35 01 41.00 10.pdf

MacArthur Lock Tainter Valve Machinery Rehab

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

35 01 41.00 10

ELECTROMECHANICAL OPERATING MACHINERY FOR LOCKS AND DAMS

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 QUALITY ASSURANCE

1.3.1 Manufacturer and Assembler

1.3.2 Millwright Services

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Critical Path Components/Systems

1.4.2 Delivery, Storage and Handling of Equipment

1.4.2.1 Packaging

1.4.2.2 Shipping, Preservation, and Storage

1.4.2.3 Transport Restrictions Through Galleries

1.4.3 Storage of Existing Equipment

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 Speed Reducers

2.1.4.2 Split Sector Gears

2.1.4.3 Split Counter Shaft Gears

2.1.4.4 Jack Shaft Gears

2.2 DESIGN CRITERIA

2.3 OPERATION SEQUENCES

2.3.1 Tainter Valve Machinery Operation

2.3.1.1 Design Considerations

2.4 SPEED REDUCERS

2.4.1 Tainter Valve Speed Reducer

2.4.1.1 General

2.4.1.2 Reducer Housing

2.4.2 Gearing

2.4.3 Reducer Shafts

2.4.4 Shaft Bearings

2.4.5 Gearbox Lubrication System

2.4.6 Seals

2.4.7 Lubrication

2.5 BEARINGS

2.5.1 Sleeve Type Plain Pillow block Bearing Assemblies

2.6 BUSHINGS

2.7 SHAFTS

2.8 SHAFT COUPLINGS

2.8.1 General

SECTION 35 01 41.00 10 Page 1 Certified Final - RTA - W911XK20R0020 - Ammendment 0002

2.8.1.1 Jaw Type Couplings

2.9 GUARDS AND COVERS

2.10 STRUCTURAL BASES AND SUPPORTS

2.11 OPEN SPUR GEARS

2.11.1 Gearing

2.11.2 Contractor Designed Split Gearing

2.12 GEAR HOUSINGS

2.13 STRUT ARM

2.14 STRUT ASSEMBLY

2.15 VALVE CONNECTION PIN

2.16 STUFFING BOX, GLAND, AND ASSOCIATED PARTS

2.17 LUBRICATION SYSTEM

2.17.1 Central Pressure Lubrication System - Grease

2.17.1.1 General

2.17.1.2 Pumping Unit

2.17.1.3 Metering Valves and Lube Point Monitors

2.17.1.4 Piping

2.17.2 Central Pressure Lubrication System - Oil

2.17.2.1 General

2.17.2.2 Pumping Unit

2.17.2.3 Piping

2.17.3 Lubrication System Accessories

2.17.3.1 Grease Gun

2.17.3.2 Services

2.18 PAINTING

PART 3 EXECUTION

3.1 STRUCTURAL FABRICATION

3.1.1 General

3.1.2 Material

3.1.3 Bolted Structural Steel Connections

3.1.4 Dimensional Tolerances for Structural Work

3.1.5 Alignment and Setting

3.1.6 Blocking and Wedges

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 SHOP QUALITY ASSURANCE

3.4.1 NDT Agency Requirements

3.4.2 Nondestructive Testing (NDT) for Flaws

3.4.3 Quality Assurance Measurements

3.4.4 Gear Nondestructive Testing Examination

3.4.4.1 Gear Teeth (Magnetic Particle or Dye Penetrant)

3.4.4.2 Gear Spokes and Hub (Dye Penetrant)

3.5 GEAR CERTIFICATION

3.6 WELDING

3.7 MISCELLANEOUS PROVISIONS

3.7.1 Cleaning of Corrosion-Resisting Steel

3.7.2 Protection of Finished Work

3.7.3 Lubrication

3.8 FIELD ERECTION AND TESTS

3.8.1 General

3.8.2 General Test Procedure

3.8.2.1 Pre Concrete Placement Testing

3.8.2.2 Commissioning Test

3.8.3 Crane Availability

SECTION 35 01 41.00 10 Page 2

3.8.4 Schedule

3.8.5 Limit Switch and Position Indication Settings

3.8.6 Open Spur Gear Alignment

3.9 MILLWRIGHT

3.10 FIELD TRAINING

3.11 STARTUP AND ACCEPTANCE TEST

3.12 Equipment Warranty

3.13 OPERATIONS AND MAINTENANCE DATA

-- End of Section Table of Contents --

SECTION 35 01 41.00 10 Page 3

35 01 41.00 10

ELECTROMECHANICAL OPERATING MACHINERY FOR LOCKS AND DAMS

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)

