Technical Specification Section 35 01 41.00 08 (REV) Amendment 0001.pdf

Tionesta - Replace Gate Operating Machinery

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

35 01 41.00 08

ELECTROMECHANICAL OPERATING MACHINERY

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 QUALITY ASSURANCE

1.3.1 Manufacturer and Assembler

1.3.2 Erecting Engineer Services

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Delivery, Storage and Handling of Equipment

1.4.1.1 Packaging

1.4.1.2 Shipping, Preservation, and Storage

PART 2 PRODUCTS

2.1 EQUIPMENT

2.1.1 Machinery

2.1.2 Electrical Equipment

2.1.3 Nameplate

2.1.4 Equipment Submittal Data

2.1.4.1 Brakes

2.1.4.2 Speed Reducers

2.1.4.3 Electric Motors

2.1.4.4 Couplings (High and Low Speed Shafts)

2.1.4.5 Pillow Block, Greaseless and Sleeve Bearing

2.1.4.6 Wire Rope

2.1.4.7 Emergency Gate Travel Drive

2.2 MACHINERY LIFTING BEAM

2.3 DESIGN CRITERIA

2.4 OPERATION SEQUENCES

2.4.1 Hoisting Machinery Operation

2.4.1.1 Sequence of Operation

2.4.1.1.1 Gate Opening

2.4.1.1.2 Gate Closing

2.4.1.2 Design Considerations

2.5 SPEED REDUCERS

2.5.1 Gate Hoist Speed Reducer

2.5.1.1 General

2.5.1.2 Reducer Housing

2.5.2 Gearing

2.5.3 Reducer Shafts

2.5.4 Shaft Bearings

2.5.5 Gearbox Lubrication System

2.5.6 Seals

2.5.7 Breather

2.5.8 Lubrication

2.6 BEARINGS

SECTION 35 01 41.00 08 Page 1 Certified Final - W911WN20B8002 - Ammendment 0001

2.6.1 Pillow Block Bearing Assemblies

2.6.2 Sleeve Bearing Gate Pickup

2.7 SHAFTS

2.8 SHAFT COUPLINGS

2.8.1 General

2.8.1.1 Gear Type Couplings

2.8.1.2 Grid Type Couplings

2.8.2 Torque Limiting

2.8.3 Gate Position Indicator

2.9 SLACK CABLE SAFETY SHUTDOWN

2.10 ELECTRIC MOTORS

2.11 BRAKES

2.12 GUARDS AND COVERS

2.13 STRUCTURAL BASES AND SUPPORTS

2.14 HOIST DRUMS

2.15 WIRE ROPE AND END TERMINATIONS

2.16 SHEAVES

2.17 PAINTING

2.18 SHOP ASSEMBLY AND TESTS

2.18.1 General

2.18.2 Alignment

2.18.3 Anti-Seize Lubricant

2.18.4 Acceptance

2.18.5 Gages

PART 3 EXECUTION

3.1 STRUCTURAL FABRICATION

3.1.1 General

3.1.2 Material

3.1.3 Dimensional Tolerances for Structural Work

3.2 MACHINE WORK

3.2.1 Finished Surfaces

3.2.2 Unfinished Surfaces

3.2.3 Pin Holes

3.3 FIELD QUALITY ASSURANCE

3.4 NONDESTRUCTIVE EXAMINATION

3.4.1 NDT Agency Requirements

3.4.2 Nondestructive Testing (NDT) for Flaws

3.4.3 Hoisting Drum Nondestructive Testing Examination

3.5 HOISTING DRUM AND SHEAVE CERTIFICATION

3.6 HOISTING MACHINERY AND DRUM SHOP LOAD TEST

3.7 WELDING

3.8 MISCELLANEOUS PROVISIONS

3.8.1 Cleaning of Corrosion-Resisting Steel

3.8.2 Protection of Finished Work

3.8.3 Lubrication

3.9 FIELD ERECTION AND TESTS

3.9.1 General

3.9.2 General Test Procedure

3.9.3 Schedule

3.9.4 Limit Switch and Position Indication Settings

3.10 ERECTING ENGINEER

3.11 FIELD TRAINING

3.12 STARTUP AND ACCEPTANCE TEST

3.13 Equipment Warranty

3.14 OPERATIONS AND MAINTENANCE DATA

-- End of Section Table of Contents --

SECTION 35 01 41.00 08 Page 2

SECTION 35 01 41.00 08 Page 3

35 01 41.00 08

ELECTROMECHANICAL OPERATING MACHINERY

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 GEAR MANUFACTURERS ASSOCIATION (AGMA)

AGMA 2015/915-1 (2002A) Accuracy Classification System - Tangential Measurement Tolerance Tables for Cylindrical Gears

AGMA 6013 (2016) Standard for Industrial Enclosed Gear Drives

AGMA 9002 (2014C) Bores and Keyways for Flexible Couplings (Inch Series)

AGMA 908 (1989B; R 1999) Information Sheet:

Geometry Factors for Determining the Pitting Resistance and Bending Strength of Spur, Helical and Herringbone Gear Teeth

ANSI/AGMA 2001 (2004D; R 2010) Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth

ANSI/AGMA 2003 (2010D) Rating the Pitting Resistance and Bending Strength of Generated Straight Bevel, ZEROL Bevel, and Spiral Bevel Gear Teeth

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

ANSI/AGMA 9005 (2016) Industrial Gear Lubrication

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

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

AMERICAN WELDING SOCIETY (AWS)

