as defined in 8.6.20 or a primer paint consisting of metallic zinc powder in an
epoxy matrix ("organic zinc"). Any "organic zinc" primer used on this project shall cure to
a dry film containing not less than 80% by weight of metallic zinc.
All paint materials, until immediately prior to use, shall be stored in the original containers
supplied by the manufacturer which shall bear labels indicating date of manufacture. All
paint materials shall be stored under conditions strictly in accordance with those
published on data sheets for each type of material and shall be used in a time period from
date of manufacture not exceeding the shelf life given on the data sheets. The Seller
shall not use outdated or improperly stored paint materials and shall promptly remove all
such materials from the work site.
8.7 Colour Schedule
8.7.1 Primer
The primer shall be of a colour which contrasts with both the prepared substrate and with
the paint colour with which the primer will be over coated.
8.7.2 Intermediate Coat
The intermediate coat, when required by the Paint Schedule, shall contrast with both the
primer and topcoat.
8.7.3 Topcoat
To be approved by the Owner.

8.8 Protection of Coated Surfaces
8.8.1 General
The Seller shall take all necessary precautions to protect shop-applied coatings on
component surfaces from damage or deterioration during all phases of painting, loading,
shipment, off-loading, storage, erection and commissioning.
8.8.2 Lifting
Lifting of coated components shall preferably be performed using only lifting eyes or lugs
installed for that specific purpose.
When lifting eyes or lugs have not been installed or cannot be used, then lifting shall be
performed using nylon slings or padded grapples. Unprotected hooks, chains or wire
rope slings shall not be used to lift coated components.
8.8.3 Shipping
During shipment, coated components shall be adequately supported using wooden

blocks, padded supports or similar means. Coated components which are stacked shall
be separated by wooden battens, mats or other padding material. Loads shall preferably
be secured using nylon straps, but if wire rope or chains are employed, coated surfaces
of components shall be protected from contact with the securing ropes or chains.
Coated components which are bundled together for shipment shall be adequately
protected from contact with each other and from contact with the securing bands or straps
using a weather resistant material such as wood.
Galvanized fasteners and other small galvanized components may be shipped loose in
sealed boxes, pails or drums. Small painted components shall be shipped in weather
resistant boxes or crates and shall be adequately padded to protect painted surfaces.
Painted structural components which are shipped deck cargo on oceangoing ships or
barges shall have all unpainted areas (e.g., field weld locations), areas painted with
primer only (e.g., friction-type bolted connections) and machined surfaces protected from
salt water spray using plastic wrap or similar means.
8.8.4 Storage
Coated components shall be stored at shops or on site in such a manner as to avoid

corrosion or degradation of coated surfaces.
Coated components which are boxed, crated or packaged shall be stored under cover
and above ground level.
Large coated components which are stored outdoors shall be supported on wooden
blocks a minimum 100 mm above ground level and shall be stored in a location such that
the possibility of damage to coatings from vehicle or foot traffic is minimized. Coated
components which are stacked shall be separated from each other by wooden blocks or
battens, or fabric or elastomer mats. For periods of outdoor storage exceeding 30 days,

the provisions of 8.8.30 shall be observed for protection of unpainted or temporarily

protected surfaces.
If, in the opinion of the Owner, painted components shipped to site with topcoat in place
appear to have excessive damage to the paint system, the Seller shall, at his sole
expense, repair the offending area in accordance with the paint manufacturer’s
specification.

9 Documentation
9.1 General
The Contractor shall submit to the Buyer documentation and drawings, including all
revisions thereof, required for the design, furnishing of equipment, erection, installation,
maintenance and operation of the Crane.
The Contractor's furnished documentation and drawings shall include, but not be limited
to, items indicated in the following subsections.
9.2 Layout Drawings

The Contractor shall submit certified drawings of all layouts, including but not limited to,
general arrangement drawings of the Crane and drawings indicating the location of items
of equipment.
9.2.1 Structural Drawings
The Contractor shall submit general arrangement and detail drawings showing the Crane
structure and the loads for which it is designed. These drawings shall include, but not be
limited to:
• Overall general arrangements showing leading dimensions and the relationship of all
the parts of the machine.
• Loading diagrams showing:
- External loads applied to the machine, including magnitude and points of

application.
- External reactions corresponding to the applied loads.

