A.07.24 Revised Statement of Work.pdf

SECTION 01 11 00

STATEMENT OF WORK

PART 1 GENERAL

1.1 APPLICABILITY

This Statement of Work specification is the basis by which the Contractor will perform all activities including but not limited to design, manufacturing, testing, installing, and incidental work involved in this contract except where additional technical specifications are provided for specific tasks within this contract.

1.2 REFERENCES

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

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 (2014) Steel Construction Manual

AMERICAN WELDING SOCIETY (AWS)

AWS D1.2/D1.2M (2014) Structural Welding Code - Aluminum

AWS D1.5M/D1.5 (2015) Bridge Welding Code

ASME INTERNATIONAL (ASME)

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

ASME B30.2 (2011) Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist)

ASTM INTERNATIONAL (ASTM)

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

ASTM A322 (2013) Standard Specification Steel Bars, Alloy, Standard Grades

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

ASTM B308/B308M (2010) Standard Specification for Aluminum-Alloy 6061-T6 Standard Structural Profiles

ASTM F1145 Standard Specification for Turnbuckles, Swaged, Welded, Forged

SECTION 01 11 00 Page 1

PN461488

NORFORK LAKE, DAM, & POWERPLANT

INTAKE GATE MACHINERY REHABILITATION

BAXTER COUNTY, ARKANSAS SOLICITATION NO. W9127S20ROO4

AMENDMENT 001 TWO SOLICITATION NO. W9127S20R0004 on 08/18/2020

ALUMINUM ASSOCIATION (AA)

AA ADM (2015) Aluminum Design Manual

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

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

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

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

U.S. ARMY CORPS OF ENGINEERS (USACE)

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

EM 1110-2-3200 (2016) Wire Rope For Civil Works Structures

EM 385-1-1 (2014) Safety and Health Requirements Manual

ETL 1110-2-584 Design of Hydraulic Steel Structures

ER 1110-2-8157 Responsibility for Hydraulic Steel Structures

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS RR-W-410 (Rev H) Wire Rope and Strand

1.3 SUBMITTALS

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

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

SD-01 Preconstruction Submittals

Gate Hanging Position Plan; G

Startup Checklist; G 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.

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

Acceptance shall be required by signature for all parties.

Test Weight Plan; G

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Gate Support Method; G Provide detailed information on the method proposed to support the gate during the work delineated in this section. The support method, engineering computations, and support drawings shall be designed and certified by a licensed professional engineer.

Gate Position Settings On Limit Switches Immediately prior to commencement of work on each gate, record the gate position settings.

Commissioning; G

Final Inspection And Acceptance Test Procedure; G

SD-02 Shop Drawings

Detail Drawings; G Detailed shop drawings for gears, shafts, bushings, hoisting wire rope, drum, limit switches, supports,lifting beam, head gate modifications and all shop fabricated metal items, shall be submitted and approved prior to fabrication.

SD-03 Product Data

Manufacturer's Literature And Equipment Data; G 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.

Registered Professional Engineer

SD-05 Design Data

Calculations For Head Gate Lifting Points And Load Path Reinforcement As Required By Design; G

Contractor Designed Gearing; G

Gearbox Lubrication System; G

Contractor Designed Sheaves; G

Hoist Machinery Design Data; G

Design Package Submittals; G

Final Calculations; G

Provide Documentation For Weld Testing and Drawing Requirements In Accordance With ER 1110-2-8157; G

Grout; G

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Sumbit Design Calculations For The Provided Aluminum Erection Supports.; G

SD-06 Test Reports

Final Inspection And Acceptance Test Report; G

Electric Motors; G

Final Operating Test; G

Startup And Acceptance Test; G Provide test reports for non-destructive tests performed on the gears, pocket wheels, drum, repair links and all fabricated welded components.

Pre-Final Inspection And Preliminary No-Load Performance Test Report; G

Final Inspection And Acceptance Test Report; G

SD-07 Certificates

American Institute Of Steel Construction (AISC) Quality Certification; G

Installation And Alignment Procedure; G Provide detailed manufacturer's and Contractor developed instructions concerning the installation and alignment procedures for the equipment to be provided. Items include gear reducers, bearings, shafts, brakes, motors, couplings, wire rope, drum, and limit switches.

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.

