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Braddock Locks and Dam - Tow Haulage Unit Installation

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 24 40

TOW HAULAGE SYSTEMS

PART 1 GENERAL

1.1 RELATED WORK SPECIFIED ELSEWHERE

1.2 REFERENCES

1.3 SUBMITTALS

1.4 GENERAL REQUIREMENTS

PART 2 PRODUCTS

2.1 GOVERNMENT FURNISHED EQUIPMENT

2.1.1 General Information

2.1.2 Equipment Furnished

2.2 EQUIPMENT TO BE INSTALLED

2.2.1 General

2.3 RETRIEVER WINCH

2.3.1 General

2.3.2 Retriever Winch Motor and Controller

2.3.3 Retriever Limit Switch

2.4 POWER PIPING

2.4.1 Flexible Lines

2.5 SHEAVES

2.6 TOWING AND RETRIEVER BITTS

2.7 WIRE ROPE SWIVELS

2.8 RAILS AND APPURTENANCES

2.8.1 Rails

2.8.2 Anchor Bolts

2.9 CONTROL SYSTEM

2.10 ELECTRICAL WIRE, CABLE AND CONDUIT

2.11 SPARE PARTS

PART 3 EXECUTION

3.1 MANUFACTURER'S SERVICES

3.2 SEQUENCE OF WORK

3.3 ASSEMBLY/INSTALLATION

3.4 INSTALLATION OF RAILS

3.5 WELDING

3.6 PAINTING

3.6.1 General

3.6.2 Field Touch-Up

3.7 CLEAN-UP

3.8 LUBRICATION

3.9 CLEANING AND FLUSHING

3.9.1 Piping

3.9.2 Hydraulic Power Units and Manifolds

3.9.3 System Cleanliness

3.10 START-UP AND ADJUSTMENT

3.11 FIELD TESTING

3.11.1 Field Test of System Operation

3.12 TRAINING

SECTION 41 24 40 Page 1 W911WN-09-B-0023 Revised by Amendment 0001

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SECTION 41 24 40 Page 2

SECTION 41 24 40

TOW HAULAGE SYSTEMS

PART 1 GENERAL

1.1 RELATED WORK SPECIFIED ELSEWHERE

Section 05 50 14 STRUCTURAL METAL FABRICATIONS

Section 05 50 15 CIVIL WORKS FABRICATIONS

Section 09 97 02 PAINTING: HYDRAULIC STRUCTURES

Section 26 20 00 ELECTRICAL WORK

1.2 REFERENCES

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

ASTM INTERNATIONAL (ASTM)

ASTM A 36/A 36M (2008) Standard Specification for Carbon Structural Steel

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE J1165 (1979; R 1986) Reporting Cleanliness Levels of Hydraulic Fluids

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Inventory of Government-Furnished Equipment; G, RE

Perform an inventory of Government-furnished equipment and furnish report to the Contracting Officer within 30 days after receipt of Notice to Proceed.

SD-02 Shop Drawings

Installation Drawings; G, ED

Scale drawings of installation, 1-1/2" = 1'-0" or larger scale are to be submitted. Additional drawings shall be provided, 1-1/2" = 1'-0" or larger scale, showing all piping, valves, fittings, plan views, sections, and elevations.

Installation and Erection Procedures; G, ED

SECTION 41 24 40 Page 3

Site specific installation and erection procedures for all components of the tow haulage system shall be submitted for approval, as soon as possible, but before any equipment is shipped to the site.

SD-06 Test Reports

Field Test Reports

Upon completion and testing of the installed system, test reports shall be submitted in booklet form showing field tests performed to adjust each component and field tests performed to prove compliance with the specified performance criteria. Each test report shall indicate the final position of any system controls.

The field testing shall include the system pressure test and operation testing in accordance with paragraph FIELD TEST.

