SPECIFICATIONS FOR ONE (1) SHIP LOADER AT MCDUFFIE COAL TERMINAL DOCK NO. 1 MOBILE, ALABAMA FOR ALABAMA STATE PORT AUTHORITY REVISION: 0 M3169 SPECIFICATIONS FOR ONE (1) SHIP LOADER AT MCDUFFIE COAL TERMINAL DOCK NO. 1 MOBILE, ALABAMA FOR ALABAMA STATE PORT AUTHORITY ASPA/SHAW SHAW GBB CONFIDENTIAL THESE DOCUMENTS AND ANY PRINT MADE THEREFROM ARE THE PROPERTY OF ASPA/SHAW GBB, L.L.C., AND MUST BE RETURNED WITHOUT REPRODUCTION OR DUPLICATION UPON REQUEST OF ASPA/SHAW GBB, L.L.C.. INFORMATION HEREON IS CONFIDENTIAL AND MUST NOT BE RELEASED OUTSIDE OF ASPA/SHAW GBB, L.L.C., WITHOUT PROPER AUTHORIZATION AND MUST BE PROPERLY SAFEGUARDED WHILE IN THE POSSESSION OF THE RECIPIENT AGAINST UNAUTHORIZED DISCLOSURE EXCEPT TO AUTHORIZED EMPLOYEES OR SUBCONTRACTORS OF THE RECIPIENT WHO REQUIRE THE INFORMATION FOR THE SPECIFIED PROJECT. THE RECIPIENT, THE RECIPIENTS EMPLOYEES AND SUBCONTRACTORS AGREE TO KEEP CONFIDENTIAL THE INFORMATION IN THESE DOCUMENTS AND ANY PRINTS MADE THEREFROM. APRIL 2009 M3169 Table of Contents SECTION 1 – SHIP LOADER CHARACTERISTICS (MINIMUM REQUIREMENTS)........1-1 1.1 GENERAL DESCRIPTION AND PERFORMANCE....................................................1-1 1.2 CAPACITY......................................................................................................................1-2 1.3 PRINCIPAL DIMENSIONS AND MINIMUM OPERATING SPEEDS......................1-2 1.4 PERFORMANCE AND DUTY CYCLE........................................................................1-3 1.5 MINIMUM DESIGN CRITERIA...................................................................................1-3 1.6 GENERAL OPERATING ENVIRONMENT AND CONDITION................................1-4 1.7 TELESCOPING SPOUT AND ROTATING SPOON....................................................1-5 1.8 TRIPPER MECHANISM................................................................................................1-5 1.9 LUBRICATION..............................................................................................................1-5 1.10 CONTROL SYSTEM......................................................................................................1-6 1.11 REMOTE CONTROL STATIONS.................................................................................1-6 1.12 POWER SUPPLY............................................................................................................1-6 1.14 SITE ACCEPTANCE......................................................................................................1-7 1.15 DRAWING INDEX.........................................................................................................1-8 SECTION 2.0 - TECHNICAL REQUIREMENTS.....................................................................2-9 2.1 STANDARD SPECIFICATIONS..................................................................................2-9 2.2 WORKMANSHIP...........................................................................................................2-9 2.3 MATERIALS...................................................................................................................2-9 2.4 ENCLOSURES..............................................................................................................2-12 2.5 GLOSSARY OF TERMS..............................................................................................2-12 2.6 SAFETY........................................................................................................................2-14 SECTION 3 - DESIGN CONDITIONS....................................................................................3-15 3.1 OPERATION FUNCTIONS AND MODES.................................................................3-15 3.2 STOWED MODE..........................................................................................................3-15 3.3 LOADER DESIGN LOADS.........................................................................................3-15 3.4 LOAD COMBINATION...............................................................................................3-17 3.5 SPEEDS.........................................................................................................................3-17 3.6 DUTY CYCLE..............................................................................................................3-17 SECTION 4 - STRUCTURAL SPECIFICATIONS.................................................................4-19 4.1 GENERAL.....................................................................................................................4-19 4.2 LOADER STRUCTURE...............................................................................................4-19 4.3 CONNECTIONS...........................................................................................................4-21 4.4 MINIMUM LOADS......................................................................................................4-22 4.5 MINIMUM LOADER STABILITY.............................................................................4-22 4.6 ALLOWABLE STRESSES...........................................................................................4-23 4.7 STRUCTURAL MAINTENANCE PROGRAM..........................................................4-23 4.8 AS-BUILT WHEEL LOAD TEST / VERIFICATION.................................................4-23 SECTION 5 - MECHANICAL SPECIFICATIONS.................................................................5-25 5.1 