Pakistan International Bulk

Terminal (Private) Limited

TECHNICAL SPECIFICATIONS FOR SHIP

UNLOADING EQUIPMENT

Two (2) Ship Unloader Cranes

Rev A2 – 19/10/2012

Source: FAM GmbH Magdeburg

HPC Hamburg Port Consulting GmbH

October 2012
Pakistan International Bulk
Terminal (Private) Limited

TECHNICAL SPECIFICATIONS FOR SHIP

UNLOADING EQUIPMENT

Two (2) Ship Unloader Cranes

Rev A2 – 19/10/2012

HPC Hamburg Port Consulting GmbH

Container Terminal Altenwerder

Am Ballinkai 1
21129 Hamburg
Germany
Phone: +49-40-74008-150
Fax: +49-40-74008-115
E-Mail: [email protected]
Internet: http://www.hpc-hamburg.de

Copyright © by HPC
19/10/2012 HOB/IB

19/10/2012 13:51 \\yolanda\daten\PROJ\SEG\24149_PIBT-Tender+Evaluation\Specifications\Unloader\20121019_Rev_A2_PIBT_38t_Grab_Ship_Unloader.doc

Technical Specifications for two 38 t Ship Unloader Cranes iii

TABLE OF CONTENTS
Page

1. INTRODUCTION 1
1.1 General Description 1

2. GENERAL CRANE FEATURES 2

2.1 Design Features 2
2.2 Design Criteria 3
2.3 Safety of Machinery 5
2.4 Classification 6
2.5 Definitions of Directions and Numbering 7
2.6 Languages 8
2.7 Standardisation 8

3. OPERATING CHARACTERISTICS 9
3.1 Lifting Capacity Requirements 9
3.2 Bulk Materials Characteristics 9
3.3 Duty Cycle 9
3.4 Speed Rates 10
3.5 Grab Motions 10
3.6 Operating Noise Levels 11

4. DIMENSIONS, PRINCIPLE PARTICULARS 12

4.1 Main Crane Dimensions and Capacities 12
4.2 Gantry Runway 13
4.3 Wheel Load Limitation 13
4.4 Quay Furniture 13

5. ELECTRICAL POWER SUPPLY 15

5.1 Main Power Supply 15
5.2 Fault Level 15
5.3 Supply Method 15
5.4 Electrical Feed Point 16
5.5 Operating Voltages 16
5.6 Crane Earthing 17
5.7 System Power Demand 17
5.8 Shore Power Supply 18

6. ELECTRICAL DESIGN 20
6.1 General Aspects 20
6.2 MV and LV Switches 22
6.3 Transformers 23

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6.4 Drive Control System 25

6.5 Motors 29
6.6 Resistors 31
6.7 Wiring and Cabling 31
6.8 Conduits and Cable Trays 37
6.9 Enclosures 39
6.10 Cubicles 40
6.11 Local Control Stations 41
6.12 Space Heaters 45
6.13 MV Cable Reel System 45
6.14 Festoon System 47
6.15 Communication System 48
6.16 Outlets 49
6.17 Illumination 50
6.18 Lightning Protection 53

7. COMPUTERISED SYSTEMS 54
7.1 Sequence Control (PLC) 54
7.2 Semi-Automatic Operation System 56
7.3 Crane Management System 56
7.4 Remote Crane Management System 61

8. MAIN TECHNICAL AND DESIGN REQUIREMENTS 64

8.1 General Safety Aspects 64
8.2 Main Frame Construction 64
8.3 Boom Construction 66
8.4 Trolley 67
8.5 Catenary Trolleys 68
8.6 Gantry 68
8.7 Hopper 69
8.8 Main Drives 71
8.9 Emergency Drives 74
8.10 Stairs, Ladders, Platforms, Walkways 75
8.11 Crane Operator's Cabin 77
8.12 Machinery House 79
8.13 Electrical House and PLC Room 81

9. MECHANICAL COMPONENTS 83
9.1 Maintainability 83
9.2 Wire Ropes 83
9.3 Sheaves 84
9.4 Drums 84
9.5 Gear Reducers 85
9.6 Bearings and Seal Rings 86

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9.7 Brakes 87
9.8 Couplings and Coupling Guards 90
9.9 Shafts 90
9.10 Trolley Rails 90
9.11 Wheels 91
9.12 Storm Anchors 92
9.13 Buffers 92
9.14 Mechanical Fasteners 93
9.15 Lubrication 94
9.16 Hydraulic System 95
9.17 Grab 97

10. SAFETY FEATURES 98

10.1 Weighing System 98
10.2 Limit Switches 99
10.3 Encoders, Cam Limit and Over-Speed Switches 102
10.4 Emergency Features 103
10.5 Interlocking Devices 105
10.6 Anemometer 108
10.7 Aircraft Warning Light 109
10.8 Anti-Collision Device 110
10.9 Video Cameras 110
10.10 Automatic Warning Sounders 110
10.11 Signal Horn 111
10.12 Fire Extinguisher 111

11. MISCELLANEOUS 112

11.1 Wire-Rope Re-Reeving System 112
11.2 Maintenance Hoist 112
11.3 Passenger and Freight Elevator 113
11.4 Test Load 115
11.5 Air-Conditioning Units 115
11.6 Labelling and Nameplates 118

12. PAINT AND SURFACE PROTECTION SYSTEM 121

12.1 General 121
12.2 Surface Preparation 121
12.3 Paint Application 122
12.4 Paint Damage after Shipment 124
12.5 Paint and Anticorrosion Guarantee 124

13. QUALITY CONTROL 125

13.1 Design Review 125
13.2 Fabrication 127
13.3 Pre-Shipment Tests 129

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13.4 Packing and Shipping 130

13.5 Provisional Acceptance Tests 131
13.6 Warranty Engineer 132
13.7 Final Acceptance 132

14. TRAINING 133

14.1 Training prior to Provisional Acceptance 133
14.2 Training after Provisional Acceptance 135

15. MANUALS 136

16. SUPPLIER'S RECOMMENDED SPARE PARTS AND SPECIAL

TOOLS 138
16.1 Special Tools 138
16.2 Spare Parts 138

ANNEX

Annex 1: Clause-By-Clause Comments to the Technical Specifications

Annex 2: Preferred Sub-Suppliers
Annex 3: Particulars of Drives
Annex 4: Wheel Load Summary
Annex 5: Anchor, Tie-Down Forces and Buffer Forces
Annex 6: Other Documents to be Presented
Annex 7: Layout of Operator’s Cabin and Consoles
Annex 8: Colour Scheme
Annex 9: Documents to be Submiitted by the Supplier for Approval
During Design Review
Annex 10: List of Abbreviations

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LIST OF TABLES
Page

Table 1: Applicable Standards (and Respective Abbreviations) 3

Table 2: Classification of Drive Mechanisms 7
Table 3: Bulk Characteristics 9
Table 4: Speed Rates 10
Table 5: Main Crane Dimensions and Capacities 12
Table 6: Minimum Motor Ratings 29
Table 7: Convenience and Welding Outlets 50
Table 8: Applicable Standards for Mechanical Fasteners 94

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Technical Specifications for two 38 t Ship Unloader Cranes 1

1. INTRODUCTION

1.1 General Description

These Specifications describe two (2) Coal Ship Unloader Gantry Cranes for
75,000 DWT vessel type (“Crane” or “Equipment”), which shall be operated by
PIBT Pakistan International Bulk Terminal (Private) Limited (“the Purchaser”) at
the bulk terminal of Port Muhammad Bin Qasim, approximately 45 km along the
Phitti Creek Channel from the Arabian Sea, Pakistan. The crane shall load coal by
grab operation into a hopper mounted on the crane.

The crane shall be used for grab handling of 38 t suspended payload under the
ropes. The crane shall be designed to handle fully loaded grab for coal over 28 m
outreach and 30 t over the full outreach of 44 m, and to handle shovel loaders of
max. 23 t by lifting lugs on the grab.

The outreach shall be sufficient for above-mentioned DWT vessel type with a
12 m wide barge alongside.

The Crane shall be capable of continuous and simultaneous hoisting and trolley
travelling at rated loads and rated speeds. Grab operation shall be designed as a
four-rope reeving system. The trolley shall be rope-driven.

The Purchaser will furnish the shore side main power supply cable and optical
fibres suitable up to the power connecting point at the quay wall.

All major equipment and systems of the Crane shall preferably be provided by
Western European suppliers manufactured in Europe.

If not otherwise stated in the contract the Supplier shall design, manufacture,
assemble, commission and pre-test the crane at their own premises and deliver,
install, commission and test the equipment at the Purchaser’s site as well as
provide training and assistance after provisional hand-over as set out in this
specification.

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2. GENERAL CRANE FEATURES

2.1 Design Features

2.1.1 Environmental Conditions

The design features, all material and equipment to be supplied and protective
treatment of steel work must be suitable for use under the environmental, marine,
salt and dust-laden conditions prevailing in Port Muhammad Bin Qasim, Pakistan
along the Phitti Creek Channel area. Mechanical and electrical components shall
be provided by well-known and reputable sub-suppliers with ample experience in
crane applications. For preferred sub-suppliers please refer to Annex 2.

The crane must be designed to work under the following ambient conditions:
• Temperature range 5 °C to 45 °C
• Direct sun impact 50 °C
• Max. operating wind speed 20 m/s
• Max. stowed speed 42 m/s
• Humidity, condensing 100%
• Dew Point, maximum 30 °C

For the design of all air-conditioning systems an ambient temperature of + 50 °C

(desert type) shall be considered. The crane must be designed to operate with
minimum maintenance under the defined conditions. It must be made sure that the
electrical and mechanical equipment does not overheat, especially where exposed
to direct sunshine.

2.1.2 Seismic Conditions

Special attention shall be given to the seismic effects in the Port area. The crane
design shall conform to the requirement of Seismic Zone 2B, 0.16 to 0.24 g.

2.1.3 Quay Wall Restrictions

Pile head capacity of 200 t

Pile spacing approx 7.5 m x 7.5 m; to be confirmed. Apron load capacity 2.0 t/m²

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2.2 Design Criteria

2.2.1 Applicable Standards

Unless otherwise mentioned, the design shall be based on the latest edition of the
applicable design standards as stipulated hereinafter:
• Structure: DASt, DIN, FEM
• Mechanical: DASt, DIN, EN, FEM, ISO, SAE, SIS, SSPC
• Safety: DIN, EN, European Machinery Directives, FEM, ISO
• Electrical: DIN/VDE, EN, IEC, IEEE, ISO

European Standards shall prevail unless otherwise specified or particularly

approved by the Purchaser. In case of inconsistencies between standards, the most
stringent requirements shall be followed, unless otherwise approved.

Table 1: Applicable Standards (and Respective Abbreviations)

Abbreviation Organisation
AWS American Welding Society
DASt Deutscher Ausschuss fuer Stahlbau
DIN Deutsche Industrie Normen
EN European Standard
FEM Federation Européenne de la Manutention
FEM 1.001 3rd Edition, 1998
IEC International Electrotechnical Commission
IEEE Institution of Electrical and Electronic Engineers
ISO International Standards Organization
SAE Society of Automotive Engineers
SIS Swedish Standard Institute
SSPC Steel Structures Painting Council
VDE Verband Deutscher Elektrotechniker

Furthermore, any applicable national and local rules and regulations shall be
observed. Such rules and regulations may include but not be limited to special
earthquake design criteria, rules of the Local Electrical Supply Authority, rules for
installation and use of elevators, rules for installation and use of fire-fighting
equipment and PIBT’s company rules for occupational safety and operational
risks. The Supplier shall make himself familiar with all applicable national and
local rules and regulations.

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Technical Specifications for two 38 t Ship Unloader Cranes 4

2.2.2 Structural Design

The crane's design shall consider the torsion forces and movements which are
developed when the motors and drive systems are activated. It shall also consider
the eccentric application of horizontal and vertical forces to structural girders and
components. The structure shall be designed with sufficient rigidity to avoid
noticeable deflections caused by trolley travel and hoisting with rated loads and
speeds. There shall also be no skewing of the structure during crane gantrying at
the specified load and speeds.

Loads and load combinations for structural design, wheel loads and stability shall
comply with FEM 1.001 and DIN 15018, 15019 for simultaneous operations and
wind loads occurring in the most severe directions. The design shall also consider
emergency stop situations.

Impact loads due to vertical acceleration of the lifted load as sensed by the main
hoist ropes shall be considered with a minimum of 30% of LS + LL. Lateral
forces due to simultaneous starting, travelling and stopping of the crane and
trolley shall be considered. Collision loads shall be determined by dynamic
analysis assuming that the gantry hits the rail end stops or another stopped crane
at full speed when power off; or (not simultaneously), the trolley hits its end stops
at full speed when power off.

Beams, frames, columns and members subject to buckling shall be designed with
regard to DIN 18800 Parts 1 to 3 in conjunction with DASt 012 and former
DIN 4114. Combined effects of shear, compression, flexure and biaxial stresses
shall be considered for the design of all flat plates, curved plates and plate
stiffening.

Bolted joint design shall correspond to DIN 18800, part 1 + 7 and DIN EN 20273.

The steel quality shall correspond to EN 10025. Steel for load bearing members
(such as main structure including bulkheads) shall correspond to S355G0 with a
Charpy-Notch test temperature of ± 0 °C. For non-load bearing steel (such as
stiffeners, attachments, platforms, stairs and ladders) S235JR shall be used.
Equivalent steel grades are subject to acceptance by the Purchaser.

For load-bearing structure the thickness of plates and rolled sections shall not be
less than 8 mm. Unless specifically approved by the Purchaser, cast iron shall not
be used for any part. All steel material shall be new, unused and suitable for the
specified ambient conditions.

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Technical Specifications for two 38 t Ship Unloader Cranes 5

Most recent practice in the manufacture of high-grade machinery shall apply to all
works carried out by the Supplier and all his sub-contractors. All work shall be
executed by workmen skilled in their particular trades. All welders, tack-welders
and welding operators shall be DIN or AWS-certified and particularly skilled for
the type of material, weld and/or process being performed. Certificates shall be
handed over to the Purchaser for revision and approval upon request.

Welding procedures shall come up to the requirements of DIN 18800, Part 7 in

conjunction with DIN 15018 or AWS D1.1-2006. The Supplier shall include in its
Bid all costs incurred in the testing and inspection of critical welding as well as
the provision of test samples. All welds executed by non-qualified or non-certified
staff shall, upon request of the Purchaser, be replaced at the Supplier’s expense.

The general design of the crane shall be in the metric system unless explicitly
requested otherwise.

Stainless steel items installed on the crane shall meet minimum DIN 1.4401
(V4A) criteria.

The crane structure shall be calculated with a well-proven computer program. All
calculations shall be submitted to the Purchaser during the design phase for
review and final approval.

2.3 Safety of Machinery

2.3.1 Conformity with the EU Machinery Directive

The crane shall comply with the requirements of the European Machine
Guidelines, particularly Machinery Directive 2006/42/EC.

The cranes have to be provided with a declaration of conformity and the CE

marking and symbol according to the relevant annexes of the Machinery
Directive. The Supplier is solely and entirely responsible for all aspects of this
conformity declaration and CE marking.

2.3.2 International Standards

Attention shall be given to all applicable international IEC and ISO standards
regarding “Safety of Machinery”, particularly to ISO 12100, ISO 14121,
IEC 62061 and ISO 13849-1 and -2.

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Technical Specifications for two 38 t Ship Unloader Cranes 6

The following emergency and safety related circuits shall comply at least with
SIL 2 or PL d respectively:
• All emergency stops and emergency off-circuits
• Ultimate stop functions for hoist, trolley/cabin, boom hoist, gantry
• Overload and overspeed protection
• Anti-collision systems (crane-ship, crane-crane)
• Snag protection
• Emergency brake systems

At least for the above functions the manufacturer shall prepare a report on the
related components of each safety related circuit thereby proving if the PFHD of
the relevant safety system complies with the required Safety Integrity Level (SIL)
or Performance Level (PL) respectively. A safety PLC is acceptable.

2.4 Classification

2.4.1 Crane Structure

The crane is to be classified as follows:

• Class of utilisation: U8
• State of loading: Q4
• Group Classification: A8

The fatigue design shall be based on a conventional number of hoisting and

trolley cycles of at least four (4) million cycles of operation, based on a design life
of 20 years and utilisation rate of 75%.

2.4.2 Drive Mechanisms

The drive mechanisms shall be designed and selected in accordance with FEM
and shall be classified as follows:

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Table 2: Classification of Drive Mechanisms

Grab Grab open/ Trolley Gantry Boom

hoist close hoist
Class of utilisation T8 T8 T8 T6 T6
State of loading L4 L4 L4 L3 L3
Group of classification M8 M8 M8 M6 M6
Minimum design lives (h) 50,000 50,000 50,000 12,500 6,300

2.5 Definitions of Directions and Numbering

The following definitions shall be applied:

2.5.1 Directions

The left and right directions are based on the operator’s view facing the water.

2.5.2 Trolley Path

The boom hinge point is the set zero point. The direction to the waterside boom
end will be indicated as plus and that to the landside back reach as minus. The
zero point shall relate to the centre of the grab.

2.5.3 Lifting Height

The lifting height shall relate to the underside of the closed grab. The gantry rail is
the set zero point. Hoisting to the maximum lifting height will be indicated as
plus. Lowering below the gantry rail to the maximum lowered height will be
indicated as minus.

2.5.4 Numbering of Legs, Motors, Gearboxes and Brakes

The numbering shall start with 01 on the waterside, left side and shall be counted
clockwise. The numbering labels of motors, brakes and gearboxes must
correspond to the electrical code numbers as specified by the electrical wiring
diagrams and shall be attached or painted preferably on the non-removable steel
structure next to the corresponding device.

2.5.5 Centre Line

The centre line is the middle of the girder/boom from back reach to boom end on
waterside.

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2.6 Languages

All signs, instruction boards, labels and nameplates installed on the crane shall be
in English.

Spare parts, maintenance and operating manuals, certificates, crane book, etc.
shall be in English.

Drawings, electrical diagrams and all calculations shall be in English.

Catalogues, original manufacturer’s product specifications and/or descriptions as

well as all supporting documentation shall be in English.

2.7 Standardisation

Mechanical and electrical components shall be standardised with cranes to be

operated in the port, using the same sub-suppliers as far as possible.
Standardisation, if applicable, shall include but not be limited to:
• Motor drive system, PLC, CMS
• Switchgears
• Reducers, brakes, motors, couplings
• Operator’s console
• Limit switches, encoders, etc.
• Floodlights
• Load cells
• Air-condition systems
• Anti-collision systems
• Paint

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3. OPERATING CHARACTERISTICS

3.1 Lifting Capacity Requirements

The maximum lifting capacity under the ropes shall be 38 t at an outreach of 28 m

and 30 t at maximum outreach.

The crane shall have a free digging capacity (nominal capacity) of 1,850 metric
tons per hour by grab operation.

The material unloaded by the grab will be discharged into one (1) hopper mounted
waterside between the legs. The capacity of the hopper shall be 2.5 times of the
grab contents (approx. 62 t). At the bottom of this hopper there shall be an outlet
to feed the conveyor belt.

The Supplier shall specify in his quotation the capacity and weight of the grab to
achieve the required grab unloading rate and the weight and lifting capacity of the
lifting lugs for the shovel loader transportation. The capacity of the grab shall be
minimum 24.7 t.

3.2 Bulk Materials Characteristics

The residual bulk unloaded from the vessel has the following characteristics:

Table 3: Bulk Characteristics

Material Bulk Density Angle of Repose Moisture Grain size

(t/m³) (Degree) (%) (mm)
Coal 0.85 – 1.0 max 38 5 0 – 50

3.3 Duty Cycle

The Supplier shall submit with its proposal a comprehensive duty cycle
calculation specifying necessary speeds and accelerations for hoist and trolley.
The duty cycle calculation shall be based on maximum rated speeds and
maximum rated loads within a tolerance of ± 5%.

The crane design, drive speeds and accelerations shall be based on the free
digging capacity of 1,850 tons per hour.

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Technical Specifications for two 38 t Ship Unloader Cranes 10

The duty cycle shall consider the average distances for discharging a 75,000 DWT
bulk vessel to the crane-mounted hopper with a 2-seconds’ stop over the basin and
a 1-second stop over the hopper. The cycle shall be repeated indefinitely at
maximum specified wind loads and ambient conditions. The duty cycle shall be
based on simultaneous operation of hoist and trolley movements whenever the
grab is free of the bulk material in the basin without considering crane, hopper or
basin clearances.

The boom hoist duty cycle shall be based on completely raising and lowering the
boom four times without dwell time, without injurious heating.

The gantry drive duty cycle shall be based on travelling without intermediate
stops at full speed along the quay against maximum wind load throughout the
whole operating range (440 m). The cycle is performed once without exceeding
the rated temperature rise.

3.4 Speed Rates

The following Table 4 depicts speeds and acceleration/deceleration times of the

crane.

Table 4: Speed Rates

Speeds Ramp time

Hoisting/Lowering with rated load 140 m/min 4.0 s
Lowering with empty grab 180 m/min 4.0 s
Trolley travel (full load) against operating wind load 260 m/min 5.0 s
Gantry travel against operating wind load 45 m/min 2.0 s
Gantry travel against 27 m/s wind speed, no load 30 m/min 3.0 s
and boom raised
Boom hoist, raise/lower: Max 5 min

3.5 Grab Motions

All motions shall be operated and positions be indicated in the operator’s cabin.

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3.6 Operating Noise Levels

In the operator’s cabin and in the PLC control room a noise level of 72 dB(A)
shall not be exceeded under all operating conditions with running air-condition
units.

The inverter sections in the electrical house shall have a maximum noise level of
85 dB(A) with ventilation an air-condition systems running.

The noise level in the machinery house shall not exceed 95 dB(A).

Relevant rules of the series of standards ISO 3740 and ISO 11200 shall be
observed.

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4. DIMENSIONS, PRINCIPLE PARTICULARS

4.1 Main Crane Dimensions and Capacities

The following table depicts detailed dimensions and capacities of the Crane.

Table 5: Main Crane Dimensions and Capacities

Description Capacity/Dimension
Cream digging capacity: 1,980 t/h
Nominal capacity: 1,850 t/h
Average capacity (technical): 1,390 t/h (0.95 t/m³)
Lifting capacity under ropes: 38 t/30 t
Grab weight max: 13.3 t
Grab contents min: 24.7 t
Lifting capacity lifting lugs for shovel loader (min): 23 t
Span (rail centre distance): 15,000 mm
Ship to be handled: 75,000 DWT
Outreach from waterside rail centre: 28,500/44,000 mm
Backreach from landside rail centre: 12,000 mm
Height under grab, above waterside rail (min): 33,000 mm
Lowest point of grab, below waterside rail: 18,000 mm
Total grab hoisting/lowering path: 51,000 mm
Clearance between portal legs (min): 16,000 mm
Maximum overall length from buffer to buffer (max): 30,000 mm
Minimum clearance under portal cross beam: 8,000 mm
Maximum boom or trolley width: 8,300 mm
Distance from centre of waterside rail centre to quay 3,000 mm
wall’s edge:
Minimum number of wheels per corner: 8
Minimum number of individually driven wheels per 50%
corner:
Gantry travel distance: ± 220 m
Cable slot positions, waterside of landside rail: LS/WS
Gantry buffer height: to be confirmed
Location of gantry motors and gearboxes: WS/LS and LS/WS
Distance LS rail to backreach belt conveyor BC01A+B: ~ 4,000/5,500 mm

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4.2 Gantry Runway

The cranes shall be designed to operate on A120 crane rails, which have a head
width of 120 mm.

Runway rails are designed with no height difference between waterside and
landside rail.

The tolerances of the gantry rails and thus the gantry alignment shall conform to
ISO 12488-1, class 2. The gantry structure shall be capable of operating on rails
with tolerances according to ISO 12488-1, class 2, table 7.

4.3 Wheel Load Limitation

The maximum vertical uniform distributed wheel load is 50 t/m WS and 40 t/m
LS. The Supplier shall furnish with its bid a comprehensive wheel load
calculation showing landside and waterside wheel loads under operating
conditions with maximum rated load, operating speeds, as well as loads in stowed
conditions. Maximum specified operating and out-of service wind speed blowing
from the worst direction shall be considered.

4.4 Quay Furniture

The cranes must be supplied with buffers which are to be mounted on the centre
line of each rail and shall be matched to neighbouring cranes or, as far as
applicable, to the end buffer of the crane rails.

The crane shall be equipped with storm anchors and with tie-downs. The Supplier
shall submit quay furniture arrangement drawings and calculations to indicate size
and locations of anchor and tie-down pits as well as jacking plates. The Supplier
shall state all relevant forces and their directions the supporting civil structure will
be subject to.

The Supplier shall submit shop drawings of all cast-in elements for storm anchors,
tie-downs, jacking plates as well as for crane rail end stoppers.

The Supplier shall deliver four (4) crane rail end stoppers.

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Availability of civil construction sites for the erection of a Ship Loader Crane, the
below stated dates are latest and might be brought foreward. Suppliers will be
informed accordingly as soon as possible:

1. Trestle bridge: November 2013

2. Jetty: May 2013

Availability of MV/LV Power Supply: latest July 2014

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5. ELECTRICAL POWER SUPPLY

5.1 Main Power Supply

Power to operate the crane will be supplied at medium voltage of 11 kV, 50 Hz,
3-phase plus earth. The tolerance range of the equipment is to be ± 5% for voltage
and ± 2% for frequency.

The required weighted average value of the power factor is to be 0.9 or higher.
The total amount of harmonics generated (if applicable) shall not exceed the
values permitted by the local power supply authority and comply with IEEE 519.

5.2 Fault Level

The power supply system design considers a maximum fault level of 350 MVA.
The fault clearance time on the crane has to be established by the Supplier by
providing a grading study taking into account the various delay times of down-
stream protection equipment.

5.3 Supply Method

The cranes’ power supply is ensured by means of a trailing cable which is coiled
onto a spiral cable reeling drum to be located at a right angle to long travel.

The trailing cable is included in the scope of the Contractor and shall conform to
DIN/VDE 0250. The cable type shall be PROTOLON (SMK), 6/10 kV with
6 optical fibre cores integrated in the cable as supplied by Prysmian or approved
equal.

The cable shall be sized based on its nominal load and short circuit conditions.
The original manufacturer’s recommended de-rating factors shall be observed
considering the use of the cable on a cable reel, the ambient temperature, and in a
slot covered with Panzerbelt, if fitted, with up to 5 other cables.

The short circuit conditions have to be related to a selectivity study of the LV and
MV network. Cable size and short circuit calculations as well as selectivity study
have to be submitted to the Purchaser in advance for approval.

The length of the power cable shall be sufficient to cover the specified gantry
travel distance from crane centre over the funnel pit.

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The Supplier shall make sure that the cable fits into the existing cable slot(s)
which may be covered with “Panzerbelt”.

5.4 Electrical Feed Point

The Purchaser will provide the shore side main power supply cable and the optical
fibres up to the electrical feed point chamber including the cable relief drums
only. The Supplier shall furnish and duly install all necessary installation material
required, and shall connect the trailing cable of the gantry crane including earthing
and optical fibres to the electrical feed point by means of cast resin cable joints.
The minimum bending radii must be strictly adhered to.

5.5 Operating Voltages

The crane operating voltages shall be 400/230 V, 50 Hz, 3-phase plus neutral plus
protective earth including:
• Motors and drive control system or as per the sub-
supplier’s standard 400 V, 50 Hz
• Convenience outlets, space heaters and illumination
system 230 V, 50 Hz
• Power outlets 400 V, 50 Hz
• Communication equipment, window wipers and washers,
emergency lights, solenoid valves as required by the
manufacturer 24 VDC/12 VDC
• Power outlets for UHF radio in the operator’s cabin 24 VDC (5 A)

Small motors and the control system shall operate within the tolerances of IEC.

The Supplier shall furnish a consumer list indicating voltage, frequency, wattage
and amperage of each consumer.

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Technical Specifications for two 38 t Ship Unloader Cranes 17

5.6 Crane Earthing

All electrical apparatus and motors shall be efficiently earthed by means of copper
tape or conductor terminating at a common point, which shall be connected to the
earthing wire of the power cable. Connections in series are not permissible. The
crane structure shall also be earthed to the equipotential busbar in the LV
switchgear room. Sleeve bearings used in the structure of the crane shall be
jumped by an earthing conductor. The earthing conductor shall be properly bolted
to a welding point.