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

Commissioning Document

Registered Professional Engineer; G

Registered Professional Mechanical Engineer; G

Registered Professional Structural Engineer; G

SD-10 Operation and Maintenance Data

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Operation And Maintenance Manuals; G Provide six hardcopies 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.

SD-11 Closeout Submittals

Final Gate Hanging, Plumb Certification; G

Machinery Operation And Maintenance Manuals; G

1.4 WORK COVERED BY CONTRACT DOCUMENTS

1.4.1 Project Description

The work includes replacement of Unit 1 and Unit 2 intake gate machinery and erection equipment and incidental related work.

Provide equipment under this specification consisting of intake gate operating machinery units. Provide complete units including base supports, geared drives, brakes, motors, heaters, shafts, bearings, wire rope, electrical equipment, local and remote indication and controls, covers, guards, gate erection supports, lifting beam, machinery bases and other necessary items to provide a complete and operable system. Provide all new internal wiring to the hydraulic board in the control room associated with the head-gate controls and limit switch fully raised and fully lowered indication. Provide interface to SCADA for all functions available at the hydraulic board, including but not limited to remote lower, gate fully lowered and gate fully raised indication. In the control circuit provide the ability to stop lowering of the head-gate if for some reason the wrong head-gate was given a command to lower. In the past, but not the case now, there was a breaker in the hydraulic board that interrupted the control power to the lower relay and therefore stopping movement.

Design all equipment in strict accordance with the requirements of EM 1110-2-2610 Mechanical and Electrical Design for Lock and Dam Operating Equipment, EM 1110-2-4205 Hydroelectric Power Plants Mechanical Design, ASME B30 Series, and CMAA Standards unless otherwise specified within.

Specifications are included and already edited for Section 35 to establish desired options and selections for bidding purposes. Since this is design build the Contractor will be expected to edit the latest UFGS in a similar manner and include similar options and selections in the design deliverables. 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 on the ultimate strength of the material. (AM001) Lifting speed shall be not less than 5 feet per minute and not greater than 7.5 feet per minute. Include all anticipated loads in the design. Loads include, but are not limited to, the loads imposed by the dead weight, hydraulic forces, downpull forces (95 kips), buoyancy forces, ice, 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.

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. Design components that might fail in

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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.

Manufacturing and assembly of the intake 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 and 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.

All Hydraulic Steel Structure components required to be painted shall be done in accordance with 09 97 02 Painting: Hydraulic Sturctures. All modifications and work required after the structure(s) have been painted shall be re-repainted.

1.4.2 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 intake gate machinery; test rig assembly details; proposed and final shop test procedures and data sheets; proposed and final field cable tensioning and 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.

All mechanical computations and drawings submitted as part of the equipment submittal data shall be stamped and signed by a registered professional mechanical engineer who has done the design himself/herself or supervised and reviewed work if done by other engineers.

All structural computations and drawings submitted as part of the equipment submittal data shall be stamped and signed by a registered professional structural engineer who has done the design himself/herself or supervised and reviewed work if done by other engineers.

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

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other pertinent information about the equipment.

1.4.3 Location

The work is located at the Norfork Dam, approximately as indicated in the drawings. The exact location will be shown by the Contracting Officer.

1.4.4 Demolition

Demolition shall not begin until delivery of the new hoist and related equipment to replace it. Remove all existing intake gate machinery, and erection equipment including, but not limited to: hoists, motors, brakes, chains, counterweights, machinery bases, equilizer beam, erection supports, and erection struts. Do not remove the head gates; head gates shall be stored on the erection supports provided by the contractor. After its removal, the existing intake gate machinery, including chain and counterweight becomes the Contractor's property. Remove from the site following all federal, state, and local laws and regulations.

1.4.5 Storage and Handling

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.

1.4.6 Intake Gate Machinery Hatch Covers, Stoplog Hatch Covers, and Frames

Remove road-level hatch covers over the intake gate machinery room and the stop log storage areas. This includes the road-level hatch covers that are above the intake gate machinery for Units 1 and 2 and those that are above the empty slots where Unit 3 and 4 intake gate machinery would be.

Blast clean and paint according to 09 97 02 Painting: Hydraulic Structures. Reinstall and seal the hatch covers with Sikaflex 1CSL or approved equal.