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

ASME INTERNATIONAL (ASME)

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

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

SECTION 35 01 41.00 10 Page 4

ASTM INTERNATIONAL (ASTM)

ASTM A1018/A1018M (2016a) Standard Specification for Steel, Sheet and Strip, Heavy-Thickness Coils, Hot-Rolled, Carbon, Commercial, Drawing, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, and Ultra-High Strength

ASTM A108 (2013) Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished

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

ASTM A290/A290M (2016) Standard Specification for Carbon and Alloy Steel Forgings for Rings for Reduction Gears

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 (2018) Standard Specification for General Requirements for Stainless Steel Bars, Billets, and Forgings

ASTM A519/A519M (2017) Standard Specification for Seamless Carbon and Alloy Steel Mechanical Tubing

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

ASTM B271/B271M (2015) Standard Specification for Copper-Base Alloy Centrifugal Castings

ASTM B584 (2014) Standard Specification for Copper Alloy Sand Castings for General Applications

ASTM D3951 (2015) Commercial Packaging

ASTM E165/E165M (2012) Standard Practice for Liquid Penetrant Examination for General Industry

ASTM E709 (2015) Standard Guide for Magnetic Particle Examination

ASTM F3125/F3125M (2015a) Standard Specification for High Strength Structural Bolts, Steel and Alloy Steel, Heat Treated, 120 ksi (830 MPa) and 150 ksi (1040 MPa) Minimum Tensile Strength, Inch and Metric Dimensions

SECTION 35 01 41.00 10 Page 5

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 10360-2 (2009) Geometrical Product Specifications (GPS) — Acceptance and Reverification Tests for Coordinate Measuring Machines (CMM) — Part 2: CMMs Used for Measuring Linear Dimensions

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

RCSC S348 (2014; Errata 2015) RCSC Specification for Structural Joints Using High-strength Bolts

U.S. ARMY CORPS OF ENGINEERS (USACE)

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

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

Purchase Agreements

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

COMPONENTS/SYSTEMS.

Shop Test Information; G , AOF

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

Shop Load Test Rig and Location; G , AOF

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

Demolition, Installation and Alignment Work Plan and Procedure; G , AOF

The contractor is required to submit a detailed work plan describing the demolition, installation and alignment procedure for all system machinery between the electric motor through to the tainter value. This includes at a minimum, jack shaft gear and pinion, counter shaft gear and pinion, sector gear, strut arm and shaft, including the alignment procedure for the pipe sleeve that houses the strut arm shaft and connects the sector gear on the dry side to the strut arm on the wet side, etc. Furthermore, the work plan must include at a minimum, type of equipment to be used, rigging procedures, load calculations, fall protection plan, onsite personnel, etc.

SECTION 35 01 41.00 10 Page 6

The work plan shall be written by an engineering firm that has documented experience with dam maintenance and rehabilitation.

This information must be included in the work plan. Furthermore, the work plan must be stamped by a professional engineer who is registered in any U.S. state and a journeyman millwright who meets the qualifications outlined in section 35 01 41.00 10, para 1.3.2.

For all newly fabricated parts, the work plan shall include an appendix listing all parts and detailed manufacturer's instructions concerning the installation and alignment procedure for the parts.

Equipment Protection Plan; G , AOF

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 , AOF

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

Commissioning; G , AOF

Operating Test Procedure; G , AOF

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.

SD-02 Shop Drawings

Detail Drawings; G , AOF

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

Materials Orders

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

Shipping Bills

Shipping Bills with the delivery of finished pieces to the site.

Reducer Shafts; G , AOF

SECTION 35 01 41.00 10 Page 7

Key Fit and Shaft Bores

SD-03 Product Data

Manufacturer's Literature and Equipment Data; G , AOF

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 split Gearing; G , AOF

Gearbox Lubrication System; G , AOF

Lubricating Oil for Speed Reducers

Centralized Pressure Lubrication System; G

SD-06 Test Reports

Sector and Counter Shaft Type Gears

Final Operating Test; G , AOF

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

Startup and Acceptance Test

Magnetic Particle Examination

Provide test reports for non-destructive tests performed on the gears 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

SECTION 35 01 41.00 10 Page 8 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.