Earthing conductors shall not run or be fixed on any access path, floor, passage or
walkway.

Any stranded earth cables shall be terminated in sweated sockets which, in turn,
shall be rigidly bolted to the earth terminals of the materials.

The earth connections of conduits shall be made by means of approved galvanised

steel connectors.

Where lengths of flexible metallic conduit connect machines or other materials,

the earth continuity shall be supplemented by a separate earth conductor
connected between the rigid conduit and the earth terminal of the materials.

Continuity of protective earthing circuit must be observed. Removal of any

equipment due to maintenance reason shall not interrupt the earthing circuit.

The whole installation shall be carried out in a neat workmanlike manner to

comply with the appropriate regulations.

5.7 System Power Demand

The power system demand will be estimated when operating at night time with all
lights on and with rated load and the critical theoretical duty.

The Supplier shall furnish with its Bid a detailed calculation for system power
demand.

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Technical Specifications for two 38 t Ship Unloader Cranes 18

5.8 Shore Power Supply

The crane shall be provided with an emergency shore supply to power the crane in
case the MV supply is interrupted due to a shutdown of the Port's supply grid or a
failure in the public grid.

The Supplier shall include necessary 3-phase/5-wire plugs and sockets with 35
meters of cable. The cable shall either be connected to a socket in the quay wall or
to a neighbouring crane. Respective shore power plugs and sockets shall be
installed at the LS/WS centre of the crane. The cable shall be stored remotely
from the crane.

The shore supply voltage shall be 400 V, 50 Hz, 125 A and shall match the
voltages on the crane by appropriate transformers, if necessary. The plug and
socket type shall match the Port’s wharf outlets and shall be approved by the
Purchaser.

The change-over from the normal supply to shore-power supply shall be provided
with all necessary interlocks, arranged as follows:
• First, when the power of the public grid fails, switch off this supply.
• Second, connect the shore power socket to the shore supply.
• Third, as soon as the shore power supply is established, the shore power
supply switch shall close automatically and feed power to the crane.
• As soon as the power from the public grid is re-established, any operation
being done shall be normally finished and then the shore-power shall be cut
off manually.

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Technical Specifications for two 38 t Ship Unloader Cranes 19

The phase rotation of the shore power system shall be monitored and interlocked.
The following minimum items should be powered by shore supply system, but not
necessarily simultaneously:
• Emergency drives
• Brakes
• Electrical house air-conditioning
• Crane control system (PLC, CMS)
• Elevator
• Conveyor belts
• Maintenance service crane in machinery house
• Convenience and power outlets
• Communication systems including links to the fibre optic system
• Anti-condensation heaters
• MV cable reel
• Walkway and interior lighting
• Trolley flood lighting 50%

The Supplier shall deliver a list of powered items for emergency operation
including data such as kW and starting current.

HPC Hamburg Port Consulting GmbH

Technical Specifications for two 38 t Ship Unloader Cranes 20

6. ELECTRICAL DESIGN

6.1 General Aspects

6.1.1 Design Criteria and Material

The electrical components, equipment and installation shall comply with the latest
revisions of IEC and DIN/VDE standards. The electrical design shall specifically
comply with IEC 61800, EN ISO 13849-1/2, Safety Rules and Regulations for
Machines as well as IEC 60204, IEC 61508 and IEC 62061 unless otherwise
specified. European directives for electromagnetic compatibility 2004/108/EC and
low voltage 2006/95/EC shall be observed.

The electrical equipment and installation shall be designed to provide reliable

power for continuous, precise and rapid crane operations at the maximum
specified ambient conditions at maximum rated loads and speeds with a minimum
of down-time. In addition to the voltage and frequency variations specified, the
supply may be polluted with interruptions and voltage spikes lasting a few
milliseconds. The operations must not be hampered by these transitory events.

The complete electrical drive control system shall be supplied on turn-key basis
by a reputable electrical manufacturer. Main motors, drive controls, PLC and
CMS shall be of Western European origin.

Wherever possible, other electric components such as master switches,

controllers, circuit breakers, limit switches and similar gear shall be of the same
manufacturer, type and rating to facilitate maintenance and to keep required spare
parts at a minimum. This may be accomplished by using oversized relays and
conductors for the lowest rated demand.

The electrical installation shall comprise all necessary drive control systems,
transformers and appropriate power distribution as well as all necessary motors,
signals, indicators, instruments, alarms, protective devices, wiring, software and
all other features. All sub-systems and auxiliary functions such as cable reels,
festoon or power chain system, brakes, elevators, flood-lighting, shore power,
service cranes, hydraulic stations, ventilation systems, AC-units, space heaters
and motor blowers, etc. shall be thoroughly incorporated in the electrical design.

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Technical Specifications for two 38 t Ship Unloader Cranes 21

All equipment of electrical installation shall be of standard manufacture. The

Supplier shall be able to make all electrical spares available within 48 hours after
Customs entry requirements have been confirmed.

All materials shall be new and of the highest grade and quality. All materials and
electrical components shall be suitable for marine environment, corrosive
conditions and be de-rated for the temperatures and humidity indicated before.
Material and components shall be of industrial heavy-duty type suitable for
moving crane applications and designed to satisfactorily operate under conditions
of moisture and adequately treated or protected against corrosion, salt, mould,
dust, sand or other destructive elements to which it may be exposed during
operation in the climate. Special consideration shall be given to avoid overheating
of equipment exposed to direct sunlight. All electrical materials (components,
sub-assemblies, etc.) shall be thoroughly tested to demonstrate compliance with
their design requirements.

All enclosures of electrical equipment shall be arranged to minimise the entry of

dust and moisture. Drive and control systems shall be suitably housed with
thermostatically controlled, de-humidifying and air-conditioning system.

The Supplier shall demonstrate with his drawings and specifications and with the
required tests that the material is capable of performing all of the required
functions with a minimum of down-time. A complete listing and description of all
electrical systems and components shall be included in the manuals called for in
these Specifications.

Space heaters shall be sized to protect the equipment when stowed and under
operating conditions at ambient temperatures as specified. Due consideration shall
be given to temperatures within enclosures and to ventilation during operation.

All materials shall be designed and located so as to ensure easy access for repair
and/or removal. In order to facilitate routine repairs or adjustments, ladders,
walkways, or access platforms shall be provided as required for convenient
access, and shall be fitted with handrails and toe plates as appropriate for the
location.

All screws, bolts, nuts, washers, pins, studs, springs, and other miscellaneous
fastenings and fittings for electrical installations shall be of stainless steel, copper,
brass, bronze or chromated steel.

Cable lugs shall be of copper, tinned.

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Technical Specifications for two 38 t Ship Unloader Cranes 22

6.1.2 Installations Exposed to Weather

All electrical components installed outside and exposed to weather, such as

motors, limit switches, encoders, AC units, junction boxes, electrical enclosures,
cubicles and panels, control stations, cameras, lasers, etc. shall be at least of
protection class IP 55 according to IEC 60529.

All junction boxes, cubicles, enclosures, control stations, cable trays, etc.,
installed outside shall be made of stainless steel. Other materials or combination
of materials shall be selected for maximum corrosion resistance. Aluminium or
aluminium alloys shall not be used for housings, fans, blowers, motors, motor
brakes, festoon parts or weather-exposed parts or components unless otherwise
indicated in the specification. Cable trays exposed to weather shall be covered.

Ferrous components contained in weather-proof enclosures shall be galvanised

after fabrication and before painting. Cadmium plating is not acceptable.

6.2 MV and LV Switches

Switchgears and circuit breakers shall correspond to the latest revisions of IEC
and DIN/VDE 0660 in general, particularly to IEC 60947 and IEC 60439.

The machinery house shall be equipped with a primary MV, 3-phase switchgear
with one incomer and a feeder for each transformer.

The MV switchgear shall consist of door-mounted, manually-operated load

disconnect switch assemblies with shunt trip coils for emergency disconnection.
Interlocked earthing switches, an emergency "MV trip" button and “POWER ON"
indication lights shall be provided.

The enclosure shall be furnished with indicators or a window for viewing switch
contacts, anti-condensation heater with a remote power on indicating light and
remote shunt trip. All control wiring shall be connected to a terminal block.

The disconnect switch shall be lockable in the open position. The locking device
shall be sized for a minimum of three pad locks. The pad locks shall be furnished
by the Supplier.

A PE grounding bar with sufficient connection points for all grounding

conductors shall be installed close to the MV switchboard.

Both drive and auxiliary power shall have independent LV main circuit breakers
for each secondary winding.

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Technical Specifications for two 38 t Ship Unloader Cranes 23

The LV main circuit breakers shall be motorised and be provided at the incoming
side with an auxiliary bus bar system to facilitate the connection of the multiple
trefoil cable bundles of single core conductors.

The LV main circuit breakers shall energise with “Control on”. It shall de-
energise in case of thermal overload, instantaneous overload (short circuit) and
under-voltage release. The latter shall be time-delayed, adjustable from 0 – 10 s.
The LV main circuit breakers shall further de-energise with an “emergency off”.
A dynamic over-voltage protection device shall be provided on the line side of the
LV main circuit breakers.

A non-resettable cycle counter shall be installed for the drive power LV main
circuit breakers.

The following values are required to be fed into to the crane’s control system and
management system.
• Each line to line voltage
• Each line current
• kVA
• kW
• kWh (mono-directional)

6.3 Transformers

The MV/LV transformer shall be designed as primary Delta and as secondary

WYE configuration. The vector group shall be Dyn 11. Design has to follow
IEC 60076 and DIN 42523 for light excavator operation up to 0 degrees. The
transformer shall be specifically made for inverter drive generated RMS and
harmonic demands.

The Supplier may either install two separate transformers for drive power and
auxiliary power, or install one transformer with one common primary side and
two secondary sides for voltages as defined in Chapter 5.5.

All transformers above 50 kVA, or as specifically required for smaller units, shall
be furnished with multiple taps above and below primary and/or secondary rated
voltage. Taps shall be rated at full capacity. Tappings shall be ± 2.50% and
± 5.00% and may be changed offline.

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Technical Specifications for two 38 t Ship Unloader Cranes 24

The transformer(s) shall be of the dry construction and self-cooled type. The
primary and secondary windings shall be made of aluminium or electrical grade
copper, encapsulated with polyester (epoxy) resin. The impedance shall be
between 5.50% and 6.00%.

The transformers shall have the following insulation levels:

• MV transformer(s) 75 kV for the primary and 5 kV secondary
• LV transformer(s) 5 kV primary and secondary.

The transformer(s) shall be mounted in the machinery house either in a

completely fenced and lockable area or in an IP23 ventilated solid steel enclosure
with removable, but bolted down panels.

The transformer(s) shall comply with Class F. The temperature rating shall be of
100 °C rising above the maximum specified ambient temperature.

The transformer(s) shall be furnished with protective thermal over-temperature

warning set at 130 °C as well as protective shutdown at 150 °C.

The transformer(s) shall have lifting lugs so that the complete unit and/or the coil
assemblies can be lifted and replaced. Vibration dampening pads under the coil
assembly and/or under total transformer assembly and core ground straps and a
ground bus shall be provided.

The low voltage side of the MV transformer(s) shall be equipped with an auxiliary
busbar system consisting of three phase Cu-bars and one PEN bar, of the same
cross-sectional area as the secondary connections of the transformer. The low-
tension multiple single-core connection cables to the LV main circuit breaker
shall be connected to these bars. The low-tension single-core cables have to be
bundled in trefoil arrangement, L1, L2, L3, PEN, with changing phase rotation
from one bundle to the next. This arrangement shall minimise current differences
between conductors of one phase.

The noise level of the transformer level shall comply with DIN 45635 Part 30.

The Supplier shall include in his scope an earthing / short circuiting device to
ground the transformer during maintenance work. The device shall consist of
three phase leads with connectors and one ground lead with connector, conductors
of finely stranded wires (120 mm²), covered by a transparent vinyl jacket. The
device shall be stored in the transformer vault together with an earthing rod.

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Technical Specifications for two 38 t Ship Unloader Cranes 25

6.4 Drive Control System

The Supplier shall offer frequency controlled AC-drives

Provision shall be made for the hoist control system to feed back power into the
network during lowering motion (4-quadrant). Harmonics generated by the crane
shall comply with IEEE 519. Active Line Modules (ALM), as supplied by
Siemens (Sinamics) or similar, shall be installed.

6.4.1 Inverter

The drive system shall be of the most recent design preferably manufactured by a
Western European company. During the warranty period, qualified specialists of
the drive system supplier shall be capable of reaching the Crane’s location within
a maximum of 12 hours. The drive system supplier shall have a local office in the
country where the crane is operated.

The drive systems shall be of AC type with a power factor always bigger than 0.9
and shall have harmonic suppression.

If a limitation of the rate of current rise for each drive inverter is required,
separate commutation chokes shall be provided.

The drive system shall be designed to minimise harmonic noise.

The drive configuration shall be as follows:

• The Crane shall be capable of continuous and simultaneous hoisting and
trolley travelling at rated loads, rated speeds and full accelerations.
Simultaneous gantry travel shall be possible at reduced speed.
• Each hoist motor shall be fed by an individual inverter. The hoist system shall
be capable of operating with reduced load and/or reduced speed, if one hoist
motor or inverter fails.
• The trolley motors shall be fed by two inverters, supplying power to the pair
of front and rear wheels respectively. In case one inverter fails the trolley
shall still be capable of operating with rated load and reduced speed.
• The gantry motors shall be fed by two inverters. The motors shall be grouped
in such a way that a smooth running of the gantry is achieved, even if one
inverter fails. This operation shall be possible also against 50% of operating
wind load at reduced speed.
• Boom hoist may share the gantry drive, trolley drive or hoist inverter.

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Technical Specifications for two 38 t Ship Unloader Cranes 26

• All drive inverter units are connected to a common DC bus system. Minimum
two (2) independent IGBT mains pulse inverters of an ample sized capacity of
66% each with an active power management shall be provided for feeding the
DC bus system. If one of the IGBT mains pulse inverters fails, operation with
reduced speed shall still be possible with the remaining mains pulse inverter.

The Supplier shall submit within his Bid a single-line diagram showing drive and
inverter configuration.

The control of all main motions shall be true digital stepless, regulated and
regenerative over the entire operating speed range of the equipment.

Each inverter drive unit shall be capable of supplying minimum 160% of the
required motor power, compiled on the basis of thermal loading, for 60 seconds,
while operating at the maximum ambient temperature and ratings to meet the
specified duty cycles. The calculation of the motor thermal capacity shall use I²t
values. The minimum speed and acceleration rates for normal operations shall be
as defined in Table 4/Chapter 3.4.

Acceleration shall be linear. In case the crane is operated in semi-automated

operation mode, accelerations may be slightly different than in manual operation.

Drives shall be controlled by digital speed. The hoist motor speed shall be
automatically controlled on the basis of the lifted load. During steady state, this
shall allow the operation of the hoist at the rated motor current guaranteeing
maximum performance.

Line contactors or other approved means for isolating the load on demand of
“Emergency Stop” or general stoppage shall be installed for each drive. Unless
de-energised by a fault, these contactors shall energise with "Control On" and de-
energise with "Control Off". The contacts in these devices shall be of the non-
welding type.

The drives shall be equipped with forced ventilation and filters. The speed of the
cooling fans shall correspond to the surrounding temperature and shall be
switched off automatically after an adjustable cooling-off period, when drives are
not in use.

The starting time including motor magnetisation shall not exceed 0.7 seconds for
the first cycle. The magnetizing needs to be maintained for a minimum of
60 seconds. The subsequent starting times for each drive shall be as short as
possible but not exceed 300 milliseconds.

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Technical Specifications for two 38 t Ship Unloader Cranes 27

The response time for a speed change, measured from master controller to motor
speed change, shall be as brief as possible but not more than 50 milliseconds for
any drive. The Supplier shall submit record charts showing master controller
signal input vs. rotation of motor.

For long line compensation, each power inverter shall have series output reactors.
Each drive shall be equipped with static, instantaneous protection for single phase,
and phase-reversal conditions of the AC line. In order to restrict current to a
predetermined value, each drive shall have a directional current limiting device. It
shall be possible to adjust settings of current, linear time, voltage, etc. with
automatic selection for different drives using the same conversion unit.

6.4.2 Operator Control

All master signal sources will be processed by a digital remote input module in
the operator's cabin. The communication through the festoon or power chain
system shall be via fibre-optic cable.

The operator shall be able to perform maximum control of each motion,

particularly at low speed. Acceleration and deceleration of each motion shall be
fully controlled by the operator unless the operator moves the master switches too
rapidly. In these cases, ramp times shall be automatically adjusted to
predetermined values.

Generally, the predetermined values for ramp times for all drives shall be
individually adjustable in the range of 0 to 10.0 seconds with intermediate steps of
0.1 seconds.

Control for each drive shall be available when the operator energises the crane
from any station. The operator may activate any motion, only after the given
drive's protection requirements are met. The drive will then follow the operator’s
reference as long as the motion is in a safe travel zone. If the operator accelerates
or de-accelerates any motion, the drive shall follow the pre-set ramp times, even if
the operator, while at high speed, immediately returns the handle to zero.

When a motion is stopped, the service brakes shall be engaged, after the motor
speed has been reduced to approx. 5-10%. When zero speed is detected,
emergency brakes, as applicable, shall engage.

If, for any reason, a motor remains stalled when initiating a motion, that drive
shall trip before a permanent motor damage can occur.

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Technical Specifications for two 38 t Ship Unloader Cranes 28

When a motion stops, the magnetizing current shall be maintained for an

adjustable period of time (1 – 2 minutes) to minimise any delays when re-starting
drives.

All hoisting motions shall be provided with torque proving sequences.

6.4.3 Transistor Units IGBT

All thyristors and/or transistors shall be installed on heat sinks with forced,
filtered air ventilation. Critical temperatures shall not be exceeded in any case. An
over-temperature protection system shall cause a last motion shutdown routine.
Voltage transient protection shall be provided. Thyristors and transistors shall
have a minimum peak inverse voltage (PIV) rating of 2.33 times the working AC
voltage.

6.4.4 Measuring Instruments, Indicating Devices and Diagnostic

System

Drive control systems shall be installed in the electric house in cubicles with
hinged front doors, front access only, open bottoms, equipped with space heaters.

Each drive shall include a display which will permit review of set parameters,
display of diagnostic messages, and actual operational values. At least the
following devices shall be installed at the respective panels:
• Hour-meters and counters:
- Control on
- Hour-meter for grab hoist
- Hour-meter for grab open/close
- Hour-meter for trolley
- Hour-meter for gantry, inverter ½
- Number of grab open/close
- Switching cycles of main circuit breakers

These counters shall be mechanical, non-resettable, mono-directional, minimum

seven digits.
• Panel-meters (or suitable combined digital units)
- Line-to-line voltage, with selector switches
- Line current, 3 ammeters
- kVA
- kW

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Technical Specifications for two 38 t Ship Unloader Cranes 29

• kWh-meter, mechanical, non-resettable, minimum seven digits including

decimal
• Each individual inverter/motor loop shall have independent, 96 mm drive
enclosure panel-meters as applicable or suitable digital panels. In the case of
multiple motors, there shall be independent panel-meters to display the
following:
- Stator voltage
- Stator current
- Actual speed

Every measuring point, current or potential shall be equipped with proper

terminals to enable the maintenance crew to connect an external instrument into
the circuit.

Furthermore, a keypad programming unit shall enable the maintenance crew to

change drive parameters. Access to all parameters shall be password-protected.

Each drive shall be provided with a diagnostic system. This system shall include
necessary fault and trouble-shooting information for all internal functions. The
diagnostic system shall be linked to the crane management system, so that faults
can be stored and called by the maintenance crew.

6.5 Motors

All electric motors to be rated according to VDE 0530 in conjunction with

publication IEC 60034-31. Motors shall be chosen to operate at the maximum
ambient temperatures and shall have a Class F winding insulation and Class F
temperature rise. The following minimum ratings are to be applied:

Table 6: Minimum Motor Ratings

Drive Duty type Duty factor

Grab hoist motor Intermittent Periodic S1 100%
Grab closing motor Intermittent Periodic S1 100%
Trolley motors Intermittent Periodic S1 100%
Gantry travel motors Intermittent Periodic S3 40%
Conveyor belt motors Intermittent Periodic S1 100%
MV Cable reel drive Intermittent Periodic S3 40%

All main drive motors shall be designed for 160 % of the torque required to
operate at the rated load at the rated speed for a minimum of 60 seconds.

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Technical Specifications for two 38 t Ship Unloader Cranes 30

However, the required acceleration rates and torques at the rated load and speed
must also be considered.

The gantry motors shall be amply designed to allow pushing another crane at
reduced speed in case of a power failure.

The ratings and design data of all motors shall be verified by the original motor
supplier. The original supplier shall confirm that the motor ratings are adequate to
meet the specified duty cycles and specifications. The main drive motors shall be
specifically designed for use on semi-conductor power inverters with a minimum
of harmonic noise. In case drives and motors are from separate suppliers, the
motor supplier shall work in close coordination with the power supply drive
manufacturer.

The protection class shall be IP 23 for motors installed in the machinery house.
Motors installed outside the machinery house shall be minimum IP 55. If external
blowers for cooling purposes are used, they shall be equipped with filters for air
entrance. Blowers shall be switched off automatically after an adjustable cooling-
off period when motors are not in use.

All main drive motors shall be equipped with a minimum of three trip thermistors
and inverter-integrated temperature sensing devices, associated evaluation and
release equipment inside the switch/control boards.

Life expectancy of main drive motors shall correspond to the respective utilisation
classes. All other motors shall have a minimum life expectancy of 25,000 hours.

All motors above 5 kW shall have space heaters.

All larger motors shall be equipped with re-greasable anti-friction ball bearings
designed to meet the requirements of thrust and radial loads. Grease fittings for
these bearings shall be of a different configuration than the other grease fittings
used on the crane. Motors shall be completely greased prior to shipment from
their place of manufacture. Small motors shall have life-time lubricated bearings.

All motors within a frame size shall be fully interchangeable being of the same
type and rating as far as practical in order to facilitate maintenance and reduce
spare parts requirements. Interchangeability includes i.a. provisions for electrical
connections, motor mounting, blowers, encoders, etc. Motor terminal boxes shall
be located on top or as such that motors are fully interchangeable within their
drive system. Terminal boxes shall be enlarged in size to accommodate increased
cable sizes due to various current carrying reduction factors.

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Technical Specifications for two 38 t Ship Unloader Cranes 31

Galvanised and painted steel sun shields shall be provided over all motors
mounted in upright position to protect against direct sunlight, ice and snow. The
shields shall be of robust construction and arranged in a manner that air can
circulate around the motor.

Silicon sealants shall not be used on or near any motor.

6.6 Resistors

If installed, resistors shall be of the punched grid type made of high alloy stainless
steel, suitable for outdoor installation.

Resistors shall be designed to 100% duty at the specified ambient conditions.

Actual current applied shall not exceed the duty rating of each individual resistor
based on conduction and convection equalling I²R loss after
• Duration factors are applied for stacking,
• Maximum specified outside ambient temperature, and
• Internal heat generated in the confined enclosure is factored in.

Resistors shall be heat resistant up to 800 °C.

The resistor banks shall be protected by a weatherproof and drip-proof, stainless

steel enclosure. The enclosure shall be either a louvered or a mesh type, with
removable access panels. The resistors shall be accessible from both sides and
shall have adequate lifting lugs. Adequate ISO/IEC warning labels shall be
provided.

6.7 Wiring and Cabling

6.7.1 General

Wiring and cabling shall conform to applicable IEC and DIN/VDE regulations.
Particularly IEC 60204-32, DIN 57281/VDE 0281, DIN 57282/ VDE 0282,
DIN EN 55011, DIN EN 61800-3 and applicable European directives for low
voltage design and electromagnetic compatibility shall be observed. Cabling
instructions of the original equipment manufacturer for electrical components
such as motors and drives shall be strictly followed.

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Technical Specifications for two 38 t Ship Unloader Cranes 32

All cables, unless otherwise specified, shall be of PVC, XLPE type or as approved
and adequately protected from direct sunlight and UV radiation. Power cables for
main drive motors shall be of 600/1000-V grade and be selected for use in
industrial applications to withstand mechanical damages after installation,
provided with concentric copper braided amour, similar to Protoflex EMV/EMC
type.

All cables shall have copper conductors of the flexible stranded type. All cables
external to enclosures shall be of minimum 2.5 mm² size for power cables and of
1.5 mm² size for control cables the latter being very fine stranded copper
conductor cables. Low voltage wiring may be smaller, but minimum 1 mm².

Cables and insulation must be selected for resistance to insect and vermin attack
and shall be oil and moisture resistant, flame retardant, thermoplastic with nylon
jacket. They shall be sized in accordance with applicable IEC, DIN/VDE
regulations using the full load amps, adequately de-rated to suit ambient
temperatures and multiple runs.

Care should be taken to match the current carrying capacity of the cable to the
characteristic release curves of the protection device. The maximum permissible
cable length (based on the short circuit current vs. release time and characteristic
of the protection device) has to be observed very carefully. Branch circuit voltage
drop shall not exceed 5% of specified voltage.

Parallel single-core cables for multi-phase systems have to be installed very

carefully, bearing in mind varying impedances of every system due to specific
arrangements (e.g. single layer or trefoil layer). The maximum permissible load
difference shall not exceed ± 10% of the calculated value. The conductors shall be
spaced so that a clamp-on ammeter can be put around every single one.

The wiring and cabling for the lighting system and for the electronic control
system shall be kept separate from the power and control wiring and shall be run
in a separate conduit and junction box system to avoid magnetic and electrostatic
interference.

6.7.2 Cable Assembly

All cabling and wiring shall be neatly fixed in a professional manner in line with
IEC regulations. Cables installed outside shall be adequately covered against
sunlight and mechanical damages. Cabling and wiring likely to contact edges of
any of the crane’s steel structure or any other edges shall be protected with
reinforced rubber.

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Technical Specifications for two 38 t Ship Unloader Cranes 33

Cabling shall be grouped and tied in respective grades and, where necessary, shall
cross other groups at right angles. All cables shall be suitably clamped,
particularly on long vertical runs and on entry into cubicles. The maximum
distance between each clamp and from the point of entry to any cubicle or
junction box shall not exceed 30 cm. All cable ties shall be UV-proof and suitable
for use in the specified ambient conditions. All cable ties used outside, even if
cables are running in covered cable trays, shall be UV-proof nylon-coated
stainless steel type. Not more than five cables shall be fixed under one fastening
device.

Cables shall be separated and isolated by their function, such as AC power, AC

control, DC power, DC control, communications, digital signals, etc. To avoid
any interference or induced noise problems, they shall not be run in the same
conduit, same festoon/power chain cable or cable tray unless with appropriate
segregation.

Voltage grades within cables shall be uniform.

Motor circuits and brake conductors shall not have common conductors. Wiring
shall consist of strictly isolated independent circuits. Motor circuits shall
terminate in their respective panels in the electrical house.

Shielded cables shall be installed as per the original equipment supplier's

recommendations (i.e. well-known 16 EMC rules). Exposed tails shall be as short
as possible. In junction boxes screens shall be earthed with correct clamps and
shall remain intact right up to the point of termination at the inverter and
respective motors. Respective junction boxes shall be made of a material to
continue the shielding effort. Cable glands shall be metallic (stainless steel or
nickel plated brass) with shield connection. Plastic motor terminal boxes and
plastic glands must not be used. The shielding for the motor cables for frequency
controlled drives has to be specified very clearly by the supplier of the inverters.
The connection between inverter and motor must not be interrupted and shall not
come into contact with any PE or PEN conductors and normal ground terminal,
structural element or the like.

Splices are not acceptable in any cable tray, conduit or fitting. Bolted splices in
motors are also not permitted. Splices or joints in feeders or branches shall be
permitted only in junction boxes in line with IEC and DIN/VDE regulations for
splices. All splices shall be made using terminal blocks. No more than two wires
shall be permitted per screw terminal, one each side. No more than one ground
conductor is permitted per termination point.

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Technical Specifications for two 38 t Ship Unloader Cranes 34

Wire crimping shall be used only when the copper conductor is exposed and
visible on the ring side of the lug to ensure proper conductor depth. Crimping
tools, approved by the lug manufacturer only, shall be used. Crimping tools shall
not release until the wire is fully crimped.