1.4 GENERAL REQUIREMENTS

The tow haulage system equipment was previously purchased by the Government and will be furnished to the Contractor at the site for installation. The Government-furnished equipment is identified in paragraph GOVERNMENT

FURNISHED EQUIPMENT.

The Contractor shall become familiar with all details of the work, verify all dimensions in the field, and shall advise the Contracting Officer of any discrepancy before performing the work.

The Contractor shall be responsible for the completion of all field-testing of the tow haulage system upon completion of installation. These specifications shall be used for establishing criteria and certain requirements for this work.

PART 2 PRODUCTS

2.1 GOVERNMENT FURNISHED EQUIPMENT

2.1.1 General Information

The tow haulage system equipment was purchased by the Government in 2004 under Contract No. DACW59-03-C-0006 with Superior-Lidgerwood-Mundy (SLM) Corporation, PO Box 39, Superior, WI 54880. The equipment is stored at Braddock Locks and Dam. The Contractor shall conduct inventory of the Government-furnished inventory to verify quantity and condition and submit a Inventory of Government-Furnished Equipment report to the Contracting Officer.

2.1.2 Equipment Furnished

The items shown on the attached Table A are included in the Government-Furnished Equipment. The Government furnished equipment includes the electrical and mechanical equipment, rail and accessories, towing and retriever bitts, anchor bolts, fasteners, and spare parts to complete the tow haulage system. The Contractor shall furnish all wiring, cables, conduits and fittings, piping, supports and incidental items required to complete the installation.

SECTION 41 24 40 Page 4

2.2 EQUIPMENT TO BE INSTALLED

2.2.1 General

The new tow haulage system includes two winch units with separate hydraulic power and output units, a main control panel, two operating stations and starter panels, wire rope cables, sheaves, rail, and additional associated hardware. The new tow haulage system shall be mounted on the top of the Land Wall as shown on the contract drawings. The power units shall be connected to the winch units with flexible hydraulic hoses and two way disconnects. The Contractor shall be responsible for installation of all new equipment (with interconnecting wiring), in order to produce the counter torque tow haulage system shown on the contract drawings.

The components of the new tow haulage system are designed to function properly within a counter torque (pull-retard) system. A description of the Government furnished items to be installed is as follows:

a. Two winch units. Each unit is horizontal, variable line pull and speed, reversible single drum type, and includes all gearing, speed reducer, hydraulic motor, hand brake, jaw clutch, wire rope, hydraulic lines, and necessary appurtenant parts. The winch units are manufactured with a hydraulic brake between the speed reducer and hydraulic motor.

b. Two hydraulic power units. Each unit is capable of producing a hold-back line tension pull adjustable from 1,000 to 3,000 pounds. The unit has a separate electro-hydraulic control to each hydraulic pump that allows adjustment between 10 and 30 percent of the line pull for hold back line tension. The control is arranged for regenerative braking of approximately 90 percent of the hold power. A brake control solenoid valve complete with speed control chokes is also included with the hydraulic circuit of each power unit. A NEMA 4 terminal box is provided for each power unit. The fan motor, oil heater, temperature switches, brake solenoid, and hold back solenoid are prewired to the terminal box.

c. Two hydraulic output units. These units function consistently within a counter torque operation. The hydraulic motor of these units includes an integral spring applied hydraulically released brake rated to prevent motion at 150 percent of maximum required system torque.

Couplings associated with the speed reducer (on the hydraulic output unit) and the winch haulage unit input shaft are also furnished.

d. Two starter panels. Autotransformers and internal wiring are meggered and all circuit breakers and contactors are checked.

Auxiliary contacts, terminal blocks, and other electrical components are included to ensure that the control system will operate as a counter torque (pull-retard) system.

e. A complete set of field piping and/or hoses between the hydraulic power units and the winches including all parts shown on the drawings, called for in the specifications, or needed for satisfactory operation.