Nondestructive Examination Certification

Gear Certification

Commissioning Document

Journeyman Millwright Certifications; G, AOF

Provide Millwright Qualification Card documentation for all Millwrights present on site who will be performing the services listed in paragraph 1.3.2.

Provide documentation showing at least 5 years of verifiable work experience on dam maintenance and rehabilitation projects for each journeyman millwright.

Provide documentation showing completion of at least one of the qualifications listed in paragraph 1.3.2 Provide documentation showing completion of at least one of the qualifications listed in paragraph 1.3.2 for all Millwrights present on site and performing services as listed in paragraph 1.3.2 .

All the above must be submitted for Government approval before any work begins.

Millwright Installation And Operation

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

SD-08 Manufacturer's Instructions

Cleaning of Corrosion-Resisting Steel; G , AOF

SD-10 Operation and Maintenance Data

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

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.

SECTION 35 01 41.00 10 Page 9

1.3 QUALITY ASSURANCE

1.3.1 Manufacturer and Assembler

Manufacturing and assembly of the tainter valve machinery 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 for the Valve Machinery (including structural supports) requires written approval from the Contracting Officer. 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 Millwright Services

Provide the services of journeyman millwright(s) to perform the demolition, installation, including alignment, and commissioning of all machinery including mechanical and electrical components.

All journeyman millwrights must meet one of the following qualifications:

a. Have completed a millwright apprenticeship program recognized by the United Brotherhood of Carpenters

b. Documentation showing 10,000 hours of millwright work experience.

c. Completion of millwright qualification testing.

Journeyman millwright(s) must have a minimum of 5 years of experience erecting equipment similar to the equipment in this contract. Submit journeyman millwright certifications showing qualifications and years of experience for each millwright present on site who will be performing services listed in this paragraph.

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Critical Path Components/Systems

Many of the components required for the mechanical equipment at a Lock have long delivery times. A large percentage of the mechanical work must be accomplished during the scheduled winter Lock shutdown period. To ensure that all work required during this time period is accomplished, present to the Contracting Officer, within 120 calendar days after receiving notice to proceed, written copies of finalized purchase agreements with component manufacturers (NOT SUPPLIERS) for the components and systems noted below.

COMPONENTS

Speed Reducers

Open Gearing

Strut Arm

SECTION 35 01 41.00 10 Page 10

COMPONENTS

Strut Assembly

Include a confirmed delivery date and point of contact at the particular manufacturer in the purchase agreements. Require the manufacturer to furnish a monthly report ( submit to the Contracting Officer on the 10th of each month) of progress on the particular component/system and any delays in the previously specified delivery date. Include both written and photographic updates to track and monitor the current status of the equipment to be furnished in the progress reports. The reporting requirements specified herein are included in the requirements of Section

01 32 01.00 10 PROJECT SCHEDULE.

1.4.2 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 lock operating equipment and subassemblies for shipment until they have been inspected and accepted for shipment at origin by the Contracting Officer or his authorized representative, unless inspection has been waived in writing. 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. Tainter Valve Machinery

1.4.2.1 Packaging

Provide equipment and subassemblies with adequate protective pads, 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 long-term storage (60 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.

SECTION 35 01 41.00 10 Page 11

1.4.2.2 Shipping, Preservation, and Storage

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

1.4.2.3 Transport Restrictions Through Galleries

The equipment to be installed on the dry side shall be transported through the galleries to the machinery rooms for final assembly. The galleries have been restricted in height and width by piping and cable trays attached to both walls and the ceiling. The clear pathway in the gallery is approximately 6 feet high and 2 feet 6 inches wide. The machinery rooms have equipment mounted on all walls and a walkway around the machinery as a clear area. It is strongly suggested to inspect the gallery from the access areas to the machinery rooms thoroughly prior to equipment delivery to verify clearances and plan the movement of equipment and dollys or other transport gear to be transported in and out of the machinery room.

1.4.3 Storage of Existing Equipment

Existing electrical equipment that is to be temporarily removed during construction (such as motors, limit switches, and encoders) must be stored in such a way that the equipment is kept dry and free of condensation.