1.4.7 Erection Support Equipment

1.4.7.1 Erection Hardware

Erection hardware and support shall be provided as indicated. Provide erection equipment for supporting the headgates while in the stored position and ensure new details are provided, sumbit design calculations for the provided aluminum erection supports. Provide new erection struts, as detailed on the drawing or equivalent, field verify all dimensions.

Provide new erection supports made of structural aluminum in accordance with the International Building Code, welding shall be in accordance with AWS D1.2/D1.2M . Design of all alumnium components shall be in accordance with AA ADM All erection equipment shall become property of the Government.

a. Erection Struts. ASTM B308/B308M

b. Turnbuckles, Eye Bolts, and Clevis. ASTM F1145, Standard Specification for Turnbuckles, Swaged, Welded, Forged

c. Steel Bars. ASTM A322

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1.4.8 Chain Pit/Counterweight Well Covers and Gate Well Grating

Blast clean and paint existing counterweight well covers and base framing in accordance with 09 97 02 Painting: Hydraulic Steel Structures. Provide grating for gate well covers.

1.4.9 Lifting Beams

Experience required by contractor is required for fabricating or modifying hydraulic steel structures in accordance with American Institute of Steel Construction (AISC) Quality Certification Program by an AISC Category CBR Certified Fabricator with a Fracture Critical Endorsement (F).

Remove existing Equilizer Beam as indicated. Provide lifting beam in accordance with ER 1110-2-8157 Responsibility for Hydraulic Steel Structures and ETL 1110-2-584 Design of HSS. All welding procedures shall conform to the requirements of AWS D1.5M/D1.5 . Provide calculations for head gate lifting points and load path reinforcement as required by design and for any modifications to the existing head gate; provide all necessary components and calculations for any modifications on the head gates.

Provide Documentation For Weld Testing and Drawing Requirements In Accordance With ER 1110-2-8157. If lifting locations are changed to accomodate new equipment provided it is the responsibility of the contractor to ensure the load path is properly reinforced and no deformation to any member will occur during operation.

Prior to removal of existing equipment of any kind the gate shall be surveyed in the fully raised and hanging position, the survey shall be used to ensure the gate is hanging back in plumb position upon completion of the work. Submit gate hanging position plan prior to the commencement of work.

Labeling and testing shall be in accorance with USACE Safety Manual, EM 385-1-1 , Section 15. Design of the lifting beam shall conform to

ASME B30.2 .

1.4.10 Wire Ropes

1.4.10.1 Storage and Handling

Wind the wire ropes on spools in the same direction as they were bent during manufacturing. Cover the spools for protection from rain, snow, and/or road spatter during shipping.

After delivery, store the wire ropes in well ventilated enclosures in the storage area and protect from the elements.

1.4.10.2 Wire Rope Selection

Provide wire rope and sockets which are the standard product of a manufacturer regularly engaged in the manufacture of wire rope, and that essentially duplicate products having been in satisfactory use for at least 5 years prior to bid opening. Wire rope shall be FS-RR-W-410, Type 1, Class 3.

Wire rope strand configuration and lay shall be selected according to EM 1110-2-3200 WIRE ROPE FOR CIVIL WORKS STRUCTURES Section 4-8. The core shall be independent wire rope core (IWRC). Wire rope shall be stainless steel for corrosion resistance in the submerged environment.

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INTAKE GATE MACHINERY REHABILITATION

Wire joints in any strand must not be closer than 18 inches in any strand. Strand pitch length shall not be less than 4-1/2 times the nominal rope diameter. The number of wires in the core strand must be equal to or greater than the number of wires in the other strands. Use the same material as the wires in the other strands, or use a material with a lower tensile strength.

Lubricate the wire ropes at the manufacturing facility. Apply the lubricant with equipment capable of forcing the lubricant between the rope wires, including the center strand.

1.4.10.3 Installation

Attach the wire rope(s) to spools or pulleys as required. Wind the wire rope under adequate tension and guide each end of the rope(s) to its proper location. Wind the wire rope in the same direction it was bent during its manufacture. Ensure that no twists or loops occur. Do not install wire rope damaged during installation by kinking, and remove from the site. Provide three dead wraps of rope on the drum.