- Internal reactive forces between machine components.
- Individual member design loads, including the load range and cycle life used for
fatigue design.
• Detailed structural drawings showing individual member sizes and arrangements.
9.2.2 Mechanical Component Drawings
The Contractor shall submit general arrangement and detail drawings of all mechanical
components.
9.2.3 Electrical Drawings
The Contractor shall submit certified drawings of all electrical power and control system
equipment, schematics, wiring diagrams, cable/conduit layouts, lighting, termination panel
details, PLC details and PLC program.

9.2.4 Shop Drawings
When stipulated in the Specification, or upon request from the Buyer, the Contractor shall
submit shop drawings to the Buyer for review.
9.2.5 Erection Drawings
The Contractor shall provide erection drawings required for the Crane to be fully
assembled and erected on site.
Erection drawings shall include, but not be limited to, the following:
• Connection details for major assemblies showing welding and bolting requirements at
all connections.
• Weights and centers of gravity of major assemblies.
• Field run cable schedules, schematics, and wiring diagrams.
9.2.6 As-Built Drawings
The Contractor shall provide the Buyer with complete set of certified full size, as-built
drawings showing all details of the Crane as actually built or constructed, plus electronic
copies in AutoCAD format. As-built drawings shall include all general arrangement
drawings, all shop drawings, all mechanical component drawings, including fully
dimensional detail drawings and material specifications for all internal and external
components, and all electrical drawings and PLC program.
9.3 Calculations
When stipulated in the Specification or upon request from the Buyer, the Contractor shall
submit for review by the Buyer, copies of design calculations and all explanatory notes
including, but not limited to the following:
• Stability calculations
• Stress analyses
• Power and load calculations
• Other design calculations where requested by the Buyer.
The Contractor shall provide complete certified design loads for the Crane support
structures and certified load data for various loading conditions, including seismic
response.
9.4 Erection Procedures

The Contractor shall submit a detailed erection procedure for the Buyer's review.

9.5 Commissioning Procedures

The Contractor shall submit written commissioning procedures for review by the Buyer.
9.6 Manuals
Vendor manuals must be comprehensive, so as to form a reliable and easy source of
access to all information necessary for the following functions. Procedures and
instructions should be simple and valid.
• Receipt and storage of equipment.
• Safety of personnel and protection of equipment during installation, operation and

maintenance of the equipment.
• Installation.
• Commissioning.
• Operation.
• Maintenance.
The manual must cover all aspects of the above functions without the need for reference
to sources outside the manual.
The manual will be used as an aid to the training of operation and maintenance personnel
and should therefore make maximum use of exploded views, technical illustrations,
charts, trees and tables.
The material in the manual must be presented in logical sequence.
It should be remembered that manuals will be required by three distinctly different groups
engaged in separate functions.
- The contractors who will install and commission the equipment.

- The equipment operators.
- The maintenance division of the operating company.
Each of these groups will be expected to operate to a large degree independent of each
other. It is therefore, essential that the manuals for each of these three functions are
separate, or can be separated without loss of identity or completeness. Some drawings
will have to be included in more than one of the installation, operation or maintenance
manuals to maintain their integrity.
Six (6) copies of each type of manual shall be provided in English language.

9.7 Quality Assurance
9.7.1 Quality Assurance Manual
The Contractor shall provide two (2) copies of the Contractor's Quality Assurance (QA)
manual. It shall be supplemented or revised to incorporate all actions necessary to bring
the Contractor's quality assurance program into full conformance with the Specifications.
9.7.2 Quality Plan
The Contractor shall submit the evidence of registration, if any, of the Contractor's Quality
System under the applicable ISO Quality Standards, or their equivalent.
The Contractor shall provide three (3) copies of the detailed Quality Plan that the
Contractor intends to employ for the work. The Quality Plan shall be provided within two
(2) weeks of Notice to Proceed, and shall include:
• Inspection and Test Plans (ITPs)
• Quality Assurance (QA) and Quality Control (QC) activities performed by or upon
suppliers and subcontractors or their products.
• A draft schedule relating dates of commencement and completion of major QA