2.3 RETRIEVER WINCH

2.3.1 General

The new retriever winch is capable of pulling the retriever bitt along the

SECTION 41 24 40 Page 5 rail. The retriever winch shall be located as shown on the contract drawings. The winch is equipped with a clutch and brake to allow the drum to free spool during upstream travel of the towing bitt. The winch shall contains 900 feet of 1/4-inch diameter, 6 X 19, regular lay, improved plow steel, IWRC wire rope. The winch has a mechanical level winder in order to properly reeve the wire rope in smooth multiple layers on the drum at a running rope velocity of 60 feet per minute. The winch is equipped with a torque-limiting high-speed coupling. The torque-limiting coupling provides protection against damage to the system if the retriever winch is energized while the bitt is attached to barges. The clutch and brake are remotely operated from the control station by means of an electric actuator that automatically engages the clutch as the brake is disengaged and visa-versa. The braking force is adjustable to keep a slight tension on the wire rope to prevent it from over running the drum while it is free spooling. The winch is shop primed and finished painted with the manufacturer's standard coating for outdoor exposure.

2.3.2 Retriever Winch Motor and Controller

Motor for the retriever is 2 HP., 3 phase, 460 Volts, with a maximum speed of 1800 RPM. The motor is rated for continuous duty at full rated horsepower, and is totally enclosed and suitable for outdoor use. The electric motor is controlled by a combination solid state reduced voltage controller with isolation contactor and fusible disconnect. The starter incorporates overload protection in all 3 phases. Control circuits include a fused control transformer. The controller is mounted in a NEMA 4 enclosure. A heater is provided for the enclosure. A protective module is provided for transient protect and is connected to the line side.

"Start-Stop," "Overload Reset," and a red "Run" pilot light are located in the door of the enclosure. The disconnect has provisions for padlocking in the open position. The NEMA 4 enclosure shall be mounted on a aluminum unistrut located near the retriever unit.

2.3.3 Retriever Limit Switch

An over-travel limit switch, corrosion-resistant, oil-tight and water-tight, is provided and shall be installed at the downstream end of the retriever rail. The limit switch tripper will be the retriever bit.

The limit switch shall be accurately aligned so that the switch will operate only when the bitt is at the downstream end of its travel.

2.4 POWER PIPING

2.4.1 Flexible Lines

A complete of flexible hoses is included with the Government furnished equipment. If the length of the furnished hoses does not meet the installation requirements, the Contractor shall provide new hoses of the correct length required meeting the following requirements. Flexible hydraulic lines shall be SAE 100R12 4 spiral (medium wire) rubber hose similar to style CE rubber hose as manufactured by the Dayco Corporation, Dayton, Ohio, 45401. Minimum burst pressure shall be 15,000 psi. Flexible hose shall be rated by the manufacturer for a working pressure not lower than 3,000 psi. Rubber or synthetic rubber shall be selected for maximum compatibility with the hydraulic fluid specified for use in the system.

Fittings shall be specifically designed for use with the hose selected, shall be equivalently rated and shall be as recommended by the hose manufacturer. Fittings shall be stainless steel and shall have straight or elbow ends as best suited to the installation conditions. Fittings shall

SECTION 41 24 40 Page 6 be permanently attached type similar to SL series coupling as manufactured by Dayco Corporation. Each hose assembly shall be factory assembled using procedures and tools recommended by the hose manufacturer. Fittings for connection to piping shall be of the split flange (Code 62) type. Fitting for connection to cylinder manifold block shall be Female Swivel, 37 degree Flare type with a Triple-lock 37 degree Flare to SAE straight thread male to male connector as manufactured by Parker, or equal.

2.5 SHEAVES

Sheaves consist of aluminum bronze bushed pulleys with forged steel shafts encased in housings of fabricated steel. The sheaves are suitable for reversible car puller systems and designed for the breaking strength of the 3/4-inch wire rope. Sheaves are shop primed and finish painted with the manufacturer's standard coating for outdoor exposure.