1.4.10.4 Verification

Wire rope shall be pre-formed and pre-stretched. Provide pre-formed wire rope, and perform testing in accordance with FS RR-W-410 to verify pre-forming. Pre-stretching shall be done by subjecting them to three cycles at 40 percent of its nominal strength. Hold the 40 percent loads for 5 minutes with 5 percent loads for 5 minutes between cycles. A method of dynamic pre-stretching may be proposed.

Perform testing in accordance with FS RR-W-410 to verify wire strength and ductility.

Perform wrapping test in accordance with FS RR-W-410 to verify stress relief.

Perform a tension test to verify the wire rope meets the accepted industry standards for nominal strength. Test two rope samples to failure to be sure the expected performance level has been met. Perform the test using suitable tension testing equipment and by qualified personnel. Submit certification of rope tension testing device. Cut the rope samples to no less than 3 feet of length. The test will not be considered valid if the failure occurs less than 2 inches from either socket or holding mechanism. Relative speed between the machine heads must not exceed 1 inch per minute.

1.4.10.5 Terminations

The wire rope end terminations must be a spelter socket type with epoxy resin. Spelter sockets must be selected to avoid galvanic corrosion and of stainless steel, as required.

1.4.11 Hoists

Hoist Machinery Design Data shall be submitted. Hoist Design Data shall be approved prior to procurement of associated materials and equipment.

Hoist design data and calculations shall be submitted in its native format for review. A hoist manufacturer representative shall be present for a pre-construction visit to become familiar with the project before design

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commences. Hoist Design Data shall be submitted for each major hoist component or system of components and shall include each of the following items which are described in the following sub-paragraphs of same title:

a) Drawing Index

b) Bill of Materials/Schedule of Equipment

c) Dimensioned Assembly Drawings

d) Detailed Shop Drawings

e) Product Data for Hoist Components

f) Design Calculations

Hoist Design Data for a complete hoist design shall be submitted in a logical order with the major components submitted first and the lesser components submitted afterwards. The Hoist Design Data submitted shall include a detailed list of components and their weight together with a current estimate of the completed total hoist weight. Examples of Hoist Components or Systems are listed below.

1) Hoist Frame

2) Hoist System (inclusive drum and wire rope)

3) Operator Station

4) Personal Access and Ancillary Items

All submittals for Hoist Design Data shall be uniquely named with the submittal and the system or component. For example: "Hoist Design Data - Frame."

All computations and drawings submitted as part of the Hoist Design Data shall be stamped and signed by a registered professional engineer who has done the design himself/herself or supervised and reviewed work if done by other engineers.

A list of proposed Design Package Submittals with submittal dates and at least one actual design package submittal shall be submitted no later than 90 calendar days after date of award. Hoist design data for the remaining hoist components or systems shall be submitted no later than 180 calendar days after date of award.

When detailed drawings are submitted, they shall be submitted with arrangement drawings and bill of materials/parts lists. Detail drawings for metalwork and machine work shall include catalog cuts, templates, fabrication and assembly details and type, grade and class of material as appropriate.

When final calculations are submitted, each section shall include reference to submittals where that section was approved. They shall be called "Final Calculations." Upon approval of the final calculations, they shall be included as a separate volume of the Operation and Maintenance Manuals.

1.4.11.1 Drums

The hoist drum shall be a centrifugally spun steel casting conforming to ASTM A148/A148M , GR90-60 spun cast steel or be a machined weldment of ASTM ASTM A829/A829M , Grade 4140 or 4340 material. 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

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the through shaft type design.

1.4.11.2 Sheaves

Conform Contractor designed sheaves to the requirements of EM 1110-2-2610 unless otherwise specified herein. Provide sheaves that are a standard product design regularly offered by a sheave manufacturing company. The sheave manufacturer must have been regularly engaged in the production of wire rope sheaves and have a minimum of 5 years' experience producing sheaves of similar size to those specified.

Sheaves should be heat-treated cast steel, ductile iron, or manganese steel and should be of standard dimensions with grooves clad with (AM001) steel.(AM001) Sheaves shall be rated for underwater duty. The hubs should be fitted with plain bearings or roller bearings with appropriate lubrication fittings. Fit the interference fit between the sheave(s) and bearings in accordance with the bearing manufacturer's recommendations to prevent slipping between the components. The sheave flange, rim thickness, web thickness, angle of contact, and inside diameter of the hub dimensions should be in accordance with the standard manufacturers' typical products for the appropriate size and construction of wire rope. Accurately machine sheave grooves for the wire rope diameter provided, smoothly finished, and free of surface defects. Flame harden the groove contact area to a minimum 50 Rockwell C for a depth of 0.060 inch minimum with a minimum contact arc of 150 degrees.(AM001) If casting is the fabrication method, produce casting pattern for the wire rope sheave that becomes the property of the Government upon completion of the contract. If heavy duty fabricated steel weldment is selected as the fabrication method, provide all engineering and design of the sheaves to satisfy the requirements specified herein and submit calculations and shop drawings. 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 for approval prior to the start of shop fabrication.