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

SECTION 35 01 41.00 08 Page 4

ASME INTERNATIONAL (ASME)

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

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

ASME BTH-1 (2017) Design of Below-the-Hook Lifting Devices

ASTM INTERNATIONAL (ASTM)

ASTM A148/A148M (2014) Standard Specification for Steel Castings, High Strength, for Structural Purposes

ASTM A29/A29M (2016) Standard Specification for General Requirements for Steel Bars, Carbon and Alloy, Hot-Wrought

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

ASTM A380/A380M (2017) Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems

ASTM A484/A484M (2019) Standard Specification for General Requirements for Stainless Steel Bars, Billets, and Forgings

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

ASTM A829/A829M (2014) Standard Specification for Alloy Structural Steel Plates

ASTM B164 (2003; R 2014) Standard Specification for Nickel-Copper Alloy Rod, Bar, and Wire

ASTM D3951 (2015) Commercial Packaging

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 281 (2007) Rolling Bearings -- Dynamic Load Ratings and Rating Life

Japanese Standards Association (JSA)

JSA JIS B 1519 (2009; R 2013; R 2018) Rolling Bearings - Static Load Ratings

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 1110-2-2610 (2013) Mechanical and Electrical Design for Lock and Dam Operating Equipment

SECTION 35 01 41.00 08 Page 5

1.2 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

Shop Test Information; G , DO

Contractor shall provide proposed shop test procedures, test rig details, final shop test procedures, and data sheets.

Shop Load Test Rig and Location; G , DO

Provide details of the Contractor designed test rig and its location for the shop load test for approval.

Installation and Alignment Procedure; G , DO

Provide detailed manufacturer's instructions concerning the installation and alignment procedures for the equipment to be furnished. Items include gear reducers, bearings, shafts, brakes, motors, couplings, sprockets, and limit switches.

Measuring Tension Procedure; G , RO

Provide details for the procedure used to measure wire rope tension during installation.

Equipment Protection Plan; G , RO

Provide detailed information on the method proposed to protect the existing equipment from such operations as power washing, abrasive blast cleaning, welding, placement of concrete, and painting.

Materials List; G , DO

Submit materials list for fabricated items at the time of submittal of detail drawings.

Commissioning; G , RO

Field Tensioning and Operating Test Procedure; G , DO

Pre-Functional Checklist

Contractor developed checklist for checks, recordings, measurements and verifications to be performed prior to start up.

Acceptance shall be required by signature for all parties.

Functional Checklist

Contractor developed checklist for checks, recordings, measurements and verifications to be performed after start up.

Acceptance shall be required by signature for all parties.

SECTION 35 01 41.00 08 Page 6

Gate Position Settings On Limit Switches

SD-02 Shop Drawings

Detail Drawings; G , DO

Detailed shop drawings for gears, shafts, bushings, limit switches, supports, lifting beam, and all shop fabricated metal items, shall be submitted and approved prior to fabrication.

Reducer Shafts; G , DO

Key Fit and Shaft Bores

Shipping Bills

Materials Orders

SD-03 Product Data

Manufacturer's Literature and Equipment Data;; G , DO

Provide catalog cuts and material data for the proposed equipment that clearly indicates compliance with the requirements of these specifications and the drawings. AGMA ratings for gear quality of all gears and gear reducers shall be submitted.

Provide the names of the manufacturers of all machinery and other equipment which it contemplates incorporating into the work, together with performance capacities and other pertinent information pertaining to the equipment.

Electric motors

SD-05 Design Data

Contractor Designed Gearing; G , DO

Gearbox Lubrication System; G , DO

Contractor Designed Sheaves; G , DO

Lubricating Oil for Speed Reducers

Travel Drives

SD-06 Test Reports

Electric Motors

Final Operating Test; G , DO

Final Field Tensioning and Operating Test; G , DO

Round Link Chain Tensioning

Submit proposed operating test procedures, final field operating test procedures, and data sheets.

SECTION 35 01 41.00 08 Page 7

Startup and Acceptance Test

Magnetic Particle Examination

Provide test reports for non-destructive tests performed on the gears, pocket wheels, hoisting chains, repair links and all fabricated welded components.

Tooth Contact Patterns

Inspection Log

Shop Assembly and Tests

Final Alignment Test 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, e.g., speed reducers. Identify any warranties that extend beyond a 1-year period.

Erecting Engineer Installation and Operation

Submit erecting engineer installation and operation certificates at the conclusion of installation and startup for each specified major equipment or subassemblies.

Nondestructive Examination Certification

Gear Certification

Drum Geometry for Synchronous Drums

Commissioning Document

SD-08 Manufacturer's Instructions

Cleaning of Corrosion-Resisting Steel; G , RO

SD-10 Operation and Maintenance Data

Operations and Maintenance (O&M) Manual; G , DO

SECTION 35 01 41.00 08 Page 8

Provide six copies of operation and maintenance manuals in accordance with paragraph OPERATIONS AND MAINTENANCE MANUALS and in compliance with Data Package 3 in Section 01 78 23 OPERATION

AND MAINTENANCE DATA.

1.3 QUALITY ASSURANCE

1.3.1 Manufacturer and Assembler

Manufacturing and assembly of the dam gate machinery units shall be performed by a Contractor and fabrication company that has been normally and regularly engaged in assembly, and manufacture of heavy machinery over the preceding 10 years. Changes to the dimensions shown on the drawings and in the Bill of Materials for the Gate Machinery (including structural supports) requires written approval from the Contracting Officer or designated representative. 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.