activities to the proposed production schedule.
This plan will be reviewed by the Buyer. The Buyer will provide written notification to the
Contractor of any alterations requested in the plan, and indicate the specific points at
which the Buyer wishes to perform tests or to witness production or QC activities
performed by the Contractor or the Contractor's suppliers or subcontractors.
The Contractor shall submit, within one (1) week after such notification by the Buyer,
three (3) copies of the revised Quality Plan which shall incorporate the changes and hold
points requested by the Buyer, along with a schedule providing the proposed dates at
which major production and QC activities will commence and conclude, and proposed
dates for each hold point.
During the course of production, the Contractor shall periodically update the Quality Plan
and schedule to reflect actual conditions, and shall provide three (3) copies of each such
revision.
All progress will be reported on an “Inspected – OK” basis.
9.7.3 Design Verification
The Contractor shall provide, for review, a detailed description of the Contractor's design
verification procedures.
9.7.4 Quality Dossier
At the completion of the Work, a quality dossier shall be submitted by the Contractor to
the Buyer. It shall incorporate all quality related documentation, including but not limited
to:

• Design review checklist
• Material certificates
• Dimension sheets
• Welding inspection reports
• Heat treatment reports
• Electrical equipment tests
• Painting control sheets
• Duly completed Inspection and Test Plans
• Initial equipped setting
• Performance and overload test results
• Baseline measurements of stress, vibration and thermal imaging.

10 List of Approved Sub-vendors

Table 6: Approved Sub-vendors - Mechanical
Sl.No. Description Tenderer
1 EM Disc brakes BCH, Electronics & power Control, Electromag Methods,

Stromkraft Control.
2 Flexible Geared Coupling Hi-cliff/ Wellman incandescent/ David Brown & Greaves
Ltd./ New Allenberry Works(NAW) / GBM
3 Slew bearing Rothe Erde
4 Other Bearings SKF/ FAG
5 Oil Seals VACCO Oil Seals/ Rubber equipment & Engineering Co.
Ltd.
6 Lubrication Lubcon/ Prakash/ AFMC/Warner.
7 Hydraulics and Power Pack Rexroth,Dennyson,Yuken,Carter, WIPRO, OSCAR
8 Hoses Aerolex,Hydrokrimp,Soni,Tekson,Sridhar
9 Idlers & Pulleys ELECON, TRF,MBE, HITECH, MASYC, ROLLWELL,

HULI, TECKPRO
10 Belting Phoenix Yule, MRF
11 Gear Boxes ELECON, GREAVES, Flender, NAW
12 Belt Cleaner, Skirts HOSCH,KAVERI, Thejo, Tega
Table 7: Approved Sub-vendors - Electrical
1 Distribution transformers Crompton, Areva, Bharat Bijlee, Voltamp
2 MV switchgear ABB, Areva, Siemens, Crompton,
3 LV switchgear (PCC, MCC,DB.PB) ABB, Siemens, Areva, Schneider Electric
4 VFD Siemens, Areva, Schneider Electric, ABB
RPG, Industrial cables, Universal cables, CCI, Polycab, Fort

5 HT cables
Gloster
6 LT cables Polycab, Universal, RPG, CCI, Lapp, Fort Gloster
7 Cable trays & accessories Apt Engg, Premier, Jamuna metals, Globe, Indiana,
8 Lighting system Havells, Crompton, Bajaj, Philips
9 Digital meters AE, MECO, Enercon,
10 Protection relays ABB, Areva, Siemens
11 Transducers ABB, AE, Siemens, L & T
12 APFC Siemens, L&T, EPCOS
13 Instrument transformers Kappa, Pragati

14 Motor Siemens, Bharat Bijlee, Crompton
15 Telephone BOSCH, HCL, Ericson, Siemens
16 PLC ABB, Siemens, Areva
Note: Tenderer can suggest any other equivalent make however this will be subject to
owner’s approval

