41_22_31_-_Refurbishment_of_Spillway_Radial_Gate_Hoists_Revised_8-20-26_0002.pdf

Webster Dam Spillway Radial Gates Repair

Refurbishment of Spillway Radial Gate Hoists (Revised)

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SECTION 41 22 31

REFURBISHMENT OF SPILLWAY RADIAL GATE HOISTS (Revised)

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Hoist Refurbishment:

1. Payment: Lump-sum price offered in the Price Schedule.

2. Include the cost of replacing the following parts, as shown on Drawings 468-D- 109 and 468-D-152.

a. Ropes and sockets (Parts 43).

b. Grease lines (Parts 22).

3. Do not include costs of removing coatings from or recoating metalwork (refer to Section 02 83 30 – Removal and Disposal of Coatings Containing Regulated Metals and Section 09 96 20 – Coatings).

1.02 REFERENCE STANDARDS

A. American Institute of Steel Construction (AISC)

1. AISC 360-16 Specification for Structural Steel Buildings

B. ASTM International (ASTM)

1. ASTM A27/A27M-17 Steel Castings, Carbon, for General Application

2. ASTM A36/A36M-14 Carbon Structural Steel

3. ASTM A123/A123M-17 Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

4. ASTM A325-14 Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

5. ASTM A563/A563M-21ae1 Carbon and Alloy Steel Nuts (Inch and Metric)

6. ASTM A572/A572M-18 High-Strength Low-Alloy Columbium- Vanadium Structural Steel

7. ASTM B36/B36M-18 Brass Plate, Sheet, Strip, And Rolled Bar

8. ASTM B103/B103M-15 Phosphor Bronze Plate, Sheet, Strip, and Rolled Bar

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9. ASTM D2240-15e1 Test Method for Rubber Property- Durometer Hardness

10. ASTM F844-07a (2013) Washers, Steel, Plain (Flat), Unhardened for General Use

C. Federal Specifications (FS)

1. FS RR-W-410F(2015) Wire Rope and Strand

2. FS RR-S-550F(2018) Sockets, Wire Rope

1.03 SUBMITTALS

A. Submit the following in accordance with Section 01 33 00 – Submittals.

B. RSN 41 22 31-1, Approval Data:

1. Detailed description and sequence of construction procedure to complete refurbishment and replacement of parts, highlighting variations (if any) from the procedures provided in this Section.

2. Detailed specifications for equipment to be used in hoisting materials and tools into and out of the spillway, as well as layout sketches indicating the locations at which this equipment will be stationed.

3. Commercial Products Data – Provide dimensional and rating data. Mark data sheets to indicate specific size, length, model number and features of items to be furnished:

a. Wire ropes, including data for:

1) Length.

2) Construction.

3) Materials and material certifications.

4) Lubricant.

5) Breaking strength.

b. Fasteners for rope clamps, shaft keepers, sheave assembly pedestalsgrease line brackets, floatwell and weirwellaccess covers, and platforms.

c. Rigid grease line product data.

d. Flexible grease line product data.

4. Certified copies of wire rope socket tension tests.

5. Checked Shop Drawings: Show dimensions, weld sizes, and materials of the wire socket components.

C. RSN 41 22 31-2, Final Data:

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1. All approved commercial products data. Clearly mark data applicable to equipment furnished.

2. Contractor Field Quality Test report.

1.04 DELIVERY, STORAGE, AND HANDLING

A. Deliver equipment on site in shipping containers with labeling in place.

B. Protect equipment from damage, moisture, and dust.

PART 2 PRODUCTS

2.01 FASTENERS

A. Cap Screws and Lock Washers for Wire Rope Clamps:

1. Quantity: (18)

2. Size:

a. Cap Screws: 1-inch x 2-1/4-inch long, threaded to match existing tapped holes in drums.

b. Lock Washers: Compatible with 1-inch cap screws.

3. Material:

a. Cap Screws: ASTM A325 or ASTM A572.

b. Lock Washers: ASTM F844.

4. Finish: Galvanized, ASTM A123.

5. Grade: Matching (not to exceed) that of existing fasteners.

2.02 WIRE ROPES

A. Refer to Sheet 36 Drawing 468-D-152 for referenced part details.

B. Wire Ropes (Parts 43):

1. Comply with requirements of FS RR-W-410F, Type 1, General Purpose, Class 3.

2. Designation:

a. 6x37 single layer construction (Class 3).

b. Right regular lay (SZ).

c. Independent Wire Rope Core (IWRC)

d. Preformed.

e. Extra-improved plow steel (XIP).

f. Galvanized-to-finished.