2.6 TOWING AND RETRIEVER BITTS

The towing and retriever bitts are fabricated from weldments of double extra strong pipe and structural steel in accordance with the details shown on the drawings. The bitts have been fabricated to suit the rail upon which it is mounted. Towing and retriever bitts are shop primed and must be field painted.

2.7 WIRE ROPE SWIVELS

Two wire rope swivels are provided for attachment of the 1-inch wire rope to each end of the towing bitt. The swivels have the manufacturer's standard coating for outdoor exposure.

2.8 RAILS AND APPURTENANCES

2.8.1 Rails

Rails for the tow haulage and retriever system are AREA 132 lb. rail. Rail clips are also provided. Rails shall be field primed and painted.

2.8.2 Anchor Bolts

ASTM A 36/A 36M, sized as shown on the contract drawings. Holes for the anchor bolts shall be drilled to the appropriate diameters, and prepared, as specified by the resin cartridge manufacturer.

2.9 CONTROL SYSTEM

The control system is designed to automatically through a single joy-stick control, infinitely vary the pulling speed and control the maximum line pull while controlling the trailing winch hold back tension in a regenerative mode. The hold back automatically regenerates approximately 90 percent of the hold back power to minimize power loss and heat build up in the hydraulic system. Each winch has the capabilities to be operated in either the hauling or hold back mode depending on the direction of the joy-stick movement from neutral. Independent jog functions for both units and for both directions is included. The control system consists of two remote mounted operating stations and one main control panel.

2.10 ELECTRICAL WIRE, CABLE AND CONDUIT

The Contractor shall furnish and install all interconnecting (point to

SECTION 41 24 40 Page 7 point) wiring for the tow haulage and retriever system. All required conduit shall be located (and of the size(s)) as shown on the drawings.

All interconnecting wiring and conduit for the tow haulage and retriever system shall conform to the specifications outlined in Section 26 20 00

ELECTRICAL WORK.

2.11 SPARE PARTS

The spare parts identified in the attached Table A have been furnished with the tow haulage system. All packages shall be clearly marked on the outside as to contents with provisions for inspection of the part without destroying the package.

PART 3 EXECUTION

3.1 MANUFACTURER'S SERVICES

The Contractor shall be responsible for making arrangements for representative(s) of the manufacturer of the tow haulage equipment who are experienced in the installation, adjustment, and operation of the equipment specified to be present at the following phases of work (some phases of work may be subject to approval by the Contracting Officer):

1) Preparatory Phase Meeting and inspection of Government furnished equipment

2) Beginning of the First Installation

3) Intermediately During the Remainder of the Installations, as required

4) Final Adjustment and Testing for the Tow Haulage System

5) Field Training

The representatives shall supervise installation, adjustment and tests of all equipment. Services of a hydraulics technician to coordinate and supervise the installation, adjustments, tests, and field instructions for the hydraulic system shall be provided by the Contractor. The hydraulics technician shall have at least five years of current experience in the installation and operation of similar systems.

3.2 SEQUENCE OF WORK

The existing capstan and pulleys located on the Middle Wall will be used during the replacement of the tow haulage equipment and shall not be relocated or rendered inoperable at any time under this contract without authorization by the Government. Periodic interruption of power to the electric capstans may be permitted. Any such interruptions shall be limited to a maximum of four hours and shall be coordinated with the Contracting Officer. The Contractor shall note the operating times of the Lock when preparing requests. The Contractor shall develop a schedule in consideration of the indicated hours of operations to minimize all interference's with his work.

3.3 ASSEMBLY/INSTALLATION

All Government furnished equipment shall be examined carefully by the Contractor, manufacturer's representative, and Contracting Officer's representative before installation. Any damage or defects discovered prior to installation shall be immediately reported to the Contracting Officer.

Payment for replacement of defective parts will be made in accordance with the Contract Clause "Changes".