1.4.11.3 Brakes

See Section 35 20 20.

1.4.11.4 Electric Motors

See Section 35 20 20.

1.4.11.5 Shaft Couplings

Shaft couplings shall be of the flexible disk, chain, gear, or jaw type of machined steel construction and capable of transmitting the applied design torques.

Provide couplings capable of the horizontal installation and design for reversing loads. 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

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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.

Flexible Disk Couplings

Use high strength stainless steel flexible disks to transmit torque and have no moving parts of backlash. Lubrication of the coupling is not required. The coupling must be of the close coupled design.

Dynamically balance the coupling in accordance with AGMA standards to achieve a AGMA 7 balance class.

Chain Couplings

Provide hardened teeth sprocket hubs with a connecting ANSI Standard Double Width Roller Chain to transmit torque. Secure hubs to the shaft by means of keys/keyways. Furnish a sealed coupling cover of stamped steel material to retain lubricant. The covers must be rounded edge design with recessed and threaded lubricant plugs to fill and retain lubricant.

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.

Jaw Type Couplings

Keyed shaft stainless steel hubs of the fail-safe spider design.

Furnish set screws to secure the hubs. Make coupling insert material of bronze to transmit torque.

1.4.11.6 Gearing

Contractor designed gearing must be engineered, designed, and manufactured by a reputable gear manufacturer who has prior experience in designing and supplying the specified size gearing. Design the 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. Grind the gears after gear cutting to achieve a minimum ANSI/AGMA Quality 11 in accordance with AGMA 2015/915-1 . The normal strength horsepower rating of the 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.

The gearbox lubrication system shall function properly at 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 baths, slingers, dams, and

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passages. Provide stainless steel 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. Due to the moist environment, an expansion chamber shall be provided in addition to the desiccant breather.

1.4.12 Hoist Machinery and Drum Shop Inspections and Tests

The following inspections and tests shall be completed at the manufacturer's facility and all testing must be complete before machinery is shipped to the site. The Government shall be made aware of anticipated testing dates a minimum of 21 days in advance in order to participate.

The Contractor shall provide all needed equipment, including but not limited to temporary stands and supports for the hoist.

1.4.12.1 Pre-Final Inspection and Preliminary No-Load Performance Test

1.4.12.1.1 General

A Final Inspection and Acceptance Test Procedure shall be submitted at least ninety (90) days prior to performing the Pre-Final Inspection and preliminary no-load performance test. The procedure shall be approved prior to performing the inspection and test. During the Pre-Final Inspection, all inspected items shall be reviewed after each portion of the inspection has been completed and prior to starting the next. Any repairs and adjustments shall be made prior to completion of the Pre-Final Inspection and before any further testing of the hoist occurs. The Pre-Final Inspection shall be successfully completed first and then the Preliminary No-Load Performance Test shall be done. The Pre-Final Inspection and Preliminary No-Load Performance Test Report shall be one complete submittal.

1.4.12.1.2 Preliminary No-Load Performance Test

The preliminary no-load performance test is the same test as the no-load performance test except that it is a trial test that the Contractor performs by themselves to make sure everything performs satisfactorily prior to performing the acceptance tests in the presence of the Contracting Officer and Government representatives. The preliminary no-load performance test need not be witnessed by the Government. The approved Final Inspection and Acceptance Test Procedure shall be used for the preliminary no-load performance test. The findings of the preliminary no-load performance test shall be recorded in the Preliminary No-Load Performance Test Report. Any anomalies shall be corrected prior to acceptance of the Preliminary No-Load Performance Test Report. See paragraphs EQUIPMENT MONITORING and NO-LOAD PERFORMANCE TEST.