1.3.2 Erecting Engineer Services

Provide the services of one or more erecting engineers onsite during the installation and startup of each defined major piece of equipment and subassembly. The erecting engineer(s) are responsible to technically supervise and provide instruction for the equipment to be installed and operated. The major pieces of equipment and subassemblies requiring engineering services is defined as follows:

a. Dam gate Machinery

Upon completion of the work and at a time designated, provide the services of one or more erecting engineers for training Government personnel in accordance with the requirements of paragraph FIELD TRAINING.

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Delivery, Storage and Handling of Equipment

Protect equipment and components from corrosion, deformation, and other types of damage. Store items in enclosed and secured areas free from contact with soil. Provide moisture proof weather protection for all equipment stored in outdoor locations. Transport, handle and store all equipment in accordance with the manufacturer's written instructions.

Remove and replace damaged items with new items. Do not prepare the major pieces of dam operating equipment and subassemblies for shipment until they have been inspected and accepted for shipment at origin by the Contracting Officer or designated representative, unless inspection has been waived in writing. Ship each subassembly completely assembled.

Submit the shipping bills with the delivery of finished pieces to the site. The major pieces of equipment and subassemblies for this contract are defined to include the following:

a. Dam Gate Machinery

1.4.1.1 Packaging

Provide equipment and subassemblies with adequate protective pads, SECTION 35 01 41.00 08 Page 9 supports, and blocking. Securely restrain equipment and subassemblies to prevent distortion or damage to the painted surfaces in transit. Any loss or damage during shipment, including damage to the painted surfaces, is the responsibility of the Contractor. Replace or repair lost or damaged items without cost to the Government. Coat all parts with a rust preventative, wrap in heavy-duty plastic, and securely contain in wooden crates. Clearly mark each crate with its contents (including contract number and Corps mark number) on the outside, with a non-ferrous metal tag, engraved with the contents, and secured to the crate with non-ferrous screws. Provide a means for inspection of the crate's contents without destroying the crate. Pack all accessories and spare parts separately in containers plainly marked "ACCESSORIES ONLY," or "SPARE PARTS ONLY."

Package each spare part or spare part assembly in a durable treated wooden crate with metallic, plastic or suitable outer shell for weathertight protection and with provisions for handling and storage (12 months).

Provide and deliver to the site the component and assembly spare parts as delineated on the drawings. Place a separate packing list, listing the contents of each crate, in a moisture-proof envelope securely fastened to the outside of the crate. Standard commercial packaging in accordance with ASTM D3951 is acceptable except where a different method or standard of packaging is specified.

1.4.1.2 Shipping, Preservation, and Storage

Provide all packing, crating, etc., necessary to ensure safe shipment of equipment. The crates shall be disposed of by the Contractor after unpacking. 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. Protect stored equipment from the weather, humidity, temperature variation, dirt and dust, or other contaminants.

PART 2 PRODUCTS

2.1 EQUIPMENT

2.1.1 Machinery

Furnish equipment under this specification consisting of four gate operating machinery units, one in the base contract plus three awardable options. Furnish complete units including base supports, geared drives, brakes, motors, shafts, bearings, wire rope, electrical equipment, controls, covers, guards, and other necessary items to provide a complete and operable system.

2.1.2 Electrical Equipment

Conform electrical equipment, including limit switches, motor starters, conduit, conductors, controls, slack cable safety devices, to the requirements of Section 35 20 20 ELECTRICAL EQUIPMENT FOR GATE HOIST.

2.1.3 Nameplate

Provide an engraved or raised metallic nameplate that is mechanically attached to each piece of equipment. Include the manufacturer's name, model designation, serial number, unit rating, application factor, reduction ratio's, and any other applicable information on the nameplate.

SECTION 35 01 41.00 08 Page 10

2.1.4 Equipment Submittal Data

Submit Equipment Data and Detail Drawings including equipment dimensional drawings, assembly drawings, catalog cuts, and material data and shop drawings showing arrangement, construction details and ratings for factory built machinery; test rig assembly details; proposed and final shop test procedures and data sheets; proposed and final field operating test procedures and data sheets, for approval. Provide all details of fabrication and assembly to include shipping and long term storage instructions. Shop drawings lacking this information will be rejected.

Approval of the material submitted in no way relieves the Contractor from the responsibility of complying with the requirements of the specifications as to the suitability and quality of materials and workmanship and the adequacy of capacity, operating speed and other essential characteristics of the gate drives. Submit drawings, catalogs, and design data necessary to clearly show the details of any changes proposed in conformity with the requirements of this specification.

Equipment, materials, and articles of construction installed or used without such approval will be at the risk of subsequent rejection.

Submit a materials list for fabricated items at the time as the detail drawings submittal.

