Tenkiller Bridge AM0004 1.24.25.pdf

Version Date: 1.24.25 FY23

U.S. Army Corps of Engineers Tulsa District

Solicitation #: W912BV24R0108

Contract Type: Design Bid Build; in-house Design Stand-Alone, C-Type Contract

For Civil Works Projects

Cherokee/ Sequoyah Counties, Oklahoma Illinois River Water Shed

Tenkiller Lake Replace Main Spillway Bridge

Amendment #0004

Document Submittal Date: January 24, 2025

Amendment 0004 Continuation Sheet

Tenkiller Spillway Dam Replace Main Spillway Bridge

Date: 1/24/205

Standard Form (SF) 30, Block 14 (continuation). Change the solicitation documents as follows.

The revised/new sections/appendices, listed below, are hereby added to, or revised, and made a part of the solicitation.

Revised sections/appendices:

SPECIFICATIONS

Revised or added/ deleted information can be located, in the specifications, by searching for an asterisk and amendment number (i.e., *AM0002).

SECTION DESCRIPTION OF CHANGE

35 01 41.00 10 Electrical Operating Machinery For locks and Dams

Paragraph 2.6 revised to clarifies the capping and abandonment of existing compressed air line.

Paragraph 3.3.1 revised to change reference to "SPECIAL CLAUSES" to "contract requirements."

REPLACE section with the REVISED section of the same number

FY23 Tenkiller Spillway Bridge Replacement Solicitation #: W912BV24R0108 January 24, 2025 Amendment 0004

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

35 01 41.00 10

ELECTROMECHANICAL OPERATING MACHINERY FOR LOCKS AND DAMS

08/20, CHG 3: 05/23

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 GATE OUTAGE

PART 2 PRODUCTS

2.1 EQUIPMENT

2.1.1 Machinery

2.1.2 Equipment Submittal Data

2.2 BEARINGS

2.2.1 Pillow Block Bearing Assemblies

2.3 TAINTER GATE DRIVE SHAFTS

2.4 DRIVE SHAFT COUPLINGS

2.5 GUARDS AND COVERS

2.6 WATER LINES

2.7 KEYS AND KEYSEATS

2.8 FIELD ASSEMBLY AND TESTS

2.8.1 Alignment

2.8.2 Anti-Seize Lubricant

2.8.3 Fasteners

PART 3 EXECUTION

3.1 REASSEMBLY OF COMPONENTS

3.2 MISCELLANEOUS PROVISIONS

3.2.1 Lubrication

3.3 FIELD ERECTION AND TESTS

3.3.1 General

3.3.2 Wire Rope Re-Tensioning

3.3.3 Limit Switch and Position Indication Settings

3.4 STARTUP AND ACCEPTANCE TEST

-- End of Section Table of Contents --

C23BRGSTENKILLER SECTION 35 01 41.00 10 Page 1

35 01 41.00 10

ELECTROMECHANICAL OPERATING MACHINERY FOR LOCKS AND DAMS

08/20, CHG 3: 05/23

"Revised by Amendment 0002 & 0004"

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 SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B4.1 (1967; R 1994; R 2004; R 2009; R 2020)

Preferred Limits and Fits for Cylindrical Parts

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

ASTM INTERNATIONAL (ASTM)

ASTM A240/A240M (2024) Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

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

1.2 SUBMITTALS

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are for information only. When used, a code following the "G" classification 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

Pillow Block And Bearing Selection ; G, DO

Coupling Materials And Design ; G, DO

Field Verify Dimensions

Tensioning Procedure ; G, DO

Gate Position Settings On Limit Switches

SD-02 Shop Drawings

C23BRGSTENKILLER SECTION 35 01 41.00 10 Page 2

Shaft Bores

Keys And Keyways ; G, DO

Fabricated Components ; G

Machinery Guards ; G

SD-03 Product Data

Operating machinery product Data ; G

Materials Certification ; G

Lubricants ; G, DO

SD-05 Design Data

Installation And Alignment Procedure ; G, DO

Gate Support Method ; G, DO

SD-06 Test Reports

Final Shaft Alignment Report

Functional Checklist ; G

Pre-Functional Checklist ; G

Startup And Acceptance Test

Final Field Tensioning And Operating Test

Field Assembly And Tests

SD-11 Closeout Submittals

Commissioning Document

1.3 GATE OUTAGE

During installation of torque shaft support assemblies and all accessories, no more than two gates are permitted to be out of service at a time. The duration that a gate is out of service must not exceed 14 calendar days.