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g. Minimum Breaking Strength = 41.8 Tons.

3. Diameter: 1 inch.

4. Quantity, length, and termination: Refer to Table 41 22 31 – Wire Rope Details below.

Table 41 22 31A – Wire Rope Details

Part Description Quantity Length* Termination

43 Rope and Socket 6 pieces total (2 per hoist)

152'-2" Both ends terminated with OPEN speltered socket.

* Measured from centerline of socket pin to centerline of socket pin.

C. Socketing:

1. Comply with requirements of FS RR-S-550F, Type A (open socket).

2. Zinc-poured type or resin type, to provide efficiency rating of 100% of the rope strength.

3. Performed by a manufacturer certifying the wire rope testing per Submittal RSN 41 22 32-1, Approval Data, in Paragraph 1.03B1.04B of this Section and in accordance with current industry practice.

a. Zinc-poured socketing: Use procedures of the Wire Rope Technical Board, P.O. Box 849, Stevensville MD 21666.

b. Resin-type socketing: Use procedures developed by the manufacturer.

4. Socket connections: Tension tested to two-fifths of rope breaking strength.

5. Do not reuse cotter pins – replace with new.

6. Wire Rope Socket Resin: Wirelock W416-7 socket compound, as manufactured by The Crosby Group, Inc., P.O. Box 3128, Tulsa, OK 74101-3128; or equal, having the following essential characteristics:

a. Formulated for use with spelter sockets.

b. Termination efficiency: 100 percent.

c. Polyester-based.

d. Cured strength not affected by cold temperatures.

e. Maximum shrinkage: 1.5 to 2.0 percent.

f. Not degraded by oily or greasy environment.

2.03 GREASE LINES

A. Refer to Sheet 11 Drawing 468-D-152 for referenced part details.

B. Grease Lines (Parts 22)

1. Rigid Grease lines:

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a. Grease lines shall be ¼-inch (0.540-inch outside diameter), schedule 80 seamless, and 0.119-inch nominal thick wall 316 stainless steel pipe.

2. Flexible Grease Line Hose

a. 3/8” braided flexible high-pressure tubing of corrosion-resistant materials with metal inner core, or hose having a synthetic inner tube with corrosion-resistant braided wire reinforcement. The hose shall be satisfactorily assembled with corrosion resistant ends. The hose shall be suitable for use with grease at a working pressure of 2,000 psi and shall be suitable for outdoor applications. The hose must be rated for temperatures between -40 degrees Fahrenheit, and 200 degrees Fahrenheit.

3. Button head grease fittings:

a. Fittings shall be stainless steel, with check ball, and zerk cap, and shall match existing fittings

4. Grease:

a. Lubriplate 630-AA

PART 3 EXECUTION

3.01 GENERAL

A. Provide required equipment for hoisting, fixing, removing, and replacing equipment.

Hoisting or holding devices, such as a lever-operated chain or wire rope puller, or a capstan will be required to handle the weight of the ropes and equipment during removal and installation.

1. The 1-inch rope weighs approximately 1.8 pounds per foot, and the open sockets weigh approximately 36 pounds each.

B. Perform removal, replacement, and refurbishment procedures for all three hoists, one hoist at a time.

1. Approval of the COR is required if alternative procedures are proposed.

C. Refurbishment includes:

1. Removal, and replacement, and reinstallation of the wire ropes (refer to Article

3.02 of this Section).

3.02 WIRE ROPE REPLACEMENT

A. General:

1. Procedures listed below are identical for each of the three radial gates.

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2. Operation of radial gates by Contractor personnel is not permitted. Refer to Section 01 14 20 – Radial Gate Operation.

3. While under tension, wire ropes shall have a minimum of two dead wraps around the drums at all times.

4. Coordinate with Reclamation 2 weeks prior to work for removal of limit switches.

NOTE: Replacement of the wire ropes will only be permitted after the guide shoes have been adjusted or modified and/or gate skin has been trimmed to allow full travel without interference. Refer to Specification Section 35 23 51 – Spillway Radial Gate Seal Replacement, 3.03, A for more details.

B. Removal Procedures:

1. Prepare the gates for wire rope removal:

a. Raise and lower each radial gate through a full cycle.

b. Position gate in the closed position with the hoist drive and gate hoist motor in the OFF position.

c. Take note of the configuration and placement of each pair of existing ropes, including the number of wraps present on the hoist drums.

2. Disconnect the existing ropes from the gate:

a. Disconnect the wire ropes from the gate by un-pinning the sockets from the gate.

