W912EF-15-R-0048-0009.pdf

W68SBV51203542

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

STANDARD FORM 30 (Rev. 10-83) Prescribed by GSA

FAR (48 CFR) 53.243

Revise the specifications for Vertical Lift Gate Systems

1. CONTRACT ID CODE PAGE OF PAGES

J 1 2

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16C. DATE SIGNED

BY 08-Oct-2015

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street, County, State and Zip Code) X W912EF-15-R-0048

X 9B. DATED (SEE ITEM 11)

28-Aug-2015

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offer is extended, X is not extended.

Offer must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing Items 8 and 15, and returning 1 copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN

REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE

CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(B).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

10A. MOD. OF CONTRACT/ORDER NO.

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

08-Oct-2015

CODE

USAED, WALLA WALLA - CONTRACTING DIV.

KENT R. BERNARD 201 N. THIRD AVENUE

WALLA WALLA WA 99362-1876

W912EF 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

W912EF-15-R-0048

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

SECTION 00010 - SOLICITATION CONTRACT FORM

The following have been added by full text:

AMENDMENT 0009

1. Revised the following Specifications (see revised Specifications for details):

a. SECTION 35 01 43.00 28 VERTICAL LIFT GATE SYSTEMS

Revised Paragraph 1.3 REFERENCES Revised Paragraph 2.3.1 Pinion.

(End of Summary of Changes)

Lower Mon. Navlock Downstream Gate Hoist Machinery Upgrade W912EF-15-R-0048 Amend-0009