PART 2 PRODUCTS

2.1 EQUIPMENT

2.1.1 Machinery

Furnish equipment under this specification consisting of four tainter type filling/emptying valve operating machinery units in accordance with the bid schedule. Machinery is located in both a wet and dry environment, separated by a wall, with mechanical transmission through a pipe sleeve.

Furnish complete units in the wet environment, including the strut arm shaft, pipe sleeve, stuffing box, gland, associated seals, bearing stand, bearing cap, strut arm, strut arm pin, strut assembly, valve pin, and keeper plates. Furnish dry environment machinery, including speed reducer, geared drives, gear housings, shafts, keys, electrical equipment, controls, and other necessary items to provide a complete and operable system. Furnish bushings in both the wet and dry and environment. Bearing support bases, dry environment bearing stands, and dry environment bearing caps are to be repainted and reused. Furnish automatic lubrication system to grease bushings and oil lubrication system for gear housing.

2.1.2 Electrical Equipment

Conform electrical equipment, including limit switches, conduit, conductors, controls, to the requirements of 26 05 00.00 40 Common Work Results for Electrical.

2.1.3 Nameplate

Provide an engraved or raised metallic nameplate that is mechanically

SECTION 35 01 41.00 10 Page 12 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.

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 tainter valve machinery; test rig assembly details; proposed and final shop inspection 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 valve 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 same 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 Speed Reducers

Type: Double reduction right angle worm gear Model Number: Custom

Exact Ratio: 57.24:1

Efficiency

Mechanical Rating - Durability - HP, Specify SAC: 40 HP

Mechanical Rating - Strength - HP, Specify SAT

Rating Calculations per applicable AGMA Standard: AGMA 8

Life Factors CL, KL

Reliability Factors CF, KR

Type of Gearing and Heat-Treatment: Helical Worm

Type of Bearings: Anti-friction Roller

Minimum L-10 Bearing Life

SECTION 35 01 41.00 10 Page 13

Method of Lubrication: Splash

Size and Number of Mounting Bolts: 1.25" dia bolts, qty 4

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: N/A

Quantity Being Furnished: 3(Base), 1(Option)

AGMA and ISO Lubrication Oil/Viscosity rating

Type of Lubricant

2.1.4.2 Split Sector Gears

Spur Gear P.D. and Spur Gear D.P.: 120 P.D. and 1 D.P.

Number of Gear Teeth: 55

Face Width of Gear: 15 in

Gear Material: Alloy Steel

Gear Heat Treatment: NQT

BHN of Gear Teeth: 187-235

Mating Pinion Gear P.D. and Mating Pinion Gear D.P.: 17 P.D. and 1 D.P.

Number of Mating Pinion Gear Teeth: 17

Face Width of Mating Pinion Gear: 15 in

Type of Construction - Forged/Fabricated

Mating Pinion Gear Materials of Construction:

Alloy Steel

Mating Pinion Gear Heat Treatment: NQT

BHN of Mating Pinion Gear Teeth: 223-262

Mechanical Rating of Gear Set - Durability - HP, Specify SAC

Mechanical Rating of Gear Set - Strength - HP, Specify SAT

Percentage of Material Yield Point Based on maximum Motor Full Load Torque

Life Factors CL, KL

Reliability Factors CF, KR

I Factor

J Factor

Number of Reduction Set

SECTION 35 01 41.00 10 Page 14

Outline Dimension Print

Weights of Gear and Pinion

Quantity Being Furnished: 3(Base), 1(Option)

Rating Calculations per applicable AGMA Standard

2.1.4.3 Split Counter Shaft Gears

Spur Gear P.D. and Spur Gear D.P.: 72.5 P.D. and 2 D.P.

Number of Gear Teeth: 145

Face Width of Gear: 8 in

Gear Material: Alloy Steel

Gear Heat Treatment: NQT

BHN of Gear Teeth: 187-235

Mating Pinion Gear P.D. and Mating Pinion Gear D.P.: 12 P.D. and 2 D.P.