1.4.12.1.3 Equipment Monitoring

During the pre-final inspection and preliminary no-load performance test and the final inspection and acceptance tests, improper operation or poor condition of safety devices, electrical components, mechanical equipment, and structural assemblies shall be monitored and recorded. Observed defects critical to continued inspection or testing shall be reported immediately to the Contracting Officer and inspection or testing shall be suspended until the deficiency is corrected or a plan is agreed to between the Contractor and the Government for resolution later in the inspections

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and testing. After corrective action has been taken, the tests shall be continued or rerun as directed until the contract requirements are met.

The following inspections shall be made:

a. Inspect for evidence of bending, warping, permanent deformation, cracking or malfunction of structural components.

b. The motors, brakes, gearing inside the hoist reducer, and other mechanical or electrical equipment shall be visually examined to ensure no damage has occurred.

c. Inspect for evidence of slippage in wire rope sockets and fittings.

d. Check for overheating in brake operation; check for proper stopping. All safety devices, including emergency stop switches and POWER OFF pushbuttons, shall be tested and inspected separately to verify proper operation of the brakes.

e. Check for abnormal noise or vibration and overheating in machinery drive components.

f. Check wire rope sheaves and drum spooling for proper operation, freedom of movement, abnormal noise or vibration.

g. Check electrical drive components for proper operation, freedom from chatter, noise or overheating.

h. Inspection covers shall be removed from gear reducers for inspection of gearing after all testing.

i. All functions of the hoist shall be demonstrated for proper operation. This includes but not limited to all alarms, all limit switches for proper operation.

1.4.12.1.4 Report

A Pre-Final Inspection and Preliminary No-Load Performance Test Report shall be submitted for approval and approved before performing the Final Inspection and Acceptance Test Procedure. The Government review period shall be according to 01 33 00 paragraph SCHEDULING for the review of the Pre-Final Inspection and Preliminary No-Load Performance Test Report.

1.4.12.2 Final Inspection and Acceptance Tests

1.4.12.2.1 General

a. The Government will not attend the final inspection and acceptance testing until the following have been completed:

(1) Submittal and approval of Final Inspection and Acceptance Test Procedure.

(2) Submittal and approval of Test Weight Plan.

(3) Successful completion of the Pre-Final Inspection and Preliminary No-Load Performance Test.

(4) Submittal and approval of the Pre-Final Inspection and Preliminary No-Load Performance Test Report.

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b. The Final Inspection Procedure shall be used for the Final Inspection and shall be performed by designated hoist inspectors.

The findings shall be recorded in the Final Inspection and Acceptance Test Report.

c. The final inspection and acceptance testing will be witnessed by the Contracting Officer and representatives, unless waived in writing.

d. Provide all personnel and equipment necessary to conduct the tests including but not limited to hoist operators, riggers, data recorders (personnel), rigging gear, test weights, and measuring instruments.

e. During acceptance testing, all collected data will be reviewed after each test has been completed and prior to starting the next test. If there are unexpected results or inconsistencies in the data, that portion of the test shall be rerun to verify the data. Any repairs and adjustments shall be made prior to completion of the test and appropriate portions of the test shall be rerun. The testing maybe re-run as many times as necessary in order to complete that portion of the testing.

f. During inspections and acceptance testing, equipment monitoring shall be performed as stated in Paragraph EQUIPMENT MONITORING.

Inspections and testing shall be suspended until deficiencies are corrected or a plan is agreed to between the Contractor and the Government for resolution later in inspections and testing.

1.4.12.2.2 Final Inspection Procedure

The final inspection procedure shall be prepared and used to record findings and results of the inspection. Operational tests shall be performed at no-load. The final inspection shall include the following:

a. Perform inspection in accordance with all the proper codes.

b. All incidental equipment including locking and indicating devices, and lights shall be checked for proper operation.

c. Verify that all brakes have been adjusted and burnished; and brake torques have been verified.

d. Verify that the hoist has been cleaned up.

e. The lifting beam shall be raised and lowered through the maximum range of travel possible at the testing facility but not less than 25 feet for the test exercising in each direction at normal speed. The lifting beam shall be stopped below the limit switch upper setting. Proper operation of upper limit switches shall be verified. Check drums for proper wire rope spooling at the upper limit. Verify the lifting beam reaches the required upper limit of travel. Proper operation of lower limit switch shall be verified by jumpering the contact or tripping the lever type limit switch. Brake action shall be tested in each direction.

f. Verify the lifting beam is level within 3/16-inch at any location of the lift. Measurements shall be made at five (5) approximately equally spaced lifting beam elevations for each test.

