BIDDERS’ CONFERENCE IT-3980 Dismantling, Refurbishment, Replacement and Supply of Electrical Overhead Travelling Cranes Up to 10 Tons Capacity 20 March

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BIDDERS’ CONFERENCE IT-3980Dismantling, Refurbishment, Replacement and Supply of Electrical

Overhead Travelling Cranes Up to 10 Tons Capacity

20 March 2014 Handling Engineering Group

Technical Specification

Handling Engineering Group 3

Technical Specification

• Scope of the supply• Delivery schedule• Documentation• Site activities

20 March 2014


Scope of the Supply

• Following our planning, ~ 50 cranes are foreseen to be subject to intervention in the next 5 years

• Dismantling, replacement of obsolete EOT cranes as well as the supply, installation and commissioning of new ones

• Five years blanket purchase contract

• Definition of a catalogue of prices (IT-3980_EN UPL)

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Scope of the Supply

Catalogue of prices is structured as follows:

• Dismantling of cranes (section 1)• Supply of new cranes (section 2)• Validation of existing rails – replacement of

existing rails (sections 3-4)• Replacement of feeding lines (section 5)• Installation equipment and manpower (section 6)• Additional features (section 7)

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Major characteristics of the supplyCrane A B C D E F G H

Construction (Single or double girder)

Single Single Single Single Single Double Double Double

Capacity [ton] 1 2 5 7.5 10 5 7.5 10

Span [mm] 12 000

Lifting Height [mm] 5000

Rails length [m] 50

Hoisting speed [m/min] 6

Cross travel speed [m/min] 10

Long travel speed [m/min] 25

Frequency converter Yes, on each direction

Brake Self-braking motor

Hook type Double, DIN-15402

Catwalk Yes, one

Access gate Yes, from both sides

Trolley feeding line Cable chain

Main operator control Remote Control incl. IR, HBC Radiomatic

Emergency operator control Push button sliding along one girder

Safety zones Two adjustable safety areas (in long and cross travel direction) where access of the hook is avoided; controlled with limit switches.

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Interventions

Category of intervention Reference section

1 Dismantling of an EOT crane See 2.2.1 herein

2 New EOT crane See 2.2.2 herein

3 Validation of existing rails See 2.2.3 herein

4 Replacement of rails See 2.2.4 herein

5Replacement of electrical feeding line (Sliding contacts, Wampfler or Vahle)

See 2.2.5 herein

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Installation equipment and manpower

Item Description

1 Rental of a 200 ton mobile crane

200 ton mobile crane, transfer and operator included

2 Rental of a 20 ton truck crane

20 ton truck crane, transfer and operator included

3 Rental of a scissor platform Scissor platform with a lifting height of 10m for two operators, transfer included

4 Team of two technicians Intervention of a team of two technicians on the CERN site, inclusive of all costs such as, but not limited to, travel and subsistence costs

5 Team of three technicians Intervention of a team of three technicians on the CERN site, inclusive of all costs such as, but not limited to, travel and subsistence costs

6 Specialist Intervention of a specialist (engineer, automation technician) on the CERN site inclusive of all costs such as, but not limited to, travel and subsistence costs

7 Work planning for radiation areas

Preparation work for installations in radiation areas with increased exposure risks (meetings attendance, documentation). See § 6.4.1 herein

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Additional featuresAdditional features Description

1 Span decrease Decrease from 12000 mm to 4000 mm 2 Span increase Increase from 12000 mm to 25000 mm 3 Lifting height increase Increase from 5000 mm to 14000 mm

4 Anti-collision system between cranes

See § 8.6 of Annex 1

5 Lighting Additional lamps for lighting the crane

working area

6 PLC control Design and supply of the components and

software, including a HMI touch panel. See Annex 2.