Number of Mating Pinion Gear Teeth: 24

Face Width of Mating Pinion Gear: 8 in

Type of Construction - Forged/Fabricated

Mating Pinion Gear Materials of Construction:

Alloy Steel

Mating Pinion Gear Heat Treatment: NQT

BHN of Mating Pinion Gear Teeth: 223-262

Mechanical Rating of Gear Set - Durability - HP, Specify SAC

Mechanical Rating of Gear Set - Strength - HP, Specify SAT

Percentage of Material Yield Point Based on maximum Motor Full Load Torque

Life Factors CL, KL

Reliability Factors CF, KR

I Factor

J Factor

Number of Reduction Set

Outline Dimension Print

Weights of Gear and Pinion

Quantity Being Furnished: 3(Base), 1(Option)

SECTION 35 01 41.00 10 Page 15

Rating Calculations per applicable AGMA Standard

2.1.4.4 Jack Shaft Gears

Spur Gear P.D. and Spur Gear D.P.: 42.333 P.D.

and 3 D.P.

Number of Gear Teeth: 127

Face Width of Gear: 4 in

Gear Material: Alloy Steel

Gear Heat Treatment: NQT

BHN of Gear Teeth: 187-235

Mating Pinion Gear P.D. and Mating Pinion Gear D.P.: 8.333 P.D. and 3 D.P.

Number of Mating Pinion Gear Teeth: 25

Face Width of Mating Pinion Gear: 5 in

Type of Construction - Forged/Fabricated

Mating Pinion Gear Materials of Construction:

Alloy Steel

Mating Pinion Gear Heat Treatment: NQT

BHN of Mating Pinion Gear Teeth: 25

Mechanical Rating of Gear Set - Durability - HP, Specify SAC

Mechanical Rating of Gear Set - Strength - HP, Specify SAT

Percentage of Material Yield Point Based on maximum Motor Full Load Torque

Life Factors CL, KL

Reliability Factors CF, KR

I Factor

J Factor

Number of Reduction Set

Outline Dimension Print

Weights of Gear and Pinion

Quantity Being Furnished: 3(Base), 1(Option)

SECTION 35 01 41.00 10 Page 16

Rating Calculations per applicable AGMA Standard

2.2 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) or

TORQUE

(Ft-Lbs)

OPERATING

TEMP. RANGE

Deg F

MINIMUM

OPERATING

SPEED

(RPM) or

(FPM)

OPERATING

TRAVEL

Reversing

CYCLES

Per Hr

MAX

TRAVEL

TIME

OPEN

(Sec)

MAX

TRAVEL

TIME

CLOSE

(Sec)

Strut Arm/Strut

Arm Shaft

395000 0 Ft-Lbs

-10 to 90 0.09 RPM Reversing 2/Hr 4.88 Mins

4.88 Mins

Sector Gear/Counter

Shaft Pinion

79 Kips -10 to 90 2.83 FPM Reversing 2/Hr 4.88 Mins

4.88 Mins

Counter Shaft

56000 Ft-Lbs

-10 to 90 0.64 RPM Reversing 2/Hr 4.88 Mins

4.88 Mins

Counter Shaft

Gear/Jack Shaft Pinion

19 Kips -10 to 90 12.09 FPM Reversing 2/Hr 4.88 Mins

4.88 Mins

Jack Shaft

10000 FT-Lbs

-10 to 90 3.85 RPM Reversing 2/Hr 4.88 Mins

4.88 Mins

Jack Shaft

Gear/Reducer Shaft Pinion

6 Kips -10 to 90 42.65 FPM Reversing 2/Hr 4.88 Mins

4.88 Mins

SECTION 35 01 41.00 10 Page 17

2.3 OPERATION SEQUENCES

2.3.1 Tainter Valve Machinery Operation

The equipment sequence of operation, interlocks and electrical controls are to match existing equipment performance.

2.3.1.1 Design Considerations

Normal operations of the lock valves for the purpose of design consist of the lock valves operating through 2 complete cycles per hour with 2 starts and 2 stops per cycle. A cycle is defined as moving the lock valve from the fully closed position to the fully opened position and back to the fully closed position.

2.4 SPEED REDUCERS

2.4.1 Tainter Valve Speed Reducer

2.4.1.1 General

The speed reducer is a double reduction, right angle worm gear type, entirely self contained in an oil tight, steel housing designed to maintain shafts and bearings in accurate alignment. Provide the gear ratio as indicated plus 5 percent. The horizontal output shaft must be double extended and have the pinion mounted on the output shaft. Provide a horizontal output shaft for position feedback with the gear reducer.