PART 2 PRODUCTS

2.1 EQUIPMENT

2.1.1 Machinery

All those who will be working near mechanical equipment must follow HECP safety regulations and guidelines as per section 01 35 26.

2.1.2 Equipment Submittal Data

Submit complete, descriptive literature, and specifications for each

C23BRGSTENKILLER SECTION 35 01 41.00 10 Page 3 manufactured product used in the hoist machinery assembly. This must include, but not be limited to: Operating Machinery product data for torque shafts, line shaft couplings, and line shaft bearings. The literature must include original, legible, manufacturer's cut sheets and data sheets that clearly indicate the physical construction, operation, mechanical and structural characteristics, dimensions, materials, load ratings, capacities, operating speeds, lubrication requirements, and associated hardware as applicable. For data sheets with extraneous data, clearly indicate which data applies by crossing out other models, or circling or highlighting the correct options. Product data must clearly show conformance with these Specifications, including, but not limited to:

product manufacturer's declarations of conformance to applicable technical standards. Submit product data prior to or concurrent with the shop drawings. Additionally, the contractor must field verify dimensions of existing equipment including but not limited to: torque shaft lengths, piping section lengths, and the flange bolt patterns to ensure proper fitment of new pillow blocks.

2.2 BEARINGS

2.2.1 Pillow Block Bearing Assemblies

The pillow block bearing assemblies include the bearings, housings, seals and hardware. The currently used pillow block assemblies will be replaced with new. Each shaft section requires 3 expansion pillow block assemblies and 2 non expansion assemblies as shown on sheet R723 of the tainter gate record drawings. Housings are to be one piece type, with painted ductile iron machined base housing with a through drilled, two bolt base.

Assembly must include heavy duty triple lip seals and use a set screw locking device. Except as otherwise specified, shaft bearings are to be high capacity antifriction spherical ball bearings suitable for radial loads with pressure lubrication fittings. Use the manufacturer's ratings for loads and speeds in determining the bearing capacity. Comply with the bearing manufacturer's recommendations for service and installation factors.

Provide locking rings, set screws, lock nuts, spacers, and the necessary sleeves to center and secure the bearings within the housing. Provide bearings which have a minimum L-10 bearing life of 75,000 hours as defined by ISO 281 based on the largest full load motor horsepower provided by the specified motor. Design the bearing and housing for grease lubrication.

Contractor must submit pillow block and bearing selection for approval.

2.3 TAINTER GATE DRIVE SHAFTS

The existing shafts tested negative for lead based paint. The Government intends to replace the existing shafts. Existing shafts have a diameter of

1.75 inches and rotate at 240 RPM. New shafts must be of the same diameter as the existing shafts and must be designed to operate at a minimum operating speed of 240 RPM and a maximum normal operating load of 66 foot-pounds. Drive shafts must be constructed of ASTM A29 Cold Formed Steel. The contractor must submit materials certification and dimensions of the drive shafts for government approval . (*AM0002)The drive shafts must be factory coated with a zinc-rich epoxyprimer and a high-solids polyurethane topcoat or approved equivalent suitable for harsh environments. The primer and topcoat must be from a single manufacturer and designed to be used together as a system. Surface preparation must be in accordance with the manufacturer's recommendation for maximum adhesion.