GENERAL.....................................................................................................................5-25 M3169 5.2 GANTRY DRIVE..........................................................................................................5-27 5.3 BOOM HOIST/SHUTTLE (IF USED).........................................................................5-29 5.4 BOOM TELESCOPING MECHANISM......................................................................5-30 5.5 GEARING......................................................................................................................5-31 5.6 COUPLINGS.................................................................................................................5-32 5.7 BEARINGS AND SEALS.............................................................................................5-33 5.8 SHEAVES, ROLLERS, AND DRUMS FOR WIRE ROPE.........................................5-34 5.9 WIRE ROPE..................................................................................................................5-35 5.10 CONVEYOR EQUIPMENT.........................................................................................5-36 5.11 LUBRICATION............................................................................................................5-41 5.12 HYDRAULIC SYSTEM...............................................................................................5-41 5.13 COLLISION PREVENTION AND BUMPERS...........................................................5-44 5.14 GANTRY SECURING DEVICES................................................................................5-44 5.15 LOADER ALIGNMENT...............................................................................................5-46 5.16 EQUALIZER PINS.......................................................................................................5-46 SECTION 6 - ELECTRICAL SPECIFICATIONS...................................................................6-47 6.1 GENERAL.....................................................................................................................6-47 6.2 MAIN POWER CABLE AND CABLE REEL.............................................................6-49 6.3 MAIN POWER DISTRIBUTION SYSTEM................................................................6-50 6.4 AUXILIARY POWER TRANSFORMERS..................................................................6-51 6.5 GROUND FAULT PROTECTION...............................................................................6-52 6.6 WIRING AND CONDUIT............................................................................................6-52 6.7 SPACE HEATERS........................................................................................................6-54 6.8 MOTORS AND BRAKES............................................................................................6-55 6.9 CONTROL EQUIPMENT.............................................................................................6-56 6.10 CONTROL SYSTEM....................................................................................................6-57 6.11 ENHANCED DIAGNOSTIC MANAGEMENT SYSTEM..........................................6-61 6.12 MOTOR CONTROL CENTER.....................................................................................6-61 6.13 CONTROLS..................................................................................................................6-61 6.14 SWITCHES AND RECEPTACLES.............................................................................6-63 6.15 PANELBOARDS AND TERMINALS.........................................................................6-63 6.16 LIGHTING SYSTEM....................................................................................................6-65 6.17 LIMIT SWITCHES & INTERLOCKING.....................................................................6-66 6.18 COMMUNICATION SYSTEM....................................................................................6-70 6.19 GROUNDING...............................................................................................................6-70 6.20 MACHINERY HOUSE VENTILATION.....................................................................6-71 6.21 NAMEPLATE, WARNING PLATES & CIRCUIT IDENTIFICATION....................6-71 6.22 BEARING BYPASS PROTECTION AND LIGHTNING PROTECTION.................6-72 SECTION 7 - MISCELLANEOUS EQUIPMENT...................................................................7-74 7.1 MACHINERY HOUSE.................................................................................................7-74 7.2 OPERATOR'S CAB......................................................................................................7-75 7.3 REMOTE CONTROL STATION AT THE MECHANISMS......................................7-76 7.4 VENTILATION.............................................................................................................7-77 7.5 STAIRS, LADDERS, PLATFORMS AND WALKWAYS..........................................7-77 7.6 FIRE SAFETY...............................................................................................................7-78 M3169 7.8 WORKBENCH..............................................................................................................7-78 7.9 TOOL AND EQUIPMENT LOCKERS........................................................................7-79 7.10 SPECIAL TOOLS.........................................................................................................7-79 