For multi-phase systems using single-core cables, entry into cubicles or other
devices shall be through non-magnetic gland plates. Individual conductors shall
be fastened with non-magnetic cable fasteners.

Proper care has to be employed for the correct sequence of arranging flat washers,
spring or lock washers and nuts.

Ground connections shall be vibration-proof with serrated or spring washers. Only

one conductor is permitted per screw connection.

Special attention shall be paid to the installation of Bus-cables. Any twisting,

stretching or squashing must be avoided by all means. EMC rules and respective
shielding requirements shall be observed. The maximum length of the cable shall
be selected according to the required baud rate and shall follow the OEM
guidelines.

6.7.3 Junction Boxes

All wiring interconnection shall be made in appropriate junction boxes or cubicles

with terminal blocks. The junction boxes and cubicles shall be large enough to
neatly accommodate all cables and to provide sufficient room for core termination
including spares without interfering with one another. They have to be code-
numbered defining device and location. The code shall also appear in the
electrical wiring diagrams.

All input and output wiring shall be connected to terminal blocks. Terminal
blocks shall be accessible and provided as per DIN/VDE. All terminal blocks
shall be sized for appropriate conductor and voltage grade. The individual
terminals have to be numbered. Only two wires are permitted per terminal, one on
each side. All terminal blocks shall be arranged in physically isolated manner.

All wires within the junction box or cubicle shall be installed according to
numerical order as shown in the electrical wiring diagrams. Wires have to be
identified whenever necessary. When connecting to the terminal blocks, ample
extra wire length shall be provided so that circuits can be transferred or
reconnected if required.

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Technical Specifications for two 38 t Ship Unloader Cranes 35

Junction boxes for emergency lighting circuits have to be identified with a red,
round label showing circuit number and device number (electrical code).

6.7.4 Colour Coding and Labelling

Colour codes shall be according to applicable IEC 60446 or VDE 0293

regulations and shall be approved by the Purchaser. All cables shall be correctly
colour-coded for their intended application and shall include a green/yellow earth
conductor. All colour coding shall be throughout the whole length for cables with
up to five conductors. Cables with more than five conductors shall be identified
by numbers.

All cables, wires and conductors, including those within cubicles, shall be
identified by numbers at all ends. All wire identification shall match the wire
numbers on the schematic wiring drawings for that function. Cables have to be
identified by their number at every point of entry or exit to or from cubicles,
devices, junction boxes, etc.

Each cable shall be uniquely identified with cable tags, which, if installed outside,
shall be punched, stainless steel flat bars and attached to the cable with stainless
steel ties. Cables installed inside may have sleeves with printed endurable cable
labels.

Each terminal block section shall have an individual code or number to be

labelled in accordance with the schematic diagrams.

6.7.5 Spare Wires

At least 10% of the control wires, but minimum four (4) wires, shall be installed
on all routes and specifically labelled as spare wires. Furthermore, minimum 10%
spare communication wires, at least two (2) wires, shall be run to each
communications point and operations station. All spare wires shall be terminated
and labelled.

At least 20% spare terminals per block shall be provided in each junction box,
cubicle or enclosure. During final commissioning at the port, there may be wiring
changes or additions required. However, 10% of unused terminal connections
shall be available after final acceptance. Field wiring changes shall not use spare
wires.

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Technical Specifications for two 38 t Ship Unloader Cranes 36

6.7.6 Optical Cable

Communication protocol between PLC and each remote I/O unit and encoders
shall be via fibre optics. Fibre optic cables shall also be installed for
communication between E-house, operator’s cabin, checker’s cabin as well as to
the port’s remote crane management and terminal operation system. At least 10%
of optical spare wires shall be installed for every application, with the exception
of the operator’s cabin, where a minimum of six (6) optical spare wires have to be
installed.

The MV trailing cable shall include a 9/125 μ single-mode optical fibre, as

approved by the Employer, with 6 optical cores. Optical cables within the crane
may be multi-mode 50/125 μ or 62.5/125 μ, with necessary switches for the
single-mode optical cores of the MV trailing cable.

The optical cables have to be able to withstand the strengths, torques and speeds
there are subject to due to gantry travel or trolley travel.

All optical cables shall correspond to EN 187000-501, 504, 505, 507, 508, 513,
605B and 601. Single-mode type shall correspond to CCITT G.652; multi-mode
type shall correspond to CCITT G.651.

Cable jackets shall be made for both indoor and outdoor industrial applications
and designed to meet the specified environment conditions.

At the festoon system, the optical cable shall be protected by an ETFE inner
jacket for crush resistance. Additionally a central strength member made of
fibreglass or epoxy shall be included to improve tension reinforcement. The outer
jacket shall be neoprene. Minimum bending radii have to be maintained by using
additional strength members.

All optical fibres shall be terminated or interconnected on appropriate patch

panels by all metal style connectors, permanently bonded to the fibre's strength
member. At least two meters spare capacity of each incoming fibre shall be
provided at the patch panels.

The method of marking the cable and fibres shall be the same as for non-fibre
cables and conductors.

The optical cable manufacturer shall have at least three years of application
experience in a similar industrial and heavy-duty environment. Recommended
installation procedures shall be strictly adhered to.

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Technical Specifications for two 38 t Ship Unloader Cranes 37

6.8 Conduits and Cable Trays

6.8.1 Design

With exception of festoon/power chain cables, all wiring shall run in cable trays,
cable ladders or conduits. Wiring and cabling exposed to the elements is
unacceptable. All cable trays or ladders in areas exposed to the elements shall be
adequately covered to protect cables against direct sunlight and mechanical
damages.

All conduits, couplings and cable trays and ladders shall match applicable IEC
and DIN/VDE rules and regulations.

Conduit shall be made of rigid galvanised steel. For moving applications flexible
liquid-tight, jacketed, spirally-wound galvanised steel conduits shall be used. All
conduit fittings shall be made of hot dipped galvanised malleable iron. Rigid
conduit installed outside shall be painted matching the colour of the crane
structure that it is mounted to.

All external cable trays and ladders shall be of stainless steel, whereas internal
cable trays or internal cable ladders shall be hot-dipped galvanised.

Maximum loading of the cable trays and ladders shall not exceed 60% of the
cross-sectional area with respective segregations and separators for different
voltage grades, AC power, DC power, communication and signal cabling, etc.

The cross-sectional area of conduit shall be dimensioned to accommodate 15%

more conductors than actually required. The conduit shall be minimum 20 mm in
diameter, unless designed for a specific application.

6.8.2 Assembly

Assembly of conduits, cable trays, cable ladders as well as installation of cables

and wiring shall follow IEC and DIN/VDE rules and regulations.

Conduits, cable trays, cable ladders, junction boxes or other fittings shall not be
mounted in the path of container travel and must not be routed across any access,
service or walkway deck.

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Technical Specifications for two 38 t Ship Unloader Cranes 38

Where practical, cables may be installed inside the crane structure, but must be
accessible at all points via internal access ladders, manholes and sufficient space.
Cables must be neatly mounted and securely fastened to cable ladders or trays
inside the crane structure. Free hanging cables or cables laid on the floor are not
acceptable.

Conduits, cable trays and ladders shall run parallel or perpendicular to the
structure they are mounted. Change of direction shall be in 90 ° angle turns,
consisting of symmetrical bends for conduits and right angle cableway elbows for
cable trays and ladders. Offsets bends in conduit shall be avoided.

Conduit and cableway support shall be made of angle steel bars or structural
shapes welded to the crane structure. All conduits and cableways shall be
mounted to the supports by means of stainless steel U-bolts, flat and lock washers
and nuts, or self-locking nuts, at intervals smaller than 1,800 mm. Cable tray
covers shall be fastened by stainless steel screws.

All conduits shall be reamed prior to assembly. Conduit ends shall be flared to
avoid any wire damage.

Where necessary, conduits shall be made watertight employing Teflon pipe

compound on all joints. Couplings, connectors and fittings shall be of the threaded
type. Conduit entrances to all motors, junction boxes, enclosures, houses and
cabins, etc., shall be from below by watertight hubs or threaded connection, if
exposed to weather. Top entry is unacceptable. Side entry is permitted only when
cables are laid with adequate water bags.

Welding on any cable tray, conduit or fittings is not allowed. When entering into
the crane’s structural members, watertight bulkhead hubs shall be used.
Penetration of cable trays, conduits or other fittings shall not weaken the crane’s
structure.

Cable trays and cable ladders shall be designed, manufactured and mounted to
avoid any damage to the installed wiring. Cable tray or ladder edges shall be
protected by rubber covers.

Earth continuity shall be provided by installing adequately insulated stranded wire

jumpers. These jumpers shall have a green/yellow jacket and wire ends shall be
terminated in approved lugs.

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Technical Specifications for two 38 t Ship Unloader Cranes 39

6.9 Enclosures

All enclosures, cubicles, panels, local control stations and junction boxes shall be
of heavy-duty and vibration-proof design. All enclosures shall be of the upright
“standing” type.

In locations permanently exposed to the weather, all enclosures including their

latches, fasteners, hoods and miscellaneous fittings shall be made of stainless
steel. Mounting plates at the internal rear sides of the panel may be of mild steel.
The protection class of exterior enclosures shall correspond to IP 55. Cover
screws shall not penetrate the watertight enclosure. Where necessary, breathers
and drains shall be provided.

Small boxes, such as lighting switches or pull boxes, may be of heavy duty
industrial plastic, fibreglass or other material approved by the Purchaser, if not
susceptible to damages.

Interior enclosures shall be coated with corrosion-resistant material and meet

IP 23 criteria.

Panels shall be accessible and removable from the front side. Covers of machinery
and panel enclosures shall be hinged. It shall be possible to open doors completely
for easy removal of components mounted inside. Latches shall be provided to
secure all covers when opened for servicing. The latches shall be adequate to
secure covers in high winds.

Cable ducting shall be provided inside enclosures to adequately route all cables,
with room for 30% more cables than required. Covers for cable channels must fit
easily into their place.

Sufficient space (at least 200 mm above the bottom) shall be allowed for the
incoming cable section to allow a clear arrangement of all cables. Supporting
structural members shall be provided to fasten them securely.

The terminal blocks shall be arranged at the rear side of the panels/enclosures
only. No mounting to the side walls will be accepted.

Junction boxes with I/O cards and all panels shall be equipped with space heaters.
Large junction boxes (e.g. terminal boxes for festoon/power chain cables) shall be
provided with internal automatic and protected fluorescent lighting and duplex
convenience outlets.

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Technical Specifications for two 38 t Ship Unloader Cranes 40

All electrical enclosures, cubicles, panels and junction boxes have to be code-
numbered defining device and location. The code shall also appear and
correspond with the codes in the electrical wiring diagrams.

6.10 Cubicles

6.10.1 General Design

Separate floor-mounted cubicles shall be provided inter alia for the crane control
system, each drive, low voltage power distribution, auxiliary lights and auxiliary
power, communication equipment, elevator, etc.

All these cubicles shall be installed in the electrical house and be equipped with
anti-condensation heaters. Cable entry shall be from underneath. All live parts
shall be covered to avoid any hazard for operating personnel. Protection shall be
easily removable. All equipment mounted inside shall be easily accessible.

The cubicles have cable ducts with 30% spare capacity and be equipped with
replaceable internal filters where required for air flow. Internal isolators are to be
provided. External interlocking switches are not allowed.

Cubicle doors shall open by at least 95 °, where possible by 180 °. Doors shall
have metering devices and emergency stop pushbuttons, where applicable.
Standard door handles without locks or keys shall be provided.

Cubicles shall be equipped with a convenience duplex outlet and internal

automatic lighting.

Cubicles shall be easily removable, either singly or in groups not exceeding

3.30 m in length. It shall be possible to disassemble the cubicle sections from the
front.

The top of the cubicles shall be braced to the electrical house wall. Mounting
plates have to be secured by chains at the top to prevent them from falling out
when the panel door is opened after a rupture of the fastening devices due to an
earth-quake. Also, a suitable channel iron shall be installed underneath to catch
the plate and prevent further sag into the cable section in case of a rupture of the
fastening devices.

All cubicles shall be from the same manufacturer and type. Standard products,
such as cubicles for drives shall match those which are custom-made. All cubicles
shall be exactly the same colour.

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Technical Specifications for two 38 t Ship Unloader Cranes 41

Nameplates shall be mounted on the cubicle front clearly indicating device name
(electrical code), plant group number and cubicle number, consistent with all
technical documentation.

6.10.2 Low-Voltage Power Distribution Cubicle

The low-voltage power distribution cubicle shall be equipped with a motorised

LV circuit breaker at the incoming side with an auxiliary bus bar system to
facilitate the connection of the multiple trefoil cable bundles of single core
conductors. Every single conductor must be accessible for a clamp-on ammeter.

Contactors, fused disconnectors or line switches for each drive shall be installed.

The low voltage power distribution system shall include auxiliary transformer(s)
and auxiliary power supplies.

A voltage surge arrester has to be provided at the line side of the circuit breaker
including isolator and fuses.

For panel meters and protection devices also refer to Chapter 6.2.

6.10.3 PLC Cubicle

The PLC cubicle door shall have a green pushbutton indicating light marked
“CONTROL ON”, a “CONTROL OFF” and a “RESET” pushbutton.

6.10.4 Auxiliary Light and Power Cubicle

This cubicle shall have pushbuttons for floodlights “ON/OFF”, walkway lights
“ON/OFF” as well as a selector switch for photocell bypass “ON/OFF”.

6.11 Local Control Stations

Local control stations shall be provided for maintenance and emergency operation
purposes. The operator at the local control station shall gain control of the
respective drive only after turning a key selector switch. The control from the
remote station shall be restricted to the respective drive function. Activating the
remote station shall disable all cab functions.

The layout of all local control stations is subject to approval by the Purchaser. The
following local control stations shall be provided:

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6.11.1 Hoist and Boom Hoist

Individual grab hoist, grab open/close and boom hoist local control stations shall
be located in the machinery house mounted near the relevant equipment to allow
operation of the drive for maintenance purposes, e.g. rope change as well as
operation with emergency motors.

The panels shall have the following devices:

• Key selector switch “ON/OFF”
• Selector switch “MAIN MOTOR/EMERGENCY MOTOR”
• Yellow mushroom head, palm operated, latched pushbutton marked “Hoist
Stop” or “Boom Stop” as applicable
• Pushbutton marked “Raise”
• Pushbutton marked “Lower”
• Pushbutton marked “Open”
• Pushbutton marked “Close

6.11.2 Trolley Drive

The control station of the trolley drive system shall be installed in the machinery
house close to the equipment.

The following devices shall be mounted on the panel of the local control station:
• Key selector switch “ON/OFF”
• Yellow mushroom head, palm operated, latched pushbutton marked as
follows “Trolley Stop”
• Pushbutton marked “Forward”
• Pushbutton marked “Reverse”

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Technical Specifications for two 38 t Ship Unloader Cranes 43

6.11.3 Rope Re-Reeving Drive

The local control station for the rope re-reeving system shall be installed in the
machinery house at suitable location. The following devices shall be provided:
• Key selector switch “ON/OFF”
• Yellow mushroom head, palm operated, latched pushbutton marked as
follows “Re-reeving Stop”
• Pushbutton marked “Coil”
• Pushbutton marked "Uncoil

6.11.4 Gantry Local Control Station

The gantry drive system shall have a suitable control station mounted at the
landside near the crane access. The following devices shall be mounted on the
panel inside a lockable enclosure:
• Control “On/Off” green illuminated pushbutton
• Pushbutton “Fault reset”
• Key selector switch “On/Off”
• Yellow mushroom head, palm operated, latched pushbutton marked as
follows “Gantry Stop”.
• Pushbutton marked "Left 10% Speed”
• Pushbutton marked “Right 10% Speed”
• Pushbutton marked “Left 100% Speed”
• Pushbutton marked “Right 100% Speed”
• Floodlights “On/Off”
• Illuminated pushbuttons “Rail brake open” / “Rail brakes close”
• Red indication light for “Storm anchors engaged”
• Key selector switch “High wind bypass”
• Pushbutton “Lamp test”

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6.11.5 MV Cable Reel Station

At the MV cable reel platform a suitable control station shall be provided. The
panel shall have the following devices:
• Key selector switch “ON/OFF”
• Red mushroom head, palm operated, latched pushbutton marked “Power off”
• Pushbutton marked “Coil”
• Pushbutton marked "Uncoil”

6.11.6 Hopper Control Station

The hopper trap door shall be controlled from the operator’s cabin. The panel
inside the cabin shall have the following devices:
• Crane Control “On/Off” green illuminated pushbutton
• Pushbutton “Fault reset”
• Red mushroom head, palm operated, latched pushbutton marked as follows
“Emergency Stop” to shut down all crane motions.
• Pushbutton marked “Hopper open”
• Pushbutton marked “Hopper close”
• Floodlights “On/Off” (Hopper working area only)
• Pushbutton marked “Spillage flap raise”
• Pushbutton marked “Spillage flap lower”
• Selector switch “Vibrators On/Off “
• Selector switch “Water Spraying On/Off “

6.11.7 Belt Feeder Control Station

The belt feeder shall be controlled from a control station. The panel shall have the
following devices:
• Crane Control “On/Off” green illuminated pushbutton
• Belt Control I+II “On/Off” green illuminated pushbutton
• Pushbutton “Fault reset”
• Red mushroom head, palm operated, latched pushbutton marked as follows
“Emergency Stop” to shut down all crane motions.

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Technical Specifications for two 38 t Ship Unloader Cranes 45

• Pushbutton marked “Belt forward”

• Pushbutton marked “Belt reverse”
• Floodlights “On/Off” (Belt area only)

6.12 Space Heaters

Space (or anti-condensation) heaters shall be provided for all control panels, drive
cubicles, switchboards, junction boxes with I/O cards, brakes with enclosures and
motors above 5 kW. They shall operate at voltages as defined in Chapter 5.5.

The independent space heater circuits shall be energised when the crane is not in
service. Space heaters in control panels, switchboards and cubicles shall be
controlled by thermostats with a maximum setting of 30 °C. Space heaters in
motors and brakes shall be automatically cut off during crane operation.

Circuit breakers for space heaters shall be monitored by the PLC.

At each heater location a red warning plate or label shall be installed, warning of
this independent power source.

6.13 MV Cable Reel System

6.13.1 Cable Reel

The power supply to the crane shall be via a cable reel system. The cable reel shall
be motor-driven and torque-controlled, fully integrated into the main drive
system, PLC and CMS system. The entire design shall include all necessary
provisions to prevent damage, stress, over-tension or any unnecessary wear of the
cable.

The torque calculation for the MV cable and the cable reel system shall be made
by the original cable reel system supplier. The calculation shall include the entire
structure and mechanical components following the load path completely through
the MV cable system.

The MV cable reel shall be mounted preferably on the left portal/leg beam
towards the landside.

The cable reel shall be of the mono-spiral multi-layer type and shall be of rigid
composite construction. The entire cable reel including tie rods and fasteners shall
be made of hot dipped galvanised steel and shall be painted.

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Technical Specifications for two 38 t Ship Unloader Cranes 46

The minimum inside diameter of the MV cable reel shall be 20 times the
respective cable outer diameter. The reels shall be sufficiently sized to allow for
three dead cable wraps on the reel inside diameter. The outside diameter shall
allow at least one additional cable wrap. The spoke-to-spoke distance of the cable
shall exceed the cable outside diameter by 10% up to a maximum of 4 mm. The
cable shall be fastened to the reel prior to entering the inner circumference.
Minimum cable bending radius has to be observed.

If pull reels are required for the cable reel system, they shall be provided with
elastomeric layers to protect the MV cable from damages.

The cable reel shall be preferably inverter driven. The gear box shall be of a
totally enclosed design, with internal oil bath lubrication.

The drive system shall supply sufficient torque to operate the cable under all
specified operating conditions. The maximum cable tension, as recommended by
the cable manufacturer, shall not be exceeded under any operating condition.

A brake mechanism shall be provided to prevent uncontrolled cable pay-out when

the cable reel drive is not energised.

A cam limit switch shall be installed to monitor the last cable turn.

6.13.2 Slip Ring Assembly

Each slip ring assembly shall be made of a minimum of four individual copper
graphite brush gears designed for the specified voltage. Brush gears and all other
devices shall be easily replaceable. The power slip ring shall have air gap
insulation.

The slip ring enclosure shall be minimum IP 65 and constructed of stainless steel
and shall contain self-regulating anti-condensation heaters.

The MV power slip ring enclosure shall be bolted down or be provided with an
adequate locking system.

6.13.3 Cable Guide System

The horizontal cable deflection system shall be of galvanised steel construction

with stainless steel fasteners and include a pendulum arm with limit switches to
provide slack cable protection, over-tension protection and change of travel
direction detection. The lifetime lubricated guide rollers must be constructed of a
non-corroding material.

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Technical Specifications for two 38 t Ship Unloader Cranes 47

The minimum cable bending radius, as recommended by the MV cable

manufacturer, has to be observed.

The cable slot position of the MV cable can vary. Therefore the guiding device
shall be adjustable.

Cable guide rollers guiding the cable from the reel to the horizontal cable
deflection system shall be spaced at minimum three meter intervals. The assembly
shall be of galvanised steel. Guide rollers shall be lifetime lubricated and of a non-
corroding material.

6.14 Festoon System

Power and control wiring shall run in highly flexible insulated cables from
junction boxes on the landside end of the girder via a festoon system to junction
boxes on the trolley. The festoon system must conform to latest revision of
applicable DIN/VDE regulations. Speed and acceleration time shall correspond to
the trolley design.

Tracks shall be “I”-shaped members and inclined over the length of the festoon
platform (girder end) to minimise collision forces and for natural acceleration/
deceleration of the system. The landside catenary trolley may be also connected to
the festoon system. A self-driven festoon system shall be installed, when deemed
necessary by the manufacturer.

The festoon system shall be fabricated of hot-dipped galvanised steel construction

with stainless steel fittings, towed by PVC coated aircraft quality stainless steel
wire ropes and relieved by UV protected expanders in sufficient quantities
(minimum four expanders between two trolleys). The running festoon system
shall have a noise level below 85 dB(A).

The festoon trolleys shall have rubber bumpers, endurable synthetically coated
100 mm diameter running wheels with permanently lubricated ball bearings
(minimum diameter 75 mm). The running, side guide and anti-lift off wheels shall
be individually changeable. The cable trolleys shall have a radius of minimum
five times the cable outer diameter and a minimum saddle turn of 180 °.

All festoon cabling shall be Prysmian Rondoflex type or similar. Power cables for
trolley/cabin motors shall be minimum 3 x 25 mm². Other power cables shall be
of 2.5 mm² size at least. Control wiring shall be minimum 1.5 mm².
Communication at low voltage wiring shall be smaller, but minimum 1.0 mm². A
separate earthing conductor of sufficient size shall be provided. The festoon

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Technical Specifications for two 38 t Ship Unloader Cranes 48

cables shall have the greatest number of strands per conductor per current
catalogue listing and conform to VDE. Shielded and intercom cables shall run in
separate cables and terminate in separate junction boxes. A 6-core fibre-optic link
between operator’s cabin and the E-House shall be part of the festoon system.
Control cables shall have at least 10% spare wires with a minimum of four spare
wires each cable.

Cable grips shall be used to relieve strains on the cables before they enter junction
boxes. Cables shall be blocked in place to avoid overlapping or twisting between
trolleys. A minimum of two extra clamps per trolley must be installed.

The entire festoon system must be installed in strict line with the manufacturer's
recommendations. Installation shall be approved by the original equipment
manufacturer.

A platform to access and service the festoon system from both sides shall be
furnished at the rear of the girder.

Special attention must be given to the height of feeder tripper belt BC07 for ship
loader, positioned in the backreach area.

6.15 Communication System

A low-voltage multi-station intercom system shall be installed for communication

between
• Operator's cabin
• Machinery/electrical house
• PLC control room
• Crane access point
• Hopper platform
• Elevator
• Cable reel platform
• Boom tip platform
• Trolley platform
• Top of A-frame
• Belt feeder control station

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All above listed stations shall have handsets with call buttons and “press to talk”
buttons and be equipped with a volume control. Units exposed to weather shall be
housed in weather-proof IP 55 corrosion resistant enclosures. The machinery
house shall have additional loudspeakers to allow communication with operating
drives.

The system shall be designed for use in the proximity of the installed semi-
conductor drive system, without any discernible noise.

The intercom system shall be independently hard-wired with shielded individually

twisted pair cables, minimum size 1.0 mm². The intercom system shall be backed-
up by an UPS with 30 minutes capacity.

The underside of the operator’s cabin shall be equipped with a loudspeaker of

minimum 100 dB(A) and 400 mm diameter to allow the operator to talk via a
microphone on his control console to personnel on the quay or vessel.

The Purchaser will install an UHF/VHF or digital radio system in the operator's
cabin. Thus provisions such as a mounting device, power supply, antenna, etc.
have to be foreseen.

6.16 Outlets

6.16.1 Convenience and Power Outlets

Convenience BS 1363 type outlets shall be suitable for operation of conventional

hand power tools. Outlets shall be duplex type, 13 A, with an industrial enclosure
suitable for marine environment minimum IP 44, and if installed outside fuse-
protected with hinged gasketed covers, IP 67.

All style and type of outlets shall be approved by the Purchaser.

Circuits for outlets shall be independent from other circuits such as illumination.
Voltages shall be as defined in Chapter 5.5.

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Technical Specifications for two 38 t Ship Unloader Cranes 50

Respective outlets shall be provided at the locations indicated in the following

table:

Table 7: Convenience and Welding Outlets

Location BS 1363 type, 13 A duplex

In the operator's cabin 2
At the boom tip 1
At the end of girder 1
At the boom, near hinge point 1
On the A-frame platform 1
In the E-room 2
In the PLC room 2
In the machinery house 4
At gantry level, on each side 2
On the trolley platform 1
On the MV cable reel platform 1
In each drive cubicle and larger junction 1
boxes/cubicle
On top of the elevator 1
At belt feeder station 1
At the hopper platform 1

In addition to the above, the PLC room shall be equipped with sufficient
convenience outlets required for printer, PC, monitor and associated equipment.

6.16.2 Emergency Power

For emergency operations the crane shall be connected to a neighbouring crane or

to a socket along the crane track. Respective CEE 125A, 3-phase/5-wire power
plugs and sockets with interlock for incoming (male) and outgoing power
(female) for the voltages and amperage defined in Chapter 5.8 shall be installed at
waterside centre of the crane. The type of plug and socket shall be approved by
the Purchaser. The plugs and sockets shall meet IP 67 criteria.

6.17 Illumination

A permanent illumination system shall be furnished on the crane for floodlights as

well as to provide sufficient illumination for all access ladders, platforms,
walkways, control cabins, electrical house and machinery house. The illumination
system shall operate at voltages as defined in Chapter 5.5.

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The following average level of illumination shall be maintained:

• Along walkways, ladders, stairs and platforms 50 Lux
• Machinery and electrical house, control room 300 Lux
• Operator’s cabin, with dimmer control 200 Lux
• Floodlights mounted along the boom and girder from backreach to
outreach to provide an illumination at quay level at an area of
± 10 m from boom centre line. Trolley floodlights not included. 100 Lux
• Floodlights to illuminate the hopper and belt feeder platform 100 Lux

Additionally, four floodlights shall be mounted underneath the operator’s cabin/

trolley to illuminate the area directly below.

A detailed Lux level calculation in accordance with DIN EN 12646 has to be

submitted in advance for approval from the nominated manufacturer of the
floodlights. The Lux level ratio shall not exceed 2:1 within a 3 m radius of any
point of the specified area. When calculating the average maintained Lux level
initial values shall be multiplied with a safety factor of 0.8. Additional shadow
lights, installed i.e. under the portal beams, shall be employed to eliminate
shadows and reach the specified Lux levels. Floodlights shall not cause glare for
berth or crane operators.

All floodlights will be of the high-pressure sodium SON type, 2 x 400 W. The
enclosure shall be IP 55 of corrosion-resistant heavy-duty material with stainless
steel fasteners. Floodlights shall be shock-proof mounted with fall-down
protection and shall be easily accessible for maintenance and repair. Floodlights
along the boom and girder shall be mounted symmetrically close to the centre line
of the boom and be intermeshed in at least two independent circuits.