11 Erection ,Testing and Commissioning
11.1 Site
The Tenderer will be responsible for his own office accommodation as well as provision of
portable toilets.
Tenderer must allow for providing and installing the necessary power cable from the site
to the nearest supply point, for a 415 Volt 3-phase supply point for general office and site
usage.
This supply may not be used for heavy welding etc.
Tenderer must also allow for the necessary piping to the nearest water supply point.
The successful Tenderer must himself apply for the necessary telephone lines for phones
and fax machines.
The Tenderer will be in control of the complete site and as such must ensure that all the
applicable regulations are enforced and provide his own security.
The Tenderer will be an employer in his own right in terms of the safety standards, and as
such would be responsible for all safety arrangements on the site.
11.2 Erection Plan

The Tenderer shall submit an erection plan along with the tender for the plant &
equipment under his scope of supply.
The plan will outline:
• The erection techniques to be employed.
• Resources planning:
• Requirement of construction power, water and storage needs.
• Deployment of erection machineries.
• Deployment of manpower of specific trade and requisite skill.
• Equipment delivery planning
• Erection material planning
• Sequencing of erection to avoid accumulation / under utilization of resource & to

achieve better progress.
• Action plan for completing critical work
Deployment of erection machineries
• The Tenderer shall submit along with the tender the following:

• List of various erection equipment such as cranes, winches etc. planned to be

mobilized and indicate specification and quantity of each item.
• List of machinery, tools and tackles such as welding transformers, welding generators
/ sets, gas cutting sets, drilling machines, chain pulley blocks, survey instruments,
etc. and indicate specification and quantity of each item.
Deployment of manpower
• The Tenderer shall submit along with the tender a list showing deployment of
manpower of the following categories indicating number of personnel, schedule and
duration of their posting at site, educational background, experience etc.
• Engineers to be engaged for design and engineering, coordination, follow-up and

expediting.
• Engineers and supervisory personnel directly attached to site work i.e. erection,
testing, commissioning and demonstration of performance guarantee values.
• Project organization set-up, preferably with job responsibility
• Organization (proposed) for implementation of the package.

12 Performance Requirements
12.1 Availability and Life of the Mobile Harbour Crane

The mobile harbour crane shall be suitable for continuous heavy duty operation 24 hours
per day, 7 days per week, at the design tonnage with periods of non operation during the
year.
The mobile harbour crane availability shall be 95% and is defined as follows:
• “Total calendar hours in a year less planned maintenance divided by the total number
of hours in a year. Planned maintenance in accordance with Planned Maintenance
Program for the Mobile harbour crane shall take no more than 500 hours per year. No
opportunistic time for planned maintenance during non-operating periods should be
considered in the Planned Maintenance Program.”
• The Tenderer warrants that the design, materials and workmanship will enable the
Owner to perform the planned maintenance as specified in the Planned Maintenance
Program during the plant shut downs defined in the preceding paragraph.
• The availability of the Mobile harbour crane should be reached as an average value,
measured on a yearly basis. The Availability shall be warranted only for the duration
of the Defects Liability Period.
• Shortfalls in the availability that are not directly caused by the Tenderer’s failure shall
not be considered as non-availability.
• Life of the Mobile harbour crane shall be designed in accordance with the FEM
Section 1.001.The testing for the same will be done in accordance with the FEM
Guidelines to ascertain the life of the major components. The components of drive
assemblies mentioned below shall be designed to meet the minimum requirement of
FEM for the following conditions:
12.2 Reliability
The mobile harbour crane reliability shall be 98% minimum and defined as follows:
“The difference between the time the mobile harbour crane is being utilized less the time
Mobile harbour crane is not in operation divided by the time the Mobile harbour crane is
being utilized”.
Process mobile harbour crane stops include all time associated with mobile harbour
crane breakdowns causing Coal concentrate flow to stop and any time associated with
the Crane’s inability to interact with the pile. All non-operational times will be excluded
from the calculations.
Furthermore the calculation of the process Mobile harbour crane stop time shall only take
into account the time period counting from the Tenderer’s receipt of the Owner’s process
Mobile harbour crane stop notice until the rectification of the defect. Defects that can be
rectified simply by the Owner’s maintenance personnel shall be rectified immediately.