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 01 43.00 28

VERTICAL LIFT GATE SYSTEMS

PART 1 GENERAL

1.1 BACKGROUND

1.2 DESCRIPTION OF WORK

1.2.1 Existing Equipment - Oil Disposal

1.3 REFERENCES

1.4 WORKMANSHIP

1.5 SUBMITTALS

1.6 MATERIAL ORDERS

1.7 WIRE ROPE UNTENSIONING AND RETENSIONING PROCEDURE

1.8 WIRE ROPE LOAD BALANCING PROCEDURE

1.9 COUNTER WEIGHT LOAD BALANCING PROCEDURE

1.10 GEAR ALIGNMENT PROCEDURE

PART 2 PRODUCTS

2.1 DOWNSTREAM GATE HOIST GOVERNMENT FURNISHED PROPERTY (GFP)

2.1.1 Gate Hoist Gearboxes (GFP)

2.1.2 Bearing Lubricant (GFP)

2.1.3 Gearbox Lubricant (GFP)

2.1.4 Open Gear Lubricants (GFP)

2.1.5 Wire Rope Lubricant (GFP)

2.2 MATERIALS, EQUIPMENT AND QUALIFICATIONS

2.3 MATERIALS TO BE SUPPLIED BY THE CONTRACTOR

2.3.1 Pinion

2.3.2 Brake

2.3.2.1 Brake Rating

2.3.2.2 Adjustment

2.3.2.3 AC Drive Motor

2.3.2.4 Terminal Leads

2.3.2.5 Mechanical Construction

2.3.2.6 Designation and Markings

2.3.3 Brake Enclosure

2.3.4 Shaft Couplings

2.3.5 Bearings

2.3.5.1 General

2.3.5.2 Anti-Friction Bearings

2.3.5.3 Pinion Shaft Bearings

2.3.5.4 Downstream Hoist Sheave Bearings

2.3.5.5 Downstream Sheave Bearing Seals

2.3.5.6 Transportation of Bearings

2.3.6 Shafting

2.3.7 Shim Stock

2.3.8 Hardware

2.3.9 Locating Pins/Bolts

2.3.10 Load Cells

2.3.11 Corrosion Preventative Agent

SECTION 35 01 43.00 28

G4EDHCMP

Line

G4EDHCMP

Line

PART 3 EXECUTION

3.1 TOXIC METALS BASED PAINT

3.2 DOCUMENT EXISTING SETUP

3.2.1 Position and Limit Switch Setting Documentation

3.2.2 Sheave Gear Initial Condition

3.3 EQUIPMENT REMOVAL

3.4 GEAR AND SHEAVE CLEANING

3.5 MACHINE WORK FOR MECHANICAL PARTS

3.5.1 Tolerances and General Information

3.5.2 Finished Surfaces

3.5.3 Unfinished Surfaces

3.5.4 Pin Holes

3.5.5 Shafting

3.6 PROTECTION OF FINISHED WORK-MACHINED SURFACES

3.7 INSTALLATION

3.8 HOIST SHEAVE BEARING REPLACEMENT

3.8.1 Lifting the Hoist Sheave

3.8.1.1 Cleaning the Pillow Block

3.8.1.2 Pillow Block Disassembly

3.8.1.3 Jacking or Hoisting the Hoist Sheave

3.8.2 Sheave Bearing Replacement

3.8.2.1 Bearing Removal

3.8.2.2 Shaft Cleaning

3.8.2.3 Shaft Seal Replacement

3.8.2.4 Bearing Installation

3.8.2.5 Alignment

3.8.2.6 Lockwire

3.8.2.7 Rust Prevention

3.8.3 Pillow Block Reassembly

3.8.3.1 Bearing Lubrication

3.9 OPEN GEAR ALIGNMENT

3.9.1 General

3.9.2 Gear Alignment Criteria

3.9.2.1 Working Load

3.10 SHAFT ALIGNMENT

3.11 BRAKE SYSTEM SETUP

3.12 DYNAMIC BALANCING OF MACHINERY

3.13 GEAR LUBRICATION

3.13.1 Gearbox

3.13.2 Open Gear Set

3.14 POSITION AND LIMIT SETTING

3.15 TENSIONING PROCEDURES

3.15.1 Wire Rope Lubrication

3.15.2 Load Cell Terminations

3.15.3 Testing Personnel

3.15.4 Monitoring Equipment

3.15.5 Transferring Counterweight Load Back to Hoist

3.15.6 Gear Alignment at Working Load

3.15.6.1 Realignment

3.15.7 Wire Rope Load Balancing

3.15.7.1 Bolt Length Adjustment

3.15.7.2 Initial Rope Tensioning

3.15.7.3 Preliminary Balance

3.15.7.4 Counterweight Balancing

3.15.7.5 Final Tensioning

3.15.8 Load Balancing Report

3.16 ALIGNMENT AFTER BALANCING

3.16.1 Gear Realignment

SECTION 35 01 43.00 28

3.16.2 Pinion Bearing Base Location

-- End of Section Table of Contents --

This page intentionally left blank

SECTION 35 01 43.00 28

VERTICAL LIFT GATE SYSTEMS

PART 1 GENERAL

1.1 BACKGROUND

The downstream lock gate is a counterbalanced vertical lift gate which is operated by hydraulically powered hoists. The gate is connected to two counterweights with multiple strands of wire rope. The wire rope passes over the uppermost surface of the hoist sheave. The two hoist sheaves support the cumulative weight of the gate, the counterweight, and the hoist ropes.

1.2 DESCRIPTION OF WORK

Under this contract, the Contractor shall replace the hoist machinery serving the downstream navigation lock gate. Old hoist mechanisms and their associated electrical equipment will be removed and new machinery, supports, and controls will be installed per drawings and specifications.

1.2.1 Existing Equipment - Oil Disposal

a. Existing Gear Boxes to be removed are filled with AGMA 5EP lubricating oil. Each gear box contains approximately 96 gallons of oil. Hydraulic Power Units (HPUs) contain approximately 100 gallons of Chevron Rando HD ISO 32 Hydraulic Oil, each.

b. Drain, package, and label oil, and hydraulic fluid from existing equipment in accordance with Section 01 57 20.00 28 ENVIRONMENTAL PROTECTION. See paragraph "Other Regulated Waste Disposal" for additional information. Used oil, and hydraulic fluid shall be turned over to the Government for disposal. Government will provide Product data and MSDS information to the Contractor, as requested.

1.3 REFERENCES

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

AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)

ABMA 8.2 (1999) Ball and Roller Bearing Mounting Accessories, Inch Design

ABMA 19.1 (1987; R 1999) Tapered Roller Bearings - Radial Metric Design

ABMA 19.2 (1994; R 1999) Tapered Roller Bearings - Radial Inch Design

ABMA 20 (1996) Radial Bearings of Ball, Cylindrical Roller and Spherical Roller Types Metric Design

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

ANSI/AGMA 2015-1 (2001A; R 2014) Accuracy Classification System - Tangential Measurements for Cylindrical Gears

ASME INTERNATIONAL (ASME)

ASME B4.1 (1967; R 2004) Preferred Limits and Fits for Cylindrical Parts

ASME B18.8.2 (2000) Taper Pins, Dowel Pins, Straight Pins, Grooved Pins, and Spring Pins

ASME B46.1 (2002) Surface Texture (Surface Roughness, Waviness and Lay)

ASTM INTERNATIONAL (ASTM)

ASTM A29/A29M (2011a) Standard Specification for Steel Bars, Carbon and Alloy, Hot-Wrought General Requirements for

ASTM A325 (2014) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM E709 (2014) Standard Guide for Magnetic Particle Examination

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 5753 Rolling Bearings - Radial Internal Clearance Second Edition

U.S GENERAL SERVICES ADMINISTRATION (GSA)

MIL-PRF-16173E Corrosion Preventative Compound, Solvent Cutback, Cold-Application

MIL-PRF-18458C Grease, Wire Rope-Exposed Gear

1.4 WORKMANSHIP

All work shall be completed in a thorough and workmanlike manner and shall conform to the best modern practice in the class of work regardless of any omission in the drawings and specifications.

1.5 SUBMITTALS

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

submittals having an "I" designation are for information only. When used, a designation following the "G" or "I" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

SECTION 35 01 43.00 28

Material Orders; I, ME

Load Cells; G, ME

Wire Rope Untensioning and Retensioning Procedure; G, ME

Wire Rope Load Balancing Procedure; G, ME

Counterweight Load Balancing Procedure; G, ME

Gear Alignment Procedure; G, ME

Testing Personnel; G, ME

SD-02 Shop Drawings

Pinion; G, ME

Pinion Shaft; G, ME

SD-03 Product Data

Brake; G, ME

Brake Enclosure; G, ME

Shaft Couplings; G, ME

Sheave Bearings; G, ME

Sheave Bearing Seals; G, ME

Pinion Bearings; G, ME

AC Drive Motor; G, EL

SD-06 Test Reports

Sheave Gear Initial Condition Report; I, ME

Initial Position and Overtravel Limit report; I, ME

Sheave Bearing Installation Measurements Report; G, ME

Load Balancing Report; G, ME

Shaft Alignment Report; G, ME

Dynamic Balancing Report; G, ME

Gear Alignment Report; G, ME

1.6 MATERIAL ORDERS

Submit material orders all appurtenant items that demonstrate purchased materials are in compliance with appropriate specifications. Product submittals shall include, but are not limited to:

a. Brake - Submit for approval detailed descriptive data covering the brake, with necessary cuts, photographs, and drawings to indicate clearly the construction of the brake and the materials used, Releasing device specifications and characteristics, and adjustments.

