35_01_40.71.pdf

Montgomery L/D Dam Gate Installation 2015

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 01 40.71

REPAIR AND REHABILITATION OF LIFT GATE EQUIPMENT

PART 1 GENERAL

1.1 SCOPE

1.2 REFERENCE DRAWINGS

1.3 SUBMITTALS

1.4 GENERAL

1.4.1 Coordination with Related Work

1.4.2 Description of Electrical Equipment

1.4.2.1 Existing Motors

1.4.2.2 Existing Brakes

1.4.2.3 Protection of Equipment

1.5 MATERIALS AND EQUIPMENT

1.6 QUALIFICATIONS

1.7 WARRANTY

PART 2 PRODUCTS (Not Applicable)

PART 3 EXECUTION

3.1 REBUILDING EXISTING GATE HOIST BRAKES

3.1.1 General

3.1.2 Installation of Rebuilt Brakes

3.2 TESTING

3.2.1 General

3.3 CLEANING AND RELUBRICATION OF EXISTING MACHINERY

3.3.1 Cleaning, Degreasing, Inspection, Lubrication and Spot Painting

3.4 OPTIONAL DRIVE SPROCKET REPLACEMENT

3.4.1 General

3.4.2 Installation

3.5 ACCEPTANCE TRIAL OPERATION AND FIELD TEST

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SECTION 35 01 40.71 Page 1 Certified Final RTA - W911WN-15-B-0004 Revised by Amendment 0001

SECTION 35 01 40.71

REPAIR AND REHABILITATION OF LIFT GATE EQUIPMENT

PART 1 GENERAL

1.1 SCOPE

This section covers the furnishing of all electrical and mechanical materials, hardware, labor, and specialty services necessary to complete the work specified herein. The work shall include removing, rebuilding, testing, and reinstallation of the brakes, and cleaning, degreasing, inspection, and spot painting of the remaining machinery components.

1.2 REFERENCE DRAWINGS

Reference drawings produced by the S. Morgan Smith Co. (circa 1934) depict the arrangement of the gate hoist equipment. It is noted that on Drawing No. 4689-X-1 two inline motors are shown on the hoisting frame. It is brought to the Contractor's attention that one of these motors was removed in the rehabilitation of the dam in 1985. The remaining motor is still the original.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation; all other submittals are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Machinery Servicing Plan; G, DO Qualifications; G, DO

Provide plans, procedures, data sheets, etc. for refurbishing the brakes as outlined in paragraph REBUILDING EXISTING GATE HOIST BRAKES and cleaning and refurbishing the machinery as outlined in paragraph CLEANING AND RELUBRICATION OF EXISTING MACHINERY.

SD-03 Product Data

Cleaning and Degreasing Products; G, DO Lubricating Oil;G, DO

The Contractor shall submit for approval all cleaning and degreasing products that are to be used. Product data shall include manufacturer's descriptive literature, test data, and all MSDS Data Sheets regarding the product.

SD-06 Test Reports

Test Data; G, DO

SECTION 35 01 40.71 Page 2

Brake Test Data; G, DO

Provide test data for the refurbished brakes in accordance with paragraph TESTING, subparagraph General and acceptance and field test data in accordance with paragraph ACCEPTANCE TRIAL OPERATION

AND FIELD TEST.

1.4 GENERAL

1.4.1 Coordination with Related Work

The Contractor shall be responsible for coordination with any related work in the replacement of the lift gates as specified in Section 35 20 16.53 INSTALLATION OF VERTICAL LIFT GATES, and hoist chain replacement as specified in Section 05 50 14.00 08 METALWORK FABRICATION, MACHINE WORK, MISCELLANEOUS PROVISIONS.

1.4.2 Description of Electrical Equipment

The existing dam lift gate hoist motors and brakes are original equipment, installed circa 1934. The motors were recently inspected and meggered and it was determined that they are in good conditions. Refurbishing the brakes described herein pertains to lift gates 5 and 7 only.

1.4.2.1 Existing Motors

The existing gate hoist motors are Westinghouse Electric Company, Type CI, wound rotor units rated at 10 HP, 3-phase, 220/440 VAC, 60 Hz. Frame size is W-326; full load current is 14.3 amps; full load speed is 1150 RPM; and nameplate ratings of the secondary windings are 34 amps at 143 volts.

