06_Specification - WIL Upper Boom Wall Brake Assembly Replacement.pdf

SECTION TABLE OF CONTENTS

Mechanical Brake

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 QUALITY ASSURANCE

1.4 CHANGES

1.5 DELIVERY, STORAGE, AND HANDLING

1.5.1 Critical Path Components/Systems

1.5.2 Delivery, Storage and Handling

1.5.2.1 Packaging

1.5.2.2 Shipping, Preservation, and Storage

PART 2 PRODUCTS

2.1 EQUIPMENT

2.1.1 Pinion Shaft

2.1.2 Bushings

2.1.3 Brake Wheel

2.1.4 Brake Arms

2.1.5 End Pin

2.1.6 Tension Bar

2.1.7 Compression Spring

2.1.8 Operating Lever

2.1.9 Nut

2.1.10 Link Pin

2.1.11 Spring Cap

2.1.12 Pin

2.1.13 Nut

2.1.14 Washer

2.1.15 Button Head Grease Fitting

2.1.16 Cotter Pins

2.1.17 Dowels

2.1.18 Eye Bolt with 4 Hex Nuts

2.1.19 Eye Bolt

2.1.20 Hook Bolt

PART 3 EXECUTION

3.1 GENERAL

3.2 FABRICATION

3.2.1 General

3.2.2 Material

3.2.3 Dimensional Tolerances

3.2.4 Alignment

3.2.5 Machining and Heat Treatment

3.2.6 Finished Surfaces

3.2.7 Unfinished Surfaces

3.2.8 Protection of Finished Work

3.2.9 Painting

3.2.10 Welding

3.3 QUALITY ASSURANCE

3.4 NONDESTRUCTIVE EXAMINATION

3.5 WARRANTY

-- End of Section Table of Contents --

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ASNT SNT-TC-1A (2016) Recommended Practice for Personnel Qualification and Certification in Nondestructive Testing

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

ANSI/AGMA 6001 (2008E; R 2014) Design and Selection of Components for Enclosed Gear Drives

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B17.1 (1967; R 2017) Keys and Keyseats

ASME B46.1 (2009) Surface Texture, Surface Roughness, Waviness and Lay

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015; Errata 1 2015; Errata 2 2016) Structural Welding Code - Steel

ASTM INTERNATIONAL (ASTM)

ASTM A27/A27M (2017) Standard Specification for Steel Castings, Carbon, for General Application

ASTM A36/A36M (2014) Standard Specification for Carbon Structural Steel

ASTM A668/A668M (2017) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM A744/A744M (2013) Standard Specification for Castings, Iron-Chromium-Nickel, Corrosion Resistant, for Severe Service ASTM A829/A829M (2014) Standard Specification for Alloy Structural Steel Plates

1.2 SUBMITTALS

Government approval is required for submittals unless designated herein as being required for “information only”. The contractors schedule should allow for Government review of submittals. All submittal disapproved or approved with revisions required shall be promptly returned for review and approval. No additional time will be provided to the contractor should a submittal require revision.

SD-01 Preconstruction Submittals

Purchase Agreements:

Purchase agreements, delivery dates and monthly progress reports shall comply with the requirements of paragraph, 1.4.1 CRITICAL

PATH COMPONENTS/SYSTEMS.

Project Schedule:

Contractor shall provide an initial project schedule within 14 calendar days of contract award. The initial project schedule shall clearly indicate contract award date, major preconstruction milestones, major construction milestones, Shipping date, and Contract performance period end date. The contractor’s initial project schedule shall show all contract requirements being performed within the contract period of performance.

Weekly Progress Reports:

Contractor shall provide to the contracting officers’ representative a concise photographic and narrative summary of progress for the previous week. The report shall update the project schedule. It should indicate deviation from the previous project schedule, issues, and milestones achieved. The report shall also forecast upcoming work.

SD-02 Shop Drawings

Detail Drawings:

Detailed shop drawings shall be submitted and approved prior to fabrication.