b. Brake Enclosure - Submit for approval dimensioned outline drawings showing specific relationships and clearances between equipment and there component parts.

c. Shaft Couplings - Submit for approval manufacture information for the motor shaft and pinion couplings.

d. Sheave Bearings - Submit for approval manufacture information for the sheave bearings.

e. Sheave Bearing Seals - Submit for approval manufacture information for the sheave bearing seals.

f. Pinion Bearings - Submit for approval manufacture information for the pinion bearings.

1.7 WIRE ROPE UNTENSIONING AND RETENSIONING PROCEDURE

Prior to performing any work on the hoist sheaves, bearings, or wire rope assemblies, the Contractor shall submit for approval a wire rope untensioning and retentioning procedure. The plan shall be prepared and stamped by a Professional engineer. The hoist wire ropes shall be untensioned by lowering the lock gate until it rests on the gate sill or other support. Government personnel will perform all gate operations. The Government's counterweight support beams shall be drawn, by the Contractor, through the lower openings in the counterweight. The counterweight shall be jacked, with Contractor furnished jacks and fixtures, until the wire ropes are no longer under tension due to the weight of the gate or counterweight.

The Contractor shall be prepared to lift the downstream gate counterweight up to twenty inches. The wire ropes shall be lifted a few inches off the drum and protected from heat and sparks during sheave welding operations.

The nuts on the counterweight rope sockets may be backed off to facilitate adding slack to the ropes. The drum shall be free to rotate for drum repair work. Included with the procedure shall be drawings and calculations for items used in the process. Each counterweight weighs approximately 360 tons. Load distributions of the support locations should be a consideration. As a minimum the procedure shall address:

1. The procedure shall consider jack locations, number of jacks, lift of jacks, stability of support beam, beam stresses through all stages, stability of jacks, plans for contractor supplied sheave support fixture, and the stability of any other materials used during the untensioning and retensioning procedure.

2. The jacking method of the counterweight shall be explicitly discussed. The method shall consider even jack rate across all jacks utilized. The method shall also guard against tipping and rotation of jacks, beams and any other supporting members.

3. The return of weight of the counter weight and ropes to the sheave in a safe and controlled manner to avoid overloading load cells or ropes.

4. The method for proper alignment of the wire ropes, their counterweight and gate connections, and the hoist sheave grooves while the counterweight load is returned to the sheave.

5. In addition include the jacking method for the sheave (112 Kips) during sheave bearing replacement. The method shall consider jack locations, number of jacks, lift of jacks, stability of jacks, plans for contractor supplied sheave support fixture, and the stability of any other materials used during sheave bearing replacement. The method shall consider even jack rate across all jacks utilized. The method shall also guard against tipping and rotation of jacks, fixtures, and any other supporting members.

1.8 WIRE ROPE LOAD BALANCING PROCEDURE

The contractor shall submit for approval a wire rope load balancing procedure, 90 calendar days prior to lock outage. Included in the procedure shall be the method for ensuring ropes are not overloaded, tools used for tightening bolts for length adjustment, the retensioning of the wire rope and removal of support beams, and the necessary steps of the testing procedure.

1.9 COUNTER WEIGHT LOAD BALANCING PROCEDURE

The contractor shall submit for approval a counterweight load balancing procedure 90 calendar days prior to lock outage. Included in the procedure shall be the method for determining the counterweights weigh half of the gate weight. This procedure must be prepared and stamped by a professional engineer. The wire rope load balancing testing personnel may be able to assist with counterweight balancing options.

1.10 GEAR ALIGNMENT PROCEDURE

Submit gear alignment procedure including calculations to determine deflection at working load so that at working load the gear alignment meets the alignment criteria specified in Part 3 of this section, paragraph entitled Gear Alignment Criteria. Submit gear alignment procedure for approval, 90 calendar days prior to lock outage.

PART 2 PRODUCTS

2.1 DOWNSTREAM GATE HOIST GOVERNMENT FURNISHED PROPERTY (GFP)

Materials that are supplied by the government are denoted with a GFP. The ensuing specifications are for informational purposes only. All materials are stored in maintenance buildings on site at Lower Monumental Lock and Dam. The contractor will be responsible for all efforts required to load, transport, and unload materials at the navigation lock towers.

2.1.1 Gate Hoist Gearboxes (GFP)

Four gearboxes have been obtained for this project. Two will be used and two will remain as spares. Gearboxes utilize a through shaft design for both the input and output shaft to eliminate the need for specific right and left gearboxes. Gearboxes supplied by the government have been load tested and have met all pre-installation criteria. Gearboxes are Brad Foote Gear Works ZT400, serial number 20132-x, where x is the unique identifier digit. The reduction ratio is 195:1 at a rating of 81 hp at

1170 RPM.

2.1.2 Bearing Lubricant (GFP)

Bearings shall be packed with Government-furnished, Chevron Ultra Duty Grease EP NLGI 2 lubricant.