SECTION 41 24 40 Page 8

The manufacturer's Installation Drawings, Installation Manual, and Operation and Maintenance Manual for the tow haulage system will be provided to the Contractor.

The Manufacturer's Representatives shall also inspect the tow haulage equipment recesses, sheave recesses, and cable trenches to verify equipment positioning, sheave alignment, cable orientation, and other pertinent dimensions, and alignments.

All components shall be installed in proper alignment, as shown on the contract drawings, to permit trouble free operation of the tow haulage and retriever systems. All fixed parts shall be securely anchored and all movable parts shall move freely without binding or obstruction. A millwright shall supervise the setting, leveling, and alignment of all winches, sheaves, and rail. It is critical that the winch bases are level and true to prevent uneven gear wear, and the winch drums are centered and squared with the lead sheave to prevent "bird nesting" of the wire rope layers.

Should there be any necessity for rearrangement of the equipment, piping, or fittings, due to field conditions or other causes, the Contractor shall submit details of any proposed change to the Contracting Officer for approval.

The installed system shall be fully tested for satisfactory operation of the tow haulage system, as stated in paragraph FIELD TEST.

3.4 INSTALLATION OF RAILS

The towing rail shall be installed as shown on the contract drawings.

Holes for anchor bolts shall be drilled accurately to provide the alignment shown. The Contractor is cautioned that embedded steel will most likely be encountered in the process of drilling the holes for the anchor bolts.

Anchor bolts shall be set into the holes with resin cartridges in accordance with Section 03 20 02 STEEL BARS AND WELDED WIRE FABRIC FOR CONCRETE REINFORCEMENT FOR CIVIL WORKS. Rails shall be secured with clips. The rails shall be perfectly level and straight, and the towing bitt (with properly adjusted wheels) shall run freely on the entire length of rail without tight spots. Tolerances for elevation and alignment of the tow haulage rail shall be as shown on contract drawings. Rails which do not conform to these tolerance shall be disassembled and reset at no additional cost to the Government. Grout leveling pads shall be placed as shown on the contract drawings. Pads shall be latex-modified portland cement grout, placed in accordance with the manufacturer's instructions.

3.5 WELDING

Piping and all equipment shall be welded in accordance with Section 05 50 14

STRUCTURAL METAL FABRICATIONS.

3.6 PAINTING

3.6.1 General

All exposed surfaces of the tow haulage equipment except corrosion-resistant steel, synthetic rubber, and plastic, have been shop primed and coated with the manufacturer's standard coating systems for exterior exposure. Surfaces of the power units which are not corrosion-resistant

SECTION 41 24 40 Page 9 have received the manufacturer's standard coating system for exterior exposure. Miscellaneous piping and support frames shall be painted as specified in Section 09 97 02 PAINTING: HYDRAULIC STRUCTURES. Insofar as practicable, the complete coating system was applied to individual components and items before assembly to ensure complete coverage and maximum protection against corrosion.

3.6.2 Field Touch-Up

Chips, scratches, and other damage to shop-applied painted surfaces, including areas rusted during long term storage, shall be repainted in the field by the Contractor. Finish field colors shall match those of marred finishes.

3.7 CLEAN-UP

Upon completion of the installation of the tow haulage system and appurtenances, all debris and surplus materials resulting from the work shall be removed.

3.8 LUBRICATION

Upon completion of the installation, all equipment, gears, linkages, and bushings shall be thoroughly lubricated prior to operation with lubricant similar and equal to "Lubriplate No. 630AA" as manufactured by Fisk Brothers Refining Co., or as recommended by the manufacturer of the equipment. All fluid levels shall be topped off with the manufacturer's recommended lubricants.

3.9 CLEANING AND FLUSHING

The Contractor shall submit for approval his plan for cleaning and flushing the piping/hoses, hydraulic power units, and hydraulic motors and shall include a list of equipment to be used and methods to ensure the required cleanliness. The system shall be cleaned and flushed prior to installation of hydraulic oil for both shop and field tests.