Materials Orders:

Submit copies of purchase orders, mill orders, shop orders and work orders for materials prior to the use of the materials in the work.

Shipping Bills:

Shipping Bills for the delivery of materials or work to the contractor’s facility.

SD-03 Product Data

Manufacturer's Literature and Equipment Data:

Provide catalog cuts and material data for the proposed equipment that clearly indicates compliance with the requirements of these specifications and the drawings. Provide the names of the manufacturers of all items which it contemplates incorporating into the work, together with performance capacities and other pertinent information pertaining to the equipment.

SD-05 Design Data

SD-06 Test Reports

Magnetic Particle Examination:

Provide test reports for non-destructive tests performed on all fabricated welded components.

Inspection Log

Shop Assembly and Tests

Final Inspection Report

SD-07 Certificates

Equipment Manufacturer's and Fabricator's Qualifications:

Provide evidence and years of experience for each of the equipment manufacturers and fabricators. Identify any certifications, standards, and/or professional organizations the manufacturers comply with or are members of.

Qualification of Welders and Welding Operators:

Submit certifications for welders and welding operators prior to commencing fabrication.

Equipment Warranty:

Provide manufacturer's standard warranty or guarantee for equipment. Identify any warranties that extend beyond a 1-year period.

Nondestructive Examination Certification

1.3 QUALITY ASSURANCE

Manufacturing and assembly of the boom wall brake assembly shall be performed by persons that has been normally and regularly engaged in assembly, and manufacture of heavy machinery over the preceding 10 years. Submit Equipment Manufacturer's and Fabricator's Qualifications showing evidence and years of experience for each of the equipment manufacturers and fabricators. Identify any certifications, standards, and/or professional organizations the manufacturers comply with or are members of.

1.4 CHANGES

Changes to the dimensions shown on the drawings requires approval from the Contracting Officer.

1.5 DELIVERY, STORAGE, AND HANDLING

1.5.1 Critical Path Components/Systems

Present to the Contracting Officer Representative, within 30 calendar days after receiving notice of contract award, written copies of finalized purchase agreements with component manufacturers for all forgings, casting, machined parts, and/or standard parts not being fully produced by an outside source. Include a confirmed delivery date and point of contact at the particular manufacturer in the purchase agreements. Provide monthly reports to the Contracting Officers’ Representative of progress on the particular material/component/part and any delays in the previously specified delivery date. Include both written and photographic updates to track and monitor the current status of the equipment to be furnished in the progress reports.

1.5.2 Delivery, Storage and Handling

Protect components from corrosion, deformation, and other types of damage. Transport, handle and store all components in accordance with best industry practices. Remove and replace damaged items with new items. Do not prepare the components for shipment until they have been inspected and accepted for shipment at origin by the Contracting Officer or his authorized representative, unless inspection has been waived. Submit the shipping bills with the delivery of finished pieces to the site.

1.5.2.1 Packaging

Standard commercial packaging is acceptable except where a different method or standard of packaging is specified or appropriate.

Individual shipping crates or pallets shall be new and undamaged and shall be accessible from below by forklift. The total weight or any individual shipping crate or pallet shall not exceed 4000 US pounds.

1.5.2.2 Shipping, Preservation, and Storage

Provide all packing, crating, etc., necessary to ensure safe shipment of equipment. The crates shall become the property of the Government.

Fill or protect the equipment with the necessary fluids, coatings, and/or preservatives to maintain in a stable condition without corrosion, deterioration, or degradation for an extended period of storage of up to 12 months. Configure the load in such a manner that it is accessible by a forklift at ground level or provide the means to offload.

Delivery shall be confirmed with the facility manager 7 calendar days prior to arrival. Delivery shall be Monday through Thursday between the local hours of 7:00am and 4:00pm. The delivery location is in the Central Time Zone. No deliveries will be accepted on federally observed holidays. Unconfirmed deliveries will not be accepted and any costs associated with unconfirmed deliveries will be borne by the contractor. All cost associated with delivery, storage and handling shall be included in the contract price.