2.1.3 Gearbox Lubricant (GFP)

Gearboxes shall be filled with Government-furnished Chevron Meropa ISO 150, AGMA 4EP type lubrication.

2.1.4 Open Gear Lubricants (GFP)

Open gear set shall be lubricated using Government-furnished Royal Purple brand Open Gear Guard XP type gear lubricant.

2.1.5 Wire Rope Lubricant (GFP)

Government-furnished lubricants shall be used for the wire rope, Kirkpatrick Dynaguard Blue for external cable lubrication.

2.2 MATERIALS, EQUIPMENT AND QUALIFICATIONS

Materials and equipment shall be the standard products of a manufacturer regularly engaged in the manufacturing of such products, which are of a similar material, design and workmanship. The standard products shall have been in satisfactory commercial or industrial use for at least two years prior to bid opening. The two-year use shall include applications of equipment and materials under similar circumstances and of similar size.

The two years experience shall be satisfactorily completed by a product that has been sold or is offered for sale on the commercial market through advertisements, manufacturer's catalogs, or brochures. Products having less than a two-year field service record may be acceptable if a certified record of satisfactory field operation, for not less than 6,000 hours exclusive of the manufacturer's factory tests, can be shown. All products shall be supported by a service organization that is able to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract. Materials, appurtenances, and equipment supplied as part of this contract shall be new and unused except for testing equipment or as indicated otherwise. Components that serve the same function and are the same size shall be identical products of the same manufacturer.

2.3 MATERIALS TO BE SUPPLIED BY THE CONTRACTOR

2.3.1 Pinion

a. The pinion gear shall be fabricated, as shown in the drawings, out of AISI 4340-HT alloy steel normalized and tempered to achieve a minimum yield strength of 135,000 psi and a Brinell Hardness of between 321 and 363.

b. Forging shall be inspected by magnetic particle examination per ASTM E709 prior to machining. Machined gears shall be inspected in accordance with Grade A-7, ANSI/AGMA 2015-1-A01 Section 7.

The pinion shall be fabricated as shown in the drawings out of 4340 HT, AGMA grade 2, alloy steel. Forging shall be inspected by magnetic particle examination per ASTM E 709 prior to machining. Pinion gears shall be inspected, measuring methods shall be in accordance with ANSI/AGMA

SECTION 35 01 43.00 28

2015-1-A01 Section 4.3 and tolerances shall be in accordance with ANSI/AGMA 2015-1-A01 Section 7.

2.3.2 Brake

Brakes must have a torque rating of between 100 lb-ft and 200 lb-ft, actuate on power failure, and have a manual release. Brakes also must be completely enclosed in a watertight, dust tight enclosing case. Brakes independent of the motor must meet the above requirements in addition to the following: AC hydraulic actuator type, spring set, with AC hydraulic pump, and hydraulic operated release.

2.3.2.1 Brake Rating

The brake shall have a torque rating not less than 100 lb-ft as seen in the gearbox input shaft. The torque rating shall be based on open construction, 1-hour duty.

2.3.2.2 Adjustment

Means shall be provided for varying torque required for holding. The brake shall have automatic means of adjusting the position of the shoes to compensate for wear. Additionally the brake shall have adjustable reaction time to allow for smooth brake application.

2.3.2.3 AC Drive Motor

The AC drive motor shall be 20 hp, of 4 pole, 3 phase squirrel cage design, suitable for operation on three phase, 480 V, 60-Hz, AC electrical power.

The AC drive motor shall be compatible with the VFD driving the motor and be inverter duty rated with service factor of 1.15. The complete unit shall be suitable for connection to the control circuit or the power circuit of the motor with which the brake is used so that the brake will set or release when the motor is deenergized or energized, respectively.

2.3.2.4 Terminal Leads

Connecting leads from the AC drive motor shall be extended outside the enclosing case and shall be terminated on the terminal block located in a watertight terminal box, which shall be rigidly bolted or equally secured to and on the outside of the lower or fixed half of the enclosing case. The terminal box shall provide for conduit entrances on four sides. All conduit entrances to the brake terminal box shall be threaded. The leads inside the brake enclosing case shall be suitably protected.

2.3.2.5 Mechanical Construction

Except for brake wheels, shoes, and electrical parts, no cast iron shall be used in brake construction. All pins, fittings, and other miscellaneous small metal parts shall be of approved corrosion-resisting metal or shall be treated to render them corrosion-resistant as required by paragraph CORROSION PREVENTION AND FINISH PAINTING. Bearings shall be fitted with bronze or other approved bushings to prevent any binding of moving parts.

Approved antifriction bearings of corrosion-resisting construction may be used. Approved means for lubrication shall be provided for all bearings, unless bearings are of an approved self-or prelubricated type. The machine work shall conform to the requirements for the motor with which the brake is used.

SECTION 35 01 43.00 28

2.3.2.6 Designation and Markings

A nameplate of suitable corrosion-resisting material shall be provided and attached to a part of the brake which ordinarily will not be renewed during its service life. The nameplate shall conform to standard practice and clearly indicate the manufacturer's name, identification symbols, serial number, and salient design features such as type, frame, torque, rating, voltage, phase, and frequency. If adjustment is required, pertinent information for making the adjustment is necessary.