Floodlights shall be controlled from a cubicle in the electrical house, from

operator’s cab and from the crane access point (local control station for gantry
drive). Additionally a photo cell shall switch the floodlights off with an adjustable
time delay when more than 1000 Lux daylight are sensored. Boom floodlights
shall be automatically turned off when the boom is lifted.

Floodlights shall have preferably separated ballasts mounted in a cubicle inside

the machinery house. Ballasts shall be Class H insulated, with a power factor not
less than 0.9.

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Further two maintenance floodlights (each 1 x 250 W each) shall be mounted at:
• Snag platform
• Boom tip
• Top of A-frame
• Hopper platform

Access and walkway lights shall be mounted in rough-service anti-vibration type

housings with stainless steel fittings. Light housings shall be adequately protected
by a cover and shall be installed on the walkways without interfering with the
required walkway clearance. Energy saving light media (preferably LED) shall be
used. Access lighting shall be controlled from the crane access point, operator’s
cab, top elevator landing and electrical house.

Lighting in the machinery house, electrical house and PLC control room shall be
adequately positioned to eliminate equipment shadows. The fluorescent type
lighting shall be vibration-proof and installed in two intermeshed circuits.
Lighting switches shall be installed beside each access door.

The machinery house, electrical house, PLC control room and operator’s cabin
shall be equipped with an independent emergency lighting system. This system
shall be fed by an independent battery pack with two hours capacity and shall be
activated when normal lights are on and power failure occurs. The illumination
level of emergency lights shall be not less than 30 Lux. Green illuminated EXIT
signs shall be mounted over every access door.

All type of illumination media must be locally available in the country where the
crane is operating.

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6.18 Lightning Protection

All electrical and mechanical equipment installed on the crane shall be protected
against damages from lightning.

All bearings shall be protected from electrical current by jumpers of finely

stranded conductors with a cross-sectional area of 120 mm² and outer
green/yellow jacket.

Bogies shall be furnished with copper shoe conductors contacting the gantry rails
to provide positive earthing.

Two lightning arrester points each at the end of the boom and on top of the pylon
shall be installed.

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7. COMPUTERISED SYSTEMS

7.1 Sequence Control (PLC)

All sequencing and inter-locking functions for drives, except emergency stops
shall be performed by Programmable Logic Controller (PLC). If there are other
individual PLCs for specific crane components they shall be able to
intercommunicate with the main crane PLC through a standard network. The
system of communication shall be properly structured, organised and
standardised. The main crane PLC shall have multi-tasking and remote
communication capabilities. The main crane PLC shall be located in the silent
room of the electric house and shall have fault logging and diagnostic function
capability.

All components of the main crane PLC shall be robust and of high data integrity
for use in industrial environments of high temperatures, dust, vibration, humidity,
electrical noise or other harsh conditions. The PLC shall be fail-safe with
redundant components to guarantee highest availability. Power failure protection
shall be provided to ensure safe operation. The PLC shall further comply with
IEC 61508 and IEC 62061 for functional safety as well as with IEC 60870–5
regarding transmission of signals.

The complete cycle time of the control system including all “bus” systems shall
be in no case longer than 20 milliseconds. The Contractor shall demonstrate the
cycle time by chart recordings i.e. input to output from operations cabin to drive
reaction time.

The PLC shall have sufficient memory capacity to hold control algorithms for
more than one process plus at least 30% redundant memory capacity. There shall
be space provided for adding additional memories. Expansion of the PLC shall be
by plug-in modules to the common rack.

The PLC shall have self-diagnostic capability both upon power on and
continuously during operation. Faults detected shall be clearly and promptly
announced on visual displays.

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The programming language shall be of any international operating system

language and suitable for sequence control purposes. It shall also allow
referencing devices by English names consisting of alphanumeric characters of
adequate length. There shall be provisions for incorporating comments in the
documentation of programmes. Security features that permit only authorised users
to amend the programmes shall be incorporated.

The controller system shall provide real-time display of programmes and all plant
data and status at remote sites. The PLC shall be provided with in- and out (I/O)
ports. There shall be provisions for adding I/O ports. 10% spare remote
Input/Output units including a minimum of two analogue I/O spares (if used) shall
be provided.

The I/O ports shall be capable of handling standard input and output signals. The
I/O ports shall be protected by surge arresters from dangerous voltages and
currents.

With exception of hardwired emergency stop limit switches, individual I/O units
shall be used for every limit switch, proxy switch, encoder or other protective
device. The communication protocol for each remote I/O unit shall be via fibre
optics with error detection capability.

Access to the series links of the PLCs shall be provided at the control room and at
the operator’s cabin.

The Supplier shall submit with his bid details (product data sheets and schematic
diagrams) showing the structure of the communication system reflecting the
above required qualities.

The PLC program as well as the crane’s fault logging and diagnostic system, shall
be accessed from the crane management system. Communication protocol
between control system and crane management system shall be Ethernet, Arcnet
or as approved by the Purchaser.

A separate and portable programming unit (one unit for four cranes) shall be
provided suitable for "on-line" operation and change of parameters. The
programming station shall be capable of showing status and overriding individual
I/Os for maintenance purposes. Additionally to the e-house, interfaces shall be
provided inside the gantry and operator cabin cubicles.

All cranes supplied under this contract shall have an identical PLC program with
identical parameterisation.

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7.2 Semi-Automatic Operation System

A semi-automatic operation system (SAOS) shall be optionally incorporated to

assist the crane operator to perform semi-automatic operation when travelling
from the basin to the hopper, including grab hoist, grab open/close and trolley
movements. The basic control of the crane shall be designed to function
independently of any other automation features. The operator may either operate
the crane under the manual or the semi-automated mode. Whichever the operating
mode may be, there shall be adequate safety features in the design to prevent any
accidental damages to equipment or human lives around the vicinity.

All necessary operating and indicating devices as well as displays with fault
messages, etc. shall be installed in the crane operator’s cabin.

7.3 Crane Management System

A complete computerised Crane Management System (CMS) with the necessary

sensors and transducers shall be installed on each crane and work in conjunction
with the PLC to provide continuous monitoring, diagnostics, and data collection
on the crane’s operating systems. The local CMS (LCMS) shall be connected to a
remote crane management system (RCMS) to be installed in the port’s workshop.
Connection shall be by the fibre optic cable which is part of the MV trailing cable.

Status and performance of the drives including the AC supply, AC motor control,
operator control, safety interlocks, and essential components like motors, gear
reducers, rope drums, etc. shall be captured and displayed on the screen for
evaluation of the crane’s mechanism.

A detailed description of the crane management system shall be submitted with

the tender documents

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7.3.1 Monitored Information and Fault Diagnostics

CMS functions shall include but not be limited to:

• Real time condition/status monitoring
• Operational data display
• Fault diagnostic with post mortem feature
• PLC data and drive data tracing
• Historical electronic logbook
• Programming software (suitable for online diagnostic and programming,
password protected)
• Reports and statistics
• Help facility to explain the usage of the installed programs
• Manuals and documentation for all relevant parts used on the crane including
electrical schematic drawings in pdf format

The status and operating data for the electrical systems and sub-systems and all
the essential components which are critical to the proper function of the crane
shall be monitored in terms of real time. This includes inter alia drive systems,
cable reel, AC units, etc.

Any abnormality in the crane’s systems and components monitored shall be

prompted and immediately displayed on the screen. On-off status and failure of all
safety interlocks, brakes, ventilation fans, air-conditioners for the electrical and
computer rooms, emergency switches, etc., shall be displayed on the screen. Data
such as operating voltages, currents, speeds and set points of all drive systems
shall also be monitored and displayed. A trend graph for a time span of up to
5 minutes for all signals must be possible.

The display shall consist of a dynamic overall sketch of the crane as well as
dynamic pictures of all subsystems. Pull-down and drill-down menus for data
display and diagnostic features shall be incorporated. A diagram of the PLC and
its hardware shall display all status and system faults with their locations.

All those signals which cause a crane stoppage and which are defined as faults
shall be stored in the historical electronic logbook for later tracing and facilitating
fault diagnosis. Information what crane functions have been selected or were
performing before and during a failure shall also be stored.

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A fault diagnosis and help screen to prompt the Port’s personnel with the
information on the nature of crane failure and remedial actions shall be provided.
An expert system shall be incorporated in the fault diagnosis to narrow down the
faults to the exact components, interlocks, switches, etc. On the help screen there
shall be information on the schematic drawing number, software page number,
component locations and possible actions to be taken to remedy the fault with
links to manuals and documentation for all relevant parts. The fault diagnosis and
help messages shall be designed to enable the Port’s technicians to remedy the
fault or confirm the exact nature of a major fault within a very short time.

Means for updating and enhancement of the help messages and information shall
be made available to Port’s personnel.

In addition to the screen display of the CMS, simple fault messages shall be
displayed on the screen in the operator’s cabin.

Historical records of faults shall be stored and they shall be easily retrieved on to
the screen or on printed formats. Such historical records are required for analysis
and corrective actions to eliminate recurring faults. Up to 10,000 historical
records shall be made available on real-time display mode. Earlier records
exceeding 500 shall automatically be downloaded to the hard disk. Download of
all historical records to USB sticks shall also be made possible. Records shall
include date, time and any relevant information.

Reports shall be generated to a screen and a printer installed in the E-house. Each
screen shall be printable. Printed reports shall be generated without delay by
manual request, on time basis or triggered by events.

7.3.2 Operating Log

The CMS shall provide operational data such as:

• Operating hours including crane on, grab hoist, trolley, gantry and boom hoist
• Performance data including productive moves per hour, idle time and down
time
• Weight measurement for each grab hoist
• Counts for grab open/close
• Shift and vessel information

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These data shall be available as numeric statistic categorised in the following

manner:
• Per vessel
• Per 8-hours shift
• Daily
• Monthly

The CMS shall also generate trend graphs plotted against variable time spans. All
data shall be stored and be easily retrieved onto the screen or on printed formats.

7.3.3 Preventive Maintenance Features

The utilisation hours of the crane’s consumables shall be captured on-line and
compared with the respective pre-set replacement intervals for consumables. The
system shall prompt the user when a part is due for replacement.

The pre-set replacement intervals shall be adjustable and the Supplier shall advise
the Purchaser on the optimal replacement intervals for the respective parts and
shall feed them into the system. The consumables shall include but not be limited
to lubrication in gear reducers and motors, hydraulic oils, air and oil filter
elements, wire ropes, brake pads, brake shoes, carbon brushes of motors, etc.

The system shall have the capacity and flexibility for adding new items and
changing any of the existing items from the above-mentioned list.

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7.3.4 Software and Hardware Requirements

The hardware shall be the latest but not less than the following:
• Windows XP or Windows 7 based computer with 2 GByte, or more, main
memory. The speed is to be the fastest possible at the time of procurement.
• 100/1000 MBit Ethernet adapter
• Hard disks with RAID level 1 to prevent data loss after hard disk failure with
- At least 2 hard disks of the same size
- Hot-swap feature to be realised depending on the function of the PC such
that when crucial functions of the crane control are involved when the PC
is disturbed or faulty then hot-swap is necessary
- Automatic hard disk failure detection with appropriate message on the
LCMS and to the RCMS
- After hard disk failure and replacement of the faulty disk, the PC must
automatically return to fail-safe configuration (may be manually
triggered). Normal operation of the PC including dependent systems must
be possible during replacement of the hard disk.
• USB interface at the front
• Keyboard
• Optical mouse
• 17” LCD monitor
• Minimum 500 GByte hard drives
• Ethernet switch and other equipment to match the Port’s systems
• CD and DVD read/write drives
• Laser printer

The software shall be a Windows-based, menu-driven, mouse-driven, multi-

tasking operating system. The on-site development of user-customised screens
shall be possible. Microsoft Office standard application software shall be
included.

An independent uninterrupted power supply shall support the cane management

system and the PLC for a minimum period of 30 minutes and shall allow the
orderly shutdown of all systems without any data loss.

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7.4 Remote Crane Management System

7.4.1 Requirements

The Supplier shall include in his scope one Central Remote Crane Management
System (RCMS) to be linked to each of the cranes by fibre optic..

The RCMS shall perform the following tasks:

• Centralising of the fault/diagnostic messages including automatic update to
LCMS
• Centralising equipment configuration data
• Centralising documentation (drawings and manuals, etc.)
• Centralising software (PLC programs, drive parameters, etc.)
• Collecting history data (faults, counters, running hours, moves, trace) for
connected equipment
• Maintenance of fault/diagnostic messages and configuration data
• On-line overview of every equipment status and access to history data (faults,
moves, counters, hours, trace)
• (Pre-) generation of preventive maintenance requirements
• Access to all equipment documentation

The RCMS is to be configured as a redundant data-base server system. All

equipment is to be connected via standard interfaces (ODBC, FTP, XML web
services).

The system is to be sized for up to 100 items of connected equipment. The RCMS
clients are Microsoft Windows XP/Windows 7 based PCs with more than
25 parallel connections.

The RCMS has to present the same information as available on the LCMS as well
as additional overviews of clustered information (per equipment type or berth etc).
A simple user-friendly interface is to be provided in which all presented data can
be saved to Microsoft Office applications (Excel, Word, etc.).

The response to data-requests on the RCMS clients under normal conditions has
to be in the range of 2 seconds. In case of long running requests, the user must be
informed about the progress, with the possibility to abort processing, or
continuing the request in the background. Cyclic available data (faults, moves,

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counters, running hours, etc.) from the LCMS systems have to be uploaded
automatically via the background process. If frequently accessed data need time to
generate, the RCMS should pre-generate these data in advance to guarantee
optimal performance at the RCMS clients.

It must be possible to automatically reload the LCMS from the RCMS. Reloading
will be manually triggered (starting with a standard installed Windows
configuration).

It must be possible to synchronise the configuration (fault message text, trace

forms, etc.) of the LCMS from the RCMS. The synchronising will support
uploading changes made on the equipment itself and distributing these changes
automatically to the other equipment.

Network traffic must be minimised. Unnecessary polling of data should be

avoided.

7.4.2 RCMS Clients

The RCMS clients are standard Microsoft Windows XP/Windows 7 PCs on which
no preinstalled software other than basic Windows components are available. In
case the RCMS clients need additional software/settings to be installed, these
must be done automatically. The user does not require administrator rights to
automatically install necessary RCMS client software components.

No additional licenses are required for RCMS clients.

All RCMS functions must be available via a dedicated Web-based user interface.
It must be possible to work in parallel on the RCMS clients without interfering
with other RCMS clients and/or without creating performance related problems
(locking, speed, etc.).

The RCMS clients must be able to load the on-line Web-based screens of the
individual LCMS systems. The RCMS clients must be able to take over full
desktop control of the LCMS.

The available functionality on the RCMS clients has to be controlled by a user

management system (preferably utilising Windows authentication). The user
management must support different combinations of users and available
functionality.

Distributed connections between the RCMS and LCMS should be recognised

automatically and reported to the RCMS clients.

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Distributed connections must never lead to data loss or data corruption. If a

distributed connection is re-established, configuration and history data must be
synchronised automatically.

PCs connected to the RCMS server will be furnished by the Purchaser.

7.4.3 Hardware

The RCMS system must be built up of a redundant database-server system to be

included in the Supplier’s scope. In normal operation the workload is allocated to
both servers. If one of the servers fails, the load is automatically shifted to the
remaining server. After recovering the faulty server, the configuration must be
automatically restored without noticeable downtime.

The system shall be backed up by a UPS with sufficient capacity for two hours
and a “smart” shutdown feature to ensure the correct procedures are followed to
turn off the servers to prevent data loss or software corruption.

The PC equipment is to be housed in (a) cubicle(s) utilising standard 19” Euro

format for rack-mounting of the components.

The following minimum components shall be provided:

• Microsoft Windows 2008 Server Systems
• Multiprocessor system with a minimum of 2 processors
• Minimum 4 GByte main memory
• 100/1000 MBit Ethernet interface
• RAID 5 disk unit with hot-spare (4 disks of minimum 500 GByte each)
• CD and DVD read/write drives
• USB Interface
• 17” LCD monitor
• Network colour laser printer for A4 and A3 paper sizes (minimum 15 pages
per minute)

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8. MAIN TECHNICAL AND DESIGN

REQUIREMENTS

8.1 General Safety Aspects

Unless otherwise specified, the mechanical design shall consider all relevant
safety aspects of DIN EN regulations regarding “Safety of Machinery”, including
but not limited to:
• DIN EN ISO 12100 (former DIN EN 292)
• DIN EN ISO 14121
• DIN EN 14492-2
• DIN EN 349
• DIN EN 13857-1(former DIN EN 294)
• DIN EN 614
• ISO 13849-1 (former DIN EN 954-1)
• DIN EN 12077

8.2 Main Frame Construction

The main frame shall be an all-welded, rigid-frame, lattice or box-girder type

construction, utilising the latest design techniques to provide an attractive
structure with a minimum of maintenance. Back-to-back angles or channels or
lattice members shall be avoided. Closed type sections of square structural steel
tubing or steel pipe shall be used wherever possible. The design shall avoid
pockets where water may collect. Bolted special joints or bolted connections of
box type or other closed connections where water seepage may occur shall be
equipped with steel pipe coupling drains.

All members, except the ones that have provisions for access to the inside for
periodic inspection, shall be made air-tight by seal welding to prevent
condensation and internal corrosion. Sealed members shall be pressure-tested.
Members filled with ballast (e.g. earthquake counterweight) shall not be sealed.
Stresses resulting from a temperature change of 22 °C of the entrapped air shall
not exceed 10% of the allowable stresses.

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Manhole with gasket covers shall be provided at the end of the members (beyond
the sealed sections), as required, for structural joints and electrical connection
checks and maintenance.

Field connection shall be made with high-strength bolts or by field welding.

All members shall be amply proportioned to provide a rigid structure. Maximum

deflections for operating conditions shall be included in the calculations submitted
to the Purchaser and shall be subject to approval.

The crane shall be designed in a way that the trolley runway is approximately
level (theoretical “zero” position) when the trolley travels without load from the
backreach to the outreach maximum position. The maximum static deflection of
the boom/girder caused by a trolley with full rated load shall not exceed from the
theoretical “zero” position:
• Waterside boom 80 mm
• Landside girder 40 mm

While handling rated loads at rated speeds at the maximum outreach/backreach

positions, horizontal displacement of the gantry structure and the boom/girder at
the boom/girder level due to the acceleration/deceleration of gantry or trolley shall
be limited to the following values:
• In gantry direction (parallel to the quay)
- At the max. outreach position ± 100 mm
- At cross beam position ± 40 mm
• In trolley direction (perpendicular to the quay)
- At any position ± 15 mm

Excessive vibrations of the crane or vibrations harmful to the crane shall be

avoided. If required by the Purchaser, the Supplier shall submit detailed
calculations that will demonstrate that the design of the trolley travel system and
the gantry structure will result in a natural frequency of minimum 0.7 Hz in the
trolley travel direction.

Special attention shall also be given to design requirements of ISO 12944 and
ISO 8501 through 8504 to allow adequate protective coating.

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8.3 Boom Construction

The boom shall be of rectangular single-box, mono-beam lattice type or double

girder construction. A trapezoid form is not acceptable.

The boom design shall provide the greatest possible strength to weight ratio. The
boom shall be hinged at the heel end. A wire-rope boom hoisting system shall be
provided, connected to the waterside end, for raising the boom structure into a
stowed position so that no part of the crane will interfere with the ship's structures.
In the stowed position, the boom shall be suspended by the ropes. For
maintenance and in case of storm the boom shall be secured by latching pins with
interlocks. Rubber buffers shall be provided to cushion the entry of the boom in
stowed position.

The trolley runway at the boom/girder shall be cambered so that the trolley path is
approximately level when the trolley travels from the backreach to the outreach
maximum position. The Supplier shall submit the camber calculations for review
by the Purchaser. Specified maximum deflection values shall be observed.

The boom hinges shall be easily accessible for maintenance and lubrication. The
easily removable boom hinge pins shall be mounted in self-aligning anti-friction
bearings or self-lubricated bronze bush. Removal of pins, bearings or bushes shall
be possible without any interference with trolley rails or other devices.

In the lowered load-handling position, the boom shall be supported by forestays,

and hinges shall have provisions for self-locking the boom into the crane structure
at the heel end to relieve the load on bearings and hinges during operation.
Forestays shall be structural shapes with link hinges. The boom wire ropes shall
not interfere with the forestay hinges. Wire rope forestays are not acceptable.

Buffer stops shall be provided at the end of the track on the waterside and
landside of the boom and on the trolley corners. An additional buffer arrangement
shall be provided to stop the trolley at the waterside end of the girder when the
trolley is in operation and the boom is raised.

Control for raising and lowering of the boom shall be done by the crane operator
from inside the operator’s cabin or optionally from the boom-hoist cabin, as
approved by the Purchaser.

A sign (60 x 60 cm) marked “Boom end” shall be visibly installed for the operator
at the end of the boom.

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8.4 Trolley

The trolley shall consist of a structural steel frame carried by four double-flanged
wheels riding on rails mounted to the crane’s boom. The trolley drive system is to
be rope-driven.

Four (4) hydraulic buffers, one on each corner, shall be installed.

The trolley shall be fleet-through type. Hoist ropes shall be running continuously
from the hoist drums through the trolley, system, and back to the drums. Hoist
sheaves located on the trolley shall provide a symmetrical reeving geometry.
Sheaves shall be mounted to minimise sway and ensure a maximum fleet angle of
3 °.

The trolley shall be completely decked with industrial gratings and shall be
enclosed with hand railing with kick plates. All openings shall be fitted with
continuous kick plates at least 100 mm high. All parts shall be safely accessible
for maintenance and replacement and arranged so that the machinery house
service crane shall reach and hoist all wheels and sheaves through floor openings
in the machinery house deck.

The trolley frame shall be equipped with integral jacking devices to support the
trolley at any point of its travel during wheel replacement. Wheel/axle and sheave
mountings shall be such that wheel/axle assemblies and sheaves are removable
vertically upward. Drop blocks shall be provided to support the trolley in case of a
broken axle.

Suitable anti-derailment/lift-off devices and interlocked storm/locking pins to

prevent movement of the trolley during maintenance operations shall be fitted. If
fitted, the adjustable side-rollers have to be easily removable and fall-down
protected. The design needs the approval by the Purchaser.

A trolley lock-out button shall be provided at any access to the trolley platform.

Trolley wheels and rails shall be sized and aligned in accordance with FEM.
Trolley wheels shall be double flanged. A dry lubrication system shall be
provided to minimise wheels' wear and tear.

Adequate UHMW rollers and slap blocks shall be installed for hoist and catenary
ropes.

The trolley shall be equipped with position transducers including synchronisation.

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8.5 Catenary Trolleys

If deemed necessary by the Supplier one catenary trolley shall run on the trolley
rails and support the hoist and trolley ropes. The catenary trolleys shall be
connected to the trolley via galvanised steel ropes including rope tensioners. The
wheel base shall be amply designed to avoid trolley skewing. The wheels shall be
double flanged of minimum 250 mm diameter and shall be easily removable. Four
side rollers shall be provided on each side. Lift-off protection, jacking pads and
drop blocks shall be installed. The UV resistant rubber buffers shall leave
minimum 150 mm free space when the main trolley hydraulic buffers are
compressed.

Adequate UHMW rollers, slap blocks and cages shall be installed for hoist, trolley
and catenary ropes.

8.6 Gantry

Each corner of the crane shall be supported by articulated gantry truck assemblies
designed to distribute the corner loads equally to all wheels under all conditions as
specified.

The equalisers and bogies shall be of heavy-steel-plate boxed construction with a

ground clearance of minimum 50 mm. Gear guards shall protect the gantry against
collisions with trucks or other obstacles at ground level. The gear and motor
protection frame shall be easily removable for maintenance.

Bogie pins and equalizer pins shall have 50 point HB hardness greater than their
housings. All pins shall be easily removable and independently greased through
annular grooves.

The motors can be mounted vertically (V1) or horizontally (B3). Protrusion into
the vehicle lanes shall be kept to a minimum. Each motor shall drive one wheel
through special gearing, to provide ample traction under the most adverse
operating conditions. All wheel bearing axle assemblies shall be identical. A
minimum of eight wheels per corner shall be provided to run on double rails. 50%
of the wheels shall be individually and directly driven.

Provisions shall be made for the drive wheels to be disengaged from the gearing
to allow the crane to be moved when its motors are out of service, preferably by a
flat flange connection. Gantry travel shall be possible if one motor fails.

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Adequate braking arrangement shall be provided to the motors, the motors being
properly interconnected to ensure that the driving load is shared equally.

The bogies shall be fitted with drop blocks and rail sweepers. It must be possible
to disassemble any wheel without disassembling the whole bogie.

The gantry shall be equipped with hydraulic buffers, arranged to contact the crane
rail end stoppers or adjacent crane buffers

Bogies (and equalizers, if applicable) shall be arranged to allow removal without

elevating the gantry legs. Suitable jack-up points, lifting beam and portable
hydraulic jacks to allow one complete bogie to be removed for repair or
maintenance shall be provided under the Contract.

The gantry shall be furnished with

• Storm anchors
• Push-down type rail brakes
• Limit switches for anti-collision
• Personnel deflecting guards to be installed near the hydraulic buffers

The crane shall be designed to push another crane at reduced speed along the rail
in case of a power failure.

8.7 Hopper

The crane shall be equipped with one (1) hopper suitable to store the quantity of
bulk material as specified. The hopper shall be designed for a maximum opening
for the grab discharge. The inclination of the walls shall be equal or larger than
60°. The hopper shall be mounted in the crane’s WS portal and shall have a
hydraulically operated trap door. The interlocked trap door shall be closed and
opened from the operator’s cabin.

The plate thickness of the hopper shall be strong enough to prevent damages by
dropping a fully loaded grab from maximum lifting height into the empty hopper.
The scales, outlets and the areas inside the hopper around the outlet shall be
reinforced by high tensile reinforced steel plates which are bolted from the
outside.

It must be possible to safely clean each outlet from the outside.

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Technical Specifications for two 38 t Ship Unloader Cranes 70

The hopper shall be equipped with a dumping grid of flat and round iron onto
which the grab could be parked for maintenance. Walkways and access shall be
provided for maintenance and inspection.

Protection steel plates against spillage shall be mounted on top of the hopper on
the crane’s rear side as well as on the left and right side. The rear side protection
steel plate shall be easily removable for grab maintenance purposes.

From the sea the hopper shall be equipped with a spillage plate which prevents the
coal from falling in the space between the vessel and the hopper.

A hopper gate for control of material flow shall be provided at the outlet of the
hopper. The gate shall be operated by a hydraulic cylinder or mechanical driven
spindle. The gate shall be controlled from the operator’s cabin.

8.7.1 Vibrators

The hopper shall be equipped with vibrators for continuous material flow. The
vibrators shall be thoroughly dimensioned, considering the extraction rate for the
hopper which shall be controlled from the operator’s cabin.

8.7.2 Weighing System-Material Flow

The hopper shall be mounted on load cells. The load cells shall be used to avoid
overloading of the hopper. Load cells of bunker shall be provided with contacts
for approx. 20%, 75% and 100%. If the total hopper capacity is reached the grab
shall not be allowed to open.

8.7.3 Water Spray System for Hopper

A water spray system shall be supplied as dust suppression for the hopper. It
consists of water tank, galvanised pipes and spray nozzles. The water tank shall be
installed beside the hopper; Volume minimum 6 m³. Filling will be done by a tank
lorry.

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8.7.4 Belt Feeder

The material shall be transferred from the hopper to the ground conveyors
(BC01A+B) in the backreach area at a controlled rate by using a belt feeder. The
belt feeder system shall be located below the hopper. The hopper load
measurement shall be used to control the belt feeder. The belt feeder only starts
after starting the ground conveyor and the conveyor’s stop must immediately stop
the belt feeder. The belt feeder shall not interfere with the clearance area within
the portal for lifting the shovel loader. The belt design should be based on DIB
22102 and 22131. The ground conveyor has a width of 1,400 mm and a speed of
3.0 m/s.

8.7.5 Spillage Flaps

These flaps shall be provided on the hopper front (waterside leg) to prevent
material spilling from the grab down onto the quay apron. These flaps shall be
arranged to be operated from the operator’s cab via rope system.

8.8 Main Drives

With regard to vibration of motors, gear reducers and rotating equipment, the
design and installation of main drives shall be in line with the applicable parts of
ISO 7919, ISO 10816 and IEC 60034-31.