3. Disconnect the existing ropes from the drums:

a. Disconnect wire ropes from the drums by removing the associated rope clamps.

b. Remove and dispose of existing ropes and sockets in accordance with Section 01 74 00 – Cleaning and Waste Management.

C. Perform the following work while the wire ropes are removed:

1. Perform spot repairs on the hoist equipment coatings, and clean and fully recoat exposed portions of the rope clamps in accordance with Section 09 96 20 – Coatings.

D. Reinstallation Procedures:

1. Prepare the new wire ropes for installation:

a. Check the lengths of each new rope pair to ensure that they are equal.

Record exact differences in length.

b. Fully coat sockets in accordance with Section 09 96 20 – Coatings, ensuring that wire rope remains protected.

c. Soak new wire ropes in manufacturer's recommended rigging cable fluid (suitable for year-round outside use, with exposure to air temperatures

41 22 31 - 7 ranging from -15 to 110 degrees Fahrenheit) for 24 hours and drip-dry for 72 hours at 70 degrees Fahrenheit or warmer.

d. Lightly grease new rope socket pins and bushings with suitable, wash-resistant grease.

2. Connect the wire ropes to the gate:

a. Connect the to the gate pinning the sockets to the gate.

3. Connect the wire ropes to the drums:

a. Using the gate hoist motor, rotate the drums back in the “lower gate” direction, stopping between 2 and 3 turns past the marked connection point, such that the wire rope clamp bolt holes for wire ropes are easily accessible. NOTE: This will provide the minimum of two dead wraps for the wire ropes.

b. Using new cap screws and lock washers per Paragraph 2.01A of this Section, connect the seized ends of the to the drum with the drum clamps carefully ensuring that they are oriented correctly.

4. Tighten the wire ropes:

a. Using the gate hoist motor, rotate the drums until the wire ropes are taught, carefully ensuring that their lengths are equal (i.e. that the relative distances between the hoist deck and the low point of the rope catenaries are within 1/4 inches).

b. Once the wire ropes are taught and equal in length:

1) Torque the rope clamp bolts into the drum shells to a fully tensioned condition per AISC 360. Trim and re-seize the clamped ends as necessary to maintain 6 to 12 inches of rope beyond the clamp bolts.

5. Repair damaged coatings in-kind to existing material and color in accordance with Section 09 96 20 – Coatings.

3.03 REPLACE 3/8” FLEXIBLE TRUNNION PIN GREASE LINE HOSES

A. The Contractor shall remove the existing 24 trunnion pin flexible grease lines and dispose of the old lines off site.

B. The Contractor shall furnish and install new flexible grease lines.

C. The Contractor shall verify the dimensions of the lines in the field prior to ordering new components.

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3.04 REPLACE AND RELOCATE RIGID GREASELINES

A. The Contractor shall extend the trunnion pin grease lines (24 total) to make the grease lines accessible from the upstream side of the bridge from the center pier platforms and bridge abutments.

B. The Contractor shall fasten rigid grease lines with 316 stainless steel brackets and 316 stainless steel anchors.

C. The Contractor shall fill all new grease lines with specified grease and bleed all air from the system prior to the final installation of the grease lines.

D. The Contractor shall pressure test the new lines with a grease gun capable of delivering a minimum 5000 psi.

3.033.05 CONTRACTOR FIELD QUALITY TESTING

A. Field quality testing of hoists shall be performed by Contractor and witnessed by the COR, unless otherwise directed.

B. Coordinate with COR for installation of limit switches two weeks prior to field testing.

C. Test the hoists at the site.

1. Raise and lower each gate several times through its full travel. A minimum of five times is required to take out the stretch in the ropes.

2. During final lowering operation of gate, pause the hoist for 1 minute approximately 6 inches above the sill elevation. Confirm that the hoist brake holds and that the gate does not drift downwards.

3. Ensure that equipment operates without abnormal noise, vibration, binding, or overheating.

D. After the ropes have been stretched, re-equalize rope tension, if required. Confirm that the rope clamp screws at the drums have not loosened and are fully tensioned.

E. Make required changes and adjustments to the hoist and associated accessories, and retest (at the option of the COR) to provide for satisfactory operation.

F. Prepare test report for inclusion into final data submittal. Record the following items:

1. Elapsed time to raise and lower the gate, and the associated change in gate elevation.

2. Limit switch settings and confirmation of operation.

3. Confirmation of equal rope tension.

4. Confirmation that the motor brake holds load without drift at intermediate opening position.

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5. Signatures of witnesses and date of test.

END OF SECTION

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