2.3.3 Brake Enclosure

The outdoor NEMA Type 4-watertight enclosing case shall be in accordance with the manufacturer's standard practice for the conditions indicated. In order that the brake mechanism will be accessible from above, when the upper half or cover of the enclosing case is removed, the enclosing case shall be constructed to give equal accessibility to all portions of the brake. The joint between the two halves shall be made with a synthetic rubber gasket, not less than 1/4 inch in width, and held in place by embedding in a groove or by other equally effective means. For those applications where the brake wheel is mounted on a shaft extension on the front end of the motor, the enclosing case shall be arranged to permit bolting to the bearing housing of the motor, the joint being made watertight with a gasket. For those applications where the brake wheel is mounted on a shaft of the operating machine or on a flange and shaft extension on the front end of the motor, suitable watertight seals shall be provided on each part of the housing. The shaft seals shall be arranged for pressure lubrication and shall be adjustable for alignment relative to the shaft. An automatic drain breather, located in a protected location, shall be provided in the lower part of the enclosing case. If the drain breather cannot be located in a protected location, the tapped hole shall be plugged and the drain furnished separately for installation in the field. The enclosing case shall be treated to render the steel resistant to corrosion.

2.3.4 Shaft Couplings

Couplings shall be capable of developing the full strength of the shafting which they connect and shall be pressed and keyed thereon.

The pinion coupling shall be a flex grid coupling with a minimum torque rating of 350 kip-in. The pinion coupling shall be keyed to the 7-1/2" gearbox shaft and the 7-1/4" pinion shaft.

The motor coupling shall be a flex grid coupling with a minimum torque rating of 8 kip-in. The coupling shall be keyed to the 2-1/8" gearbox input shaft and the shaft of the motor selected.

The absolute gate position encoder coupling shall be a flex grid coupling keyed to the 1/2" encoder shaft on one side and the 1-1/4" location indicator drum shaft on the other side.

Brake wheels shall not be used in lieu of couplings. Guards of expanded metal shall be provided for all couplings and adjacent rotating shafts, if existing guards do not exist. Guards shall provide for ease of access for maintenance. Application of couplings shall be in accordance with manufacturers recommended practice unless otherwise noted herein.

2.3.5 Bearings

2.3.5.1 General

Bearings shall be so designed as to be easily replaceable and shall be placed as close as shown in the plans. Where feasible, bearing bases for gear trains shall be made in one piece to ensure that alignment and spacing will be maintained. Where welded construction is employed for bearing housing assemblies or pedestals, the weldments shall be stress relieved.

Bearing fits shall be as recommended by the manufacturer for the application. Bearing bases and pillow blocks shall have solid bases and shall be held securely in place by one of the following methods:

a. Fitted bolts installed with plain washers and double nuts.

b. Machine bolts and dowels. The dowels shall be of such size as to adequately locate the device and resist the total shearing forces.

c. Shear blocks at both sides of the bearing with welds adequately sized to resist shear.

Pillow blocks with hollow bases will not be allowed.

2.3.5.2 Anti-Friction Bearings

Anti-friction bearings shall be of standard types most suitable for the respective application and shall have both inner and outer races. Ball and roller bearings shall conform to the applicable requirements of the ABMA 19.1, ABMA 19.2 and ABMA 20. The manufacturer's published ratings shall be used in determining the bearing capacity. Fixed bearings shall be secured against a shaft shoulder by means of a locknut and bearing lockwasher as described in ABMA 8.2. Floating bearings shall be secured against a shaft shoulder by means of a retaining ring or locknut and lockwasher, except that floating bearings at intermediate points on shafts may be secured with a tapered sleeve and locknut and lockwasher. Bearings, except as noted below, shall have a L-10 life of 5,000 hours.

2.3.5.3 Pinion Shaft Bearings

The pinion shaft bearings shall be SKF 23036/W33 spherical roller bearings, or approved equal, in a pillow block housing with the following characteristics: Accommodate a 7.00" to 7.23" dia shaft, cast steel housing, triple ring seals. Bearings shall have a load rating of 163 kips (dynamic) and 281 kips (static). Two per pinion and two spares for a total of 6 bearings.

2.3.5.4 Downstream Hoist Sheave Bearings

The downstream hoist sheave bearings shall be SKF, part no.

23088KYMBW507C08C3, for compatibility with existing pillow block. Two per sheave and two spares for a total of 6 sheave bearings.

2.3.5.5 Downstream Sheave Bearing Seals

The four downstream gate hoist bearing seals shall be furnished by the Contractor and shall be SKF, Part No. B-8815-23. One complete set for each sheave bearing for a total of 6 sets of seals, 4 sets to be used with the replacement bearings and 2 spare sets of seals.

2.3.5.6 Transportation of Bearings

Bearings shall not be loaded during transport. If bearings are mounted on shafts, the bearings shall not be used to support or stabilize shafts during transportation.

2.3.6 Shafting

The pinion shaft shall be fabricated in accordance with the drawings from AISI 4340 HT alloy steel conforming to ASTM A29/A29M 4340 with a minimum yield strength of 100-110 ksi. Provide and install two (2) pinion shafts.

2.3.7 Shim Stock

Shim stock, as necessary for vertical alignment, is to be located beneath the bearing pillow block, below the mounting bracket connecting the motor and bearing, beneath the brake, and beneath the gearbox.