Motors are rated 1 hour 50 degrees C rise, splash and weatherproof, and have grease lubricated cartridge type ball bearings.

1.4.2.2 Existing Brakes

The existing brakes are Cutler-Hammer AC Torque motor operated shoe brakes, type RS - Bulletin 507 10 inch. The AC torque motor brake units are rated for 190 ft-lbs (1 hour intermittent) and 125 ft-lbs (continuous duty), 1-phase, 440 VAC, 60 Hz.

1.4.2.3 Protection of Equipment

Temporary covers shall be provided as necessary to protect lift gate machinery after it is removed from the pier. All machinery components shall be protected from the weather during refurbishment and storage and until they are reinstalled on the pier and the machinery housings are reinstalled.

1.5 MATERIALS AND EQUIPMENT

Materials and equipment for the brake assemblies shall conform to the respective publications and other requirements specifically addressed herein. The existing brakes shall be refurbished by an Authorized Cutler-Hammer repair facility service center with experience servicing all brands of brakes. Only OEM (Original Equipment Manufacturer) parts or suitable aftermarket parts and factory approved repair procedures shall be utilized.

SECTION 35 01 40.71 Page 3

1.6 QUALIFICATIONS

All work shall be performed in a skillful and workmanlike manner in accordance with the best modern shop practice, and shall be performed by mechanics especially skilled for each kind of work and under competent supervision and direction. All materials and equipment shall be installed in accordance with recommendations of the manufacturer as approved by the Contracting Officer. Workmanship shall be of the highest grade and in accordance with modern practice.

1.7 WARRANTY

The guarantee period for the rebuilt brakes shall be extended one year from the time they have been accepted. The Contractor shall make written transfer of all manufacturers' warranties to the Government upon acceptance of the work by the Contracting Officer.

PART 2 PRODUCTS (Not Applicable)

PART 3 EXECUTION

3.1 REBUILDING EXISTING GATE HOIST BRAKES

3.1.1 General

The Contractor shall inspect, repair, test, and re-install two existing hoist brakes for each gate. The vendor selected to perform the brake refurbishing service shall be an authorized Cutler-Hammer brake repair facility with experience servicing all brands of brakes including Cutler-Hammer.

Work shall include but not be limited to the following: thorough dismantling and inspection of all parts; cleaning and degreasing of all parts; bases inspected for cracks and straightness; control arms and yokes inspected for cracks; all springs, pins and bushings replaced; shoes inspected and replaced or relined with; thruster/torque motor tested, re-insulated or rewound as required; Welding and machining of worn parts as required; all component parts painted before assembly; renewal parts supplied and installed as required; units assembled and tested to meet original manufacturers new brake criteria.

3.1.2 Installation of Rebuilt Brakes

Brakes shall be accurately installed following refurbishing. Brakes shall be remounted in the position shown on the Reference Drawings provided. The Contractor shall provide new nuts, bolts and shims for remounting the brakes in correct alignment and elevation on their mounting frame. Brakes shall be mounted inline with motors so that the alignment of the shaft relative to the centerline of the worm gear shaft is as shown (Ref Dwg 4689-X-1). The alignment (in any direction) and elevation of the brakes shall be within + 1/16 inch of the theoretical position.

3.2 TESTING

3.2.1 General

Contractor shall submit a complete report on all work and testing results for the refurbished brakes. Once the brake has been re-installed, the Contractor shall test and verify proper operation. Contractor shall assure

SECTION 35 01 40.71 Page 4 proper fit and alignment of the refurbished brake, to the existing machinery shaft and the motor.

3.3 CLEANING AND RELUBRICATION OF EXISTING MACHINERY

3.3.1 Cleaning, Degreasing, Inspection, Lubrication and Spot Painting

The Contractor shall submit a Machinery Servicing Plan for cleaning, degreasing, inspecting, lubricating, and touchup painting of the hoist machinery, The plan shall identify the methods and products that will be used for this work; shall indicate the methods for controlling and collecting the byproducts; and identify the methods for disposal of the byproducts. The plan shall identify by name the commercial facility at which the byproducts will be disposed.

Existing components of the hoist equipment shall be cleaned and degreased, inspected and lubricated prior to installing the new hoisting chains.