7 Coupled operation (master - slave system)

See § 4.23 of Annex 1

8 3-D safety zones See § 4.22 of Annex 1

9 Electronic safety barriers Photocells on the walkway to detect the presence of people and avoid any crane

movement

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Order procedure

• Items will be ordered by the means of release orders

• Each order will be accompanied by a questionnaire specifying: Technical data of the crane subject to intervention Type of activity (dismantling, supply, replacement…) Additional features Context of installation

• Contractor will be required to confirm the price

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Order procedure

• Prices for items which are not covered will be extrapolated from the catalogue of prices

• Negotiation before order

• No committment to order

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Provisional schedule for the interventions

Category of intervention

Submission of design report

(Max. time after the release order)

Delivery / installation

(Max. time after the release order)

Acceptance tests at CERN /

Completion of works(Max. time after the

release order)

1 Dismantling of an EOT Crane - - 6 weeks

2 Validation of Rails - - 6 weeks

3Replacement of Electrical Feeding Line

2 weeks 1 month 6 weeks

4 Supply of a New EOT Crane 2 weeks 6 weeks 2 months

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Documentation

Format for Electronic Documents

The contractor shall submit all documents produced in electronic format:

Final 3-D models in a format compatible with CATIA®;

Drawings in PDF®, AUTOCAD® and/or HP-GL® format;

Text documents in Microsoft Word® and PDF® format;

Lists of cables and bills of materials in Microsoft Excel® and PDF® format;

Schedules in Microsoft Project® and PDF® format;

Electric circuit diagrams in a format compatible with IGE-XAO SEE Electrical® and PDF® format.

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Documentation

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16. DOCUMENTS TO BE ATTACHED TO THE BIDThe bidder shall submit the following technical documents together with his bid: An example (i.e. a standard template used by the bidder) of mechanical layout drawings containing at least the following information: hook in its extreme positions in the three directions, minimum gap between the crane and the fixed obstacles, installed power and loads transmitted from the wheel to the rails and details of access ways to the crane and of the maintenance areas;An example of an electrical circuit diagram;An example of graphical functional description of the control system behavior (see Annex 2 of the technical specification);An example of the electrical cubicle layout drawings;An example of the operator control’s layout;An example of a risk assessment;An example of an installation method statement containing at least the following information: mobile crane used and its position, sequence of operations and means of protection;An example of a proposed maintenance plan for a new crane covering the two years warranty period to be carried out by the contractor as part of the supply;An additional five years maintenance plan for a new crane starting after the warranty period. CERN reserves the right to disqualify any bidder who does not supply all the requested documents.


Documentation4.3 Documentation Set for Design and Schedule ApprovalFor each EOT crane covered under a release order, the contractor shall submit to CERN for approval (see § 5.5.3 herein) the following set of documents as part of the design report:

4.3.1 Mechanical and Electrical Design Information• Risk assessment (referring to EN ISO 12100 Safety of Machinery); • Mechanical layout drawing showing the following information: hook in its extreme positions in the three directions, minimum gap between the crane and the fixed obstacles, installed power, loads transmitted from the wheel to the rails and details of access ways to the crane and of the maintenance areas;• Electrical circuit diagrams;• Electrical cubicle layout drawings;• When applicable, graphic functional description of the control system behaviour (see Annex 2);• Layout of operator controls.

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Documentation4.4 Documentation Set to be provided to CERN Prior to Factory Acceptance Tests Before the factory acceptance tests, the contractor shall provide to CERN for approval:

4.4.1 Factory Acceptance Tests Procedure…

4.4.2 Full Set of Technical DocumentsThis shall comply with European Directives: 2006/42/EC, 2004/108/EC and 2006/95/EC:

• Mechanical and electrical design information (“as-built” versions of the mechanical and electrical design – including mechanical detail drawings with definitive weights);• Final 3-D model of the crane for integration into CERN’s infrastructures layout;• Bill of materials including the following information: manufacturer, manufacturer’s model, price, lead time, dimensions in mm, weight; the contractor shall highlight the recommended spare parts with the ordering details;• Separate list of all bearings installed on the crane (including those which are contained in commercial parts). For each bearing, the following information shall be provided: manufacturer, code, location (e.g. long-travel wheel axle);• List of electrical cables;• Operating and maintenance manuals in English AND French (complete manual structure according to European Directive 2006/42/EC);• Separate operator’s manual, in English AND French, including all important crane characteristics and use instructions.