2.3.8 Hardware

All mounting hardware shall be high strength. Bolts are to conform to ASTM A325 Type 1 or better. All nuts shall be equipped with washers and jam nuts.

2.3.9 Locating Pins/Bolts

All locating pins/bolts setting final locations shall be replaced.

2.3.10 Load Cells

The contractor shall supply ten Geokon 4900x-60-3 type load cells. It is imperative that the the load cells supplied match the existing load cells installed (qty 48). Each set of load cells consists of an annealed copper washer, spherical bearing, bearing plate, and a load cell. The cells have a 3-inch inside diameter. The cells are approximately 5 inches tall. The load cell bodies are made from an annulus of high strength steel in which vibrating wire strain gages are embedded; 3-6 strain gages are used to minimize the effects of off-center loading. "Or equal" submissions will not be accepted. The load cells shall be onsite prior to the hoist rope removal. The load cells shall be equipped with Bendix PT06F-12-10P terminations.

2.3.11 Corrosion Preventative Agent

The contractor shall provide corrosion preventative agent meeting or exceeding MIL-PRF-16173E GR1.

PART 3 EXECUTION

3.1 TOXIC METALS BASED PAINT

The existing paint system has a primer containing Toxic Metals Based Paint. Rehabilitation activities likely to disturb the existing paint shall be performed in compliance with the provisions of SECTION 02 83 33.13 28 TOXIC METALS BASED PAINT REMOVAL AND DISPOSAL. Equipment and bases shall be painted per SECTION 09 97 02.00 28 PAINTING, and as indicated on the drawings.

3.2 DOCUMENT EXISTING SETUP

Contractor shall document existing setup and conditions specified below.

3.2.1 Position and Limit Switch Setting Documentation

The gate control system relies on two types of limits, positional control limits and overtravel limits. The positional limits consist of drums wound with 1/8" and 3/16" diameter wire ropes connected to the gate and counterweight. For each current limit the contractor shall use a laser measurement tool or some other appropriate tool to measure the gate height in two locations on the gate, one on the North side and one on the South side near the wire rope attachment locations. For the overtravel limits the contractor shall also document the position of the baskets which engage the weighted limit. The contractor shall verify that the baskets are at the same elevation on the ropes when re-installed. The contractor shall notify the government a minimum of three days before the documenting of limit positions. A government representative may be on hand to verify all measurements and positions. Contractor shall submit the Initial Position and Overtravel Limit report within 14 days of wire rope unloading

3.2.2 Sheave Gear Initial Condition

Contractor shall document which tooth starts and stops the hoist cycle.

Teeth are identified by stamped numbers on each tooth. The contractor shall also document the wire rope location on the sheave to facilitate returning each wire rope to its original grove on the sheave. The vertical alignment of the ring gear shall be documented to facilitate realignment after bearing replacement. Contractor shall include this information in the sheave gear initial condition report within 14 days of wire rope unloading.

3.3 EQUIPMENT REMOVAL

When the wire ropes have been unloaded per the approved procedure, the contractor shall drain gearboxes and hydraulic power unit of oil and dispose of in a legal manner. The contractor shall remove the hydraulic power unit, hydraulic motor, sheave bearing, brake, and gearbox. The removed hydraulic power unit and hydraulic motor are to be turned over to the government personnel. The components shall be removed in such a manner that will not damage the base metal. Areas where components are removed shall be ground smooth with base material. The removed sheave bearings, brakes, and gearboxes shall become the property of the contractor.

3.4 GEAR AND SHEAVE CLEANING

The Contractor shall clean the surface of the hoist sheave and drum spur gear removing old lubricant from all surfaces. The Contractor shall select a cleaning method which will not mar the sheave. The Contactor shall contain and dispose of all debris, cleaning tools, materials and solvents in a safe and legal manner.

After cleaning, the contractor shall visually inspect teeth, both sides for damage. Teeth with significant damage shall be recorded in reference to the starting position using stamped numbers. The intent of recording tooth condition is to rotate the drum upon new equipment installation and locate the teeth that are in the best condition relative to the locations throughout the lift/lower cycle of highest loading. Inspection results shall be included in the sheave gear initial condition report along with vertical alignment measurements and any recommendations for fitness for service. Contractor shall submit the sheave gear initial condition report within 14 days of wire rope unloading.

3.5 MACHINE WORK FOR MECHANICAL PARTS

3.5.1 Tolerances and General Information

Tolerances, allowances and gages for metal fits between plain,non-threaded, cylindrical parts shall conform to ASME B4.1 for the class of fit shown or to the dimensions shown. Tolerances for machine-finished surfaces designated by non-decimal dimensions shall be within 1/64-inch unless otherwise specified. Tolerances for machine-finished surfaces designated by decimal dimensions shall be as follows, unless otherwise specified or shown on the contract or reference drawings. Note that these tolerances are for general machine work for non-critical components.

1 place....... +/- 0.030 2 places...... +/- 0.010 3 places...... +/- 0.001 Sufficient excess material stock shall be allowed on surfaces requiring machining to ensure true surfaces of solid material while maintaining the specified minimum or finished plate thickness. Finished contact or bearing surfaces shall be true and exact to secure full contact. All surfaces shall be finished in accordance with the contract drawings to ensure proper operation when assembled. Parts shall be accurately machined and all like parts shall be interchangeable. All drilled bolt holes shall be accurately located to ensure interchangeability.