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

Submit Manufacturer's Literature and Equipment Data for approval. Include the names of the manufacturers of all machinery and other equipment contemplated for incorporation into the work, performance capacities and other pertinent information about the equipment. As a minimum, include the following Manufacturer's Literature and Equipment Data :

2.1.4.1 Brakes

Manufacturer's Name

Type

Model Number

Continuous Duty Torque Rating

Torque Adjustment Range

Supply Voltage

Type of Conduit Box Standard

Type of Lining

Type of Bearing

Type of External Brake Release Mechanism

SECTION 35 01 41.00 08 Page 11

Brake Wheel Size

Type of Bore Straight

Bore Size

Brake Wheel Material

Brake Wheel Model Number

Space Heater Manufacturer/Type/Size (KW)

Space Heater Manufacturer/Type/Size (KW)

Type of Enclosure

Enclosure Model Number

Torque Gauge Included Yes

Torque Scale Included Yes

Weight of Brake

Weight of Enclosure

Outline Dimensional Print of Brake

Outline Dimensional Print of Enclosure

Quantity Being Furnished

2.1.4.2 Speed Reducers

Manufacturer's Name

Type

Model Number

Exact Ratio

Efficiency

Mechanical Rating - Durability - HP, Specify SAC

Mechanical Rating - Strength - HP, Specify SAT

Rating Calculations per applicable AGMA Standard

Life Factors CL, KL

Reliability Factors CF, KR

SECTION 35 01 41.00 08 Page 12

Type of Gearing and Heat-Treatment

Type of Bearings

Minimum L-10 Bearing Life

Method of Lubrication

Size and Number of Mounting Bolts

Weight and Air Volume of Unit without Oil

Weight and Air Volume of Unit with Oil

Outline Dimensional Print

Keys and Keyway Dimensions

Type of Breather

Quantity Being Furnished

AGMA and ISO Lubrication Oil/Viscosity rating

Type of Lubricant

2.1.4.3 Electric Motors

Manufacturer's Name

Type

Frame Number

Unique Serial Number

Certified Factory Motor Test Data, High Speed & Low Speed

Motor Performance Curves, High Speed & Low Speed

Enclosure Type

Input Voltage, Phases, Frequency

Full Load Amps, High Speed & Low Speed

Locked Rotor Amps, High Speed & Low Speed

Insulation Type

Temperature Rise

Drive Output Shaft Size/Tolerances

SECTION 35 01 41.00 08 Page 13

Space Heater Manufacturer/Type/Size (KW)

Input KW, Input Voltage

Conduit Box Size-Motor

Conduit Box Size-Heater

Drain Description (Manufacturer and Type)

Full Load Torque, High Speed & Low Speed

Upper Limit Torque, High Speed & Low Speed

Lower Limit Torque, High Speed & Low Speed

Locked Rotor Torque, High Speed & Low Speed

Percentage Slip, High Speed & Low Speed

Outline Dimensional Print

Weight of Motor

Quantity Being Furnished

2.1.4.4 Couplings (High and Low Speed Shafts)

Manufacturer's Name

Type

Model Number

Bore Sizes and Tolerances

Number of Keyways

Keyway Sizes and Tolerance

Recommended Shaft Size and Tolerance

Recommended Key Size and Tolerance

Recommended Key Material

Keyways Filleted - No

Materials of Construction

SECTION 35 01 41.00 08 Page 14

Catalog Rating - Torque, HP/100 RPM

Service Factor Based on Catalog Rating

Angular Misalignment

Parallel Offset Misalignment

Axial Movement

Torque and HP/100 RPM Capacity of Low Speed Coupling with Anticipated Shaft Fits

Type of Lubrication

Assembly Procedure of Hub with Shaft

Weight

Outline Dimensions Print

Quantity Being Furnished

2.1.4.5 Pillow Block, Greaseless and Sleeve Bearing

Manufacturer's Name

Type

Model Number and Size

Bearing Housing Material

Sleeve Bearing Material/Grade

Coefficient of Friction

Composite Thickness (Greaseless Composites)

Percentage Water/Oil Swell (Greaseless Composites)

Coefficient of Thermal Expansion

Crush Strength (Greaseless Composites)

Bearing Bore Diameter

Bearing Bore Floating

Type of Bearing

Static Capacity of Bearing

Thrust Capacity of Bearing

Basic Dynamic Capacity of Bearing

Load Capacity of Bearing

L-10 Life of Bearing

Type of Seals

Type of Lubrication

Grease Grooves Included Yes

SECTION 35 01 41.00 08 Page 15

Weight

Independent Laboratory Test Results (Greaseless Composites)

Outline Dimensional Print

Quantity Being Furnished

2.1.4.6 Wire Rope

Size

Classification, Type and Construction

Material

Lay

Delivery Length

Tensile Strength

Ductility

Pre-Forming Certification

Pre-Stretching Procedure/Certification

Sockets and End Termination

Speltering Material

Speltering Procedure/Certification

Type of Lubricant

Multi-Wire Rope Tensioning Procedure

2.1.4.7 Emergency Gate Travel Drive

Wheel Size

Wheel Loads

Wheel Hardness

Hand Wheel Diameter

Hand Wheel Pull

Type of Lubricant

Dimensional Print

SECTION 35 01 41.00 08 Page 16

2.2 MACHINERY LIFTING BEAM

Supply a lifting beam designed to the requirements of ASME BTH-1 Design Category A Service Class 0, and designed to lift the gate operating machinery specified in this Section. Submit detail drawings including dimensional drawings, assembly drawings, catalog cuts, and material data and shop drawings showing arrangement, construction details and ratings for approval. Approval of the material submitted in no way relieves the Contractor from the responsibility of complying with the requirements of the specifications as to the suitability and quality of materials and workmanship and the adequacy of capacity and other essential characteristics of the lifting beam. The lifting beam shall be clearly marked with its maximum capacity in tons and ASME BTH-1 Design Category and Service Class. Include any slings required to connect the lifting beam to the gate operating machinery. The lifting beam shall be designed to be used with the 20-ton Government overhead bridge crane in the control tower, and shall be delivered to the project site with or before the first gate operating machinery.