The following circumstances/time periods shall not be considered as process Mobile

harbour crane stops:
• Any Mobile harbour crane stops beyond the direct control and responsibility of the
Tenderer
• Any Mobile harbour crane stops caused by improper operation and/or maintenance
• Any Mobile harbour crane stops caused by impact of third parties.
• Any Mobile harbour crane stops caused by circumstances that are internationally
considered as cases of Force Majeure
• Any stop time exceeding the reasonable repair time due to inefficient performance of
the rectification work and/or due to lack of recommended spare parts on site
• Any Mobile harbour crane stops caused by failure of the site’s power supply
• Any Mobile harbour crane stops caused by failure of the downstream or upstream
equipment depending on the mode of operation.
The Reliability shall be warranted only for the duration of the Defects Liability Period and
subject to proven strict obedience of the Tenderer’s Operation and Maintenance manuals.
12.3 Planned Maintenance

The Tenderer warrants that the design, materials and workmanship will enable the Owner
to perform the planned maintenance as specified in the Planned Maintenance Program
during the plant shut downs defined in the preceding paragraph.
The availability of the Mobile harbour crane should be reached as an average value,
measured on a yearly basis. The Availability shall be warranted only for the duration of
the Defects Liability Period. Shortfalls in the availability that are not directly caused by the
Tenderer’s failure shall not be considered as non-availability.
Conditioning monitoring system to be implemented
12.4 Performance Testing of Mobile harbour crane
12.4.1 General
The machine shall be performance tested by the Tenderer. Coordination of activities and
operational requirements will be by the Owner.
The dates and times of the tests shall be nominated by the Owner to suit its train arrival
schedules.
Testing of the Mobile harbour crane will demonstrate the ability to achieve the stated
design Ship un-loading rate.
Co-ordination of activities and operational requirements will be by the Owner.

Performance test will commence after successful completion of load commissioning and
No-load commissioning. No-Load commissioning will commence after successful
completion of erection of the Mobile harbour crane and corrections of all deficiencies and
omissions to Owner’s satisfaction.
12.4.2 Performance Protocols
After the equipment are completely erected at site, each item/ equipment will be
thoroughly inspected for correctness and completeness of the installation and they
shall be subjected to final tests as to performance and guarantee to be carried out in
the presence of Tenderer or his representatives and the Owner or his representative to
demonstrate that the performance of the equipment conforms to relevant standards
and specifications and meet the requirements as given in this specification. The tests/
checks to be conducted shall be generally as under:
For each equipment, the load test shall be conducted in stages. The equipment shall be
run for 8 to 10 hours continuously at no load, 25%, 50% of the rated capacities or at
rate mutually agreed upon between Supplier and Owner or their representative. The
intervening period shall be available for making adjustments and arrangements by the
Tenderer as may be required. The equipment shall be capable of unloading of coal as
given in this specification.
All the specified speeds of the equipment shall be measured under full load conditions.
Proper operation of all limit switches and signals like L.T. limit switches, limit switches for
rail clamps, limit and safety switches for cable reeling drums, limit and safety
switches/ alarm for centralized lubrication systems, anti-collision device etc, shall be
demonstrated by the Tenderer in the presence of Owner or his representative.
During operations of the equipment at no load and at full load, performance of all the
drives shall be checked in respect of current drawn by the motors, temperature rise,
vibrations, gear box noise and its heating, bearing heating etc. consumption of power and
various consumptions like lubricants etc. shall also be measured and compared with the
respective rated values.
All signals and alarms for the operator in the cabin shall be demonstrated and
performance of all by-pass devices in the operator's cabin shall also be
demonstrated.
Testing of the software and hardware of PLC and instrumentation shall be demonstrated.
Any other observations/ tests felt necessary for judging the performance of the
machines and mutually agreed between Tenderer and Owner shall be carried out.
If during the test runs, there is an interruption exceeding 2 hours due to any cause
other than power failure or shortage of input materials for which the Owner is
responsible, the test run shall be discontinued and fresh date shall be decided
mutually by both the parties.