3.5.2 Finished Surfaces

Surface finishes as indicated or specified shall be in accordance with ASME B46.1. Values of required roughness heights are arithmetical average deviations expressed in micro inches. These values are maximum. Lesser degrees will be satisfactory unless otherwise indicated. Compliance with surface requirements shall be determined by sense of feel and visual inspection of the work compared to Roughness Comparison Specimens in accordance with the provisions of ASME B46.1. Values of roughness width and waviness height shall be consistent with the general type of finish specified by roughness height. Where the finish is not indicated or specified it shall be that which is most suitable for the particular surface, provide the class of fit required and shall be indicated on the shop drawings by a symbol which conforms to ASME B46.1 when machine finishing is provided. Flaws such as scratches, ridges, holes, peaks, cracks or checks which will make the part unsuitable for the intended use will be cause for rejection.

3.5.3 Unfinished Surfaces

All work shall be laid out to secure proper matching of adjoining unfinished surfaces unless otherwise directed. Where there is a discrepancy between adjoining unfinished surfaces they shall be ground smooth or machined to secure proper alignment. Unfinished surfaces shall be true to the lines and dimensions shown and shall be ground free of all projections and rough spots. Depressions or holes not affecting the strength or usefulness of the parts shall be filled in using an approved method.

3.5.4 Pin Holes

Pin holes shall be bored in accordance with the dimensions and tolerances shown or noted.

3.5.5 Shafting

All shafting shall be as shown or noted. Fillets shall be provided where changes in section occur. Cold-finished shafting may be used where keyseating or grinding are the only machine work required.

3.6 PROTECTION OF FINISHED WORK-MACHINED SURFACES

Machined surfaces shall be thoroughly cleaned of foreign matter. All finished surfaces shall be protected by suitable means. Finished surfaces of ferrous metals to be in bolted contact shall be washed with an approved rust inhibitor and coated with an approved rust resisting compound for temporary protection during fabrication, shipping and storage periods.

Unassembled pins and bolts shall be oiled and wrapped with moisture resistant paper or protected by other approved means.

3.7 INSTALLATION

The contractor is responsible for all labor, materials, and equipment required for installing replacement drive system for the downstream gate.

The contractor shall rotate the hoist sheaves to the locations determined by USACE. The rotation will be based on the gear tooth inspections discussed previously. The contractor shall provide and install the pinion shaft, gear and bearings. The contractor shall install the government furnished gearboxes and pinion shaft couplings. The gearboxes will come completely assembled. The contractor shall install all components between the electric motor brake and the high speed input shaft. The contractor shall also install the service brake on the input shaft on the opposite side of the gearbox from the motor.

3.8 HOIST SHEAVE BEARING REPLACEMENT

After sheave weld repairs are complete, the Contractor shall remove the hoist sheave bearings and replace with new bearings. All hoist shaft seals at the downstream gates shall be replaced. The replacement bearings and the seals shall be furnished by the Contractor.

3.8.1 Lifting the Hoist Sheave

To allow for bearing replacement, the hoist sheave shall be lifted to remove the load from the bearing, as follows.

3.8.1.1 Cleaning the Pillow Block

The Contractor shall remove residual bearing and wire rope lubricant from the pillow blocks and the shaft in close proximity to the pillow blocks prior to disassembling the pillow blocks.

3.8.1.2 Pillow Block Disassembly

The pillow blocks shall be disassembled in place. The Contractor shall remove the upper half of the pillow block housings permitting free vertical movement of the bearing. Both pillow blocks shall be disassembled prior to hoisting or jacking the gate sheave for bearing removal to prevent damage to the bearings, shaft, or pillow block housing.

3.8.1.3 Jacking or Hoisting the Hoist Sheave

The hoist sheave shall be jacked or hoisted until the outer bearing races are clear of the pillow block housings. Previously a cushioned saddle was used to remove and replace one bearing at a time. The Contractor shall submit jacking fixture drawings in the Wire Rope Untensioning and Retensioning Procedure submittal. The Contractor is responsible for protecting the sheave grooves and gear teeth from damage while supported by jacks or hoists. All damage to the hoist sheave resulting from jacking or hoisting shall be repaired by the Contractor at no additional cost to the Government.

3.8.2 Sheave Bearing Replacement

3.8.2.1 Bearing Removal

The contractor shall remove the hoist sheave bearing utilizing the hydraulic bearing removal system incorporated into the hoist shaft. The contractor shall provide all piping, fittings, pumps, and valves necessary to utilize the hydraulic bearing removal system. If necessary, constant axial loading may be applied to the inner bearing race while the hydraulic bearing removal system is pressurized. Any galling or scoring of the shaft due to forced removal of the bearing by means other than the hydraulic system shall be repaired at no additional cost to the Government.

3.8.2.2 Shaft Cleaning

The Contractor shall clean shaft surfaces which will be in contact with the bearings or seals. The Contractor shall use soft rags and solvents to remove old lubricant and dirt. Any scoring of the machined surface that may result in reduced effectiveness of the hydraulic bearing removal system shall be reported to the Contracting Officer.

3.8.2.3 Shaft Seal Replacement

The Contractor shall replace the shaft seals on all pillow block housings.