8.8.1 Hoist/Grab System

The grab hoist and grab open/close systems shall be located in the machinery
house, each one based on a single rigid foundation. The hoisting and open/close
motions shall be driven by electric motors via flexible couplings through totally
enclosed gears coupled to the respective drum. One fail-safe disk brake mounted
directly on each of the high speed shafts of the reducers shall bring the load to rest
from full speed without undue shock within the specified distance.

The idler end of each drum shall be fitted with high-tensile shafts and run on
heavy-duty self-alignment roller bearings enclosed in fabricated steel. The drive
end of the drums shall be connected directly to the low speed shaft of the reducer
via a drum coupling. In total four ropes, double-reeved, shall be used for carrying
loads and open/close the grab. The length of the spiral grooved portion of the
drums shall be sufficient to accommodate the complete hoist rope in a single layer
with three additional dead turns and two free grooves.

Each drum shall be equipped with a cam-limit switch.

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Technical Specifications for two 38 t Ship Unloader Cranes 72

8.8.2 Trolley Travel System

The trolley shall be rope-driven.

The drive system shall be mounted in the machinery house based on a single rigid
foundation. The trolley forward and reverse motions shall be driven by an electric
motor via a flexible coupling through a totally enclosed gear coupled to a trolley
rope drum. One fail-safe disk brake mounted directly on the high speed shaft of
the reducer shall bring the trolley to rest from full speed without undue shock
within the specified distance.

The idle end of the drum shall be fitted with a high-tensile shaft and run on heavy-
duty self-alignment roller bearings enclosed in fabricated steel. The drive end of
the drums shall be connected directly to the low-speed shaft of the reducer via a
drum coupling.

Gearing, couplings and shafting shall be designed for reversing loads.

In total two ropes, double-reeved, shall be used for towing the trolley. The rope
reeving system shall be fleet through type with sheaves on the trolley.

The length of the spiral grooved portion of the drum shall be sufficient to
accommodate the complete trolley ropes in a single layer with two additional dead
turns and one free groove.

If deemed necessary by the Supplier an automatic trolley rope tensioning system

shall be provided.

Trolley wheels, axles and sheaves shall be accessible for removal.

Buffer stops shall be provided at the end of the track on the waterside and
landside of the boom and on the trolley corners. An additional buffer arrangement
shall be provided to stop the trolley at the waterside end of the girder when the
trolley is in operation and the boom is raised.

Position transducers including synchronisation shall be provided.

8.8.3 Gantry Travel System

Minimum 50% of the wheels at each corner shall be individually and directly
driven and operationally braked by drum brakes.

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Technical Specifications for two 38 t Ship Unloader Cranes 73

The drive of each wheel shall consist of an AC electric motor, a flexible coupling,
a drum brake driving through an enclosed oil-lubricated helical reducer which is
flat flanged to the wheel. Location of the motors and gearboxes shall be as
indicated in Chapter 4.1.

The motors shall be properly interconnected to ensure that the driving load is
shared equally and skewing is eliminated. Gantry travel shall be possible if one
motor or one inverter fails. The gantry drive system shall be designed to allow
pushing another crane at reduced speed in case of power failure.

8.8.4 Boom Hoist System

The boom hoist drive shall be a single complete unit on a rigid foundation in the
machinery house.

The boom hoisting motion shall be driven by an electric motor via a flexible
coupling through a totally enclosed gear to the hoist drum. One fail-safe disk
brake mounted directly on the high speed shaft of the reducer shall hold the load.

The boom shall be raised and lowered by the boom hoist machinery, located in the
machinery house, through two independent sets of wire rope and reeving, either
one of which shall be adequate to safely raise or lower the boom. The ropes for
the boom hoist shall lead from the single layer drum to the gantry frame top, then
to a multi-part reeve-up between the boom and the gantry frame top. The dead
ends of the reeve-up shall be independent but equalised and shall be safely
accessible for inspection at the cross girder or M&R platform of the upper
forestay hinges. All parts of the reeving system shall be designed to withstand
motor stall and maximum brake torque without exceeding 75% of the yield of the
material used.

Provision shall be made to prevent rope being paid off the boom hoist drum
without proportionate lowering of the boom (slack rope protection).

In stowed position the boom shall be suspended by the ropes. For maintenance
and storms the boom shall be secured by latching pins with interlocks. Rubber
buffers shall be provided to cushion the entry of the boom into the A-frame
structure. Control for raising and lowering of the boom shall be done by the crane
operator from inside the operator’s cabin.

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Technical Specifications for two 38 t Ship Unloader Cranes 74

The brake system shall consist of two independent brake systems, one service
brake and one emergency brake system. The service brake shall be located
between high speed coupling and the gear reduction unit. The emergency brake is
installed at the non-driven end of the rope drum.

Over-speeding shall be controlled by an over-speed switch and an encoder

connected to the boom hoist drum, set to engage the emergency brake at 110%
rated speed.

8.9 Emergency Drives

An auxiliary emergency drive systems operating at the voltages defined in

Chapter 5.5 are to be provided for:
• Hoist/grab
• Boom hoist
• Trolley travel

Main hoist and boom hoist emergency drive system shall consist of individual
electrical motors, couplings, gear reducers and local control stations. The hoist
emergency drive shall be chain-driven; the boom hoist emergency drive shall be
connected to the boom hoist gear box by a switch over coupling.

The emergency hoist system shall be permanently installed, preferably on top of

the main hoist gear boxes. The chain shall be stored in a metal box in the locker in
the machinery house.

The trolley emergency drive system shall consist either of an electrically driven
winch installed at the cross girder or of two emergency drives mounted on the
trolley drive gear boxes by means of a switch-over coupling.

Proper means to operate respective brake systems during emergency operation

shall be provided. Key selector switches and appropriate fail-safe limit switches to
be provided.

The power supply to operate the emergency drives, related safety functions and
brake systems shall be taken from the main crane power supply system, and in
case of power failure from a 125 A shore power supply or a neighbouring crane.

The Supplier shall submit with its bid a detailed description of the proposed
system.

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Technical Specifications for two 38 t Ship Unloader Cranes 75

The hoist/grab emergency drive shall be capable of lifting an empty grab from
minimum lifting height below crane rail to maximum lifting height above crane
rail in less than 10 minutes.

The boom hoist emergency drive shall be capable of raising the boom to
maximum position within maximum 60 minutes.

The trolley emergency drive shall be capable of moving the trolley with rated load
from the tip of the boom beyond the hinge point within 10 minutes. In addition the
system shall be capable to move the trolley into its parking position and
underneath the machinery house’s service crane.

8.10 Stairs, Ladders, Platforms, Walkways

Based on DIN EN 13586 the crane shall be provided with stairs, ladders,
platforms and walkways for safe and easy service, maintenance and inspection of
all components and structural flanges to which access is required. These platforms
shall not restrict crane operation. The top handrail shall be not less than 1,100 mm
above platform level, clearance to structure shall be at least 50 mm; provision of
kick plates and knee rungs shall be foreseen. The inner width of stairs and
platforms shall be minimum 600 mm. The angle of stairs mounted to the structure
shall not exceed 50 °.

Handrails shall be of tubular type. Handrails shall be continuous and pre-

fabricated sections shall not be connected by welded joints. Handrail ends shall be
sealed to avoid water ingress. Stanchions are to be of steel angles suitably sized to
provide rigid support to handrails. All stanchions are to be bolted to steel frame
structures but not attached to platform gratings.

All stairs treads, handrails, kick plates, stanchions and gratings shall be made of
hot-dipped galvanised steel. Stanchions, handrails, kick plates, platform and stair
supports, ladders, backrests, etc. shall be painted. Gratings and stair treads shall
not be painted. All stair treads on stairs shall be anti-slip type.

All screws, bolts, nuts, washers, pins, studs, springs, and other miscellaneous
fastenings and fittings shall be of stainless steel unless otherwise approved.

The operator's cab, machinery house, cable reel platform and other parts to be
serviced, maintained and supervised shall be safely accessible by means of stairs
and walkways.

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Technical Specifications for two 38 t Ship Unloader Cranes 76

Spiral stair cases are not allowed. Vertical ladders should be avoided, but - if
absolutely necessary as a result of space restrictions - may be accepted subject to
the Purchaser's approval. Ladders exceeding 6.0 m in length are not permitted
unless suitable rest platforms are provided. Ladder inside legs (if not sealed) may
be continuous if provisions for fall-arrest full-body harnesses are made. The pitch
between the ladders' rungs shall not exceed 300 mm, the rungs being at least
300 mm wide. Ladders shall be equipped with safety cages unless otherwise
approved by the Purchaser.

The access to the crane shall preferably be at the landside/landside of the crane.

The operator’s cabin access shall be via a platform mounted on the crane
structure. The access platform and the cabin platform shall be furnished with a
lockable gate. The gates shall have a toe-plate.

A walkway all around the machinery/electrical house shall be provided. The roof
shall be accessible by a ladder. Handrails along the perimeter of the roof shall be
provided.

Service platforms shall be provided, i.e. at the boom latching position on the top
of the A-frame, for the forestay joints in stowed position, for the festoon or power
chain, for the catenary trolleys and snag unit, at the leg/cross girder connections,
etc. Access to the top of the A-frame shall be by stairs.

The boom/girder shall have a walkway over the full length. In case of emergency
it must be possible to safely get off the trolley at any position of the boom or
girder. At the boom hinge point there shall be a boom access gate. A lock-out
selector switch shall be installed at the gate to impede boom hoisting while
activated.

A window washing platform shall be installed under the landside end of the
girder. Any access to the cabin shall be protected by a lockable gate with toe-
plate.

At all hazardous locations on walkways and platforms there shall be a lockable

self-closing type gate. Chains shall be avoided wherever possible.

Access hatches of horizontal members with a depth of more than 600 mm shall be
provided with internal ladders. Where an access hatch is positioned in a walkway,
suitable means shall be provided to ensure that the hatch is closed after use.

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Technical Specifications for two 38 t Ship Unloader Cranes 77

8.11 Crane Operator's Cabin

The operator's cabin shall be able to travel separately on the left side of the boom
providing full visibility of all operations. The cabin shall not be hit by a swinging
grab nor travel beyond the hinge point if the boom is raised. It shall be possible
for the operator to leave the cabin at any position of the cabin.

The cabin framing shall be securely (fall-down protected, earth-quake proof)

fastened to the leg by means of high-strength structural fasteners. Particular
attention shall be given to isolate the cabin from shocks and vibration.

The cabin shall be of double-walled steel construction designed to minimise heat

gain and dust ingress. The cabin shall be weatherproof under all weather
conditions, fire resistant and insulated to restrict noise level to 72 dBA or less at
the operator's position. The space between the double-floor plates shall be used
for electrical wiring. The upper floor plate shall be vinyl-covered and bolted to
provide access to the electric wiring.

The cabin door shall be of galvanised metal weatherproof marine hinged type and
shall be equipped with suitable means for exterior locking and a door stopper
preventing swinging of the door due to wind gusts. The door shall have a safety
glass in the upper section and have a minimum height of 2.20 m. A drip shield
shall be installed over the windows and the door.

If floor windows are provided they shall be hinged and fitted with safety bars such
that, if the windows are removed or opened, the safety bars remain in position to
prevent the operator from falling through an open window. These windows shall
be from minimum 12 mm clear safety glass. Upper windows of tinted safety glass
shall be provided to give the complete view of all operations. Lotus glass for all
windows is preferred. Upper windows shall also be of hinged type and shall have
adjustable sun blinds.

All cabin windows shall be designed in a way that will allow the operator easy
access for cleaning. Electrically operated parallel wind shield wipers with washers
shall be provided for lower front and side operator cabin windows. It shall be
possible to change or remove the motors and nozzles from the inside of the cabin.
The water reservoir shall be easily accessible for refilling.

A combined air-condition/heater unit of industrial type should be provided. The

heating elements must be easily exchangeable. A separate heater may also be
installed. In addition, a window demisting system shall be provided.

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Technical Specifications for two 38 t Ship Unloader Cranes 78

The interior trim shall be accomplished by using modern decor material,

incombustible and not giving off noxious or toxic fumes in case of fire. Interior
trim shall be easy to clean.

An upholstered, fully-adjustable spring or air-cushioned chair with weight

adjustment shall be provided with comfortable access to all control and devices
and maximum view. The seat/control unit shall have a swivel base of at least
120 degrees to each side. The two compartment-type consoles shall be provided
with horizontal and vertical movements. One collapsible wall-mounted cushioned
chair for an instructor/ second driver shall be provided at a suitable location. The
seat covers shall be made of fabric.

With the exception of the hopper outlet trap doors all operations of the crane shall
be controlled from the operator's cab.

All controls shall be readily accessible to the operator when seated and oriented in
a way that the crane will respond in the direction that the operator moves them.
All controls and indicating devices shall be labelled. The PLC monitor, if
installed, shall not be affected by sunlight.

Activation of controls shall be of the digital joystick type and automatically

position into “0”. The joysticks shall have pushbuttons on top to open and close
the grab.

Provisions shall be made for installation of a communications radio adjacent to

the driver's control together with telephone, microphone and loudspeakers.

Seats, operating and control equipment shall be constructed according to the latest
developments in ergonomics and suitable for a permanently-manned working
position.

Complete operating instructions for the proper use of the crane shall be provided
in the cab.

A cupboard for storage of items such as coats, lunch buckets, portable water
cooler and other items shall be provided. A beverage cup holder shall be mounted
to the right side console of the operator’s chair.

The Supplier shall submit with its Bid a layout of the crane operator’s cabin and
consoles including proposed locations of all control systems for approval.

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Technical Specifications for two 38 t Ship Unloader Cranes 79

8.12 Machinery House

A water- and dust-tight machinery house shall be provided with design and
dimensions of ample size to adequately accommodate all items of mechanical
equipment including the transformer and the maintenance service crane under
overload condition. Safe access and working space around all machinery
equipment must be provided according to o IEC with a minimum clear walk space
of 600 mm. Machinery House shall be located on the LS/WS area, to allow lifting
of shovel loader inside the portal.

The structure shall consist of steel-frames and an inclined roof. The walls shall
consist of min. 1.5 mm thick galvanised and painted corrugated steel plates with
insulated cladding. The floor is made of chequered plates on steel supporting
members, positively fixed to the crane's superstructure to prevent vibration.
Insulated cladding shall be double-skin sandwich type with a maximum U-value
of 0.5 W/m²K for machinery house walls and roofs of approximately 50 mm
thickness. The roof shall have sufficient slope to avoid standing water. Gutters
with downspouts shall be installed over walkways around the machinery house.

At least two lockable access doors of the panic type design with windows (safety
glass) shall be furnished. Doors shall be provided with automatic door closures
and latching devices to hold the doors open if desired. The doors shall be of
galvanised metal weatherproof hinged type and shall have a door height of
minimum 2.00 m. Sliding doors are not acceptable. Drip shields shall be installed
above doors and openings in the wall.

A sliding access hatch shall be provided in the floor to allow for removal and
lowering of the largest piece of equipment. Additional hatches shall be provided
to reach the heavy components on the trolley and lower the grab to ground level.
Hatches shall be secured by kickboards and removable handrails. The stanchion
sockets and other items shall be of no tripping hazards.

The machinery room shall be provided with necessary maintenance equipment

such as maintenance service crane, rope re-reeving blocks, work bench fitted with
vice and a locker for storing tools. The workbench shall be at least 2 m long and
1 m wide. The vice shall be mounted on one side and a bench-mounted at least
14 mm vertical drilling machine on the other side. Adjacent to the bench, space
shall be provided for a grinding machine and portable arc welding apparatus.
Electrical outlets will be provided for each one of them. An industrial basket type,
X-ray compatible stretcher shall be mounted inside at the machinery house wall
next to the nearest entrance door of the crane access stairs.

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Drilling and grinding machines and welding apparatus will be furnished by the
Supplier. One mobile electrical air compressor shall be provided with minimum
10 bar, 200 l/min suction capacity and a reservoir of at least 10 litres. The mobile
air compressor shall have a hose of minimum 10 m length.

Guides with openings as small as practical shall be provided for protection of

ropes where they pass through openings in the machinery room walls. Penetration
through the roof is not allowed. Openings shall be shrouded with heavy-duty
rubberised fabric to reduce water and dust penetration to a minimum. The design
shall also prevent birds from entering the machinery house.

Permanent ladders and a maintenance platform for the machinery hoist service
crane shall be provided.

The machinery house shall be adequately ventilated with positive pressure to

prevent undue temperature rise under working conditions. Such ventilation
arrangements shall be duplicated and sited in the most advantageous position for
good ventilation with air ingress vents protected against entry of sand and dust by
filters. The stainless steel filters are to be easily removable from inside the house
for cleaning purposes.

The machinery house’s ventilating system shall operate continuously during crane
operation and if required, by thermostat, at other times. The fan(s) shall have
sufficient capacity to prevent heat build-up which may be damaging to any
component. Temperature in the machinery house must not exceed the specified
maximum ambient temperature by more than 5 °C when measured 1.5 m above
floor level. As a minimum, it shall have the capacity to change the total volume of
air in the machinery house in 10 minutes.

All cable conduit pipes laid on the machinery house floor are to be grouped
together and covered with removable chequered steel plates so that there is no
hindrance or hazard to personnel movement within the machinery house.

The machinery shall have drain holes with plugs for cleaning purposes and to
avoid any standing water.

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8.13 Electrical House and PLC Room

The crane shall be equipped with a separate electrical house with an integrated
PLC room of sufficient size to contain all required electrical/electronic control
cabinets and motor control centres. These rooms shall meet the structural design
criteria of the crane and may be integrated inside the machinery house. The rooms
shall be dampened, air conditioned and dehumidified.

The electrical house shall be framed with structural steel, thoroughly braced to
withstand all stresses produced by operating machinery. The sides of the control
room shall be covered with galvanised and painted corrugated sheet
steel/cladding. The room shall be adequately insulated to prevent undue
temperature rise under working conditions. Insulated cladding shall be double-
skin sandwich type with a maximum U-value of 0.5 W/m²K for E-house walls and
roofs of approximately 50 mm thickness. Interior insulation shall be protected by
damage-resistant covering. Insulation shall be provided directly under the
electrical house floor.

The room should be equipped with minimum three lockable doors. One door shall
lead to the machinery house and two doors shall lead to the outside on opposite
sides. Windows shall be integrated into the wall/doors to monitor the machinery
house and the PLC room, if separate.

Doors shall be of weatherproof galvanised self-closing hinged type design of

2.20 m height and sufficient size to remove cubicles. Sliding doors are not
acceptable. Drip shields shall be provided over the doors. Automatic closer and
latch to hold the door in the open position shall be provided. Drainage (with
plugs) shall be provided to prevent collection of standing water.

The room will be made as air-tight as practical, with joints, conduit, pipe or other
attachments which pierce the insulation, being sealed at the point of entry after
installation.

The PLC room shall be provided with necessary maintenance equipment such as
desk and chair, PCs, etc., lockable cabinets, adequately sized for a complete set of
documentation, test instruments and gauges as deemed necessary by the Supplier.
Space shall also be provided so that drawings and manuals can be stored and
referenced without placing them on the floor.

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Technical Specifications for two 38 t Ship Unloader Cranes 82

Flooring shall be removable and covered with 6 mm thick black rubber anti-static
matting with non-skid walking surface. Matting shall be suitable for use at
switchboards, with a resistance of the specified crane’s main power supply
voltage. The space below the flooring shall be sufficient for cabling installed in
different layers according to different types of utilisation (power, control,
communication, etc.).

Provisions shall be made within the electrical room such that any piece of
electrical equipment can be easily removed to ground level. The ceiling of the E-
house shall be provided with running beams or lugs at appropriate locations so
that heavy electrical components can easily be dismantled from the cubicles by
the means of a chain hoist.

The Supplier shall provide for the safety of personnel ample space and/or safety
devices around electrical equipment. Clear walk space around controllers and
other electrical equipment shall be in accordance with IEC. The minimum width
for escape routes, with cubicle doors open, shall be considered. Doors shall have
their hinges arranged in such a way that they close in the direction of the escape
route. The last and first cubicle door shall open to the wall but not interfere with
the escape route to the panic doors.

The E-house and PLC room shall be equipped with smoke detectors.

The specified noise levels (see also Chapter 3.6) shall not be exceeded under any
conditions inside the electrical house and PLC room with doors closed. The layout
shall be as follows:
• The PLC, CMS and work table shall be installed in a separated noise-reduced,
air-conditioned area with one panic-type door leading outside.
• Noisy equipment such as inverter with high cooling fans shall be installed in
an air-conditioned section.
• Access between the two rooms shall be by a glass-panelled panic–type hinged
door of sufficient size to allow for changing of equipment or cubicles.

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Technical Specifications for two 38 t Ship Unloader Cranes 83

9. MECHANICAL COMPONENTS

9.1 Maintainability

To reduce maintenance down time and cost, maintainability factors should be

introduced into the crane design whenever practical.

Restricted accessibility of modules, assemblies and other items largely contributes

to the extension of repair time. The configuration of the hardware and its layout in
the crane shall make sure that free and easy access be provided to maintenance
personnel, tools and equipment required to perform the repair task.

All parts shall be designed in a way that easy assembly, adjustment, removal for
replacement and accessibility for lubrication, inspection and maintenance is
achieved. Major machinery shall be provided with lifting lugs.

9.2 Wire Ropes

The Supplier shall furnish all wire ropes complete with fittings.

Rope, sheave diameter and drum diameters shall be selected according to

DIN 15020 and FEM. The safety factor for wire ropes shall be six (6) excluding
eccentric load.

The type, construction and lay of the wire ropes shall be: IWRC 6 x 36 =
216 wires with metallic core (EN 12385-4 or equivalent international standard),
with wire breaking strength of 1770 N/mm². The boom hoist rope of the same
design shall be galvanised and can be accepted with wire breaking strength of
1960 N/mm².

All wire ropes shall be treated with the lubricant approved by the Purchaser at the
point of manufacture. The wire ropes shall also be re-lubricated in the field prior
to being placed in service. The Supplier shall furnish the Purchaser one copy of
the test certificate for each wire rope on the crane prior to the time the crane is to
be certified.

Catenary ropes shall be galvanised and be fitted with wire rope clamps according
to DIN EN 13411-5 and thimbles. Boom hoist ropes shall be fitted with cast rope
sockets similar to DIN 83313. Respective reduction of breaking strengths shall be
considered. All rope fittings shall be galvanised.

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Technical Specifications for two 38 t Ship Unloader Cranes 84

Special attention shall be given to the hoist wire rope reeving to prevent ropes
from snagging or contacting structural steel, electrical components or cabling.
Where necessary, replaceable slap blocks or rollers made of UHMW or other
suitable material with life-time lubricated and sealed anti-friction bearings shall be
provided to prevent damage to wire rope which would otherwise contact the steel
structure during operations.

9.3 Sheaves

Sheaves shall be selected according to FEM, DIN 15020, DIN°15062 and 15063.
Running sheaves shall have a minimum pitch diameter of 30 times the rope
diameters for the main hoist and catenary trolley drive and 24 times the rope
diameters for the boom drive. Auxiliary/equalizer sheaves shall have a minimum
pitch diameter of 16 times the rope diameters.

Sheaves shall be of steel and be provided with steel guards of at least 12 mm thick
steel plates to prevent the ropes from jumping out of the grooves. The grooves
shall be hardened. Hardness at a depth of 3 mm shall be minimum 340 HB.
Bearings shall be of special cylindrical roller bearing type. Sheave blocks shall be
designed to be lowered to ground level in one piece without previous
disassembling of sheaves. Installed sheaves within the same system shall be
interchangeable.

Tolerances shall be indicated and gauges provided to indicate worn-out sheaves.

In addition, the Supplier shall recommend repair/replacement methods and
periods to ensure safe operation.

The arrangement of the drums and sheaves shall be such that the fleet angle of the
rope shall not exceed 3 degrees.

Supporting grooved rollers shall be of UHMW or similar material, have sealed

roller bearings and rope guards. The roller diameter shall be minimum 200 mm.

9.4 Drums

Wire rope drums shall be selected according to FEM and DIN 15020, DIN 15061
and 15062. The pitch diameter shall not be less than 30 times the rope diameters.

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Single-layer rope drums shall be of high-grade cast or welded rolled steel with
machined grooves. The grooves shall be smooth and well-rounded. Three (3) full
wraps shall remain on the drum when the rope is paid out under normal conditions
and two (2) empty grooves shall remain on the drum when the rope is fully
retracted. After machining the grooves, the wall thickness shall be measured
ultrasonically to prove the minimum required thickness. The results shall be
recorded. The drum flanges shall by at least 120 mm higher than the diameter of
the drum.

All hoist wire rope drums shall be driven directly from the low-speed shaft of the
respective reducer.

Drums shall be mounted on shafts utilising anti-friction type bearings to assure

shaft alignment and minimise vibration.

Drums shall be stress-relieved before machining and shall be statically balanced

with installed emergency brake disks and rope clamps.

Rope anchorage shall be of approved design and shall avoid the necessity for
splicing rope ends after the ropes have been reeved onto the crane.

The arrangement of the drums and sheaves shall be such that the fleet angle of the
rope shall not exceed 3 degrees.

Drip trays with handles shall be provided under each drum. Suitable splash
protection shall be installed in front of the drums.

9.5 Gear Reducers

Gear reducers shall be designed and rated in accordance with FEM and DIN 3990
or ISO 6336, but with a minimum service factor of 1.5 for trolley and gantry and
1.75 for hoist.

Manufactured gear reducers for the hoist/grab, boom hoist, trolley, gantry and
cable reel drives shall be selected by multiplying the nameplate kW rating of the
designed driving motor by this service factor in order to obtain the equivalent
nominal mechanical rating which shall be used as the basis for selecting the
respective gear reducer from the manufacturer's rating tables.

The thermal ratings of the gear reducers shall not be exceeded during continuous
duty-cycle operations at the maximum specified ambient temperature.

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The high-speed stage of the reducers shall be of helical or herring-bone gears. The
other stages can be either helical or spur gears. All gears shall be either through-
hardened or carburized and hardened. Minimum safety factor for bending stress
for all stages shall be 1.4. The safety factor for contact pressure for all stages shall
be higher or equal to 1.0.

The reducers shall be entirely self-contained in an oil-tight welded steel or cast

iron housing. Bearing shall be of anti-friction type. Heavy duty double oil-seal
rings shall be installed. The hoist/grab reducer shall preferably have contactless
seals.

All gear housing shall be provided with suitable means to gauge the oil-level and
an outlet drain cock for oil particle sampling. The drain cock shall be furnished
with a lever and a screw-on cover lid.

Each reducer shall be provided with a permanently attached name plate containing
the following information: the name of the manufacturer, the reduction ratio, the
rated mechanical and thermal capacity, the rated speed and the service rating or
service class.

All gear boxes shall be horizontally mounted except for gantry drive. Lifting lugs
shall be provided on upper and lower section.

9.6 Bearings and Seal Rings

All rotating bearings on the crane shall be of the anti-friction type in metric sizes
and manufactured by manufacturers approved by the Purchaser.

The bearing life shall be as requested by the related classification. For the main
hoist sheave bearing life, the maximum rotating speed of the main hoist and
trolley operation shall be considered.

The tabulated static capacity of the bearings shall not exceed 70% under any
operating conditions.

Bronze sleeve bearings, if approved by the Purchaser for use in certain locations,
shall be designed on a conservative basis after determination of the PV-factor
(unit pressure times surface velocity) and proper consideration of the operating
conditions.

All bearing stands shall be of fabricated steel machined as required and securely
mounted on base by means of bolts and dowels if applicable.

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Adequate shim allowance shall be provided between all bearing stands and
structural bases to permit initial alignment and subsequent realignments if
required.

Bearings and housings shall be sealed by caps or spring-loaded lip-garter type

seals and, except for reducer bearings, provided with pressure grease lubrication.
Bearing seals shall be one of the more commonly used metric sizes.

Bearing housings shall have removable caps to facilitate periodic inspection of the
shafts by non-destructive methods. Closed end cartridges shall not be used.

All bearings used throughout the crane shall be standardised as far as possible. All
gantry wheel bearings shall be identical.

9.7 Brakes

9.7.1 General Aspects

Design of brakes shall generally conform to DIN 15431 through 15436.

High speed service brakes shall be of the spring set, thruster operated shoe or disk
type.