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INTAKE GATE MACHINERY REHABILITATION

g. Verify the lifting beam hangs plumb and with no twist.

h. For the hoist, while slowly hoisting the lifting beam, the main power source shall be disconnected, by pressing the emergency stop button at the operator control station, verifying that there are no more than one fourth (1/4) of a brake wheel revolution, and that the brake will set. The test will be repeated while slowly lowering the lifting beam and again while the lifting beam is not moving. (AM001) .

i. The intake gate hoist "Emergency Stop" pushbutton shall be operated to ensure all power is removed from the hoist machinery when activated.

1.4.12.2.3 Test Sequence

The Final Inspection shall be successfully completed and then the hoist shall be tested according to the sequence provided in the acceptance test procedure.

The lifting beam shall be tested prior to hoist load tests.

1.4.12.2.4 No-Load Performance Test

a. During the test for each condition specified below, a full set of measured readings shall be recorded for each direction for the hoist motion. Measured readings shall be taken from the input terminals of the motor and shall include true RMS voltage and true RMS current.

Hoist speed shall be computed based on motor speed. Data recorded shall be included in the Acceptance Test Report.

b. Performance requirements are defined in SECTION 35 20 20 ELECTRICAL EQUIPMENT FOR GATE HOISTS. The following performance tests shall be performed at no-load: Hoist No-Load Performance. For the hoist, the lifting beam shall be raised and lowered operating at normal speed.

Results of the No-Load Performance Test shall be included in the Final Inspection and Acceptance Test Report, submitted for approval.

1.4.12.2.5 100 Percent Rated Load Performance Test

a. During the test for each condition specified below, a full set of calculated and measured readings shall be recorded at normal speed in each direction for the hoist motion. Calculated readings shall be taken and shall include output voltage, output current, output frequency, and motor speed. Measured readings shall be taken from the output terminals and shall include true RMS voltage and true RMS current. Hoist speeds shall be computed based on motor speed. Data recorded shall be included in the Acceptance Test Report.

b. Performance requirements are defined in SECTION 35 20 20 ELECTRICAL EQUIPMENT FOR GATE HOISTS. The following performance tests shall be performed using a test load of 100 percent of rated load (tolerance of +4%/-4%):

(1) Hoist Loss of Power Performance. For the hoist, hoisting the test load, the emergency stop pushbutton shall be pressed to verify that the test load will not lower and that the brake will

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INTAKE GATE MACHINERY REHABILITATION

set. Verify that there are no more than one-fourth (1/4) brake wheel revolution. This test shall be repeated while lowering the load and while stationary.

(2) Hoist Performance. For the hoist, the lifting beam shall be raised and lowered operating at normal speed.

Results of the 100 percent rated load performance test shall be included in the Acceptance Test Report, submitted for approval.

1.4.12.3 125 Percent Rated Load Performance Test

Unless otherwise indicated, the following load test shall be performed using a test load of 125 percent of rated load (tolerance of 0%/-4%):

Hoist Dynamic Load Test. For the hoist, the test load shall be raised and lowered at least two feet or one complete revolution of the drum whichever is greater, operating at normal speed. The hoist shall be completely stopped at least once in each direction to ensure proper brake operation.

Results of the 125 percent rated load performance test shall be included in the Acceptance Test Report, submitted for approval.

1.4.12.4 Lifting Beam

The lifting beam shall be load tested and shall be used for load testing the hoist.

1.4.12.5 Final Inspection and Acceptance Test Report

Submit a final inspection and acceptance test report and insert it as a separate section in the operations and maintenance manual.

1.4.13 Instrumentation and Controls

See Section 35 20 20.

1.4.14 Electrical

See Section 35 20 20.

1.4.15 Structural Bases and Supports

Provide structural bases and supports for the intake gate machinery.

Structural bases and supports shall be constructed with structural steel and designed in accordance with AISC 325 and ASME B30.2 . Painting shall be in accordance with specification 09 97 02. Grout material required by design for sturctural bases shall be submitted with design calulcations to the governemnt for approval.