Delivery Information:

US Army Corps of Engineers, Wilson Lock 704 S Wilson Dam Road Florence, AL 35630

Facility Manager:

Gerald Choat 256-764-5226 Gerald.D.Choat@usace.army.mil

PART 2 PRODUCTS

2.1 EQUIPMENT

Furnish equipment under this specification consisting of:

BILL OF MATERIALS

MARK DESCRIPTION MATERIAL

NO.

REQD

64N438-6 Pinion Shaft Steel Forging 1

8 Bushing Phosphor Bronze 1 9 Bushing Phosphor Bronze 1

10 Brake Wheel Cast Iron 1 11 Brake Arm Steel Casting 1 12 Brake Arm Steel Casting 1 13 End Pin Steel Forging 1 14 Tension Bar Alloy Steel Forging 2 16 Compression Spring Spring Steel 1 17 Operating Lever Steel Forging 1 18 Nut Steel 3 19 Link Pin Alloy Steel Forging 3 20 Spring Cap Structural Steel 1 21 Pin Steel 1 26 Nut Steel Forging 1 27 Washer Structural Steel 1 31 Button Hd. Grease Fitting 3/8" P.T. Mfr's Std 1 32 Straight Key 1-1/2" x 1" x 12" Key Steel 2 33 Washer 5" Ø OD x 3/8" x 3-5/16" Ø ID Structural Steel 1 34 Cotter Pin 1/2" Ø x 4" Steel 1 35 Cotter Pin 3/8" Ø x 4-1/2" Steel 1 36 Cotter Pin 3/8" Ø x 2" Steel 1 37 Dowel 1/2" Ø x 1" Brass 4 39 Cotter Pin 1/4" Ø x 3-1/2" Steel 3

64N439-7 Eye Bolt - 4 Hex. Nuts Steel Forging 1

10 Eye Bolt Steel Forging 1 20 Hook Bolt 5/8" Ø, 2 Nuts, Stl. Washer Steel Forging 1

2.1.1 Pinion Shaft

Make Pinion shaft (64N438-6) from high-strength alloy steel in accordance with ASTM A668/A668M and to the dimensions and tolerances indicated in the contract drawings to insure rigid alignment. There shall be a high-grade machine finish all over with an average surface finish of 32 micro-inches. Keyways must have fillet radii. Provide keys for all shafts. Design shafts in accordance with the requirements of ANSI/AGMA 6001. All shafts must have standard keyways and keys in accordance with ASME B17.1, Class II. Submit all fabricated dimensions of the keyways and keys.

2.1.2 Bushings

Provide a grease lubricated alloy bronze bushing (64N438-8 and 64N438-

9) to the dimensions and tolerances indicated. For the bushing material use aluminum bronze alloy and conform to the requirements of ASTM B148, C954. Machine the bushing from a solid piece of material to acquire the shape and surface finishes indicated. Provide a surface finish of 32 micro-inches or better on the running bearing surface.

Mate the bushing surface with the pinion shaft to achieve the indicated tolerances and to confirm uniform bearing contact.

2.1.3 Brake Wheel

Provide the cast iron brake wheel (64N438-10) as indicated on the contract drawings. Machine brake wheel to meet the dimensions, surface finish and tolerances indicated. Machine keyways to match the pinion shaft (64N438-6). Keyways must have fillet radii. Any casting patterns developed become property of the Government and must be packaged for long term storage with the pertinent part identification provided on the exterior packaging.

2.1.4 Brake Arms

Fabricate brake arms (64N438-10 and 64N438-11) from steel castings conforming to ASTM A27/A27M,Grade 70-36, or Grade 70-40. Machine brake arms to meet the dimensions, surface finish and tolerances indicated.

Any casting patterns developed become property of the Government and must be packaged for long term storage with the pertinent part identification provided on the exterior packaging.