Emergency brakes shall be spring set, hydraulically released calliper brakes

operating directly on the rope drums.

Brakes shall be fitted with non-combustible asbestos-free linings not adversely

affected by moisture. High speed service brakes shall have automatic wear
compensation and sintered pads. All brakes shall be equipped with external hand
release. Interlocks to shut down operation of the respective drives unless all
brakes are released within a preset time shall be provided.

Brakes for motors exposed to the weather shall be enclosed in corrosion resistant
housings with easily removable access cover for adjustment and repair. Brake
covers shall be light so that they can be removed by one single person. All brakes
shall be easily accessible, maintainable and replaceable.

Signals identifying the status of each brake (released, engaged) shall be sent to the
PLC.

The OEM (Original Equipment Manufacturer) of the brakes shall submit thermal
capacity calculation, brake deceleration calculation and calibration certificate for
spring set brakes.

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9.7.2 Service Brakes

Hoist/Grab Brake

Each hoist/grab motor shall have minimum one thruster-operated service disk
brake. Brake disks shall be mounted on the hoist/grab reducer high-speed shaft
between motor and reducer.

Each brake or set of brakes mounted on one side of the reducer shall be able to
stop and hold the rated load without motor assistance.

The entire set of all service brakes mounted on the hoist drive shall be of
sufficient dynamic and thermal capacity
• to stop and hold the rated load from the rated speeds within 1.5 m lifting
height with no regenerative or dynamic motor braking applied,
• to stop 125% rated load from 120% rated speed to zero without motor
assistance and with integral thermal protection,
• to hold 140% of SWL.

This capability shall be demonstrated during tests on completion.

The hoist/grab service brakes shall have a condition monitoring system similar to
VSR, Messrs. Bubenzer.

Boom Hoist Brake

The boom hoist motor shall have a thruster-operated service disk brake. The brake
disk shall be mounted on the boom hoist reducer high-speed shaft extension
between motor and reducer.

The boom hoist service brake shall stop the boom from rated speed within
2 seconds. However, the boom hoist brake shall be of sufficient dynamic and
thermal capacity to stop the boom from 120% rated speed to zero without motor
assistance.

Trolley Brake

The trolley motor shall have a thruster-operated drum or disk brake. The brake
shall stop the trolley under rated load from full speed in 3 seconds without
regenerative motor braking.

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Gantry Brake

Gantry brakes shall be thruster-operated drum, disc or motor-mounted brakes.

Gantry motor brakes shall be capable of stopping within 3 seconds and holding
the crane from full speed with maximum operating wind load without
regenerative motor braking or other gantry braking provided.

9.7.3 Boom Hoist Emergency Brakes

Spring set, hydraulically released calliper brake(s) shall be provided operating

directly on the drums.

Each emergency brake shall have an interlock in case the brake pads are below
safety thickness.

The springs shall be tested and certified, and the brake sets shall have a related
spring adjustment indicator.

The hydraulic unit for shall have individual lines to the boom hoist emergency
brakes. The hydraulic power pack shall be supplied from the brake supplier.

The set of boom hoist emergency brakes shall stop the boom from rated speed
within 2 seconds. However, the set of boom hoist emergency brakes shall be of
sufficient dynamic and thermal capacity to stop the boom from 120% rated speed
to zero without motor assistance.

9.7.4 Gantry Rail Brakes

The crane shall be equipped with automatic push-down type brakes.

With the assistance of the gantry drive motor brakes, the gantry rail brakes shall
be designed to hold the crane against winds of 30 m/s blowing from the most
adverse direction at any location on the runway.

The hydraulic power packs (one for each side) shall be supplied from the brake
supplier and enclosed with stainless steel housing.

The rail brakes shall engage after an adjustable time delay when the crane is not
gantrying or is de-energised/”control off”. Unless the wind speed is greater than
27 m/s, rail brakes shall be released when the crane is energised/”control on”
before gantry movement.

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9.8 Couplings and Coupling Guards

Couplings shall be flanged forged steel with exposed bolts, except for the rope
drum couplings, and be of the flexible type and shall transmit only torque. The
flexible coupling can be combined with an integrated brake drum according to
DIN 15435 and/or brake disk.

Calculations of couplings will be based on DIN 740 and the manufacturer

recommendation and shall be verified by published catalogue data. The service
factor will be calculated for:
• Crane operation
• Moderate shock load
• Over 16 hours of daily operation
• Over 160 starts per hour

The service factor shall take the required gear reducer service factor into
consideration.

Removable steel guards shall be installed over all couplings.

All couplings' nuts shall be secured to prevent their release due to vibration.

9.9 Shafts

All shafts shall be based on DIN 743 and fabricated from high-grade steel and
shall be adequately sized for the wheels, drums, bearings and/or gears. Complete
data covering the physical and chemical properties and heat treatment of the
material proposed shall be shown on the drawings.

9.10 Trolley Rails

9.10.1 Rail

An A-profile trolley rail shall be mounted on the boom and girder. The rail shall
be sized considering the permissible wheel/rail contact pressure according to
FEM. The rail shall be of a minimum tensile strength of 690 N/mm². Each trolley
rail shall be supported on a structural member with a continuous web centred
under the rail web. Shims shall not be used.

Trolley rail alignment is based on FEM.

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Rail sections shall be joined with complete penetration welds and ground smooth
to an accurately machined template. Joints shall be staggered so that no two
trolley wheels pass over joints simultaneously. Each rail run shall be secured
against axial movement by welded shear bars near the hinge.

Special care shall be given to the rail design at the hinge point. The trolley travel
shall be completely smooth. The overlapping section shall be minimum 150 mm
and the rail ends shall be bevelled. The rails must be rigidly supported at this
section.

9.10.2 Trolley Rail Clips

A steel reinforced synthetic rubber pad of convex design shall support the trolley
rail, which shall be secured by adjustable rail clips. The rubber pad shall have
high abrasion resistance.

The rail clips and base plates shall be made of forged or cast steel, EN 10025,
S355J0 and allow a minimum of 4 mm lateral adjustment in both directions by
using self-tightening bolts and self-locking nuts. A synthetic rubber nose shall be
vulcanized to the rail clip, capable of constraining the rail vertically and able to
withstand the rail lateral loads. The instructions of the original manufacturer with
regard to cleanliness, evenness and painting of contact areas, tolerances as well as
torque settings have to be strictly followed.

A solid bar or A-type rail continuously welded to the boom/girder structure may
be used as an alternative design. In this case, the welded rail shall not be
considered in the structural calculation of the boom/girder.

9.11 Wheels

Wheels shall be selected according to FEM 4.2.4 and DIN 15070 through 15090.

Non-driven wheels shall be shrunk or press fit to live axles. Driven wheels shall
be flat flanged to the gear box to allow quick disconnecting.

9.11.1 Gantry Wheels

Gantry wheels shall have a minimum diameter of 800 mm and shall be double
flanged. Wheels shall be of GS 42 CrMo 4, with a strength of 750 – 900 N/mm².

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9.11.2 Trolley Wheels

Trolley wheels shall have a minimum diameter of 630 mm and shall be double-
flanged. Wheels shall be of GS 42 CrMo 4, with a strength of 750 – 900 N/mm².
Trolley wheels may be without flanges, but a sufficient adjustable side-roller
system has to be offered. The adjustable side-rollers have to be easily removable
and fall-down protected. The design needs to be approved by the Purchaser.

9.12 Storm Anchors

The crane shall be equipped for gantry, trolley and maintenance hoist drive with
manually operated storm anchors that engage with sockets in the wharf or on the
runway. For trolley and gantry drive, storm pins on each side are required.

The Supplier shall submit details and calculations for the gantry storm anchors
and sockets for the respective civil construction of the wharf.

The manually operated and gravity engaged storm anchors for gantry shall be
mounted on a structural frame secured to the sill beams. The storm anchors shall
be designed to hold the crane against the maximum specified stowed wind load
parallel to the gantry runway without assistance of the gantry brakes. The storm
anchors shall need no uplift protection to hold the crane. The hand lever shall be
secured when not lowered.

Trolley storm anchor sockets shall be provided at the trolley parking position and
at the respective maintenance positions for trolley wheel replacement.

Interlocks shall prevent gantry or trolley travel if at least one storm anchor is
lowered or in a socket.

9.13 Buffers

Hydraulic and rubber buffers shall be designed according to DIN 15018

considering also FEM 2.2.3.4. Wind condition in the most adverse direction shall
be considered.

The buffers shall stop the travel motion without damage to the crane structure in
case the end-of-travel limit switches fail. The emergency stop limit switch
locations and buffer design shall be based on the involved response times and
inertia.

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Each hydraulic buffer shall have a single piece, UV-resistant rubber bellow with
zipper to protect the cylinder from corrosion.

9.13.1 Gantry

Hydraulic buffers shall be located at the ends of the gantry truck assemblies and
match with the crane rail end stop. The buffers shall be designed to stop a crane
from full speed without causing damage to the steel structure and attachments.

Gantry buffers when fully compressed shall project at least 75 mm beyond any
part of the gantry truck assembly.

An externally mounted limit switch shall be installed to allow slow down. It shall
be possible that the crane can work with compressed buffers or can be pushed
along the wharf by another crane in case of power failure.

9.13.2 Trolley

The trolley shall be equipped with hydraulic buffers, one on each corner. Buffers
shall be designed to stop a fully loaded trolley travelling at a rated speed of 70%.

9.13.3 Rubber Buffers

Rubber buffers shall be UV-resistant and shall be installed at the following

locations:
• The boom travel shall be stopped at the top of the A-frame by rubber buffers
without causing damage to the boom. The rated stall torque of the boom hoist
motor shall be considered. The buffer shall be fixed by four bolts/nuts.
• If necessary due to the rope reeving, the catenary trolleys shall be equipped
with rubber buffers, one on each corner.
• Maintenance Hoist: the rubber buffers and stops shall be provided at the limits
of travel with sufficient energy absorbing capacity to prevent damage.

9.14 Mechanical Fasteners

All bolts, nuts, washers and fasteners shall be of metric design and 8.8 grade for
normal and 10.9 grade for high-tensile bolts. Bolted joints of the main structure
assembly shall follow DIN 18800 part 1 and part 7 and DIN EN 20273.

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Threaded fasteners subjected to fluctuating tensile loads shall be pre-tensioned.

For all high tensile bolted connection for the main structure assembly
manufacturer’s instructions for pretension forces and applied tension loads shall
be clearly followed. The applied tension load shall not exceed 60% of the
pretension force.

Bolts, nuts and washer shall inter alias correspond to the DIN or ISO standards as
stated in Table 8 below.

Table 8: Applicable Standards for Mechanical Fasteners

Description DIN ISO

Hexagon high-tensile bolts and nuts 931 4014
934 4032
6914 7412
6915 7414
Washers for high-tensile bolts 6916 7416
Fasteners and similar parts former 267 -
Ribe-CS bolts for slap blocks 7991 10462
Self-locking nuts 982 7040

Respective DIN or corresponding ISO norms shall be indicated on all mechanical

drawings. Other international norms are subject to approval of the Purchaser.

Bolts with diameter higher than 12 mm shall be galvanised or approved corrosion-

resistant alternative; bolts with diameter 12 mm or lower will be stainless steel.

Fastenings shall be secured with locking devices. Critical areas, such as trolley
wheel keeper plates, shall have fastener groups wired together. If these are
galvanised another appropriate method of fastening the groups shall be provided.
Lock-nuts, lock-washers, set screws and snap rings are not acceptable on rotating
equipment.

9.15 Lubrication

Lubrication of all mechanical operating parts shall be in accordance with the

manufacturer's instructions. Oil lubrication shall be provided for speed reducers
and other items needing lubrication. Drain cocks with lever and screw-on cover
lid shall be installed wherever possible with sufficient space for a drain pan.

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Lubrication of other mechanical parts shall be by means of high-pressure grease

introduced through industrial button-type fittings DIN 3404 M10x1 of brass,
Monel or stainless steel. The fittings shall be centralised as much as possible and
readily accessible from permanent walkways or shall be piped to convenient
locations. Each greasing point must be clearly marked with a red paint spot and be
furnished with red caps.

The Supplier shall furnish lubricants in accordance with the original

manufacturer’s recommendations in sufficient quantities for initial lubrication of
the cranes. The Supplier shall provide a signed checklist signifying the equipment
has been properly lubricated. All motors shall be lubricated at the manufacturing
site.

The Supplier shall also supply a list of oil and grease lubricants needed for each
reducer, coupling and all other equipment prior to the start of field erection to
ensure that all recommended types of lubricants are available in the Purchaser’s
country. Only one maker of lubricants shall be used on the cranes and will be
nominated by the Purchaser.

9.16 Hydraulic System

All hydraulic power packs shall be filled with environment-friendly hydraulic

fluids meeting minimum SAE Class 5 cleanliness level. Hydraulic units shall be
appropriately designed according to ISO 4413 for each duty required, self-
contained with filters, gauges, test points and level indicator. Wherever possible,
components shall be standardised and interchangeable. Only metric type joints
according to DIN 2353 shall be used.

If the snagload protection is integrated into the hydraulic system, it shall have two
(2) redundant pumps and motors. Hydraulic units for emergency and rail brakes
shall be provided by the respective brake supplier. Hydraulic units installed
outside shall be housed in a stainless steel enclosure.

The hydraulic system shall be designed in accordance with ISO 4413 tested to
minimum 150% safe working pressure with no component used in excess of the
original manufacturer's regular catalogue rating. It shall be capable of working in
the climatic conditions specified, for the long periods appropriate to intensive
container handling. Set points for pumps and valves shall be selected to avoid any
possible hysteresis.

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In addition to ISO 4413 the following points shall be observed:

• The stainless steel reservoir shall have a minimum of 120% filling capacity,
one magnetic plug, a combined oil temperature and fluid level gauge, an oil
drain valve at the lowest point and be easily cleanable.
• A low-fluid and a high-temperature sensor shall be interlocked to the
PLC/CMS and disconnect the hydraulic pumps.
• Suitable supports shall be provided to eliminate vibrations or movements of
pipe and equipment. Hydraulic stainless steel pipes type DIN EN 10305 shall
be supported by clamps with a metal cover type DIN 3015 with a maximum
distance of 1 m between two clamps.
• Where feasible, connections between components shall be flexible hose,
adequately supported, with swivel fitting terminals. The number of different
sizes and variations of fittings shall be kept to a minimum. Plastic hose shall
not be used.
• Flexible pipelines shall be of wire braid reinforced rubber hose tube according
to DIN EN 853 and shall be of the preferred nominal sizes unless otherwise
approved by the Purchaser. End connections of flexible pipes shall have
threads of the re-usable type, capable of being fitted without the use of special
tools.
• Systems shall have adequate filtration to remove particles 10 microns or
bigger in size and maintain this level during operation. Filter elements shall be
readily replaced and serviceable during system operation, located in readily
accessible areas. Automatically switched dual filters shall be used throughout.
Indicators shall be provided on each filter.
• Cylinders shall have chrome plated stainless steel rods and pins shall be
hardened with grease provisions. Cylinders shall withstand pressures at least
1.5 times the maximum operating pressure. The safe working pressure shall
be stamped on the cylinder. Cylinders shall be cushioned at each end.
• Electric motors shall run with maximum 1500/1,800 rpm (as applicable) and
have flexible couplings towards the hydraulic pumps.

All hydraulic components shall be of standard manufacture. Pumping and control

units shall be furnished by one supplier only.

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9.17 Grab

9.17.1 Design

The crane shall be equipped with four rope rod-type clamshell grabs for coal
handling. One grab shall have a minimum capacity of 24.7 tons, the other one of
at least 19.0 tons.

The cutting edges of the scoops shall be made of an extra wear-resistant material
(400 HB). The hinge point of the grab shall be used with fully sealed anti-friction
bearing. The gap between edges when closed shall be not greater than 3 mm. The
shells shall have lifting lugs for transportation of shovel loaders.

Demag type or equivalent connections serve for quick connection and

disconnection of the grab and hoist ropes of the crane.

The grab shall have a centralised lubrication system.

Access ladders shall be integrated into the grab design for quick change of the
wire rope connections.

9.17.2 Spare Grab

The supplier shall provide one spare grab of each type and three gooseneck
trailers, one for each spare grab plus one additional trailer, which shall be supplied
to allow quick exchange of the grab underneath the crane.

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10. SAFETY FEATURES

10.1 Weighing System

10.1.1 Load Cells

The system is based on two (2) individual load cells, one for each hoist wire rope.
The load cells with a capacity of up to the minimum braking load of the individual
wire rope are to be fitted “in line” with the wire ropes. No levered system is
allowed. The outputs for overload and snag load shall be digital and suitable for
the input to the PLC. The load cell shall have adjustable separate, threshold
settings for overload and snag load detection. Results of snag load or overload
shall be recorded .The load cell shall have an accuracy of ± 0.5% and the whole
system of + 3% when the load weight is stored.

The processing time measured from the input of load cell signal to setting the
overload of snag load signal shall not exceed 5 milliseconds.

10.1.2 Overload

A system shall be provided which shall automatically stop the hoisting motion and
allow lowering only if an operator attempts to lift a load in excess of 110 ± 5% of
the rated single, twin-lift and hook capacity of the crane. An override shall be
supplied to allow adjustment to 125% for dynamic testing purposes and 140% for
static testing purposes only, based on a maximum rated load.

An analogue load indicator with the corresponding loading zones marked in

green, yellow and red together with one digital load indicator must be provided
inside the operator’s cabin.

10.1.3 Snag Load

The purpose of the snag load protection is to safeguard the crane structurally and
mechanically from a snag.

For any rope load less than 200% of the maximum operating load (incl. impact)
the snag load protection shall not trip.

The snag load energy absorption shall be by hydraulic cylinders with relief
valve(s).

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The resetting of the cylinders to the "zero" position following a snag incident shall
be by a snag reset button at the local control station.

As an alternative, a SOS snag load protection system from Messrs Malmedie with
Bubenzer brakes may be offered.

10.1.4 Slack Rope Protection System

The slack rope protection system is connected to the load cells and shall
automatically shut down the lowering motion and allow hoisting only when the
main hoist rope becomes slack. This shall prevent the operator from paying out
too much rope and then accelerating rapidly under no load before the load is lifted
up again. The system shall prevent ropes from jumping out of sheaves, reduce the
shock loads on ropes and structure.

When the operator wants to raise the grab and “slack rope” is indicated, the
hoisting speed shall be limited to slowdown speed until minimum 80% of the tare
weight of the lifting device has been reached.

The boom hoist system shall have a mechanical slack rope protection to prevent
playing out of too much wire rope and detect the loss of one of the boom hoist
wire ropes.

10.2 Limit Switches

Limit switches shall be used for emergency and safety circuits to ensure trouble-
free operation under all conditions in line with EN 1088. Care shall be taken to
protect the limit switches by adequate positioning or other means to prevent
malfunction or spurious operation. Where possible, contact-less devices shall be
used. All limit switches shall be heavy-duty type and shall be labelled for
respective functions.

The limit switch contact form shall be selected to ensure fail-safe operation in the
event of a failure of the switch. For emergency or safety functions, the limit
switch has to be of the positive (forced) action, non-slip drive type.

If proximity switches are used in safety-related circuits, they have to be in

conformity with ISO 13849-1/Cat. 3. Fork lever switches shall not be used.

All limit switches shall be mounted in easily accessible positions to facilitate

adjustments, maintenance and replacement.

Limit switches for external use shall be in IP 55 enclosure.

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Alternatively a safety PLC may be supplied, complying with IEC 62061.

In addition to the functions specified or identified elsewhere in these

specifications, limit switches shall be furnished for any additional functions that -
due to peculiarities in design - may be required for safe and efficient operation.
Such switches shall meet the specifications above or be part of a safety PLC.

Limit switches shall be furnished and installed for the minimum following
functions:

10.2.1 Hoist/Grab
1. Up slow-down: to slow the main hoist speed to predetermined value when
approaching the upper limit of grab hoist travel
2. Up slow-down check: to control if step number 1. has been effected
3. Up stop: to stop the main hoist at the extremes of grab hoist travel
4. Ultimate upper hoist stop: to stop the main hoist in case the up stop switch
fails 500 mm above the extreme grab hoist travel
5. Dock slow-down: to slow the main hoist lowering speed to a predetermined
lower value (~ 10%), at a certain level above the hopper. These contacts are
jumped when the trolley is above a vessel.
6. Down slow-down: to slow the main hoist lowering when five turns are left
on the rope drum
7. Down slow-down check: to control if step number 6 has been effected
8. Down stop: to stop the main hoist lowering when less than three turns are
left on the rope drum

10.2.2 Trolley/Cabin Travel

Waterside
1. Ultimate travel stop
2. Trolley/Cabin travel stop to stop the trolley at the maximum outreach
position
3. Slow-down check
4. Slow-down to slow the trolley/cabin speed when approaching the forward
end position
5. Ultimate stop (boom raised)
6. Stop (boom raised): to stop the trolley/cabin at the forward limit of travel

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7. Slow-down, limit switch: to slow the trolley/cabin speed when approaching

the forward limit of travel with the boom raised
8. Parking position: to interlock with the boom hoist control so that the boom
cannot be raised unless the trolley/cabin is over the dock in its parking
position
9. Boom clear: to interlock with the boom hoist control so that the boom
cannot be raised unless the trolley/cabin is over the dock in its parking
position
10. Trolley/cabin clear: to interlock with the boom hoist control so that the
trolley/cabin cannot travel unless the boom is in the lowered position and
supported by the forestays or is in the fully raised and secured position
11. Hopper protection

Landside
1. Ultimate trolley/cabin travel stop
2. Trolley/cabin travel stop to stop the trolley at the maximum backreach
position
3. Slow-down check
4. Slow-down limit switch, to slow the trolley/cabin speed when approaching
the backreach end position
5. Hooper and conveyor protection

10.2.3 Boom Hoist

1. Lower stop: to stop the boom lowering when the weight of the boom is
supported by the forestays and to be interlocked with the hoist and trolley
motions to prevent trolley travel onto the boom unless the boom is
supported by the forestays
2. Upper stop: to stop the boom in the raised position after it has entered the
boom locking devices
3. Lower slow-down: to reduce the speed of the drive when the boom is near
the down position so that shock loads to forestays and boom reeving is
minimised
4. Upper slow-down: to reduce that speed of the drive and to recalibrate the
current limit so that the stall torque of the drive will not damage any part or
the crane if the upper stop fails
5. Boom latching pin: to check if the latching pin is engaged or open

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10.2.4 Gantry

To be co-ordinated with the prevailing dock conditions.

1. Slow-down: to slow the crane speed at ends of gantry travel
2. Slow-down check: to control if step number 1. has been effected
3. Stop: to stop the crane at ends of gantry travel
4. Anti-collision between crane: analogue to steps 1. to 3.
5. Anti-collision between crane and vessel
6. Compressed buffer check: to allow the crane to work with compressed
buffers

10.2.5 Slack Rope

Slack rope devices shall be provided both for the hoist/grab ropes and the boom
hoist ropes to prevent excessive rope motions.

10.2.6 Operator’s Cabin Access Gates

The operator’s cabin platform access gates shall be equipped with a locking
device that keeps the gates shut unless the trolley is in the parking position.
Trolley travel shall be disabled if one of the gates is open. The function shall be
displayed in the operator’s cabin and be logged in the CMS.

If applicable, the same requirements shall be observed for the window washing
platform.

10.2.7 Override

Key-operated spring-return selector override switches shall be installed in the

respective cubicles in the E-house to allow bypassing of the software limits and
travel limit switches for hoist, trolley and gantry with reduced speeds. The
switches shall not be located in the operator’s cabin.

Snag load shall not be bypassed.

10.3 Encoders, Cam Limit and Over-Speed Switches

Encoders, cam limit and over-speed switches shall be directly mounted. Chain-
driven switches are not acceptable.

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10.3.1 Encoders

Encoder with fibre optical connections shall be installed in the following locations
and connected to the PLC:
1. Two (2) absolute encoders, one on each hoist/grab drum
2. Two (2) pulse tachometers, one on each hoist/grab motor
3. One (1) absolute encoder on the boom hoist drum
4. One (1) pulse tachometer on the boom hoist motor
5. Two (2) encoders on trolley drive, on different axles
6. Two (2) encoders on gantry drive, one on LS and one on WS

10.3.2 Cam Limit Switch

1. One (1) cam limit switch on one of the hoist/grab drums
2. One (1) cam limit switch on the boom hoist drum
3. One (1) cam limit switch on each cable reel drive

10.3.3 Over-Speed

Over-speed of hoist and boom hoist drives shall be monitored by encoders on the
respective drums and motors as well as a mechanical over-speed limit switch
mounted on each drum. Emergency brakes shall trip if the rated speeds are
exceeded by more than 10%.

A combined encoder/cam/overspeed device, e.g. “Unit one” as supplied by

Hübner is preferred, compliant with the required SIL level.

10.4 Emergency Features

Independent of the control system, separate fail-safe hard-wired protective devices

shall be installed. All contacts are wired in series connection and shall adhere to
ISO 13850 category 0.

Three emergency situations will be distinguished and are separately hard-wired,

i.e.:

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10.4.1 Emergency Stop

In this case, the operation personnel shall activate the emergency stop pushbuttons
(mushroom head, red) which will cause every motor drive of the crane to stop and
engage all brake systems without time delay, thus preventing any danger arising
from moving machinery or parts.

Location of the pushbuttons:

• One (1) inside the operator's cabin on the lateral control board
• Two (2) in the machinery house
• One (1) at each crane leg, to be reached from ground level
• One (1) at crane access
• One (1) on the trolley
• One (1) on hopper/conveyor platform
• Two (2) at boom, one at boom tip and one at halfway
• One (1) at MV slip ring assembly
• At any other location deemed necessary by the manufacturer

All other consumers on the crane remain in function.

Additional emergency stop pushbuttons shall be installed at local control stations

as defined in Chapter 6.11.

10.4.2 Emergency Off

In case the maintenance crew is working on MV equipment, transformer or LV

equipment inside the electrical room, and if there is the danger of coming into
contact with live parts of the electrical system, the emergency-off pushbutton will
trip the main switch/circuit breaker of the MV power supply on the crane.

Location of these pushbuttons

• in the electrical house and control room

• transformer vault
• at the MV switch board
• any other location deemed necessary by the manufacturer

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10.4.3 Limit Switch Emergency Stop

Any one of the drives which activates an emergency limit switch (e.g. ultimate
stop) shall switch off only this particular drive, leaving all other drives unharmed.
An emergency limit switch bypass pushbutton shall be provided in the particular
drive section of the control board for use of the maintenance personnel only, in
order to reactivate the drive and move the device into the opposite direction.

10.5 Interlocking Devices

Adverse results of system faults and incorrect operation shall be avoided through
a fail-safe design based upon a variety of interlocking functions by limit switches
and/or software functions. Interlocks shall be provided for, but not necessarily
limited to, the following:

10.5.1 Hoist/Grab

The raise motion for each hoist/grab unit shall be subject to a minimum of the
following interlocks:
1. Any control fault
2. Emergency stop
3. Emergency brakes release
4. Disk brakes release and contacts
5. Travel limits
6. Stall motor
7. Torque proving
8. Slack rope (slow-down speed)
9. Overload
10. Snag load
11. Motor blower(s) running
12. Trip thermistors
13. Emergency drive engaged
14. Remote station engaged
15. Boom fully raised or lowered
16. Boom anti-collision

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The lower motion for each hoist/grab unit shall be subject to a minimum of the
following interlocks:
1. Any control fault
2. Emergency stop
3. Brake limits
4. Travel limits
5. Stall motor
6. Torque proving
7. Slack rope (slow-down speed)
8. Motor blower(s) running
9. Trip thermistors
10. Emergency drive engaged
11. Remote station engaged
12. Boom fully raised or lowered
13. Boom anti-collision

Torque proving: Service brakes shall not release until a minimum of 10% of
armature current are detected and/or rated load will not sack.

10.5.2 Trolley/Cabin

The trolley/cabin motion shall be subject to a minimum of the following

interlocks:
1. Any control fault
2. Emergency stop
3. Brake limits
4. Boom full up or down
5. Boom anti-collision
6. Trolley/cabin travel limits
7. Hoist/grab slack rope
8. Snag load
9. Overload
10. Trolley/cabin access gates

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11. Stall motor

12. Motor blower(s) running
13. Trip thermistors
14. Trolley/cabin storm pin
15. Trolley/cabin travel lock-out
16. Washing platform
17. Emergency drive engaged
18. Local control station engaged
19. Hopper protection

The trolley/cabin access gate limit switches shall be designed in a way to keep the
door locked all the time unless the trolley is in the parking position.