7.11 WIND ALARM AND ANEMOMETER......................................................................7-79 7.12 NAMEPLATES.............................................................................................................7-80 7.13 WIRE ROPE RE-REEVING WINCH...........................................................................7-80 7.14 BOOM CONVEYOR ELECTRONIC SCALE.............................................................7-80 7.15 MANUAL MAINTENANCE HOIST...........................................................................7-80 7.16 NOISE LEVELS............................................................................................................7-81 SECTION 8 CLEANING AND COATING........................................................................8-82 8.1 GENERAL....................................................................................................................8-82 8.2 SURFACE PREPARATION.........................................................................................8-82 8.3 COATING APPLICATION..........................................................................................8-83 8.4 SPRAY APPLICATION...............................................................................................8-84 8.5 BRUSH APPLICATION..............................................................................................8-85 8.6 COATING SYSTEM A.................................................................................................8-85 8.7 COATING SYSTEM B.................................................................................................8-87 SECTION 9 SHIPPING AND ERECTION........................................................................9-88 9.1 GENERAL....................................................................................................................9-88 9.2 PACKING AND SHIPPING.........................................................................................9-88 9.3 PRE-SHIPMENT CERTIFICATE................................................................................9-89 9.4 DELIVERY....................................................................................................................9-89 9.5 CONTRACTOR SUBMITTALS..................................................................................9-89 9.6 CLEAN UP AND FINAL ACCEPTANCE...................................................................9-90 SECTION 10 QUALITY ASSURANCE............................................................................10-91 10.1 SCOPE.........................................................................................................................10-91 10.2 GENERAL...................................................................................................................10-91 10.3 RECORD KEEPING...................................................................................................10-92 10.4 INSPECTION METHODS..........................................................................................10-92 10.5 FABRICATION INSPECTIONS AND TESTS..........................................................10-97 10.6 SHOP ERECTION INSPECTION AND SHOP TESTS.............................................10-99 10.7 DELIVERY INSPECTIONS.....................................................................................10-101 10.8 ACCEPTANCE/PERFORMANCE TESTS..............................................................10-101 10.9 CERTIFICATION.....................................................................................................10-105 10.10 FINAL INSPECTION AND PUNCH LIST..............................................................10-105 SECTION 11 ADDITIONAL EQUIPMENT...................................................................11-106 11.1 GENERAL.................................................................................................................11-106 11.2 SPARE PARTS..........................................................................................................11-106 SECTION 12 – MAJOR COMPONENT SUPPLIERS.........................................................12-107 SECTION 13 – DRAWING AND TECHNICAL DATA, SUBMITTAL LIST, MINIMUM REQUIREMENTS & SCHEDULED SUBMITTAL DATES..................................13-109 M3169 SECTION 1 - SHIP LOADER CHARACTERISTICS (MINIMUM REQUIREMENTS) 1.1 GENERAL DESCRIPTION AND PERFORMANCE The scope of these Specifications shall include, but not necessarily be limited to, the design, supply, delivery, transportation, erection and testing of a traveling, rail-mounted ship loader, trailer and collapsible type tripper, complete with all other items contained in these Specifications, ready for service at the McDuffie Coal Terminal, Dock No. 1, Mobile, Alabama for the Alabama State Port Authority. The Loader shall comprise a rail mounted, electrically powered, traveling tower, gantry type structure capable of loading coal at a minimum discharge rate of 4500 metric tons per hour (defined at the rate at which coal can be transferred from a dock conveyor to vessel sizes ranging from 35,000 DWT, to Panamax 75,000 DWT, to Cape 150,000 DWT). The loader shall be capable of a minimum outreach of 40 ft. (12.19m) to maximum outreach of 100 ft. (30.48m) from the centerline of waterside rail to centerline of telescoping spout. It is required that the sizing, motion and conveyor speeds, and capacity be based on the following: • Material o Material