Furnish the services of one or more competent erecting engineers from the equipment manufacturer/fabricator to supervise and direct the erection and installation of this equipment.

1.4.16 Erecting Engineer

Furnish the services of one or more competent erecting engineers from the equipment manufacturer/fabricator to supervise and direct the erection and

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INTAKE GATE MACHINERY REHABILITATION

installation of this equipment. The erecing engineer shall be a registered professional engineer licensed in the United States and with 5 years related experience.

a. The erecting engineer(s) must be present for all shop erection, inspections, tests, installation and operation of all equipment at the project site.

b. The erecting engineer has responsibility for the equipment meeting all the requirements of these specifications and fulfilling all the Contractor's guarantees.

c. The erecting engineer must verify the fit and alignment of mating components prior to erecting in the field and be present during final connection and all commissioning and field testing for contract compliance. The erecting engineer must keep records of all measurements taken during installation and testing.

d. Upon completion of the installation, commissioning, and startup for each specified major equipment or subassemblies, each erecting engineer must submit a erecting engineer installation and operation certification approving the installation and operation of the equipment.

1.4.17 Testing and Certification

1.4.17.1 Drum Nondestructive Testing

Perform nondestructive testing on all wire rope hoisting drums. After stress relief, test the surfaces of all completed welds including adjacent heat-affected zones and face of drum grooves/sockets using a liquid dye penetrant method for the presence of flaws. Alternate methods of non-destructive testing which would be equal to or more effective than the liquid dye penetrant method may be used if approved by the Contracting Officer.

All wire rope hoisting drums and sheaves must have the grooves verified for size and contour with a groove gage (nominal size plus full oversize percentage). The grooves must meet the contact area and groove dimension limitations established within the Wire Rope Users Guide. All wire rope grooves and running surfaces must be unpainted.

1.4.17.2 Field Erection and Tests

1.4.17.2.1 General

Perform field erection and field tests. Install the machinery under supervision of the erecting engineer under the provisions of paragraph ERECTING ENGINEER. Submit the installation and alignment procedure and install in with the approved procedure. The procedure must include consideration of all the other work that is obligated to be performed at the Dam; and also the operating regime for the Dam gates which the Government will enforce, as described and specified in the SPECIAL CLAUSES. Base the procedure on a proper sequence of construction that will complete the work with safety, efficiency, and in full accordance with these specifications. Submit for approval any Gate Support Method to be used. Include detailed information on the method proposed to support the gate during the work delineated in this section. The support method, engineering computations, and support drawings shall be designed and

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INTAKE GATE MACHINERY REHABILITATION

certified by a licensed professional engineer.

1.4.17.2.2 General Test Procedure

The Contractor shall submit the commissioning, startup and operational checklist test procedures, with a blank test results data sheet for each, prior to the commencement of any tests. Complete all Startup checklists prior to performing Operational tests. The testing must comply with the requirements herein and as specified below. Inspect each piece of equipment for smooth operation and proper alignment and check all necessary clearances to ensure vibration, binding, or excessive heat does not occur in any moving part. During the test, provide readings of motor current, RPM, voltage, and bearing temperature. Stop the test immediately if there is any undue noise, vibration, or heat developed in any of the equipment. After correction of alignment and/or all other causes for the interruption of the test, reinspect the unit and resume testing when permitted by the Contracting Officer. Submit final operating test results for each unit.

1.4.17.2.3 Limit Switch and Position Indication Settings

Immediately prior to commencement of work on each gate, record the gate position settings. Submit the Gate Position Settings on Limit Switches.

Refer to the pre-recorded limit switch and position indication requirements as specified Section 35 20 20 ELECTRICAL EQUIPMENT FOR GATE HOIST. Following a thorough check of alignment, clearances, and readiness to operate, operate the machinery with due care to set the travel limits and confirm control or monitoring functions. The settings of the limit switch and control points must conform to the indicated requirements.

1.4.17.3 Final Gate Plumb Hang Certification

Immediately prior to commencement of work on each gate, record the gate plumbness to the nearest 0.01 degrees. Submit final gate hanging, plumb certification. The gate shall be hung back into the original position prior to the start of work in order to ensure the side guide rollers follow the guide rails to obtain a proper seated/seal position on the sill.

1.4.17.4 Field Training

Provide field training for a minimum of 8 personnel conducted by the erecting engineer for operating staff after…