Minimum Dry Film Thickness (DFT) for the system must be 6 mils. Any

C23BRGSTENKILLER SECTION 35 01 41.00 10 Page 4 damaged incurred during transportation or installation must be repaired by the Contractor with a minimum SSPC-SP-1: Solvent Cleaning and SSPC-SP-2:

Hand Tool Cleaning before reapplying the coating.(*AM0002)

2.4 DRIVE SHAFT COUPLINGS

The existing couplings are to be replaced with new components. The new components must be constructed of machined steel and must be capable of transmitting the applied torque. Each shaft section includes 3 floating couplings. 1 in the middle connecting shaft sections together, and 1 on each end to connect to the smaller reducer shafts as shown on sheet R727 of the record drawings. The main drive shafts are 1.75 inches in diameter and the reducer shafts are 1 inch in diameter. Contractor must submit coupling materials and design for approval. Provide couplings designed for reversing loads and a minimum 240 RPM operating speed. The couplings are to be capable of handling a maximum normal operating load of 66 foot-pounds .

Design couplings to compensate for angular, parallel and axial misalignment. Provide couplings with a general service factor of 1.0 applied to their selection and design based upon the anticipated application and expected service. Provide couplings with sufficient capacity to develop the full strength of the shafting which they connect and are to be pressed and keyed thereon. Contractor must utilize gear type couplings. All hub bores are to meet the dimensional and tolerance specifications in accordance with ASME B4.1 unless otherwise indicated.

Provide an FN2 fit between all coupling hubs and shafting. The key fit design is to be in accordance with paragraph entitled KEYS AND KEYSEATS.

Submit the fabricated dimensions of the shaft bores . Equip couplings with lube plugs; enclose and seal with an elastomeric O-ring to retain the lubricant. Provide couplings which are 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. Contractor must submit shop drawings for all fabricated components . (*AM0002)The couplings must be factory coated with a zinc-rich epoxy primer and a high-solids polyurethane topcoat or approved equivalent suitable for harsh environments. The primer and topcoat must be from a single manufacturer and designed to be used together as a system. Surface preparation must be in accordance with the manufacturer's recommendation for maximum adhesion. Minimum Dry Film Thickness (DFT) for the system must be 6 mils. Any damaged incurred during transportation or installation must be repaired by the Contractor with a minimum SSPC-SP-1: Solvent Cleaning and SSPC-SP-2: Hand Tool Cleaning before reapplying the coating.(*AM0002)

2.5 GUARDS AND COVERS

Provide safety guards or covers as shown on the Contract Plans to protect the operators from accidental contact with moving parts. Guards and covers must be hinged to provide access to parts requiring lubrication or regular maintenance. Guards must be designed by the contractor and stamped by a PE. Contractor must submit shop drawings for the machinery guards prior to fabrication for approval.

2.6 WATER LINES

The existing compressed air line will be removed and a new waterline will be provided to wash down mechanical equipment. The new water line must follow the same path as the original compressed air line and include

C23BRGSTENKILLER SECTION 35 01 41.00 10 Page 5 valves at each pier so equipment can be washed by hose. The existing compressed air line has a diameter of 1.5 inches. The entire above ground section of the existing line must be replaced with new piping of the same diameter. (*AM0004)The below ground portion of the existing compressed air line must be capped off and abandoned in place.(*AM0004) All above ground piping equipment must also be replaced including the valves. The new waterline must be Schedule 80 steel pipe with threaded connections. NPT coarse threads must be used with pipe dope or other sealants to create leak free connections. The body flange of the valves must have an internal pipe thread to suit 3/4 inch pipe and the end of the valves must have 3/4 inch exposed hose threads. Coordination with civil will be necessary for the demo of the above ground portion of the existing line and the location of the new waterline. No water service main to the bridge exists, so 3/4 inch camlock quick couplings will be provided at each end of the line for the supply of water.

2.7 KEYS AND KEYSEATS

All shafts are required to utilize standard keyways and keys in accordance with ASME B17.1 , Class II. Recommended key chamfers and keyway fillets must be used. Submit all fabricated dimensions of the keys and keyways .