description – Metallurgical Coal o Max. Lump size – 2” x 2” o Material density – 50 lbs/ft3 [801 kg/m3] 60 lbs/ft3 - [961 kg/m3] o Moisture content – 5 ~ 15% o Angle of Repose - 35 ~ 40o – 37.5o for design The Loader shall be equipped with luffing and telescoping type boom or shuttle type boom, capable of being moved to clear the design vessels’ structures. For luffing type, safety hatches shall be provided to secure the boom in its raised position, suitably interlocked with operating motion. The Loader shall be completely equipped in all respects with electric motors, motor controls, boom luffing and telescoping machinery, shuttling machinery (if used), traveling machinery, telescoping spout and rotating spoon, conveyor systems with chutes and hopper, trailer and collapsible type tripper, compatible with the existing dock conveyor, electrical protective devices, emergency and operating brakes, operator’s cab, machinery enclosures, all other essential items required to provide a complete, efficient and “trouble free” operating installation. The Loader shall be equipped to operate manually from operator’s cab or remotely with wireless controls, to maximize the efficiency of loading. Simultaneous conveying with any one of the other Loader motions (luffing, telescoping boom, shuttling boom (if used), gantry and telescoping spout/spoon). Remote control of individual operations, for maintenance purposes, will also be included. M3169 1-1 The boom telescoping shuttle movement shall be capable of extending the boom conveyor to any position from its fully retracted to fully extended limits and must be able to accomplish this movement if the boom is inclined up to 40 degrees above horizontal, in order to lift the loading spout over the hatch coaming of larger vessels. The operating incline (luffing) of the boom conveyor can vary from 8 degrees below horizontal to 12 degrees above the horizontal. The boom luffing can be raised from its lowest horizontal position to a fully raised position to clear the fender line. If shuttle type boom is used, the boom conveyor and telescoping spout will be capable of any position from maximum outreach of 100 ft. to minimum near waterside leg. The boom hoist or shuttle drive(s) and all electrical equipment shall be mounted upon the Loader structure with a properly accommodated protective enclosure. The electrical control equipment to be housed in a separate air-conditioned enclosure. The gantry drive system shall utilize totally enclosed reducers, without any open gearing. Structural, mechanical and electrical design, the loading condition, stability and duty cycles shall be as defined in the Specification and shall comply with the statutory requirements for safety, etc., as defined in Section 2.6. The structural fatigue life, mechanical durability and electrical thermal sizing requirements shall be based on the design rated loading capacity. The Loader shall be capable of continuous duty cycle operations at speeds up to full speed with the weight of material and shall comply with the requirements of the F.E.M. standards, Section II, “Rules for the Design of Mobile Equipment for Continuous Handling of Bulk Materials”. The duty cycle requirements and FEM classification are provided in later sections of these Specifications. The Loader shall be easily maintained and suitable for operation in the atmosphere conditions described in Section 1.6. These Specifications contain many references to “equal to” or “ASPA approved equal.” It will be ASPA’s right and discretion to approve or disapprove a Contractor’s alternative proposed supplier. 1.2 CAPACITY Rated Design 4500 MT(metric tons)/hour (Based on the coal delivered by a dock conveyor, with 72” belt width at a speed of 720 ft./min. The belt is located 33.0 ft. (10.06m) above the waterside rail.) 1.3 PRINCIPAL DIMENSIONS AND MINIMUM OPERATING SPEEDS The speeds and dimensions below are noted as minimum only. The Loader’s design must be based on achieving the capacity ratings noted above. Speeds and/or dimensions must be increased as necessary to achieve the ratings. M3169 1-2 Maximum Outreach from waterside rail (centerline rail to centerline maximum spout location) 30.48m (100 ft.) Minimum Outreach from waterside rail (centerline rail to centerline minimum spout location) 18.29m (40.0 ft.) Gage (Distance Between Rail Centers) 18.29m (60.0 ft.) Rail 135 lb/yd (75mm width) Belt Boom conveyor 72” width Trailing conveyor 72” width Minimum Telescoping Spout Distance 15.2M 50ft. Boom conveyor 720 fpm Trailer conveyor 720 fpm Clearance of Boom Structure Above Rail (Under Operating Conditions) (at 12 degrees for luffing type) 22.8m (75.0 ft.) Clearance Under Portal 12.19M 40 ft. Boom hoist time (from level to stowed position) 6 minutes Boom Telescoping 15 m/min (50 ft/min) Boom Shuttle (if used) 15m/min (50 ft/min) Gantry travel 30.5 m/min (100 ft/min) Minimum Number of Wheels Per Corner 4 1.4 PERFORMANCE AND DUTY CYCLE The Loader shall be capable of simultaneous loading and any other one motion (luffing, telescoping, shuttle (if used), telescoping spout/spoon, and gantry), along with all the necessary conveying components. All components and equipment shall be designed or selected to meet the most rugged, uninterrupted, bulk handling applications in extreme climatic and atmospheric conditions. Mechanical and electrical equipment shall be selected for the critical cycle involved, plus torque ratings and thermal heating capacity. The Contractor shall submit a theoretical duty cycle analysis for