2.3 DESIGN CRITERIA

Provide equipment and machinery to meet the anticipated operating conditions as specified by the following design criteria.

COMPONENT DESIGN CRITERIA

ITEM MAXIMUM

LOAD

(Kips)

OPERATING

TEMP.

RANGE Deg F

MINIMUM

OPERATING

SPEED

(FPM)

OPERATING

TRAVEL

Reversing

CYCLES MAX

TRAVEL

TIME

OPEN

MAX

TRAVEL

TIME

CLOSE

NOTES

Gate Hoist

230 32 - 90 0.5 13 ft 1 per day 26 min

26 min For normal operations

Gate Hoist

35.3 32 - 90 0.5 111 ft 1 per year 4 hrs 4 hrs For gate open to dogging position

Ensure the equipment and machinery does not exceed the maximum limiting dimensions as shown on the drawings. Also ensure the complete gate hoisting machinery, including all required lubricants, wire rope, lifting beam, and any slings or other items required to lift the machinery, does not exceed a total weight of 40,000 pounds.

Design equipment in strict accordance with the requirements of EM 1110-2-2610 Mechanical and Electrical Design for Lock and Dam Operating Equipment unless otherwise specified within. Equipment shall be designed for the normal loads using factors of safety applicable to the type of service and the particular part with a minimum factor of safety of 5 based

SECTION 35 01 41.00 08 Page 17 on the ultimate strength of the material. Include all anticipated loads in the design. Loads include, but are not limited to, the loads imposed by the dead weight, hydraulic forces, buoyancy forces, ice, upper and lower connecting links, and seal friction. In addition, design each part or component, including speed reducers (excluding wire rope), for a unit stress not in excess of 75 percent of the yield strength of the material under loads resulting from the locked rotor torque of the electric motor.

Design components that might fail in buckling compression for a minimum factor of safety of 3.0, using the Euler or J.B. Johnson formulas. Apply the factor of safety to the maximum load on the member and the critical buckling load. Model the end fixity coefficient for pin-end conditions.

Both the normal loads and loads resulting from the locked rotor torque of the electric motor shall be considered for gate operating equipment.

Allowances for shock and impact will not be required unless specifically identified. Submit for approval all equipment modification design calculations.

2.4 OPERATION SEQUENCES

2.4.1 Hoisting Machinery Operation

The equipment sequence of operation, interlocks and electrical controls are as indicated. Conform equipment and hardware with the requirements of Section 35 20 20 ELECTRICAL EQUIPMENT FOR GATE HOIST.

2.4.1.1 Sequence of Operation

2.4.1.1.1 Gate Opening

a. Motor and brake are energized (brake is released).

b. Motor starts and opens the gate at full speed.

c. Gate position is device proven to be at end of travel.

d. Motor and brake are de-energized (brake is engaged).

2.4.1.1.2 Gate Closing

The sequence for closing the gate is identical to that for opening, except the gate moves in the opposite direction to the closed position.

2.4.1.2 Design Considerations

Normal operations of the dam gates for the purpose of design consist of the dam gates operating through 1 complete cycle per day with 2 starts and 2 stops per cycle. A cycle is defined as moving the dam gate from the fully closed position to the fully opened position and back to the fully closed position.

2.5 SPEED REDUCERS

2.5.1 Gate Hoist Speed Reducer

2.5.1.1 General

The speed reducer shall be of adequate reduction, right angle type, entirely self contained in an oil tight, steel housing designed to maintain shafts and bearings in accurate alignment. Provide the gear

SECTION 35 01 41.00 08 Page 18 ratio as indicated plus or minus 1.5 percent. Provide a horizontal output shaft for position feedback with the gear reducer. Design, rate and manufacture the speed reducers in accordance with AGMA 6013 with all components meeting the requirements of ANSI/AGMA 6001 . The gearing must be rated in accordance with ANSI/AGMA 2003 and ANSI/AGMA 2001 . In all cases where these standards or this specification are in conflict with one another the more conservative design standard takes precedence.

2.5.1.2 Reducer Housing

The reducer housing must be heavy duty cast steel or welded steel construction and have dowel pins at all parting seams for accurate gear and bearing alignment. Split the reducer housing to facilitate disassembly for maintenance and repair. Design the dry well such that the speed reducer can be completely filled with oil while in storage and the oil can be drained out of the dry well when the speed reducer is to be put into service. Design the base thickness and width with adequate rigidity and stiffness to not contribute additional stress on the mounting bolts.

All surfaces must be smooth and flat and easy to clean. Provide the upper and lower housings with large, rugged lifting lugs. Provide all required oil drains, fill ports, breathers, heater ports, filtering ports, and inspection covers in the housing. Provide a main oil drain at the lowest point possible on the reducer housing. Fit the main oil drain with a 1-inch stainless steel ball valve with a pressure-temperature rating of 2000 psig at 100 degrees F. Plug the valve on the open end. Also provide the lower bearings with drainable deepwell bearing end caps as indicated. Locate drain and fill plugs for speed reducers so as to be readily accessible on the completed units and provide with extension piping where required. Manifold and pipe the drains to a single point with a shutoff valve and threaded cap on the exterior of the housing so that it is easily accessible. Internally raise lower bearings within the housing to prevent bearings from being the lowest point in the housings.

Top side inspection covers are not acceptable. Provide side inspection access covers. All dimensions indicated must remain as shown as a minimum for proper machinery alignment.