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DocumentationDocumentation Set to be Delivered at the Time of Acceptance Testing at CERN

In addition to electronic versions, three paper copies of the following documentation shall be provided:Technical file as defined by the following European Directives: 2006/42/EC, 2004/108/EC and 2006/95/EC;Instructions for lifting machinery as defined by Directive 2006/42/EC;CE certification of the crane and documentation and certificates part of the supply; acceptance will not be granted until all documentation duly updated has been received;When applicable, PLC documentation as per Annex 2.If, after a period of operation, it becomes apparent that additional instructions are needed, the contractor shall provide these instructions at CERN’s request at no additional cost.Any modifications made during assembly, commissioning and during the warranty period by the contractor for whatever reason shall be integrated into the documentation at no additional cost and the updated copies shall be sent to CERN within two weeks after each modification.

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Site Activities

5.9.1 Joint Inspection Visit at CERN Once a release order is placed and at least two weeks before the start of any dismantling or installation work, a joint visit will be organized by CERN. The contractor shall, together with CERN, evaluate the dismantling or/and the installation work and establish the work methods and risks related to the work to be carried out by the contractor.The contractor’s technical responsible shall participate in the joint inspection visit and shall ensure that all work methods and safety information as listed in § 6 herein will be respected and all safety documentation has been completed and can be presented. CERN might request the contractor to revise his documentation following the joint inspection visit.

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Site Activities

5.9.2 Execution of Dismantling and Installation Works at CERN The dismantling works shall start only after arrival at CERN of the new equipment forming part of the supply.During installation works, the contractor’s personnel shall respect all procedures and safety precautions defined in the contractor’s installation method statement and the safety files accepted by CERN. It is the contractor’s responsibility to ensure that his personnel is trained and authorized to perform the works concerned.Waste shall be handled in accordance with chapter 3.22 of the document Working on the CERN Site document (https://edms.cern.ch/document/1155899/5.0); special attention shall be given to dismantling of equipment containing oil in order to avoid the contamination of the ground.The contractor shall assign a sufficient number of qualified personnel as stipulated in clause 11 of the General Conditions of CERN Contracts.

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https://edms.cern.ch/document/1155899/5.0


Site Activities

5.9.3 Lifting Manoeuvres at CERN The contractor shall be responsible for the execution of all lifting manoeuvres on site. The main lifting operations shall be studied, planned and documented by the contractor as part of the design study work.The execution includes the supply to CERN of sufficient and experienced personnel and of all tooling, access and lifting equipment (such as mobile working platforms, mobile cranes and forklifts) necessary for dismantling, installation and commissioning of the EOT cranes. The contractor is responsible for the correct registration of his personnel.Only electrically powered lifting equipment shall be used in the underground areas.Note: In case of underground installation, the contractor shall be responsible for the handling operations needed to remove obsolete components and assemblies from the cranes and to take them to the bottom of the access shaft, from where they will be handled by CERN transport personnel. The same applies for the handling operations needed for the installation of new components.

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Site Activities

6.4 Works in Radiation AreasSome cranes covered by the contract might be installed in areas where workers may be exposed to ionising radiation. In order to access a radiation area, the contractor must comply with all the requirements of § 3.13, 3.14 and 3.15 of the document “Working on the CERN Site”. The contractor remains responsible to obtain the relevant authorisations for work in radiation areas from the competent body in the CERN member state where he is established and its recognition by the CERN host state concerned. The contractor must organise the dosimetric follow-up of his personnel and provide basic training on the risks associated with the exposure to ionising radiation.At the start of the contract, the contractor shall foresee an additional 2.5 days for obtaining the required dosimeter, access and work authorizations during which he shall attend, at his own cost, a radiation protection course as described in § 3.13 of the document "Working on CERN site".

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Site Activities6.4.1 Work planningWork in areas representing a risk of increased exposure to ionising radiation will require the contract or to observe special precautions to limit the exposure of his personnel; he will be requested to attend two to three coordination meetings at CERN and to submit a detailed description of all the phases of the dismantling and installation works. The detailed work planning including the adopted work methods is subject to formal approval by the relevant CERN bodies before the start of the work. Note that only the planned and agreed work methods are authorised; any changes are subject to further approval. It may be required for the personnel to wear personal protective equipment such as respiratory masks or protective clothing (to be provided by the contractor).6.4.2 Material and waste controlEquipment and materials used in and removed from radiation areas are subject to radiological control by CERN. Produced waste remains property of CERN and shall remain at CERN and shall not be eliminated by the contractor. The contractor shall inform CERN without delay of any such case. An estimate in terms of waste volume, weight and type must be provided before the start of work.

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