The shaft must be 3/4 inches in diameter and extend to provide a direct coupling to drive a rotary cam limit switch. The input shaft shall match that the drawings. 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.

2.4.1.2 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 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 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

SECTION 35 01 41.00 10 Page 18 indicated must remain as shown as a minimum for proper machinery alignment, as well as interchangeability with existing speed reducers.

2.4.2 Gearing

Provide helical gearing made from high strength alloy steel that is hardened with subsequent quenching and tempering to produce a hardened gear. Grind the gears after gear cutting to achieve a minimum ANSI/AGMA 11 Quality in accordance with AGMA 2015/915-1 . Integrally cut the helical pinions on the pinion shaft.

2.4.3 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.

2.4.4 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.

2.4.5 Gearbox Lubrication System

The lubrication system must be a splash type system using a synthetichydro-carbon lubricant conforming to the requirements of ANSI/AGMA 9005 . The gear reducer manufacturer must design the lubrication system. Install external and internal piping as required to provide adequate lubrication to the gear meshes and bearings. Define, document and submit the pressure losses, total flow rate, and expected flow rate to each component and/or gear mesh. 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 lubrication fittings for all grease lubricated bearings 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 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.

2.4.6 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.

SECTION 35 01 41.00 10 Page 19

2.4.7 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 in compliance with ANSI/AGMA 9005 and be AGMA 5EP. 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.

2.5 BEARINGS

2.5.1 Sleeve Type Plain Pillow block Bearing Assemblies

Perform Nondestructive examination on all existing bearing stands and caps located in the dry environment. Perform inspection in accordance with the requirements of Paragraph NONDESTRUCTIVE EXAMINATION. Bearings found to have unacceptable relevant indications are cause for rejection and shall be replaced with new fabricated replacements that match existing fits, and material conforming to ASTM A668 Class A forged steel.

Provide split type bearing pillow block, painted ASTM A668 Class A forged steel machined base housing with a through drilled, eight bolt base as shown in the drawings. The sleeve type plain bearings must be a bronze alloy material suitable for the installation and conform to the requirements of ASTM B271/B271M or ASTM B584, Alloy 86500. The sleeve type plain bearings shall have flanges and be split with shims to fit into the bearing housing bore. Use retaining cap screws to secure the plain sleeve bearings through the flange as shown on the drawings.

Provide machined grease and oil grooves in the interior of the bearing unless otherwise shown. Break all edges of the grease grooves to provide a minimum 1/8 inch fillet radius.

2.6 BUSHINGS

Fabricate bushings from bronze castings conforming to ASTM B584 Alloy 86500. Machine bushings to meet the dimensions, surface finish and tolerances indicated. Any casting patterns developed become property of the Government and must be packaged for long term storage with the pertinent part identification provided on the exterior packaging.

2.7 SHAFTS

Provide shafts to match existing dimensions. Shafts shall be forged steel conforming to ASTM A290/A290M , Grade 5, Class F. 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. End plate shall be structural steel conforming to ASTM A36/A36M. Gasket shall be sheet gasketing made of

SECTION 35 01 41.00 10 Page 20 synthetic fiber with NBR binder.

2.8 SHAFT COUPLINGS

Shaft couplings shall be of the flexible jaw 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 1800 RPM operating speed. The couplings must be capable of handling a maximum torque of 1500 inch-pounds. Design couplings to compensate for angular, parallel and axial misalignment.

Couplings must have a general service factor of 1.0 applied 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 Jaw Type Couplings

The monitor couplings shall be provided with keyed shaft hubs of the fail-safe spider design. Furnish set screws to secure the hubs.

2.9 GUARDS AND COVERS

Remove existing safety guards and fencing prior to demolition of machinery. Safety guards and fencing shall be stored and protected from damage during the Contract and shall be reinstalled upon complete of new work. Damage to any existing guards or fencing shall be repaired or replaced by the Contractor. Provide new 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.

2.10 STRUCTURAL BASES AND SUPPORTS

Structural bases are to remain in place. Paint shall be tested for lead and lead work shall be handles in accordance with Section 09 97 02 PAINTING: HYDRAULIC STRUCTURES. Clean and visually inspect bases for cracks or flaws. Report any structural deficiencies to the Contracting Officer. Existing lifting eye hooks are not structurally rated. Contractor is responsible for installing any required lifting eye hooks for work under this Contract.