10.5.3 Boom Hoist

The boom hoist motion shall be subject to a minimum of the following interlocks:
1. Any control fault
2. Emergency stop
3. Brake limits
4. Stall motor
5. Torque proving
6. Travel limits
7. Trolley/cabin position
8. Boom full up or down
9. Boom anti-collision
10. Boom latching pin
11. Boom hoist slack rope
12. Boom access gate
13. Boom lock-out button at access gate
14. Wire rope overlapping
15. Emergency drive engaged
16. Local control station engaged
17. Dead man switch integrated into the driver’s seat

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10.5.4 Gantry

The gantry motion shall be subject to a minimum of the following interlocks:

1. Any control fault
2. Emergency stop
3. Service brake limits
4. Rail brakes
5. Storm pin position
6. High wind
7. Boom fully raised or lowered
8. Boom anti-collision
9. Snag load
10. Overload
11. Gantry anti-collision and buffers
12. Cable reel left/right limits
13. Cable reel empty
14. Cable reel slack cable
15. Cable reel over-tension
16. Local control station engaged

10.6 Anemometer

An anemometer and wind direction indicator shall be provided on top of the A-

frame withstanding winds up to 60 m/s with an accuracy of ± 2% of the full range.

The unit should include a time delay adjustable from 5 to 20 seconds in order to
eliminate the nuisance tripping due to sudden wind gusts and shall not be sensitive
to salty environment and vibration.

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The anemometer or anemometer receiver's output shall be scaled, isolated and

suitable for input to the control system (4 – 20 mA). The wind speed and direction
shall be displayed on a monitor (or agreed alternative) inside the operator’s cabin
and shall show the direction with respect to the boom such that the operator
clearly knows where the wind is coming from. The acoustic warning signal shall
be adjustable in volume and duration and shall sound when the adjustable warning
level is reached.

The instrument shall be provided with channel set points adjustable for field
setting at any desired wind velocity, and shall be installed in the electrical control
room

When the wind reaches the shutdown level, all motions shall come to a normal
stop. In case the wind speed falls below the shutdown level again, all crane
systems revert to normal.

If the wind speed stays above the shutdown level, the alarm may be silenced by
the reset button, and all crane motions will be enabled. The operator can complete
the actual operation and drives against the wind to the crane parking position and
engages the storm pins.

The system shall be suitable for crane application in a marine and highly corrosive
environment, insensitive to vibrations. Original manufacturer’s recommendations
for installation shall be strictly followed.

10.7 Aircraft Warning Light

Two (2) aircraft warning lights of LED type shall be provided, one on top of the
main frame (highest point during operation) and one at the tip of the boom
(highest point when stowed). Wattage, type and configuration shall follow the
FAA regulations.

A UPS system with a minimum capacity of 36 h shall be installed.

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10.8 Anti-Collision Device

An FCMW or ultra-sonic based type anti-collision device to prevent the crane

from colliding with adjacent cranes during gantry travel shall be provided. The
device shall reduce the gantry speed of the crane to creeping speed of 5 m/min
when it is 10 m from the adjacent cranes, and shall bring the crane to a complete
stop before the crane’s bumper comes into contact with that of adjacent cranes.
The gap between the bumpers of one crane to the bumper of the next crane shall
be maintained at 300 mm when the crane comes to the complete halt. Limit
switches for ultimate stop shall be furnished. An override switch shall allow
positioning the cranes adjacent to each other (compressed buffer to buffer, or
pushing mode).

The boom shall be equipped with a contact-less anti-collision device on both

sides, preferably from Messrs Sick, type LMS211-30206.

All contact-less anti-collision devices shall be designed to work under any

weather conditions.

10.9 Video Cameras

Four (4) high-contrast, auto-focus, anti-vibration colour video cameras shall be

installed in suitable marine type enclosures to observe the crane rails and one (1)
video camera to observe the boom hoist up stop operation and forestay hinge
points. The 15” monitor inside the operator’s cabin shall have split screen mode
for up to four (4) images and automatic change-over function. Public TV
reception shall not be possible. The cabling shall run independently and shall be
shielded.

Cameras and cables shall be installed strictly according to the manufacturer’s

instructions.

10.10 Automatic Warning Sounders

Electrically-operated automatic warning "sounders" of minimum 105 d(B)A shall

be mounted on each gantry leg and shall sound automatically whenever the gantry
motors are energised.

In addition (or combined with above), a flashing light, with amber dome, 360°-
rotation and weather-proof enclosure shall be provided outboard at each gantry leg
at dock level.

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10.11 Signal Horn

Under the operator’s cabin, an electrically operated signal horn shall be installed
to warn personnel working at quay level or on the vessel. The noise level shall be
of approx. 110 dB(A) measured underneath the cabin at 1.50 m height.

The signal horn shall be activated from the operator’s cabin, preferably from a
joystick’s button.

10.12 Fire Extinguisher

Fire extinguishers as specified in DIN EN 2, coloured and installed in accordance

with the local rules and regulations shall be provided. The following minimum
provisions are to be made:
• One (1) unit to be installed in the operator's cabin (2.5 kg)
• Two (2) at the machinery house (5 kg)
• One (1) in the electrical room (5 kg)
• One (1) in the PLC control room (5kg)
• One (1) at quay level, adjacent to the access ladder (5 kg)
• One (1) at quay level, at waterside (5 kg)
• One (1) unit to be installed on the MV cable reel platform (2.5 kg)
• One (1) at the snag hydraulic station (5 kg)
• One (1) at feeder belt/hopper platform (5 kg)
• One (1) in the elevator (2.5 kg)

The E-room shall be protected by an automatic fire protection system similar to

FM200.

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11. MISCELLANEOUS

11.1 Wire-Rope Re-Reeving System

A self-contained motor-driven wire-rope reeving device shall be provided and

arranged to allow convenient re-reeving of the hoist/grab ropes and boom hoist
ropes during routine rope replacement. The device will be mounted on a common
base (20’ flat); for ropes replacement it will be placed at ground level.

The winch shall accommodate four (4) regular commercial cable reels for the size
and lengths of the ropes used on the cranes. Two (2) inverter-controlled motors
with thruster-operated brakes shall be supplied on the winch to control the pay-out
of the replacement rope during re-reeving operations.

If sufficient, the 32 A welding outlet socket at the crane access shall be used for
power supply. Otherwise, the shore power supply or 125 A outlet at the crane
shall be utilized. A cable of sufficient length (in the worst case from the backreach
to the quay edge) with a suitable plug shall be provided and stored on a cable
rack. The remote station shall be enclosed in a stainless steel housing of IP 55.

To replace any rope, one end of the old rope shall be connected to a new rope with
the other end attached to the empty spool. The spool shall be powered to pull the
new rope through the system. In suitable locations on the trailer/flat and on the
crane, rope blocks shall be installed to direct the ropes to eliminate damages. The
crane shall also be furnished with lashing eyes for chain hoists for easy rope
replacement.

11.2 Maintenance Hoist

11.2.1 Machinery House’s Service Crane

A bridge crane of adequate capacity (minimum 10 t), complete in all respects,

undertaking all lifting of equipment and machinery for maintenance and removal,
shall be installed in the machinery house. The crane shall be so arranged that it
can reach and lower any of the equipment and machinery inside the machinery
house and to ground level.

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All motions to be driven by electric motors. Special attention shall be given to

slow starting speeds to avoid jerky movements. The remote control unit is
attached by a pendant which is securely parked. Arrangements shall be provided
to secure the crane in its parking position against movement when not in use.

The M+R crane shall be capable of lifting the wheels from the trolley and lower a
grab to ground level. The minimum hoist speed shall be 10 m/min and 3 m/min
for reduced speed.

The crane shall comply with FEM class 1Am.

The pendant remote control unit shall be equipped with all necessary pushbuttons
for operation as well as with a red mushroom type emergency stop button.

The manufacturer’s nameplate and SWL shall be attached to the crane.

11.2.2 Maintenance Cranes

Maintenance cranes of sufficient capacity for chain hoist operation shall be

installed at the following locations:
• Above the snag load protection system
• Top of the A-frame
• Near the sheave blocks on the boom
• Boom tips

11.3 Passenger and Freight Elevator

A suitable electric rack and pinion-driven passenger and freight elevator shall be
offered for the comfortable, safe and quick delivery of operation and maintenance
personnel, portable tools and spare parts up to the level of the MV cable reel,
operator’s cabin and main machinery house. The elevator shall be installed on the
same leg where the crane access is located..

The main technical characteristics are:

• Lifting capacity four people, 400 kg
• Nominal lifting speed 30 - 40 m/min

The design, manufacturing and erection of the elevator shall be in accordance with
the producer's standard specifications for such type of elevators and comply with
the local regulations.

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This elevator shall also be operated in case of power failure by the auxiliary
power supply.

Control stations shall be installed on each landing, inside the elevator as well as
on the cabin roof. If possible, all electrical controls shall be fully integrated in the
crane PLC and CMS.

The elevator shall function under maximum operating wind speed and when the
gantry is moving.

The structural components shall be hot dipped galvanised. All other components
shall be high corrosive-resistant coating and shall be suitable for marine
environment. The elevator shall be protected in areas reachable from the access
stairs. The protection plates shall be made of hot-dipped galvanised steel.

All landings shall have interlocked doors.

Furthermore the elevator shall have the following features:

• Emergency stop (red mushroom head latched type)
• Alarm pushbutton
• Warning buzzer for overload
• Warning buzzer in case doors were left open
• Telephone
• Internal lights, shutting off after 5 min of operation
• Ventilation
• External alarm bell
• Over-speed device
• Ladder for reaching the roof through the escape hatch
• Safety windows in doors
• Interlocks for doors and roof hatch
• Fire extinguisher
• Operation and emergency instruction boards inside cabin in the specified
languages
• Manual operation lever for descent in case of power failure

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11.4 Test Load

The Supplier shall include in his scope and furnish an appropriate test load to the
Purchaser’s site. The test load shall consist of a base frame with concrete blocks
of different weights, ready for testing purposes of 100%, 110% and 125% rated
load of the supplied grab. Concrete blocks shall be designed for forklift and crane
handling. The design shall be approved by the Purchaser. A calibration certificate
shall be provided.

11.5 Air-Conditioning Units

11.5.1 General Design Aspects

Air-conditioning systems shall be installed in the electrical house, PLC control

room and operator’s cabin. All air-conditioning systems shall be designed for the
specified ambient conditions and design temperature as defined.

The air-conditioning systems shall be capable of maintaining conditions of

maximum 24 °C dry bulb and maximum 50% relative humidity under any
operating condition.

All air-conditioning and associated equipment shall be designed, installed and

commissioned in strict compliance with the original equipment manufacturer’s
specifications and guidelines. The manufacturer’s recommendations on
installation practices and recommended clearances for airflow and servicing shall
be adhered to. The design and installation techniques applied shall conform to
established air-conditioning industry practices and be comparable to European
standards.

The selected equipment shall be of a robust design and construction suitable to

withstand the vibrations and movements of the crane operation. Residential
(domestic) type air-conditioners are not acceptable at any location.

The equipment shall be configured to ensure that no water is to be able to drip

from the units onto flooring, cubicles or any electrical/electronic equipment or
personnel. Condensate drip trays and drainage systems shall be configured or
suitably modified to accomplish this.

All refrigeration and airside equipment exposed to ambient conditions shall be

manufactured from non-corrosive materials and protected against saline and
humid atmosphere. Motors and compressors shall be at least of the protection
class IP 55. Refrigerating connecting pipes shall be insulated.

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Condenser coils shall be manufactured to have protection against saline coastal

atmosphere. All corrosion protective coatings shall be factory applied. In exposed
locations, the condensers shall be shaded as far as possible against direct exposure
to sunlight.

Air-conditioning units shall operate with environmental friendly gas with low
ozone depletion and global warming potential, such as Frigen R407C or R410A.

Instructions on the use of the air-conditioner shall be clearly displayed near the
units control in the language specified in Chapter 2.6.

Spare parts for the supplied units must be locally available and the equipment
warranties and service shall be supported by local agents.

The selected A/C units shall be subject to approval by the Purchaser.

11.5.2 Electrical House

The air-conditioning system for the electrical house and PLC control room shall
consist either of central air-conditioning units installed outside with respective
ductwork or of several split unit types. The air-conditioning system shall consist
of at least two (2) units, each one independently capable of maintaining the
specified conditions. 3 x 50% or more units are also acceptable, provided that
there is at least one (1) spare unit and the other units are capable of maintaining
the specified conditions at any time. Heat pumps (reverse cycle) are not required.

For the purpose of sizing the air-conditioning systems of the electrical room and
PLC room, the Supplier shall submit a detailed heat load calculation including
effects of power loss calculation, heat transgression through the thermally
insulated E-house cladding, humidity, solar radiation, etc., considering ample
spare capacity. The heat load calculation is subject to approval by the Purchaser.

In case the air-conditioners are of the packaged ducted type, they shall be
mounted on the machinery house roof or on a platform adjacent to the machinery
house. Each unit is to be fitted with two compressors.

All supply and return air ducts and associated airside equipment shall be designed
as low pressure systems and installed to achieve a minimum pressure drop and
leakage in the airside system.

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A/C units feeding into a common ductwork shall have lightweight backflow
dampers fitted in the air handling unit’s (AHU) supply air outlets to prevent air
recirculation through the standby unit. The dampers shall offer minimum
resistance to the airflow.

The supply air duct system shall have main shut-off dampers fitted adjacent to the
AHU and branch dampers fitted before each supply air grille.

Supply and return air grilles and registers shall be generously sized to minimise
high velocity drafts in the conditioned space.

Each system shall maintain the air-conditioned space under a slightly positive air
pressure.

Local electrical disconnects shall be installed adjacent to the condensing units and
air handling units.

All external ductwork shall be insulated with min. 50 mm thickness rigid fibre
glass insulation (or equivalent value approved alternative), covered with 16-gauge
aluminium cladding. All internal ductwork shall be insulated with min. 25 mm
thickness rigid fibre glass insulation (or equivalent value approved alternative).

Access panels shall be installed in the ductwork wherever fire or backflow

dampers are fitted.

Where the ductwork, cabling or piping is subject to damage by personnel, a

suitable walkover or protective cladding shall be provided.

Each unit shall be controlled by a 4-stage electronic thermostat with digital

temperature read-out. The thermostat shall have a sensor remotely positioned in
the return air duct sampling the average return air temperature. The thermostat
shall be of a tamperproof type. Control units are to be mounted in convenient
locations and be connected directly to the main units. Remote control units are
unacceptable.

A run time sharing system shall be installed to automatically change over the lead
unit(s) to standby unit. The changeover period shall be as defined by the
equipment supplier. The functionality for this purpose may be done by the main
control system of the crane and be interfaced with each unit. In the event of the
lead unit(s) failure, the air conditioning systems shall be fitted and configured for
automatic changeover from lead unit(s) to standby unit. The cause of the failure
shall be logged by the crane management system. The temperature, monitored by
the thermostatic control, shall activate the spare unit if the temperature exceeds

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28 °C for a sustained period of 2 minutes. The cause of the failure shall be logged
by the crane management system.

The electrical/electronic panels of the AC system shall be mounted within a

separate sound-dampened, air-conditioned, dehumidified room within the
electrical house.

11.5.3 Operator’s Cab

The operator’s cab shall be thermally insulated and be provided with an air-
conditioning system to maintain the specified conditions.

Cooling and heating functions shall be controlled by a thermostat.

The air-conditioner shall be of split design with the airflow distributed in the cab
by a diffuser, dripless type indoor unit. For the purpose of sizing the AC unit, the
Supplier shall prepare a detailed heat load calculation for both cooling and heating
functions. The calculation shall be subject to approval by the Purchaser.

As far as applicable, the design aspects mentioned in Chapters 11.5.1and 11.5.3

shall be considered.

11.6 Labelling and Nameplates

All components shall be supplied with a function-indicating nameplate

immediately adjacent and symmetrical to the materials. The nameplates shall
enable the operator and maintenance personnel to get a quick and accurate picture
of the overall relationship and relative functions of the components. Additionally,
each component shall be identified by its electrical code number according to the
wiring diagrams.

The following requirements shall be met:

1. Nameplates shall be provided for all devices on switchboards to identify

circuit, function, indication or purpose. Nameplates for function or service
shall include code number of the device as per wiring diagrams. The
electrical code number shall also identify the place of installation.

2. All enclosures, junction boxes, cubicles and panels, where the function and
application is not immediately self-evident as judged by appearance,
location or other indications, or the service relationship to other materials is
not readily apparent shall be furnished with an electric lighting arrow
symbol.

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3. Any special precaution, maintenance or operating instructions shall be

included on the nameplates or on a separate plate attached to the materials.
Any equipment over 500 kg in weight shall have it stated on the unit.

4. In addition to the nameplates provided by the manufacturer of individual

components, each major item of electrical materials shall have a nameplate
designating its function and service.

5. Nameplates for cubicles, enclosures, panels and junction boxes shall be

engraved phenolic plates, UV- and heat-resistant. Lettering size shall be
3 mm minimum. Nameplates must be attached to the outer side of the
enclosures.
Standard nameplates for motors, reducers, and brakes as well as P&I
diagrams for hydraulic units must be of stainless steel, be legible and may
be engraved or stamped. These nameplates shall be attached with stainless
steel screws.
Nameplates covered with paint will be a cause for rejection.

6. All conductors shall be identified by colour codes, wire numbers and prefix
at each terminal to which they are connected, in accordance with the wiring
diagram. Cables to be identified at both ends.

7. Nameplates showing the manufacturer's name, address and trademark shall

be attached to both sides of the crane. This information shall be displayed
on a stainless steel plate inside the cabin, too.

8. If applicable, a nameplate showing the CE marking symbol shall be

provided.

9. Separate nameplates showing the safe working loads (SWL) of the crane in
metric tons shall be attached to the gantry in a visible manner at the lower
part of the sill beams.

10. The Purchaser's logos shall be prominently displayed in size and at locations
to be approved by the Purchaser.
In addition, the Purchaser’s identification tag shall be displayed analogue to
the logo.

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11. All warning and instruction boards shall bear the appropriate ISO symbols
as well as the written description (first aid, fire-fighting instructions, general
warning for maintenance and work on electrical equipment, danger signs,
signs such as “men at work”, “access for authorised personnel only”, etc.)
have to be included and installed at the proper locations .

12. ISO symbols for “No smoking” shall be installed at the access to the crane,
in the operator’s cab, machinery house and electrical room.

13. The numbering of motors, reducers, and brakes shall correspond to

Chapter 2.5.4. The numbering must correspond to the electrical code
numbers as specified by the electrical wiring diagrams.

14. A stainless steel plate with all lubrication points of the crane shall be
installed in the machinery house.

15. All cubicles and junction boxes installed outside shall have laminated
wiring diagrams installed at the inner side of the door.

16. All nameplates (with the exception of the manufacturer’s plates at

gearboxes, brakes, motors, couplings), signs and boards shall be in the
languages defined in Chapter 2.6.

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12. PAINT AND SURFACE PROTECTION SYSTEM

12.1 General

All metallic surfaces of the crane except nameplates, stainless steel and wearing or
internal surfaces of mechanical parts shall be painted. As used herein, "exposed
surfaces" means surfaces exposed to the atmosphere; and "sealed surfaces" means
interior surfaces of members sealed by welding and pressure tested.

The surface preparation and paint application shall be carried out in accordance
with DIN ISO 8501-8504, DIN ISO 12944, DIN 55928-8, as well as SIS 05 5900.
The applicable corrosion class according to ISO 12944 is C4.

The paint manufacturer's recommendations shall be strictly adhered to. The paint
manufacturer shall supervise, inspect and certify all paint applications. The paint
surveyor shall be certified according to international standard such as SSPC,
Frosio, NACE with the highest applicable stage.

The Supplier shall provide within his Bid a detailed paint specification using one
of the paint suppliers listed in Annex 2. The final colour scheme shall be defined
by the Purchaser in a later project stage.

12.2 Surface Preparation

All surfaces to be painted shall be cleaned by sandblasting.

Any oil, grease, dirt or chemical contamination shall be removed using solvent
washing or other suitable means before sandblasting exposed or sealed surfaces.
Special attention shall be given to welding seams. Welding flux in crevices, any
welding spatter, slivers, laminations and underlying mill scale shall be removed
by the best mechanical means. To assure proper adhesion and build-up of coatings
all exposed edges of steel shall be rounded.

The steel surfaces shall be cleaned as per SIS 05 5900 or ISO 12944 minimum to
Grade Sa 2.5. The resulting surface shall be of uniform mottled grey appearance
with a surface anchor pattern of 50 – 100 microns.

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Only dry sandblasting grit or mineral shop procedures are acceptable. The method
of preparing the metal surface shall remove all mill scale, rust, rust scale, paint or
foreign matter by use of abrasives propelled through nozzles. Sandblasting shall
only be allowed when the surfaces’ temperature is 3 °C above the dew point.

Prior to application of any prime coat, the blasted surface shall be rendered dust-
free. After sandblasting has been completed, no acid washes or other cleaning
solutions or solvents shall be used on metal surfaces.

Blasting and painting operations shall be strictly separated so that there is no

likelihood of blasting contamination falling on the painted areas.

Application of the initial paint coat shall be applied within four (4) hours of
blasting or as recommended by the paint manufacturer. Where painting is not
started within this time or visible rusting occurs, the blasting of the surface shall
be repeated.

12.3 Paint Application

All paints shall be applied in strict adherence to the manufacturer’s instructions as

to application, weather, temperature and coating thickness. Special attention shall
be given to the paint specification for galvanised items.

The coating system should comprise at least the following layers for:
1. Exposed surfaces:
a) One coat of epoxy base zinc dust or inorganic zinc rich primer. The
dry film thickness of this coat shall be 50 – 75 microns. The content of
zinc should be not less than 92%.
b) One intermediate coating of epoxy polyamide of 125 – 200 microns.
c) A finish coat of polyurethane enamel of minimum 50 – 75 microns.
Total dry film thickness for the system shall be not less than 280 microns.
Each coat shall be of a contrasting colour.
2. Sealed surfaces:
Areas which are air-tight sealed and not accessible will be treated with shop
primer.
3. Unsealed surfaces:
a) All inner unsealed surfaces shall be treated with primer, minimum
50 microns dft.
b) One coat of epoxy mastics, min. 125 microns, of grey white colour,
RAL 9002 shall be applied.

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4. Galvanised surfaces:
a) Galvanisation shall correspond to EN ISO 1461. Components to be
galvanised shall be dipped in a zinc bath of minimum 450 °C. The
zinc coat shall be minimum 70 microns.
b) Galvanised surfaces shall be treated with primer, minimum
50 microns dft
c) Top coat of polyurethane enamel of minimum 80 microns dft.

Surfaces shall be cleaned from dust, any contaminants or moisture not more than
72 hours prior to the application of the next coat. The drying period of the
previous coat shall comply with the manufacturer’s product specification.
However, paint shall not be applied if the surface temperature is less than 3 °C
above the dew point or the ambient temperature is less than 5 °C or higher than
45 °C.

Generally, painting shall be done by spray application before assembly. Brush

application shall be used after assembly in inaccessible areas only. The coating
shall be spread evenly without holidays, runs, sags, brush marks, variation in
colour, texture or sheen.

The intermediate and finish coat shall be applied only after welding has been
completed. Welding after painting is not allowed. All welded attachments or
brackets shall be mounted before coating. Bolted attachments and connections
shall be trial-fitted before coating.

All finished surfaces shall be thoroughly protected, left clean and completely
covered to avoid any further damages during assembly. Prior to application of any
coat, all damage to previous coats shall be repaired. Damaged surfaces shall be
mechanically wire-brushed or disk-sanded, feathering the edge and overlapping
slightly onto the intact coated area. Coating repair shall be done strictly in
accordance with the instructions of the paint manufacturer.

All coating materials shall be supplied in unopened and clearly identifiable

containers. No mixing of paints shall be allowed. Coatings shall be thinned only
as per the recommendations of the paint manufacturer.

For standard buyout components the manufacturer's standard paint system will be
acceptable if the sub-supplier can demonstrate that the paint system used is
compatible with the specified marine environment. However, gantry and trolley
motors and gearboxes shall have colours as per paint schedule.

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12.4 Paint Damage after Shipment

Where damage to the paintwork has occurred during shipment, removal of transit
members or other incidents, the paint coatings shall be repaired in accordance
with the paint manufacturer procedures. The Supplier shall ensure that this work
is undertaken by qualified and experienced personnel and details of all repair
areas shall be noted and properly supervised, inspected and checked at all stages
of the repairs.

To avoid paint damages due to flame cutting, all lashing lugs or stiffening
structure used for shipping purposes shall be bolted or permanently installed.

12.5 Paint and Anticorrosion Guarantee

All painting works shall be guaranteed for a period of ten (10) years referring to
grade Re 3 of the European Scale of Degree of Rusting for Anticorrosive Paint.

In cases where more than the specified percentage of total coated area of each
structural members, mechanical equipment or attachments such as brackets, stairs,
ladders, handrails, platforms etc. become rusted, blistered or peeled, within five
years after taking over the crane, the Supplier shall repair these free of charge.

This guarantee shall cover rusting, blistering, cracking and peeling of the paint
system according to ISO 4628. Loss of gloss, discoloration, and rusting due to
wear and tear or mechanical damage caused by improper use by the Purchaser
shall be exempted from the guarantee.

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13. QUALITY CONTROL

13.1 Design Review

The design review includes an approval of all design drawings, calculations and
original manufacturer’s product specification for compliance with the Purchaser’s
technical requirements. Annex 9 contains the minimum scope of documents to be
submitted for approval during the design review period.

The Purchaser’s review does not relieve the Supplier in any way from compliance
with specifications unless deviations are presented in writing and are explicitly
accepted by the Purchaser. Any of the Purchaser’s comments or approvals of the
submitted documents shall not waive the Supplier’s duties, responsibility or
obligation to achieve satisfactory performance of the crane. Errors or omissions in
the crane design are the sole responsibility of the Supplier.

All documents, drawings, calculations and catalogues, etc. shall be in the

languages as defined in Chapter 2.6.

Drawings shall be in a well rounded scale and minimum in A3 size.

The Supplier shall distribute two (2) hardcopies to the Purchaser, and three (3)
hardcopies to the Purchaser’s appointed consulting engineer. Furthermore, one (1)
electronic copy (as PDF) or as required for calculation review shall be provided.

13.1.1 Conceptual Drawings

If not otherwise agreed, within two (2) weeks of the contract agreement coming
into force, the Supplier shall submit conceptual design drawings showing at least
the following details:
• General arrangement
• Trolley arrangement
• Operator’s cab/layout of consoles
• Boom and girder configuration
• Hinge point
• Machinery house and electrical room arrangement

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• Layout of each drive system

• Gantry equalisers, bogies, wheel arrangement

If not otherwise agreed, the Purchaser shall review and approve or make
comments within two (2) weeks after having received the complete set of
drawings.

13.1.2 Detailed Design Review

Following review and acceptance of the conceptual design and prior to fabrication
of components, the Supplier shall, if not otherwise agreed, submit all detailed
drawings and design calculations for review within eight (8) weeks from the date
the contract is coming into force.

The scope of documents to be submitted shall include but not be limited to the
scope listed in Annex 9.

If not otherwise agreed, the Purchaser shall review the drawings and calculations
and approve or make preliminary comments within four (4) weeks after receipt of
each batch, followed by design review meetings to discuss any comments on the
drawings and calculation.

Ultimately 15 weeks from the date of contract coming into force the Supplier shall
incorporate all comments which the Purchaser may have into the drawings and
calculations. Final drawings and calculations shall be approved within one
(1) week from receipt of these.

All revised resubmittals shall be clearly indexed, showing revision date, revision
indices and revision contents on the revised drawing or calculation.

The Purchaser anticipates the normal review process will consist of revising the
initial submittal and back-checking the first resubmittal. The Supplier is subject to
a backcharge if he does not cooperate to minimise the number of resubmittals
needed to complete the submittal process.

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13.2 Fabrication

The quality control during fabrication and assembly shall be the sole
responsibility of the Supplier.