2.1.5 End Pin

Provide end pin (64N438-13) from high-strength alloy steel forging in accordance with ASTM A668/A668M and to the dimensions and tolerances indicated. There shall be a high-grade machine finish all over with an average surface finish of 32 micro-inches. Threaded end of the end pin shall be 2½”-4-UNC-2A/2B. Do not drill and ream 3/8” hole.

2.1.6 Tension Bar

Machine Tension Bar (64N438-14) from high-strength alloy steel forging in accordance with ASTM A668/A668M and to the dimensions and tolerances indicated.

2.1.7 Compression Spring

Compression Spring (64N438-16) shall be produced from 7/8” diameter spring steel wire as shown on the contract drawings. 10 coils, 8 active coils, Ends closed and ground, 2,350 lbs. capacity at working height.

2.1.8 Operating Lever

Machine operating lever (64N438-17) from high-strength alloy steel forging in accordance with ASTM A668/A668M and to the dimensions and tolerances indicated. 3-1/2” diameter plates may be ASTM A36

2.1.9 Nut

Nut (64N438-18) shall be a heavy slotted jam nut 1¾”-5-UNC-2B

2.1.10 Link Pin

Link pin (64N438-19) shall be machined from high-strength alloy steel forging in accordance with ASTM A668/A668M and to the dimensions and tolerances indicated. Threaded end shall be 5 UNC class 2. Surface finish shall be 32 micro-inches.

2.1.11 Spring Cap

Spring Cap (64N438-20) shall be machined from A572 structural steel

2.1.12 Pin

Pin (64N438-21) is a clevis style pin and shall be provided as shown on the contract drawings.

2.1.13 Nut

Nut (64N438-26) for end pin shall be a heavy hex nut. Threads shall be

2½”-4-UNC-2B

2.1.14 Washer

Washers (64N438-27) and (64N438-33) for end pin shall be machined from ASTM A36/A36M structural steel plate

2.1.15 Button Head Grease Fitting

Manufacturer’s standard product. See contract drawing (64N438-31)

2.1.16 Cotter Pins

Supply Manufacturer’s standard steel cotter pins for the end pin (64N438-34), and (64N438-35), the “Clevis” pin (64N438-36), and link pin (64N438-39). Package and label cotter pins to prevent damage or loss during shipping and so they can easily be identified during installation. Cotter pins will be installed by others.

2.1.17 Dowels

Manufacturer’s standard brass dowel (64N438-37) material. Package and label dowels to prevent damage or loss during shipping and so they can easily be identified during installation. Dowels will be installed by others.

2.1.18 Eye Bolt with 4 Hex Nuts

Eye bolt (64N439-7) is integral with the compression spring. Eye bolt shall be forged steel and of the dimension specified on the contract drawings. Supply eye bolt with 4 hex nuts. Threads shall be with 1”-8-

UNC-2A/2B.

2.1.19 Eye Bolt

Eye bolt (64N439-10) shall be forged steel, shouldered type and of the dimensions specified in the contract drawings. Supply eye bolt with hex bolt and steel flat washer. Threads shall be 5/8”-11-UNC-2A/2B.

2.1.20 Hook Bolt

Hook bolt (64N439-20) shall be forged steel, shouldered type dimensions specified in the contract drawings. Supply eye bolt with hex bolt and two (2) steel flat washer. Threads shall be 5/8”-11-UNC- 2A/2B.

PART 3 EXECUTION

3.1 GENERAL

Parts shall be fabricated and assembled in the shop where possible and tested to confirm proper fit. Notify the Contracting Officer at least 10 calendar days before testing. The witnessing of a particular test may be waived by the Contracting Officer. Design and furnish any test rig and facilities (within the continental United States) suitable for performing the tests.

3.2 FABRICATION

3.2.1 General

Fabricate components and assemblies in compliance with the contract drawing, these specifications and sound professional practice.