Gears and sprockets shall be degreased using cleaning and degreasing products and by a method approved by the Contracting Officer. All oil from gear boxes shall be drained. Degreasing shall be completed after the machinery base has been lifted from the dam pier. All open gearing, shafts, motors, covers, guides, cases, etc. shall be degreased. The enclosed gear boxes shall have the oil drained, lids removed, and all sludge and sediment cleaned from the inside (bottom and sides) of the case. All residue of this degreasing operation shall be controlled and collected into storage drums and the drums transported for disposal to a commercial facility that is permitted to accept this form of industrial waste. Handling and disposal of the byproducts shall be in accordance with Federal, state and local environmental laws and regulations. Once cleaning and degreasing has been completed, the Government will inspect gears, gear boxes,and other components. The Contractor shall notified the Contracting Officer at least 48 hours in advance of when the equipment will be ready for inspection. Prior to the Government inspection, the Contractor shall inspect and measure the existing drive sprockets to verify the tooth profiles and pitch are within the tolerances shown on the reference drawings. The new spare drive sprockets will only be installed if the existing sprockets are beyond the tolerances specified for the new chains.

The awardable option for changing the drive sprockets is covered in paragraph OPTIONAL DRIVE SPROCKET REPLACEMENT. Following the inspection, the Contractor shall fill gear boxes with new lubricating oil and shall lubricate all gears and sprockets with Government-furnished oil and grease. New gaskets shall be supplied for the gear box lids and inspection covers. All residue of oil and lubricant on surfaces not to be lubricated shall be removed with an approved solution. Touch-up paint surfaces as required before and after installation in accordance with Section 09 97 02

PAINTING: HYDRAULIC STRUCTURES.

3.4 OPTIONAL DRIVE SPROCKET REPLACEMENT

3.4.1 General

If the inspections and measurements of the existing drive sprockets outlined in Paragraph Cleaning, Degreasing, Inspection, Lubrication and Spot Painting indicate that the sprockets need to be replaced, the option for installing new Government-furnished drive sprockets will be awarded.

The sprockets shall be replaced in pairs, so both sprockets for a gate shall be replaced even if only one sprocket is determined to be out of spec.

SECTION 35 01 40.71 Page 5

3.4.2 Installation

The drive sprocket is an integral part of the final drive shaft of the gear train, with the large bull gear installed on the end opposite the sprocket.

The Contractor shall become familiar with the machinery and submit a detailed sprocket replacement plan for approval. The basic steps to replace the sprockets include: removing position transducer; removing chain guard; removing chain; unbolting pillow block bearings; carefully lifting and removing sprocket/bull gear assembly from the machinery base using nylon slings; removing bull gear and keys from old sprocket shaft (light press fit); cleaning and inspecting bull gear, keys and bearings;

installing bull gear and keys on new sprocket shaft (light press fit);

carefully lowering sprocket/bull gear assembly onto machinery base using nylon slings; aligning gears and sprocket; bolting pillow block bearings;

lubricating sprocket and bearings; installing chain; installing chain guide; installing and calibrating position transducer. The approximate weight of the sprocket shaft gear is 3,500 pounds, the approximate weight of the sprocket shaft is 580 pounds,and the approximate weight of the chain guard is 330 pounds.

3.5 ACCEPTANCE TRIAL OPERATION AND FIELD TEST

After the gate assembly has been installed, including reinstallation of operating machinery, the Contracting Officer will examine the complete system for final acceptance. Operation and field test data and brake test data shall be furnished to the Contracting Officer. The assembly will be examined first to determine whether or not the workmanship conforms to the specification requirements, as determined by the Contracting Officer. The Contractor shall operate the gate throughout its full operating range a sufficient number of times to demonstrate proper operation. The gate shall be operated from the local control station at the dam pier. The initial operation of the gate assembly shall be conducted in the dry. With the gate in the seated position and uniformly blocked so that the wheels and guides are in uniform contact with the track plates, the rubber seals shall be checked to ensure that they are uniformly compressed against the seal plates. The trial operation and testing of the gate assembly shall be conducted with the normal operating pool hydrostatic pressure. Adjustments shall be made to the operating equipment until all components function as required. Defects, as determined by the Contracting Officer, shall be corrected at no additional cost to the Government. The trial operation and testing shall be repeated after defects are corrected.

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SECTION 35 01 40.71 Page 6

3.5 ACCEPTANCE TRIAL OPERATION AND FIELD TEST