each drive prepared by the electrical control system supplier which verifies the adequacy of the selected equipment for the specified cycle. Each submittal shall include, but not be limited to, calculations and catalog information which substantiates the equipment design. (See Section 3.6) 1.5 MINIMUM DESIGN CRITERIA The Loader will comply, unless noted otherwise, in all respects with the current legislation and relevant regulation of the F.E.M. Section II, document FEM 2 131/ 2 132 “Rules for the Design of Mobile Equipment for Continuous Handling of Bulk Materials”, and relevant other design standards noted in these Specifications. The Loader shall be designed for continuous duty rating with service life greater than twenty-five (25) years and for continuous twenty- four (24) hours operation per day. The Loader shall be designed according to the following classification: Complete Machine: A8 Structural Components: E8 M3169 1-3 The drive mechanisms shall be designed according to the following classifications: MECHANISM CLASS OF SPECTRUM GROUP UTILIZATION CLASS Boom and Trailer T9 L4 M8 Conveyor Boom Shuttling (if used) T5 L4 M7 Boom Luffing T5 L4 M7 Boom Telescoping T5 L4 M7 Gantry Traveling T5 L4 M7 Classifications of individual structural and mechanical components shall be consistent with classification of the structure or mechanism containing the component. 1.6 GENERAL OPERATING ENVIRONMENT AND CONDITION The Contractor shall study the onerous climatic conditions which exist, as failure to do so may result in the production of a Loader and equipment unsuitable for the required application. The site of the works in Mobile, Alabama is in an area of high and low temperature and high humidity, which in conjunction with a salty, coal dust-laden marine environment produces very severe corrosive conditions. The design features, all material and equipment supplied and the protective treatment of steelwork must be designed for the following conditions: Item Low High Electrical -10°C 40°C Mechanical -10°C 40°C Structural -10°C 40°C (Plus allowance for solar radiation that may increase surface temperature to 50°C) Relative humidity Up to 100% The Loader and equipment will be designed to operate with minimum maintenance in the defined conditions, and care must be taken to ensure against overheating of the electrical and mechanical equipment, especially where exposed to direct sunlight. The Loader and its components shall be designed for wind loads as specified by local codes, but no less than those specified in Section 3.3, Loader Design Loads. The Loader and its components shall be provided with appropriate lightning protection. M3169 1-4 1.7 TELESCOPING SPOUT AND ROTATING SPOON The telescoping spout and rotating spoon is to be suspended from the discharge end of the conveyor with a hinged device which shall allow the spout to be tilted by hydraulic mechanism for loading. The telescoping spout shall be provided with a telescoping stroke of 50 ft. (15.24m). A height indicator shall be provided in the cab to indicate relative height of the spout. Telescoping shall be activated by an electrical winch. At the end of spout, it shall be equipped with a rotating spoon which shall be designed to be removable by quick disconnect clamps. The operator shall have complete control of the spoon from operator’s cab and via wireless remote station. The control of spoon shall be variable and shall allow operator to position the spoon in and out of the flow of material, elevate and rotate to allow maximum ”throw” of material, for distance and direction. The spoon shall be oversized as required so that there is no loss of material capacity. In order to service spoon, or stow, in the case of luffing boom, the boom shall be fully raised, shuttle retracted and spoon assembly lowered to a platform attached to A-Frame. If shuttle boom type crane, the spout shall be retracted to a location over dock and platforms be provided, as necessary, for maintenance. Spout shall have a hydraulic mechanism to tilt spout up to 25° for loading. 1.8 COLLAPSIBLE TRIPPER AND TRAILING CONVEYOR MECHANISM The collapsible tripper, which is to interface with the existing dock conveyor, and the trailing conveyor shall be provided as an integral part of the Loader. The tripper shall be capable of being raised or lowered depending on the mode of operation. It is preferable that the hoisting system (raising/lowering) shall be by means other than hydraulic, unless specifically approved otherwise by ASPA. The design of mechanical and electrical systems for trailing conveyor shall be identical to that required for boom conveyor and other pertinent sections of the Specifications. 1.9 LUBRICATION Speed reducers, enclosed gears, and gear type couplings shall be oil lubricated. High-pressure button type grease lubricating fittings shall be provided for all sheave bearings, shaft anti-friction bearings, sleeve bearings, pins and surfaces in sliding contact, and equalizer pins. Pins shall be drilled and grooved annularly at the midpoint of each bearing member. Each bearing member shall have separate lubrication passage and fitting. Motors shall be lubricated at the manufacturer’s plant and utilize a different type grease fitting. Wire ropes shall be internally and externally lubricated by the manufacturer with the manufacturer’s recommended lubricant. The Contractor shall submit a schedule indicating their complete lubrication plan, technical specification, and recommended maintenance procedure. (See Section 5.11). M3169 1-5