2.5.2 Gearing

Provide gearing made from high strength alloy steel that is hardened by an appropriate method with subsequent quenching and tempering to produce a through or case hardened gear as deemed appropriate for the application.

Grind the gears after gear cutting to achieve a minimum ANSI/AGMA Quality 11 in accordance with AGMA 2015/915-1 . If using pinions, helical or other, integrally cut the pinions on the pinion shaft. If using spiral bevel gears,make spiral bevel gears from high strength alloy steel with case hardened teeth, crown lapped for quality and smooth operation.

2.5.3 Reducer Shafts

Make shafts from high-strength alloy steel in accordance with ASTM A668/A668M and of sufficient size and as indicated to insure rigid alignment. All 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.

SECTION 35 01 41.00 08 Page 19

2.5.4 Shaft Bearings

The shaft bearings must be high capacity antifriction roller bearings suitable for both radial and thrust loads. All bearings must have a minimum L-10 bearing life of 75,000 hours based on the largest full load motor horsepower provided by the specified motor.

2.5.5 Gearbox Lubrication System

The lubrication system must be a splash type system using a synthetic hydro-carbon lubricant conforming to the requirements of ANSI/AGMA 9005 .

Design the lubrication system to function properly at both nameplate speed ratings using the specified lubricating oil. All gears and lower bearings must be oil lubricated. All upper bearings must be oil and/or grease lubricated. Provide all required oil slingers, dams, and passages.

Provide grease lines and lubrication fittings for all grease lubricated bearings and mounted on the reducer housing such that the bearings can be easily identified and lubricated from the side of the reducer housing.

Equip the reducer with a sight gauge and dipstick in order to observe and measure the oil level. Also, fit the speed reducer with an oil sample valve arrangement. The valve must be a 1/4-inch stainless steel ball valve with a pressure-temperature rating of 2000 psig at 100 degrees F and be fitted with a plug on the open end. Locate the oil sample port on the reducer housing such that an oil sample can be drawn (through the sample valve) from a point that is approximate 1/2 of the operating oil level in the reducer.

2.5.6 Seals

Provide spring loaded grease-purged dual lip seals for all shaft extensions. Design and size all seals to withstand the pressure head developed when the speed reducer is completely filled with oil (storage condition) without leaking.

2.5.7 Breather

Provide all reducers with a hygroscopic breather with threaded fittings for installation to prevent problems caused by moisture and particulate matter contamination in the reducer when it breathes in and out due to temperature fluctuations. The breather must filter particles down to 3 microns in size. The hygroscopic agent must change color signifying when the unit requires replacement, i.e., when the desiccant is saturated with moisture. Air flow stoppage through the breather under freezing conditions is not allowed.

2.5.8 Lubrication

Lubricating oil for speed reducers must have good resistance to foaming under normal operating conditions and be noncorrosive to speed reducer components. Provide the oil in accordance with the gearbox manufacturer's requirements unless otherwise specified herein. Submit lubricant characteristics, physical properties and product data. Provide lubricant suitable for infrequent intermittent duty operation of the speed reducers with an ambient temperature range from minus 10 degrees F to plus 110 degrees F. Lubricate couplings and bearings in accordance with the manufacturer's instructions.

SECTION 35 01 41.00 08 Page 20

2.6 BEARINGS

2.6.1 Pillow Block Bearing Assemblies

The pillow block bearing assemblies include the bearings, housings, seals and hardware. Housings must be split type, with a through drilled, four bolt base. Split housings must have dowels or steps to provide alignment accuracy. Except as otherwise specified, shaft bearings must be high capacity antifriction spherical self-aligning roller bearings suitable for both radial and thrust loads with pressure lubrication fittings. Use the manufacturer's ratings for loads and speeds in determining the bearing capacity. Service and installation factors shall be in accordance with the bearing manufacturer's recommendations. The bearings shall be capable of withstanding the total resultant normal loads and axial loads placed on the hoist drum.

Provide floating type bearing as indicated. Provide end caps on open ended shafts. All cap bolts must be SAE Grade 8. Provide locking rings, set screws, lock nuts, spacers, and the necessary sleeves to center and secure the bearings within the housing. All bearings must have a minimum L-10 bearing life of 75,000 hours as defined by ISO 281 or JSA JIS B 1519 based on the largest full load motor horsepower provided by the specified motor. Design the bearing and housing for grease lubrication and equip with labyrinth type shaft seals made of materials suitable for the working conditions and lubricant to be used to exclude foreign matter and retain lubrication without leakage under both static and dynamic operating conditions.

2.6.2 Sleeve Bearing Gate Pickup

Provide sleeve bearing for the Emergency Gate Pickup in accordance with dimensions shown on the contract drawings. Bearing material shall meet the requirements of ASTM B164.

2.7 SHAFTS

Calculate and design shafts to satisfy the requirements of Corps of Engineers' guidance specified in EM 1110-2-2610 . Design shafts at minimum to provide a factor of safety of 5 when maximum load condition stresses are compared to the ultimate strength of the material and the stresses produced by the maximum torque of the motor do not exceed 75 percent of the material yield strength. Equations used for design must meet the requirements of the ASME shafting code. Apply a combined shock-and-fatigue factor of 1.25. Limit the maximum shaft bending moment shaft deflection to 0.01 in/ft of length at the maximum rated load. The torsional shaft deflection must not exceed 0.08 deg/ft of shaft length.

2.8 SHAFT COUPLINGS

Shaft couplings shall be of the gear or grid type of machined steel construction and capable of transmitting the applied design torques.