3.9.1 Piping

The piping/hoses supplied by the Contractor for field installation shall be free of all scale, dirt, grit, or other foreign matter. The piping shall be cleaned at the source of its fabrication and then sealed to prevent accumulation of foreign matter during transportation to the site. The piping shall remain sealed during storage at the project site. The seal shall be removed just prior to installation. After installation has been completed the entire system shall be free of chips of wood, dirt, grit, waste or other foreign matter. Before connection of piping to the hydraulic power units, all hydraulic piping shall be flushed. Hydraulic oil shall be circulated through each and every pipe and hose until the returning oil meets the requirements for system cleanliness.

3.9.2 Hydraulic Power Units and Manifolds

The existing hydraulic oil shall be drained, and each hydraulic power unit shall be flushed. The hydraulic reservoir shall be filled with new hydraulic oil as specified and the oil filtration system activated with a 10-micron filter element in the filter. The oil shall be circulated and filters changed as they become clogged until the unit runs for 24 hours without becoming clogged. After flushing of the fluid in the reservoir is

SECTION 41 24 40 Page 10 complete, by-pass loops with filters shall be installed on manifold ports and the pumps shall be run alternately until all passageways have been flushed and until the returning oil meets the requirements for system cleanliness. All other manifold ports shall be fitted with temporary piping, valve and filter with connection to the reservoir and the oil circulated until the cleanliness specified above is reached.

3.9.3 System Cleanliness

Upon completion of installation and prior to any testing, the system cleanliness shall conform to SAE J1165, ISO Code 16/13.

3.10 START-UP AND ADJUSTMENT

The Contractor shall be responsible for providing a Manufacturer's Representative (SLM) and qualified personnel for startup and adjustment of all components and operation and maintenance instructions to the Government operating personnel for a minimum period of eight hours. Arrangements for start-up shall be in accordance with paragraph "TRAINING." The Contractor shall make all arrangements with the equipment manufacturers to provide qualified representatives for start?up for a period of eight hours at Braddock Locks, Monongahela River.

3.11 FIELD TESTING

Field test procedures shall be submitted as described in paragraph SUBMITTALS. All tests shall be conducted in the presence of a representative of the Contracting officer.

3.11.1 Field Test of System Operation

Upon completion of site installation, and prior to acceptance of the installation, the Contractor shall subject the new tow haulage system to operating tests to demonstrate satisfactory functional and operating efficiency. The field test shall be performed in the presence of the Government. The test shall include a measured resistance pull utilizing four standard barges loaded to capacity (about 900 TON per barge), removed from the lock chamber under operating conditions, starting at zero velocity and operated at maximum acceleration to a minimum velocity of 100 feet per minute. The resistance pull shall be measured by installing a dynamometer or calibrated strain gage system between the towing bit and the barges.

Both the resistance and the velocity shall be recorded throughout the test.

All tests shall be conducted at such times as the Contractor Officer may direct. All instruments, facilities, electricity, and labor required to properly conduct the tests shall be provided by the Contractor at no additional cost to the Government. Any deficiencies found by these tests shall be corrected by the Contractor and the tests repeated at no additional cost to the Government.

3.12 TRAINING

The Contractor and Manufacturer's Representative (SLM) shall provide filed field training for Government personnel. The appropriate Manufacturer's Representative shall conduct the field training. Training shall be provided to all crew shiftsfor one day and shall generally be from 3 to 8 hours for all new equipment. Start-up, operation and routine maintenance of equipment shall be part of this training. The Contractor shall submit a proposed agenda for the required training and request a training date(s), by written request, a minimum of 30 days prior to the proposed training

SECTION 41 24 40 Page 11 date(s). The written request(s) shall be given to the Contracting Officer. The Contracting Officer shall have final approval of course outline, materials and training dates. Testing of the system operation, as specified in paragraph "TESTING AND OPERATION," shall be separate from the above specified training.

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