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2.11 OPEN SPUR GEARS

2.11.1 Gearing

Make all spur gearing from high strength alloy steel that is hardened with subsequent quenching and tempering to produce a through hardened gear.

Grind the gears after gear cutting to achieve a minimum ANSI/AGMA Quality 11 in accordance with AGMA 2015/915-1 . Integrally cut the pinions on the pinion shaft. Make keys of ASTM A108, UNS G10180 ( ASTM A1018/A1018M ), keystock. Certified material test results for the drive pinion and drive pinion shaft are required.

The overall dimensions and configurations of new spur gears and mating shafts must be as indicated. Large gears shall be split to fit through a 6'-0" x 2'-0" opening. All gears must be manufactured to achieve a AGMA gear quality of 8 or better and be supplied as match marked sets. Factory test all gears in accordance with the TESTING paragraphs of this specification. Spur gear teeth must be of the involute form. Fabricate sector, counter shaft, and jack shaft gear rings from ASTM A668/A668M forged steel, Class J. Gear hubs and arms can be fabricated from rolled steel plate. Harden the gear teeth as specified to measure at any point on the tooth face within 187-238 BHN after finishing. Cut pinion gears from solid steel and fabricate from ASTM A290/A290M forged steel, Grade 3, Class C. The Brinell Hardness must be a minimum 50 (BHN) greater than the Brinell Hardness of the mating gears. Harden the pinion gear teeth as specified to measure at any point on the tooth face within 223-262 BHN after finishing. The ends of the pinion teeth must be end relieved to prevent end loading. Crown the gear teeth as indicated.

2.11.2 Contractor Designed Split Gearing

Contractor designed split gearing must be engineered, designed, and manufactured by a reputable gear manufacturer who has prior experience in designing and supplying the specified size gearing. Submit the manufacturer's required calculations and shop drawings for the design and fabrication of the identified gearing prior to the start of shop fabrication. Design the spur gears in accordance with ANSI/AGMA 2001 with life factors CL and KL equal to unity and reliability factors CR and KR equal to 1.00 or greater. The reduction set number used in the design calculations cannot be greater than 3. The normal strength horsepower rating of the spur gears cannot exceed 1/2 of the peak strength horsepower rating as determined by ANSI/AGMA 2001 . Durability rating of gears must be as determined by ANSI/AGMA 2001 and based on a service factor of 1.

2.12 GEAR HOUSINGS

Fabricate gear housings out of sheet steel in accordance with ASTM A568, matching the dimensions on the drawings. Gear housing oil retainer shall be replaced with an oil seal with dual lip seal, Heavy-Duty metal outer case, felt excluder. Seal shall be provided with Stainless Steel finger type spring to maintain appropriate pressure on seal. Seal lip shall be NBR material Gear housing gasket shall be a sheet gasketing made of synthetic fiber with NBR binder product.

2.13 STRUT ARM

Fabricate strut arm from steel castings conforming to ASTM A148/A148M , Grade 90-60, or from forged steel conforming to ASTM A 668 Class J.

Machine strut arm to meet the dimensions, surface finish and tolerances as

SECTION 35 01 41.00 10 Page 22 indicated. Any casting patterns developed become property of the Government and must be packaged for long term storage with the pertinent part identification provided on the exterior packaging. Fit the bushing into the strut arm as indicated on drawings.

2.14 STRUT ASSEMBLY

Fabricate strut assembly (strut bearing, strut connection, and strut retainer)from steel forgings conforming to ASTM A668/A668M, Class J.

Machine cast parts to meet the dimensions, surface finish and tolerances indicated in drawings. Any casting patterns developed become property of the Government and must be packaged for long term storage with the pertinent part identification provided on the exterior packaging.

Fabricate strut assembly steel forgings, (strut nut, strut adjusting nut, strut extension, and pin) conforming to ASTM A668/A668M , Class A.

Fabricate strut out of ASTM A519/A519M seamless steel tube and assemble as shown on the drawings.

2.15 VALVE CONNECTION PIN

Fabricate a valve connection pin from forged steel conforming to ASTM A668/A668M , Class K.