The Purchaser may appoint supervisors to monitor project progress and inspect
quality of workmanship on stage or permanent basis. These inspections may be
used to evaluate progress payments by the Purchaser. For the purpose of quality
inspection, the Supplier shall delegate an on-site project manager who is fluent in
English.

The Supplier shall establish a Quality Inspection Plan, defining extents of

inspection and tests as well as holding points. The Quality Inspection Plan shall be
subject to approval by the Purchaser. Furthermore, the Supplier shall submit
certification records of welding and inspection personnel for review.

For each inspection or test, the Supplier shall give the Purchaser or his appointed
supervisor timely notice. The Quality Inspection Plan shall include, but not be
limited to the following:
• Incoming steel material
• Incoming mechanical and electrical buy-out components
• Traceability of material and components from the prime mill source to final
assembly
• Steel cutting, forming and machining
• Heat treating, stress relieving and other special treatments
• Weld preparation and quality of welds
• Dimensional accuracy and flatness
• NDT of welds
• Air pressure tests of sealed structures
• Sandblasting
• Coating
• Lower frame, upper frame, boom and trolley girder assemblies
• Fit-up, pre-assembly and tack welding of frames
• Verification of interfaces of each major structural assembly including welding
inspection and bolt torque verification

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• Overall dimensions
• Trolley rail alignment, evenness and straightness before and after assembly
• Gantry alignment
• Alignment measurement of trolley wheels
• Assembly of drives with regard to alignment, proper direction of rotation,
vibration, fit and adjustment of brakes
• Electrical wiring and equipment, including conduit, junction boxes,
enclosures, panels, interconnecting wiring
• Proper equipment, cable and wire identification marking
• Measuring and recording of all insulation resistances and loop impedances
• 30 mA injection tests for residual earth fault protection equipment
• Proper installation of all miscellaneous equipment and subsupplier’s products
• Accessibility
• Cleanliness, neatness and overall workmanship
• Final painting

The Supplier shall develop a program for NDT on all critical welds. Welds shall
be uniquely labelled on drawings and shall include a code defining the category of
weld. All welds and all weld testing shall meet DIN or AWS requirements. All
welds shall be tested 100% VT. Full penetration welds subject to tension shall be
tested 100% UT. Fillet welds on fracture critical members shall be tested
100% MT.

The Purchaser or the appointed supervisors may also ask for destructive tests or
chemical analysis of material samples from independent laboratories to the
account of the Supplier.

The Purchaser or the appointed supervisors may also participate in field

performance tests of the drive systems at the sub-supplier’s premises. The
Supplier shall give timely notice of such tests. In any case, the Supplier shall keep
record of all documents related to the buy-out components, such as data sheets,
OEM certificates, performance test records, safety tests, vibration test
measurements, etc. The records shall be handed over to the Purchaser for review.

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The Purchaser or the appointed supervisors shall have unlimited access to the
fabrication site, mills, warehouses and workshops of the Supplier and sub-
contractors. Inspection will be performed in such a manner that work is not
unnecessarily delayed, unless any work that is subject to inspection is completed
without approval of the supervisors or is rejected. The Supplier shall then, at his
own expense, remedy or have the work stopped until inspection and approval is
completed.

For the purpose of construction supervision, the Supplier shall provide free of
charge furnished offices including international telephone and high-speed Internet
access. Local transport within or between fabrication facilities as well as to/from
the hotel and airport shall also be provided free of charge.

13.3 Pre-Shipment Tests

If the crane is to be shipped fully erected, it shall be completely tested at the

Supplier’s facility before shipment.

Tests shall include, but not be limited to the following:

• Motion tests
• Maximum speeds and accelerations of all drives (with the exception of gantry,
if not possible)
• All interlocking functions
• All safety functions
• Brake tests
• Grab tests
• Miscellaneous function test such as bumpers, lighting, noise level, load cells,
elevator, etc.
• Load tests
• Dynamic and static overload tests (125% and 140% SWL)
• Rope-re-reeving device
• Crane weighing

Not later than 120 days prior to the commencement of tests, the Supplier shall
submit to the Purchaser a comprehensive test protocol for approval. The test
programme shall adequately demonstrate the crane’s compliance with these
specifications.

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The electrical vendor of the crane control and drive control system shall provide
qualified personnel to commission, test and fine-tune all controls and drive
systems. The personnel shall be present until the crane is shipped.

The Purchaser or his appointed supervisors shall be present for witnessing and
approval of tests.

13.4 Packing and Shipping

The crane shall preferably be shipped fully erected.

After pre-shipment inspection and testing at the Supplier’s facility in the presence
of the Purchaser or his appointed Supervisors, the cranes shall be loaded for
transportation. Proper lifting devices and securing arrangements shall be used, in
order to protect cranes against any damage during loading and in transit. Loading
and transportation shall be done in compliance with international transportation
rules. 60 days prior to shipment, the Supplier will submit for review his sea
fastening drawings and calculations for loading and securing the cranes on the
vessel as well as the unloading procedure at the Purchaser’s port. An independent
marine surveyor shall inspect and approve provisions taken for ocean transport. A
copy of his certificate shall be submitted to the Purchaser prior to the departure of
the vessel.

All mechanical and electrical equipment shall be properly covered and secured to
prevent damage from movement, moisture, storm conditions, etc. Space heaters
shall be powered during the voyage.

To avoid any paint or structural damage when removing by flame cutting, all sea
fastening shall be installed permanently or bolted to the crane. Thus they have to
be installed in a manner to avoid any interference with operation or obstruct
visibility of the driver. However, during loading and unloading of the equipment,
the paint may be subject to damage. These damages shall be touched up with paint
supplied and shipped with the equipment.

If shipment is by ocean transport, all exposed surfaces shall be washed with fresh
water immediately after arrival. All salt spray shall be removed immediately at the
Purchaser’s site.

Except for repair of damaged items such as platforms, walkways, stairs and
ladders, field welding will not be allowed. Prior to repair of damage to any
structural members, the Supplier shall submit his methods of repair for review by
the Purchaser.

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The Supplier shall repair any damage of the Purchaser’s facilities occurring as a
result of his activities in off-loading, preparing and testing the cranes. This
includes damage to fender systems, curbs, dock surface, pavement and utilities.
All debris resulting from his activities shall be removed and properly disposed.

13.5 Provisional Acceptance Tests

After final erection, commissioning, adjustment and lubrication have been

completed and the crane has otherwise been made ready for operation, acceptance
tests shall take place at the Purchaser’s premises in the presence of the Purchaser
or his appointed supervisors. The Supplier shall furnish with his bid, information
about the site requirements for all activities concerning final assembly,
commissioning and testing at the Purchaser’s site.

The Supplier shall prepare formal test procedures for all required tests and submit
them to the Purchaser for approval 90 days prior to the scheduled acceptance tests.

The acceptance test shall include, but not be limited to:

• Safety features
• Interlocking functions
• Gantry tests
• Overload tests (110% and 125%)
• Semi-automatic operation
• CMS and RCMS tests
• Shake-down and endurance tests

The endurance test shall consist of full duty cycles with rated load. The duration
of these test cycles is to be repeated for 24 hours, the last eight (8) of which are to
be trouble-free.

During the endurance and overload testing, measurements are to be taken of the
voltage and ampere readings at the LV incoming line and drive motors; speeds as
well as temperature readings of motors, gear reducers and brakes. These
recordings shall form part of the test report to be established by the Supplier.

All instruments necessary for communicating and testing shall be provided by the
Supplier. The Supplier shall also furnish the operators unless otherwise agreed
with the Purchaser.

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In case the crane is to be shipped knocked-down and assembled at the Purchaser’s

site, the complete set of tests as specified in Chapters 13.3 and 13.5 have to be
carried out.

The Supplier is furthermore responsible for obtaining all regulatory body

inspection certificates necessary for the commercial use of the crane.

The electrical vendor of the crane control and drive control system shall provide
qualified personnel during final commissioning and acceptance testing. If not
stated otherwise in the contract, the personnel shall be present for a period of four
(4) weeks after the cranes have been provisionally accepted (i.e. taken into
commercial operation).

The Purchaser will provisionally accept the cranes only after:

• All tests have been completed to the satisfaction of the Purchaser
• All specified documentation has been provided
• Any spare parts used during the tests have been replaced
• Punch list items have been completed
• Manuals have been provided to the satisfaction of the Purchaser
• Training has been completed to the satisfaction of the Purchaser

Any agreed "punch list" items not completed prior to provisional acceptance shall
be completed during the initial three (3) months of the warranty period.

A final inspection of the cranes by the Purchaser and the Supplier shall also
include the clean-up of the area used by the Supplier.

13.6 Warranty Engineer

If not stated otherwise in the contract, the Supplier shall further delegate one
qualified mechanical and one qualified electrical engineer to remain at the
Purchaser’s Site for a period of six (6) months after the Equipment has been
provisionally accepted.

13.7 Final Acceptance

The cranes will be finally accepted after the end of the warranty period.

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14. TRAINING

The Supplier shall provide dedicated training for the Purchaser’s operating
and maintenance personnel on all equipment installed or furnished under
this contract.

The training sessions shall include operation, maintenance and servicing of all
mechanical and electrical components of the crane. For the drive and crane control
system training shall be provided by the vendor of the respective system(s). All
trainers shall specialise in their field and be fluent in the English language.

Not later than three months prior to shipment of the cranes, the Supplier shall
submit detailed instruction manuals to the Purchaser for review. The submittal
shall include the scope of training, dates of training sessions, names and
qualifications of the training specialists as well as samples of the training
contents.

The Supplier shall submit final and revised instruction manuals including all
comments made by the Purchaser not later than one month before arrival of the
cranes at the port.

14.1 Training prior to Provisional Acceptance

14.1.1 Operators’ Training

The Supplier shall carry out the operators’ training of the Purchaser’s staff during
and after the on-site commissioning period in the port. If not stated otherwise in
the contract, the training shall be for a minimum period of six (6) days for four (4)
groups of operators. The content shall include but not be limited to the following:
1. Instruction and hands-on training on the cranes’ start-up procedure
2. Instruction on lighting control and communication
3. Instruction and hands-on training on normal container handling operation in
the cab
4. Instructions on consoles and PLC monitor and touch-screen, as applicable
5. Instructions on video control system

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6. Instructions on sway-control and semi-automatic operations

7. Instruction and hands-on training on normal shutdown procedure
8. Instruction on the use of equipment for emergency features, such as
emergency stop buttons, escape routes, fire-fighting equipment, etc.

14.1.2 Maintenance Training

The Supplier shall carry out the maintenance training of the Purchaser’s staff after
final commissioning in the port has been completed. If not stated otherwise in the
contract, the training shall be for a period of ten (10) days for two (2) groups of
five (5) mechanics and five (5) electricians each. The content of the training shall
include but not be limited to the following:
1. Instruction and hands-on training on starting and shutdown procedure
2. Instruction and explanation of all the components and devices on the crane
(separately for electrical and mechanical staff)
3. Lectures on electrical/electronic control systems of the crane and adjustment
method/standards both in classroom and on the crane
4. Lectures on mechanical/hydraulic systems of the crane and adjustment
method/standard both in classroom and on the crane
5. Inspection, preventive maintenance and repair of operationally critical
components
6. Preventive maintenance routines for all mechanical, structural and electrical
equipment
7. Instruction on hands-on trouble-shooting and repair
8. Explanation of special tools, gauges or jigs
9. Instruction on the use of equipment for emergency features, such as
emergency stop buttons, escape routes, fire-fighting equipment,
communication, etc.

The training sessions shall include at least 50% mechanical/electrical contents

(separated for mechanics and electricians), 25% hands-on trouble shooting and
25% hands-on crane management system.

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14.2 Training after Provisional Acceptance

If not stated otherwise in the contract, six (6) months after provisional acceptance,
the Supplier shall arrange for a five (5) days’ training session for ten (10)
mechanics and ten (10) electricians.

The training session shall refresh the contents listed in Chapter 14.1.2 putting
emphasis on trouble-shooting and preventive maintenance. Additionally and
together with the Purchaser’s maintenance staff, the Supplier shall inspect each
crane delivered on this contract und conduct all function and safety tests. The
minimum time required per crane to complete maintenance inspection shall be
four (4) hours.

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15. MANUALS

The operations, maintenance and spare parts manuals shall cover all
components installed on the crane including those of third-party suppliers.
All manuals must be prepared and arranged in a user-friendly way complete
with detailed indexes, section dividers, cross-references, etc. Information
on components that are not installed shall be removed.

All documents must be in the languages as specified in Chapter 2.6. A digital

copy of the manuals shall be provided on a CD-ROM. All information shall also
be incorporated in the crane management system and shall be easily retrievable.

Two (2) hardcopies of documents shall be supplied in neat bound folders at least
three months prior to shipping of the crane for review by the Purchaser.

Four (4) copies plus one (1) CD-ROM of final manuals shall be delivered before
provisional acceptance of the cranes including the Purchaser’s comments.

Manuals shall conform to the following requirements and include:

• Operation manual including description of all operating functions, start and
shutdown of the crane
• Maintenance manual for lubrication and inspection of the cranes including
schedules for preventive routine and major maintenance of mechanical and
electrical equipment
• Routine and major inspection schedules for the structure
• The instructions shall include typical mechanical and electrical trouble-
shooting procedures for all installed equipment on the crane.
• Preventive maintenance, repair and overhaul instructions shall include
mechanical drawings and circuit diagrams of the machinery and electric
components including illustrations and exploded views and clarifying text.
The text shall be specific, concise, factual and clearly worded so that qualified
maintenance personnel without previous experience on the equipment are able
to follow the instructions. The instructions shall enable the maintenance
personnel to perform adjustments, minor and major repairs and overhaul,
complete or partial removal and replacement of units including disassembly
and reassembly of all mechanical and electrical components of the crane.
Details such as tolerances, capacities, and bolt torque rates, etc. shall be
indicated.

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• Software manuals including a list of PLC parameterisation

• A copy of all “as built” electrical record drawings (single line drawings,
wiring diagrams and cable lists). Every cable shall be listed with its cable
number, source and target (including electrical code number), length, type,
cross-sectional area, number of conductors, rated voltage and measured
insulation resistance.
• A part list containing all items of equipment on the crane, whether this item
was purchased by the Supplier or supplied by a third party. The manual shall
contain name of the device’s manufacturer, type, serial number, technical
details, and cross-reference to the electrical code numbers.
• Original spare part manuals for each item of equipment installed on the crane.
All references of spare part numbers and descriptions shall be to the original
equipment manufacturers name, part number and description and not to the
part number and description assigned by the Supplier (unless the Supplier is
the original equipment manufacturer). The Supplier’s part number and
description may be provided in addition to the required information.
• A "Crane Book" in English language. The crane book shall contain
information about the crane characteristics and commissioning test results. It
shall be delivered together with each single crane.
• A complete set of mechanical as-built drawings

Final “as built” documentation shall be supplied during the initial four (4) months
of the warranty period.

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16. SUPPLIER'S RECOMMENDED SPARE PARTS

AND SPECIAL TOOLS

The Supplier shall include in his Bid recommended special tools and spare
parts list.

16.1 Special Tools

The Supplier shall optionally quote in his Bid for:

1. Special electrical instruments, measuring/recording and testing devices
required for fault detection and maintenance/repair on the electric control
and drive system
2. Special mechanical tools required for the crane maintenance, repair and
inspection. These shall include, but not be limited to special adjusting tools,
snap ring pliers, impact wrenches and wrenches for bolts in excess of
38 mm body diameter as well as jacks for gantry and trolley. Each tool and
wrench shall be stamped so as to be easily identified as to its size and
special use, if any.
3. A wire rope lubticator shall be part of the Special tools.

16.2 Spare Parts

The Supplier shall submit with his Bid spare part lists including the following
information:
• Sequence number
• Supplier's part number
• Electrical code number
• Item description
• Quantity
• Unit price
• Total price
• Delivery time

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The spare parts shall be individually priced. Spare parts normally recommended
by the Supplier for a two years’ period shall be clearly marked. The Purchaser
may choose or not spare parts from the submitted list at a later project stage. The
Purchaser may also order parts directly from the respective subcontractor or
vendor.

16.2.1 Mechanical Spare Parts

The mechanical spare part list shall at least include:

• Hoist/grab, boom hoist, trolley and gantry gear box, one (1) of each type
(left/right as applicable)
• Hoist/grab, boom hoist and catenary sheaves complete with bearings, one (1)
of each size
• Gantry and trolley wheels, one (1) of each type
• Hoist/grab high-speed coupling, one (1) complete set
• Brake units for hoist, trolley, boom hoist gantry, one (1) of each type
• Each type of brake disc
• Brake assemblies such as each type of brake pad and linings, each type of
brake thruster
• Hoist/grab rope, one (1) set
• Slap blocks and UHMW rollers
• Hydraulic buffer, one (1) of each type
• Hydraulic spares including one (1) type of each hose, filter, gaskets, all kinds
of directional, check, pressure relief, butterfly and throttle valves,
thermometers, manometers, float switches, pumps and solenoid valves
• One festoon carrier assembly including saddle, rollers, buffers, steel rope,
expanders
• Any other spare part the Supplier deems necessary for two years of operation.

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Technical Specifications for two 38 t Ship Unloader Cranes 140

16.2.2 Electrical Spare Parts

The electrical spare part list shall at least include:

• One (1) motor for hoist/grab, trolley/cabin, boom, gantry, MV cable reel
• Power inverters, one (1) of each type
• Each type of power semi-conductor device used on the crane including
thyristors, power rectifiers, diodes, excluding diodes mounted on printed
circuit boards.
• CPU rack including power supply
• Electronic circuit boards used on the crane including boards used in the PLC,
drive control system, CMS system, crane overload/weighing system, crane
diagnostic system, or intercom system, one (1) of each type and size
• Input/output cards and modules, one (1) of each type and size
• Consumable protective device including the control fuses, motor protection
fuses or semi-conductor fuses, circuit breakers, contactors, one (1) of each
type
• Master control switch, one (1) of each type
• Festoon cable/power chain cable, one (1) of each type
• MV trailing cable, one (1) full length
• Limit switches, encoders, proxy switches, one (1) of each type
• Air-craft warning light
• Gantry flash warning light
• Load cell
• Each size floodlights, two (2) per crane
• Walkway lights, two per crane
• 10% fluorescent lamps and bulbs
• Boom/ship, crane/crane ultrasonic/laser anti-collision devices
• Convenience and welding outlets
• Any other spare part the Supplier deems necessary for two (2) years of
operation

HPC Hamburg Port Consulting GmbH

Technical Specifications for one 38 t Ship Unloader Crane A

ANNEX 1: CLAUSE-BY-CLAUSE COMMENTS TO THE

TECHNICAL SPECIFICATIONS

The Supplier shall furnish a list with clause-by-clause comments containing all
deviations/alterations or options from the given Technical Specifications of the
Tender Document.

The list shall refer to the numbers in sequence of these Technical Specifications in the
following way:

Item No. Required by the Purchaser Deviation

1.1
1.2
1.3
…

HPC Hamburg Port Consulting GmbH

Technical Specifications for one 38 t Ship Unloader Crane B

ANNEX 2: PREFERRED SUB-SUPPLIERS

Bidders shall observe the preferred Sub-supplier list contained in the Technical
Specification but are free to list more than one and alternative sub-suppliers against
each item of the component. Quoted rates and prices will be deemed to apply to
whichever Sub-supplier is appointed, and no adjustment of the rates and prices will be
permitted.

The Purchaser reserves the right to delete any proposed Sub-supplier from the list prior
to award of contract. During contract negotiation the list shall be completed, stating the
approved Sub-supplier for each item.

No. Component Preferred Sub-Supplier Offered Sub-

Supplier
1 Electrical drive systems Siemens
2 Grab Verstegen
3a Belt feeder Beumer, FAM
3b Vibrators
4 Subcontractor for structure fabrication
5 AC Motors Hoist/Grab Siemens
Boom hoist Siemens
Trolley Siemens
Gantry Siemens
6 Electrical switchgears MV
Siemens
LV
7 MV transformer Siemens
8 Gear reducers Hoist/Grab
Boom hoist
Trolley Flender
Gantry
Emergency drives
9 Service brakes Hoist/Grab? Bubenzer
Boom hoist
Trolley
Gantry
10 Emergency brakes Boom hoist Bubenzer
11 Couplings Hoist/Grab
Boom hoist Flender, Bubenzer
Trolley / Gantry
12 Wheels Gantry
Trolley
13 Wire ropes Hoist/Grab
Boom hoist Bridon
Catenary trolley

HPC Hamburg Port Consulting GmbH

Technical Specifications for one 38 t Ship Unloader Crane C

No. Component Preferred Sub-Supplier Offered Sub-

Supplier
14 Sheaves Gosan
15 Rail brakes Bubenzer, Sibre, Hillmar
16 Personnel lift Alimak,
17 Machinery house crane
18 Rail clip system Gantrex
19 Hydraulic equipment Vickers, Parker
20 Hydraulic Buffer Gantry/Trolley Oleo Europe
21 Lubricants
22 Cable reels MV cable Wampfler
23 Cables MV cable Prysmian
23 Festoon system Wampfler,
24 Festoon cables Prysmian
25 PLC Siemens
26 CMS Siemens
27 Telecommunication systems Gai-Tronic, Vershoven
28 Air-conditioning equipment York, all AC units to be
from the same
manufacturer
29 Bearings Drives
Sheaves FAG, INA, SKF
Wheels
30 Encoder Hübner, Pepperl &
Proxy switches Fuchs, Schmersahl,
Limit switches Eurchner, Turck
31 Load cells PAT
32 Paint supplier Hempel, Jotun
33 Floodlights Philips
34 Entire operator’s cabin Brieda
35 CCTV system
36 Fire fighting system
36 Anti-collision system Sick

HPC Hamburg Port Consulting GmbH

Technical Specifications for one 38 t Ship Unloader Crane D

ANNEX 3: PARTICULARS OF DRIVES

Drives Hoist/Grab Gantry Trolley/Cabin Boom

Hoist

Motors
Manufacturer
Type of motor
Quantity
Enclosure IP rating
Class of insulation/
temperature rise
Type of cooling
Rating (kW)
RPM at rated output
Voltage
Duty rating
Quantity of inverters

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Technical Specifications for one 38 t Ship Unloader Crane E

ANNEX 4: WHEEL LOAD SUMMARY

Wheel loads shall be indicated under the specified wind speeds blowing in the
most severe direction considering rated load in the extreme outreach or
backreach position respectively.

Waterside Landside

Max. single wheel load in operating condition,

max. operating wind speed (kN)
Max. single wheel load in stowed condition, max.
stowed wind speed (kN)
Wheel spacing (mm)
Max. uniform distributed load at quay (kN/m)
Max. corner load (kN)
Max. horizontal load in parallel to the rail (kN)
Max. horizontal load perpendicular to the rail
(kN/m)

The wheel load calculation shall adhere to FEM and include at least the following
combinations:

Wheel Load Combinations

Type of load Operating condition Stowed condition
WOP0 WOP1 WOP2 WOP3 WOP4 WOP5 WS1 WS2
Boom Boom Boom Boom Boom Boom Boom Boom
down down down up down down up down
DL Dead load x x x x x x x x
TL Trolley load x x x x x x x x
LS Lifting System x x x x x x x x
LL Lifted Load x x x x x
IMP Impact load x
LATT Trolley lateral load x
LATG Gantry lateral load x
COLG Gantry collision load x x
COLT Trolley collision load x
WLO Wind load operating x x x x x
WLS Wind load stowed x x

HPC Hamburg Port Consulting GmbH

Technical Specifications for one 38 t Ship Unloader Crane F

ANNEX 5: ANCHOR, TIE-DOWN FORCES AND

BUFFER FORCES

kN

Max. anchor forces

Max. tie-down forces
Max. gantry buffer forces

HPC Hamburg Port Consulting GmbH

Technical Specifications for one 38 t Ship Unloader Crane G

ANNEX 6: OTHER DOCUMENTS TO BE PRESENTED

Apart from the previous information to be filled in the previous annexes, the
Supplier shall present with its Bid the following additional documents:

• Proposed single line diagram

• Total power consumption
• Proposed paint specification
• PLC/CMS and RCMS description
• Semi-automatic description
• Communication system
• Unloading, assembly, testing space requirements
• List of tools
• List of spares as specified
• Layout of Operator’s Cabin and Consoles
• Conveyor belt and drive details

HPC Hamburg Port Consulting GmbH

Technical Specifications for one 38 t Ship Unloader Crane H

ANNEX 7: LAYOUT OF OPERATOR’S CABIN AND

CONSOLES

HPC Hamburg Port Consulting GmbH

Technical Specifications for one 38 t Ship Unloader Crane I

ANNEX 8: COLOUR SCHEME

The colour scheme is for information purposes only. The final layout and colour
code is to be agreed during the design stage.

Item Description Colour RAL

1 Main Structures
1a Main steel structure blue
1b Boom blue
1c Gantry (bogies, equalizer, rail brake, red
anchor, etc.)
1d Hopper blue
1e Spillage Flap Tbc
2 Stairs, Walkways, Platforms; Galvanised and painted,
Ladders tbc
3 Machinery /E-House
3a Outside Tbc
3b Inside White grey 9002
3c Floor White grey 9002
4 Trolley/Cabin Tbc
5 Operator’s Cab
5a Outside Tbc
5b Inside White grey 9002
7 Maintenance Crane Traffic orange 2009
8 Hydraulic Unit Enclosures Tbc
9 Mechanical Components
9a motors and reducers installed outside Tbc
9b Motors and reducers installed inside the Standard of the Supplier
machinery house
9c Brakes Standard of the Supplier
9d Wheels Black 9005
9e Sheaves Tbc
10 Guards for Rotating Parts Tbc, with black stripes 9005
14 Miscellaneous
14a Cubicles panels, large junction boxes grey
installed inside
14b Obstacles Tbc with black stripes 9005

HPC Hamburg Port Consulting GmbH

Technical Specifications for one 38 t Ship Unloader Crane J

ANNEX 9: DOCUMENTS TO BE SUBMIITTED BY THE

SUPPLIER FOR APPROVAL DURING
DESIGN REVIEW

If not otherwise stated in the contract, the following documents shall be

submitted to the Purchaser no later than three (3) months after the contract
agreement coming into force.

HPC Hamburg Port Consulting GmbH

Technical Specifications for one 38 t Ship Unloader Crane List of Abbreviations

ANNEX 10: LIST OF ABBREVIATIONS

Abbreviation Description
' Foot/feet
" Inch/es
A Ampère
AC Alternate current OR air condition
ALM Active line module (Siemens only)
cm Centimetre/s
CMMS Computerised maintenance management system
CMS Crane management system
dB(A) A-weighted Decibel
DC Direct current
dft Dry film thickness
EMV = EMC Electromagnetic compatibility
ETFE Ethylene-tetrafluorethylene
g Ground acceleration
h Hour
HB Hardness Brinell
HV High Voltage
Hz Hertz
I/O Input/output
IGBT Insulated gate bipolar transistor
IT Information technology
IWRC Independent wire rope core
kV Kilo Volt
kVA Kilo Volt Ampère
kW Kilo W att
kWh Kilo W att hour/s
l Litre/s
LAN / WLAN Loca area network / Wireless local area network
LCD Liquid-crystal display
LCMS Local crane management system
LS Landside
LV Low Voltage

Pull
m Metre/s
M&R Maintenance and repair
mm Millimetre/s
ms Milliseconds
MV Medium Voltage
N Newton
NDT Non destructive testing
OEM Original equipment manufacturer
PC Personal computer
PE / PEN Protective earthing / Protective earthing neutral
PIV Peak inverse Voltage
PL Performance level
PLC Programmable logic control
PVC Polyvinyl chloride
RAID Redundant array of independent discs
RCMS Remote crane management system
RMG Rail-mounted gantry (crane)
rpm Revolutions per minute
RTG Rubber-tyred gantry (crane)
s Second/s
SAOS Semi-automatic operation system
SIL Safety integrity level
STS Ship-to-shore (container gantry crane)
t Ton/s
Tbc To be confirmed
TLS Trim list skew
UHF Ultra high frequency
UHMW Ultra high molecular weight
UV Ultraviolet
V Volt/s
VDC Volts direct current
VHF Very high frequency
W Watt
W/m²K Watt per squaremeter Kelvin
WS Waterside
XLPE Cross-linked polyethylene

HPC Hamburg Port Consulting GmbH