12.4.3 Tests
Details of the test methodology for full automatic operation shall be as described in the
Tenderer’s testing procedures. Tests shall include the following requirements as a
minimum:
Static load test
The purpose of static load test is to examine the load bearing capability of the crane and
its structural members and components.
The test will be considered successful if the test result shows that there is not any crack,
permanent deformation, painting peeling off and/or any damage that affect the crane
performance and safety, not any loosening or damage at joints and connection is found
after test.
Before static test the trolley is traversed along full length of its rail to and fro for several
times with 0.7P (P is rated load under grab) load and at 0.75V (V is rated speed of trolley
traversing). After the load is removed position the trolley at several points mentioned
below to determine measuring base points:
• At max. outreach measured from seaside rail centerline;
• At max. backreach from landside rail center line.
Position the trolley in turn at the above said two points and add gradually the load from
0.75P up to 1.4P without any shock or impact. The load in lifted to 100~200mm above
ground and is hold for 10 minutes. Then the trolley traverse away and measure actual
deflection of the girder.
Dynamic load Test
The purpose of dynamic test is to verify the machine running and performance data and
capability of various movements and brakes.
The test is considered as successful
• If no abnormal action of safety devices is found,
• No connection loosening or damage is found and
• All electrical switches are operated normally after dynamic test has been completed.
Individual operation of Each mechanism
During testing the machine will be operated in accordance with operating procedure and
the speed and acceleration and deceleration rate shall be within normal range.
With rated load P and 1.2 P and at points a, b and c as above determined respectively
operate hoisting up and down for 3 times and recorded. Then trolley traversing, grab lift
and opening/closing and gantry travelling shall be operated separately,speed measured
and recorded.

Simultaneous operation
With rated load P and operate hoisting, closing and trolley traversing simultaneously.
Boom hoisting test
Duty cycle time will be measured.
Duty cycle test will be made in accordance with specified path and measure time and fill
in the duty cycle chart.
Brake performance test. will be by using motor analog method to check whether braking
torque reaches 150% of rated load torque.
Rated Productivity Test
The machine is subject to rated productivity test after successful load test.
This test is conducted in accordance with JISB 8809-1968 recognized worldwide.
Rated productivity (capacity)
Q=q×n (t/h)
Q=V×r×y
N=3600/T
Where: q --- material weight grabbed into the grab (t)
V --- Volume of the grab (m3)
r --- Bulk density of material
n --- Number of cycles per hour
T --- Duty cycle period (sec)
y --- Rate of fullness of grabbing
Test conditions:
• With a fully loaded coal vessel, grabbing at the top of material within 20% coal;
• A skilled operator completes 10 times of grabbing and visually evaluates that the grab
is full of material (if not full re-grab it). The three max. results are taken from ten and
average value of the three is taken as “q”;
• Hosting, closing and trolley are run at rate speed with allowable error within +10%
and – 5%;
• The grab shall travel along a shortest distance from intersecting point of mean tide
level and centre line of the ship to a point above the hopper centre for grab

unobstructed opening to grab material and move to the hold and discharge material,
measure the time T;
• Rated capacity has allowable error – 5%.
12.4.4 Testing Rate
Mobile harbour crane at 3600 t/h average & 4000 t/h peak.
12.5 Performance Guarantee

The equipment shall be considered to have performed satisfactorily when
• Design capacity of material is delivered with all its drives and accessories functioning
properly over a minimum period of eight (8) hours.
• It runs successfully for a continuous period of 15 days at the rated capacity.
• Hoisting, slewing and traveling on load.
12.6 Productivity Acceptance Criteria

The Mobile harbour crane shall successfully unload coal without any further fine-tuning or
adjustments. The stockpiles shall be stacked without interruption attributed to the Mobile
harbour crane and at the specified Average and Design stack rates. It is anticipated that
the test will be performed within a 7 day period depending on the tippling rates.
Should the Mobile harbour crane’s performance fail to meet any part of the criteria, the
Tenderer shall perform such modifications as are necessary and begin the test from the
start. Costs associated with the modifications shall be borne in total by the Tenderer as
well as all costs associated with the extended performance testing process.
Performance guarantee values and penalty for non fulfilment of the same shall be as
follows:
Description Performance guarantee value, Acceptance limit with penalty Rejection Point
t/hr
Mobile harbour crane 1500 t/hr average free digging Up to 10 t/hr below rated capacity 10 t/hr below the average
rate and 2400 t/hr Cream Penalty will be @ 0.5% of equipment capacity,
Digging Rate cost for every 5 t/hr shortfall in
capacity
If the performance of the equipment falls below the guaranteed value indicated above the
Tenderer shall rectify it to restore to the guaranteed value within the contract period.
However even after rectification, if the guaranteed performance parameters are not
achieved then penalty indicated will be levied.