2.16 STUFFING BOX, GLAND, AND ASSOCIATED PARTS

Fabricate stuffing box and gland from forged steel conforming to ASTM A668, Class A. Split gland as indicated on drawing to permit removal from shaft.Provide new seals for watertight construction. Packing rings shall be 1" square compression fiber braid. Gasket shall be a sheet gasketing made of synthetic fiber with NBR binder.

2.17 LUBRICATION SYSTEM

Supply automated grease lubrication system at each corner to grease all existing lubrication points of the tainter valve machinery. Contractor shall design the grease lubrication system for the machinery and submit for approval. The lubrication system shall be capable of delivering NGLI #2 grease. Grease lubrication system shall be electronically operated by it's own local controller. Grease lines shall be routed similar to existing. Support grease lines to each bearing and protect from mechanical damage. Grease lines passing through the pipe sleeve shall be Schedule 80 stainless steel pipe in the wet environment. Prefill grease lines before connection to bearings. Terminate grease lines above baseplate for connection to lubricating grease pump.

2.17.1 Central Pressure Lubrication System - Grease

2.17.1.1 General

Provide each corner with its own individual electric motor-driven centralized pressure lubrication system, designed to deliver the proper predetermined or metered quantity of lubricant to each individual bearing, nut,and pin. The controller shall be capable of indicating both proper functioning and a system fault status through the use of LEDs and a digital display. Mount pressure pump, individual metering devices, and any required auxiliary operating accessories suitably on baseplate. System shall be furnished complete and ready for operation, including sufficient lubricant to fill each pressure pump lubricant reservoir. Submit complete centralized pressure lubrication system design to Contracting Officer for

SECTION 35 01 41.00 10 Page 23 review and approval. Furnish lubricant recommended by pump manufacturer, subject to approval of Contracting Officer.

The controller shall also be capable of transmitting a fault status to the existing lock PLC system through a digital input card located in the existing control system cabinet. The contractor is responsible for the wiring between the grease controller and the PLC input card. The existing network of HMI's will be programmed to display an alarm whenever this fault signal is received. The programming of the HMI's and PLC's will be performed by the government.

2.17.1.2 Pumping Unit

Provide electric motor-driven central pumping unit as a complete assembly, consisting of positive displacement piston type pump, flow-directing valve (if required), lubricant reservoir, suitable pressure gage to indicate pump discharge pressure, operation counter, pressure protective device, and other auxiliary accessories as required to give a complete and workable unit conforming to requirements specified. Pump shall be of multiple individual piston, positive displacement type utilizing hardened steel pistons closely fitted to cylinder bores to eliminate the need for packing, and spring-actuated check valves shall not be required for its operation. Life Rating of pump shall be more than 2 million cycles at rated pressure. Pump shall deliver not less than 6 cubic inches of lubricant per minute against a pressure of not less than 2,000 psi measured at the most remote bearing connection. Lubricant reservoir shall be of suitable metallic construction, shall have a capacity of not less than 24 pounds of lubricant, shall be provided with suitable means that will ensure positive priming of pump at all times (such as an atmospheric or spring-loaded follower plate), an indicator to show quantity of lubricant in reservoir, an air bleed to eleminate air pockets, and a screened fill connection to permit filling reservoir by transfer pump without exposing lubricant to atmosphere. Provide pump unit with a fully automatic control system, and other required auxiliaries necessary to give a complete and workable system. Provide a 120 volt controller that is capable of being programmed to operate the grease pump for a selected duration of time, at selected intervals. A Lubrication Monitor shall be provided to integrate with the Controller to monitor up to 24 lubrication points, providing an alarm signal to the controller in the case of abnormal flow measurements.

2.17.1.3 Metering Valves and Lube Point Monitors

Provide metering or measuring valve for each existing lubrication point.

It shall be fully hydraulic in its operation, requiring no internal springs or check valves. Valve size to be determined by the pump manufacturer. Mount valves on existing wall plate. Measuring valves shall be provided with indicator pins showing operations of the valves.

Provide lube point monitor for each existing lubrication point. Point monitors shall work with dualine systems and shall be capable of sensing whether grease is being delivered at the point of lubrication. The point monitor shall be compatible with NLGI 2 grease and meet the required pressures/flowrates or the system. Lube point monitor shall provide signal back to lubrication monitor panel.

2.17.1.4 Piping

Dry environment system piping shall be steel…