2.8.1 General

Provide couplings capable of the horizontal installation and design for reversing loads and a maximum 1800RPM operating speed. The couplings must be capable of handling a maximum torque equal to the stall torque of the motor. Design couplings to compensate for angular, parallel and axial misalignment. Couplings must have a general service factor of 1.0 applied

SECTION 35 01 41.00 08 Page 21 to their selection and design based upon the anticipated application and expected service. Couplings must be of sufficient capacity to develop the full strength of the shafting which they connect and must be pressed and keyed thereon. All hub bores must meet the dimensional and tolerance specifications in accordance with AGMA 9002 unless otherwise indicated.

The key fit must be in accordance with ASME B17.1 , Class II. Submit the fabricated dimensions of the key fit and shaft bores. Equip couplings with lube plugs; enclose and seal with an elastomeric O-ring to retain the lubricant. Couplings must be oiltight under both static and dynamic operating conditions. Use SAE grade 8 bolts unless specifically used for shear applications by the manufacturer to achieve published shear strengths. Minimize misalignment for gear couplings by not exceeding the manufacturer's recommendations for installation limits pertaining to gap-hub separation, angular alignment, and parallel offset alignment measurements.

2.8.1.1 Gear Type Couplings

Flanged with exposed bolt, double engagement, made of forged steel.

Couplings must transmit torque by means of external gears on hubs engaging in internal gears on the coupling sleeves. Machine gears in accordance with AGMA 9002 and AGMA 908.

2.8.1.2 Grid Type Couplings

Keyed shaft hubs with slotted faces to connect each coupling half through an interlocking tapered high tensile metal alloy grid. The grid must be fully enclosed in a sealed horizontally split cover to retain the lubricant. The covers must be rounded edge design with recessed and threaded lubricant plugs to fill and retain lubricant.

2.8.2 Torque Limiting

In order to protect the wire rope and hoist machinery, the maximum motor output torque shall not exceed a force greater than 70% of the breaking strength of the wire rope or 75% of the ultimate strength at any machinery component.

2.8.3 Gate Position Indicator

Provide a mechanical indicator on each gate hoist showing the position of the bottom of the roller gate. The indicator shall show the range from the gate closed position to where the gate is just below the operation floor elevation for dogging as shown on reference drawing 038e-U1-55/1A.2. The display shall be graduated in 1-foot increments.

2.9 SLACK CABLE SAFETY SHUTDOWN

The gate operating machinery shall be provided with a slack cable safety switch. Should the gate get stuck in the gate slot while lowering the gate, the slack cable safety switch shall detect the slack cable condition and shut down the operation of the hoist in the down direction and provide an audible alarm to the operator. The hoist shall remain operational in the up direction.

2.10 ELECTRIC MOTORS

Motors must conform to the requirements set forth in Section 35 20 20

ELECTRICAL EQUIPMENT FOR GATE HOIST

SECTION 35 01 41.00 08 Page 22

2.11 BRAKES

Brakes must conform to the requirements set forth in Section 35 20 20

ELECTRICAL EQUIPMENT FOR GATE HOIST

2.12 GUARDS AND COVERS

Provide safety guards or covers where necessary to protect the operators from accidental contact with moving parts. Provide openings in guards and covers as necessary to provide access to parts requiring lubrication or regular maintenance.

2.13 STRUCTURAL BASES AND SUPPORTS

For specific requirements for welded structural steel bases, frames, and supports see Section 05 50 15 CIVIL WORKS FABRICATIONS.

2.14 HOIST DRUMS

The hoist drum must be a centrifugally spun steel casting conforming to ASTM A148/A148M , GR90-60 spun cast steel, or a machined weldment of ASTM A829/A829M , Grade 4140 or 4340 material as indicated. Each drum must have full end diaphragms to transfer the supported load to the operating shaft. Stress relieve the entire drum after welding and before finish machining. Heat treat the drum spool face through flame hardening to achieve a surface hardness of 375-400 BHN after final machining. The hoist drums must be of the through shaft type design and welded to the drum shaft. Size the drum as required. Weld the drum flange to the drum and fabricate of ASTM A36/A36M steel. Fabricate the drum shaft from ASTM A29/A29M, Grade 1045 cold finished steel with a minimum yield and tensile strength of 50,000 psi and 70,000 psi, respectively psi.

2.15 WIRE ROPE AND END TERMINATIONS

Comply with Section 35 01 70.13 WIRE ROPE FOR GATE OPERATING DEVICES for the hoisting wire rope and end terminations.

2.16 SHEAVES

Conform Contractor designed sheaves to the requirements of EM 1110-2-2610 unless otherwise specified herein. Design the sheaves for the normal operating conditions with sufficient safety factors so that the maximum unit stresses do not exceed 75 percent of the yield points of the materials of construction based on the maximum hoisted load. Engineer, design, fabricate, and assemble the sheave units. Design the sheave assembly in accordance with the Crane Manufacturers Association of America (CMAA) standards and in accordance with ANSI standards and OSHA'S interpretation of their regulations for drums/sheaves for mill type cranes. Prepare and submit all required calculations and shop drawings for the design and fabrication of the hoisting sheave assembly to the Contracting Officer or designated representative for approval prior to the start of shop fabrication.