2.8 FIELD ASSEMBLY AND TESTS

2.8.1 Alignment

Conform alignment of interconnecting shafts to the installation requirements of the coupling and gear manufacturers in accordance with standard AGMA practices. Coupling alignment is required per coupling manufacturer to no greater than 75% of allowable tolerance. Accurate alignment must be obtained by the use of stainless steel shims or other approved methods so that no binding in any moving parts or distortion of any member occurs before it is fastened in place. Only the pillow blocks as shown should, and must, be shimmed. The contractor must acquire approval to shim, move, or otherwise reposition the machinery, including but not limited to: the bull gear, parallel reducer, worm gear reducer, motor, break, and limit switch. The contractor must not use undersized bolts or washers, commerical shims must be used. All shims used for alignment must be new and free of any manufacturing defects. All existing shims from the components that require adjustment must be removed from service and replaced with new. Shim metallurgy, thuckness, and hardness must conform to ASTM A240/A240M grade 304 standards. Shims must be approximately sized for the associated bolt with the shim slot not to exceed the hold down fastener by more than 0.125 inches while allowing for a quarter inch back-off once in place. Shims must provide at least 75% contact between each machined foot and its point of contact on a baseplate, frame, or soleplate. The contractor must submit a final shaft alignment report for each of the couplings outlined in section 2 to include Angular and Offset.

2.8.2 Anti-Seize Lubricant

Assemble all threaded portions of the assemblies using an anti-seize lubricant that prevents galling of parts and corrosion, allows for easy disassembly of parts, and reduces friction unless otherwise noted or specified. Select anti-seize lubricant that is a standard product designed for the intended use.

C23BRGSTENKILLER SECTION 35 01 41.00 10 Page 6

2.8.3 Fasteners

All fasteners removed during work must be replaced with new components.

Torque requirements for each size of fastener must be per the following charts (for exceptions, see below).

Values are for lubricated threads, SAE Grade 2 bolt material. Threads must be lubricated by use of a liquid thread locking material or use of lubricant, if thread locking is not required. If contractor has any questions concerning torque for bolts during re-assembly, contact the COR.

SAE GRADE 2 (74,000 Tensile Strength) Size (DIA) Foot Pounds

1/4" 4

5/16" 8

3/8" 16

7/16" 25

1/2" 35

9/16" 55

5/8" 75

3/4" 135

7/8"

1" 200

Values are for lubricated threads, SAE Grade 5 bolt material. Threads must be lubricated by use of a liquid thread locking material or use of lubricant, if thread locking is not required. If contractor has any questions concerning torque for bolts during re-assembly, contact the COR.

SAE Grade 5 (120,000 Tensile Strength) Size (DIA) Foot Pounds

1/4" 8

5/16" 15

3/8" 25

7/16" 45

1/2" 70

9/16" 100

C23BRGSTENKILLER SECTION 35 01 41.00 10 Page 7

Size (DIA) Foot Pounds

5/8" 140

3/4" 240

7/8" 400

1" 500

Values are for lubricated threads, SAE Grade 8 bolt material. Threads must be lubricated by use of a liquid thread locking material or use of lubricant, if thread locking is not required. If contractor has any questions concerning torque for bolts during re-assembly, contact the COR.

SAE Grade 8 (150,000 Tensile Strength) Size (DIA) Foot Pounds

1/4" 8

5/16" 18

3/8" 35

7/16" 55

1/2" 80

9/16" 110

5/8" 170

3/4" 280

7/8" 480

1" 680

PART 3 EXECUTION

3.1 REASSEMBLY OF COMPONENTS

All parts to be reinstalled must be thoroughly cleaned as required to provide a fully functioning system. Rust, dirt, grit, and other foreign matter must be removed. Holes and grooves for lubrication and all bushings or bearings must be cleaned before re-assymbly. Bushings or bearings must be pre-lubricated with appropriate grease or lubricant before assembly.