3.2.2 Material

Material must be straight before being laid off or worked. If straightening is necessary, straighten by methods that do not impair or alter the metal. Sharp kinks, bends, or overcuts of material are cause for rejection of the material. Material with welds will not be accepted except where welding is specified, indicated, or otherwise approved. Flame cutting of material is not allowed. Shearing must be accurately done and all portions of the work neatly finished. Corners must be square and true unless otherwise indicated.

3.2.3 Dimensional Tolerances

Measure dimensions with an approved calibrated steel tape, vernier caliper, micrometer of approximately the same temperature as the material being measured at the time of measurement.

3.2.4 Alignment

The alignment of all parts with respect to each other must be true within the respective manufacturer's tolerances required.

3.2.5 Machining and Heat Treatment

Rough machine the forging prior to heat treatment for mechanical propertied. Finish-machine each part within the dimensional tolerances indicated. Dimensionally verify all parts.

3.2.6 Finished Surfaces

a. Surface finishes indicated or specified herein, must be in accordance with ASME B46.1. Flaws such as scratches, ridges, holes, peaks, cracks, or checks which will make the part unsuitable for the intended use are cause for rejection.

b. Where the finish is not indicated or specified, the type of finish is that which is most suitable for the particular surface and provides the class of fit required. Maximum surface roughness of any surface is

250 micro-inch. Indicate surfaces to be machine finished by symbols which conform to ASME B46.1.

3.2.7 Unfinished Surfaces

In so far as practicable, lay out all work to secure proper matching of adjoining unfinished surfaces. Where there is a large discrepancy between adjoining unfinished surfaces, chip and grind smooth or machine to secure proper alignment. Unfinished surfaces must be true to the lines and dimensions indicated and must be chipped or ground free of all projections and rough spots. Fill depressions or holes not affecting the strength or usefulness of the parts in a manner approved by the Contracting Officer.

3.2.8 Protection of Finished Work

Thoroughly clean machined surfaces of foreign matter. Protect all finished surfaces by suitable means. Unassembled pins and bolts must be oiled and wrapped with moisture-resistant paper or protected by other approved means.

3.2.9 Painting

Paint all exposed ferrous surfaces. Paint equipment and components not otherwise specified by manufacturer's standard coating system.

Standards coatings must be compatible with the lubrication and environmental conditions specified or recommended. Touch up all damaged painted surfaces prior to shipping. Painting of nonferrous metals and corrosion resisting steel will not be required unless otherwise specified.

3.2.10 Welding

Qualify welders, perform welding, welding inspection, and corrective welding, in accordance with AWS D1.1/D1.1M. Use procedures, materials, and equipment of the type required for the work. Submit welder certifications for each welder stating the type of welding and position qualified for, the code and procedure qualified under, date qualified, and the firm and individual certifying the qualification tests. If the qualification date of the welding operator is more than 6 months old, the welding operator's qualification certificate must be accompanied by a current certificate by the welder attesting to the fact that he has been engaged in welding since the date of certification, with no break in welding service greater than 6 months.

3.3 QUALITY ASSURANCE

Perform all quality inspections and tests in accordance with this specification and test industry practice. Implement and maintain an inspection log to include copies of all descriptive data for all specified inspections and tests. Make the inspection log available immediately to the Government's inspector upon request. Submit a complete copy of the inspection log to the Government at the end of specified inspections and tests. The Government reserves the right to witness any and all specified quality procedures. Provide the

Government with one-week advance notice of QC procedure scheduling to allow time for witness coordination. Fully test replacements for all rejected parts as specified herein.

3.4 NONDESTRUCTIVE EXAMINATION

Conduct NDT examinations using suitable equipment and qualified personnel in accordance with ASNT SNT-TC-1A. Submit nondestructive examination certification of qualified persons, procedures and equipment performing or used for nondestructive testing.

3.5 WARRANTY

Submit manufacturer's standard warranty or guarantee for supplied equipment and material. Identify any warranties that extend beyond a 1-year period. All materials and workmanship shall be warrantied for a minimum period of 1-year.

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