2.17 PAINTING

Paint all exposed ferrous surfaces with the manufacturer's standard coating system. Standards coatings must be compatible with the lubrication and environmental conditions specified or recommended. Touch

SECTION 35 01 41.00 08 Page 23 up all damaged painted surfaces after installation. Paint must at a minimum provide for zinc chromate primer, 2 coats of varnish, and gray enamel to result in a minimum dry film thickness of 2.5 mils. Painting of nonferrous metals and corrosion resisting steel will not be required unless otherwise specified.

2.18 SHOP ASSEMBLY AND TESTS

2.18.1 General

a. Each machinery unit consisting of the motor, brake, reducer, wire rope drums, wire rope, couplings, and bearings must be completely assembled on its structural steel base (machinery base as indicated) in the shop and tested in the presence the Contracting Officer or designated representative. Notify the Contracting Officer or designated representative at least 10 calendar days before testing of each machinery unit. This notification includes information on how many units will be tested and the estimated time frame involved with each test.

b. The witnessing of a particular test may be waived by the Contracting Officer or designated representative; however, the approved commissioning shop test procedures, notification, and documentation must still be performed as required by these specifications. Once informed that Government personnel will witness the test(s), notify the Contracting Officer or designated representative that a particular test is scheduled as planned a minimum of 48 hours prior to the test(s). Perform all necessary preparations and preliminary testing prior to issuing the 48 hour notification.

c. Commence testing upon the arrival of Government personnel at the scheduled location and time. Design and furnish a test rig and facilities (within the continental United States) suitable for performing the tests. Submit details of the test rig and its location. Address in the submittal aspects including adequacy of rig strength, including, but not limited to, foundations; access to the test rig; availability of suitable power and cranes; how the work will be protected; how the test measurements will be made; and how test results can be verified. Clean all bearing surfaces and lubrication lines and lubricate reducer bearings, couplings, and gears before tests are begun. Fill all speed reducers with the specified lubricating oil; transfer of lubricating oil from one unit to another is not allowed. Electrically connect and operate the motors, brakes, and controls at rated voltage. Test and ship the motor, speed reducer, and brake machinery components to the job-site fully assembled on the structural steel base (machinery base as indicated).

d. Machinery that is not tested or arrives on site without the machinery base installed will be rejected. Reimburse the Government for all travel, lodging and per diem costs incurred for any Government witness tests that fail to meet the contract specifications or performance requirements and result in the factory testing being terminated, postponed or rescheduled to correct the deficiencies.

2.18.2 Alignment

Conform alignment of interconnecting shafts to the installation requirements of the coupling and gear manufacturers in accordance with standard AGMA practices. Accurately align each machinery or structural

SECTION 35 01 41.00 08 Page 24 unit by the use of stainless steel shims or other approved methods so that no binding in any moving parts or distortion of any member occurs before it is fastened in place. The alignment of all parts with respect to each other must be true within the respective manufacturer's tolerances required. Set machines true to the elevations indicated.

2.18.3 Anti-Seize Lubricant

Assemble threaded portions of the assemblies using an anti-seize lubricant that prevents galling of parts and corrosion, allows for easy disassembly of parts, and reduces friction unless otherwise noted or specified.

Anti-seize lubricant must be a standard product designed for the intended use.

2.18.4 Acceptance

All readings taken from the equipment, components or assemblies are required to be within the specified limits. Failure of any part to meet these contract requirements is cause for rejection of the entire quantity until action is taken to correct defects and prevent recurrence and such actions have been approved by the Contracting Officer or designated representative. Retesting is subject to the same random sampling and testing procedures as the original lots.

2.18.5 Gages

Make gages available to the Government at the fabrication site for use in checking critical dimensions. Gages are steel tape, vernier, micrometer, Gar S22 Surface Finish Comparator, etc.

PART 3 EXECUTION

3.1 STRUCTURAL FABRICATION

3.1.1 General

Fabricate components and assemblies in compliance with the requirements of Section 05 50 15, CIVIL WORKS FABRICATIONS unless otherwise specified herein. Where specification requirements are similarly covered in both sections, apply the more stringent requirements.

3.1.2 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.

3.1.3 Dimensional Tolerances for Structural Work

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. Dimensions must comply with the dimensional tolerance specified in ASTM A484/A484M .

SECTION 35 01 41.00 08 Page 25

3.2 MACHINE WORK

3.2.1 Finished Surfaces

a. Surface finishes indicated or specified herein, must be in accordance with ASME B46.1 . Determine compliance with specified surface by sense of feel and by visual inspection of the work compared to Roughness Comparison Specimens in accordance with the provisions of ASME B46.1 .

Values of roughness width and waviness height are not specified but must be consistent with the general type of finish specified by roughness height. 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 .

3.2.2 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 or designated representative.

3.2.3 Pin Holes

Pin holes must be bored true to gages, smooth, straight, and at right angles to the axis of the member. Perform the boring after the member is securely fastened in position.

3.3 FIELD QUALITY ASSURANCE

Perform all specified quality control inspections and tests. 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 control (QC) 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 for the original lots.

3.4 NONDESTRUCTIVE EXAMINATION

3.4.1 NDT Agency Requirements

Conduct NDT examinations using a testing agency adequately equipped and competent to perform such services or using suitable equipment and qualified personnel. In either case, provide written approval of the examination procedures and perform the examination tests in the presence of the Contracting Officer or designated representative. Persons

SECTION 35 01 41.00 08 Page 26 performing the NDT examination must be qualified for the specific procedure used in accordance with ASNT SNT-TC-1A . Submit nondestructive examination certification of qualified persons, procedures and equipment performing or used for nondestructive testing.

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