Enclosed chambers or passages must be examined to make sure they are free from foreign materials. Pipe wrenches, cold chisels, or other tools likely to cause damage to the surface of shafts, nuts, or other parts must not be used for assembling or tightening parts. Bolts and screws must be tightened firmly and uniformly, but care must be taken not to overstress

C23BRGSTENKILLER SECTION 35 01 41.00 10 Page 8 the threads. When a half nut is used for locking a full nut, the half nut must be placed first and followed by the full nut. Threads of all bolts, nuts, and screws must be lubricated with an approved lubricant before assembly (unless a thread locking material is required). Threads of corrosion resisting steel bolts and nuts must be coated with an approved anti-galling compound. Driving and drifting bolts or keys will not be permitted. Each machinery or structural unit must be acccurately aligned so that no binding in any moving parts or distortion of any member occurs during operation. The alignment of all parts with respect to each other must be true within the respective tolerances required. Components must be set true to the original plans as shown in the drawings.

3.2 MISCELLANEOUS PROVISIONS

3.2.1 Lubrication

Drain and re-fill gearboxes with JT-7 SAE 85W-140, clean and lubricate open gearing with asphaltic gear lubricant, and lubricate wire ropes with VitAlife 400. Lubricate bearings with Mobil XHP 222, and couplings with Mobil EP NLGI 3. Submit all lubricants for approval prior to starting lubrication work.

3.3 FIELD ERECTION AND TESTS

3.3.1 General

Submit the installation and alignment procedure and install in accordance with the approved procedure. The procedure has to include consideration of all the other work that is obligated to be performed at the site; and also the operating regime for the gates which the Government will enforce, as described and specified in the (*AM0004) SPECIAL CLAUSEScontract requirements(*AM0004) . 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 tainter gate during the work delineated in this section. The support method, engineering computations, and support drawings have to be designed and certified by a licensed professional engineer.

3.3.2 Wire Rope Re-Tensioning

Upon completion of the shaft re-alignment, insert load pins into lifting bracket and socket eye bolt assembly. Apply forces to the cables by means of tensioning the eye bolts using a spanner wrench. Equal tensioning will be considered achieved when the registered forces on the load pins are within 5 percent of each other. After the units have been installed and the field tensioning tests are complete, operate each complete gate, to demonstrate to the satisfaction of the Contracting Officer that the requirements of the specifications have been met and that the performance of the equipment is satisfactory for the purpose intended. During the test, provide readings of the load pins at 20%, 50% and 100% of gate openingto the Contracting Officer. Submit final field tensioning and operating test results for each unit. After successful completion of tensioning, contractor must remove load pins and replace with recessed pin and nuts with cotter keys. Prior to wire rope re-tensioning, contractor must design and submit a tensioning procedure including shop drawings for all fixtures that will be used during the process and have it signed by a licensed engineer.

C23BRGSTENKILLER SECTION 35 01 41.00 10 Page 9

3.3.3 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 in paragraphs above. 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 need to conform to the indicated requirements. Ensure that the upper and lower limit switches are accurate within +/- 1/20 of a foot.

3.4 STARTUP AND ACCEPTANCE TEST

Submit the pre-functional checklist for approval that includes checks, recordings, measurements and verifications to be performed prior to start

up. Signature by all parties is required for acceptance. Following the completion of installation, checkout, adjustment, and setting the limit switches, perform a startup and acceptance test on each machinery unit.

Perform the startup and acceptance test in accordance with the approved commissioning functional checklist , record and submit the results on test result forms of the procedure. Signature by all parties is required for acceptance. Include a demonstration of proper functioning of the limit switches and position indicator accuracy in the acceptance test. For acceptance, the machinery unit(s) are to be successfully operated through a minimum of three complete cycles to satisfy the Contracting Officer that the requirements of the contract have been met and that the performance of the equipment is satisfactory for the purpose intended. Motor current draw must be recorded during operation.

Upon successful completion of the field tests, all equipment will be examined by the Contracting Officer, Erecting Engineer, Contractor, Project Personnel, and if found to comply with the contract it will be accepted by signature of all parties in a prepared commissioning document .

Signatures and Acceptance will not occur until all found deficiencies have been corrected. submit copies of the signed commissioning document document to the Contracting Officer.

-- End of Section --

C23BRGSTENKILLER SECTION 35 01 41.00 10 Page 10