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Volume III – Specifications Coal handling facility at Berth 11, Mormugao Port, Goa

Section 7 – Mechanical Specifications Bid Package Document

2 SITE CONDITIONS ....................................................................................... 4

3 CODES AND STANDARDS ............................................................................ 7

BMT Consultants India Section 7.1 – Page i

5.16 CHAIN DRIVES ................................................................................................................ 19

6 STRUCTURAL DESIGN REQUIREMENTS ...................................................... 28

7 ELECTRICAL & CONTROL SYSTEM DESIGN REQUIREMENTS ........................ 34

BMT Consultants India Section 7.1 – Page ii

8 CORROSION PROTECTION ........................................................................ 52

BMT Consultants India Section 7.1 – Page iii

8.2.3 Work Not Included ................................................................................................ 53

BMT Consultants India Section 7.1 – Page iv

10 LIST OF APPROVED SUB-VENDORS ...................................................... 68

12 PERFORMANCE REQUIREMENTS ......................................................... 72

Table 2: Ship sizes .............................................................................................................. 5

Table 3: Ventilation & Air-conditioning design conditions ................................................. 27

Table 4: Electrical System Voltages Nominal Voltages .................................................... 36

Table 5: Paint Schedule .................................................................................................... 58

Table 6: Approved Sub-vendors - Mechanical .................................................................. 68

Table 7: Approved Sub-vendors - Electrical ...................................................................... 68

BMT Consultants India Section 7.1 – Page v

1.2 Work Included

Table 1: Relevant Drawings

Drawing Title Drawing Number

Master Plan BMTI – 1211 – Gammon – ME – D – 101

Flowsheet BMTI – 1211 – Gammon – ME – D - 201

Belt Conveyor SBC-01 – General Arrangement BMTI – 1211 – Gammon – ME – D – 301

The Work shall include, but not be limited to the following:

BMT Consultants India Section 7.1 – Page 1

• Boom, boom arm, and boom luffing machinery.

• Hydraulic or rope type grab bucket.

• Centralized automatic lubrication system to provide continuous lubrication to all points

- On board electrical room;

- Switchgear, MCCs, VFDs, PLCs

• Match marking and labelling of all components.

• Recommended spare parts list for field erection and start-up.

• Special tools required for field erection and maintenance.

• Weights of all major components for field erection purposes.

• All documentation as listed in this Technical Specification.

• First fill of lubricants.

• Production and commissioning schedule.

• Ocean freight, inland freight, brokerage, duties and insurance to site.

• Site erection supervision.

• Testing and commissioning of the complete Crane system.

BMT Consultants India Section 7.1 – Page 2

• Training of maintenance personnel.

1.3 Packaging and Shipping

Provision of all necessary transportation documentation, including Material Safety Data

1.4 Supervision for Site Erection and Start-Up

• Supervise the unloading, erection, installation, testing and commissioning of the

• Instruct the Buyer's operating personnel in operations and maintenance procedures

• Calibrate the Cranes to meet guaranteed performance and to optimize operation.

Manufacturer’s representatives (the Contractor’s subcontractors) shall be available, as

BMT Consultants India Section 7.1 – Page 3

2.1 Site Location

2.1.1 Road link

Refer section 1.1.1.3.2 of “Volume I – Employer’s Requirement”.

2.1.2 Rail link

Refer section 1.1.1.3.1 of “Volume I – Employer’s Requirement”.

2.1.3 Air Link

The nearest airport is at Goa which is about 7.4 km away by road.

2.2 Meteorological and Oceanography Information