3.8.2.4 Bearing Installation

The bearings are spherical roller bearings with tapered bore and shall be mounted directly on the shaft. The bearings shall remain wrapped and kept clean until they are needed for installation. Shaft surfaces on which the bearings will be mounted shall be clean and free of nicks or burrs. Shaft tapers and bearing housings for fixed bearings shall have surface finishes of 125 RMS or better on all surfaces directly in contact with the bearing.

The shafts shall be lightly lubricated with machine oil prior to installation of the bearings. The Contractor shall measure the radial internal clearance (RIC) of each bearing prior to installation. Reference the bearing manufacturer's literature to determine the correct procedure for measuring RIC. If no procedure is available the Contractor shall utilize ISO 5753. The RIC shall be measured periodically as the interference fit is increased during bearing installation. The Contractor shall not exceed the manufacturer's recommended reduction of RIC and the installed RIC shall be greater than or equal to the minimum recommended RIC. The Contractor will be required to remove and reinstall the bearings at no additional cost to the Government if these criteria are not met.

Contractor shall submit the radial internal clearance measurement report.

The radial internal clearance measurement report including the initial and installed RIC for each bearing replaced shall be included in the sheave bearing installation measurements report and also in the functional test data portion of the Operations and Maintenance Manual. See SECTION 01 78 23.00 28 OPERATION AND MAINTENANCE DATA: Testing and Performance Data.

3.8.2.5 Alignment

During the installation process the Contractor shall keep the face of the inner bearing race perpendicular to the longitudinal axis of the shaft to within 0.050 inches. Final alignment of the inner bearing race shall be within 0.0020 inch of perpendicular for downstream gate hoist bearings.

Vertical alignment of ring gear shall be held to original condition or better. If shimming is required under the lower pillow block housing replace existing shims with new shims as necessary. Sheave bearing alignment measurements and ring gear vertical alignment measurements shall be included in the sheave bearing installation measurements report which shall be submitted within 14 days of sheave bearing installation.

3.8.2.6 Lockwire

The Contractor shall secure all lock plate cap screws with lockwire upon completion of the bearing installation and alignment.

3.8.2.7 Rust Prevention

The contractor shall coat all machined surfaces with a Contractor provided rust prevention agent prior to replacing the upper half of the bearing housing. The rust preventative agent shall meet or exceed MIL-PRF-16173E

GR1.

3.8.3 Pillow Block Reassembly

The contractor shall reassemble the pillow blocks in reverse order of disassembly.

3.8.3.1 Bearing Lubrication

The Contractor shall insure all bearings are clean and packed with Government provided DY 75 lubricant. The downstream gate bearings require approximately five (5)gallons of lubricant per bearing.

3.9 OPEN GEAR ALIGNMENT

3.9.1 General

The sheave gears and pinions (open gearing) shall be aligned to the criteria listed below. Alignment shall be checked at working load.

3.9.2 Gear Alignment Criteria

The gears shall be aligned so that there is a minimum of at least 85 percent tooth contact across the tooth faces at working load. The contact pattern shall be considered an area indicating a consistent length and depth of the tooth pattern (i.e. a rectangle). For reference gear center to center distance is 119.58 inches.

3.9.2.1 Working Load

Working load shall be taken as the maximum load experienced by the drive system during a lock cycle of opening and closing the gate. For initial calculations the counter weights each weigh 360 tons and gate weighs 720 tons approximately and the acceleration ramp shall be taken as 0.01 ft/s^2.

3.10 SHAFT ALIGNMENT

Shaft alignment of motors, gearboxes, shafting, and pinion shafts shall be made using a laser system and documented. After final alignment has been made, a shaft alignment report shall be prepared and submitted and shall include identification of shafts being aligned, readings for the four (4) alignment parameters; vertical and horizontal, angularity and offset.

Verification checks shall be made when directed by the Contracting Officer.

Shims under 0.200 inches thick shall be pre-stamped stainless steel shims.

Tolerances for the motor and gearbox alignment shall be 0.5 mil for offset misalignment and 0.2 mil/inch for angular misalignment. Tolerances for gearboxes floating shafts shall be 2.0 mils for offset misalignment and 0.8 mil/inch for angular misalignment. The tolerances for the gearbox to pinion shaft alignment shall be 0.5 mil for offset misalignment and 0.2 mil/inch for angular misalignment. The shaft alignment report shall be included in the functional test data portion of the Operations and Maintenance Manual.

See SECTION 01 78 23.00 28 OPERATION AND MAINTENANCE DATA: Testing and Performance Data.

3.11 BRAKE SYSTEM SETUP

The brake wheels shall be mounted to shafts as shown in the plans and aligned to remaining brake assembly per manufacturers recommendations.

Brakes shall be adjusted to the torque settings requested by the government. Calculations indicate this value to be 100 ft*lb.

3.12 DYNAMIC BALANCING OF MACHINERY

Perform dynamic balancing of the hoist motors and the gearbox input shafts with the brake wheels and couplings installed.

a. Record initial dynamic balance analysis data, including vibration velocity and vibration displacement at rated motor rpm for the drives and also at twice the rated motor rpm for the main hoists.

b. Identify and quantify unbalance and make corrections as necessary to obtain balance quality grade of ISO 1940 G 2.5.

c. Record final dynamic balance analysis data, including vibration velocity and vibration displacement at rated motor rpm for the drives and also at twice the rated motor rpm for the main hoists.

Submit dynamic balancing report. The dynamic balancing report shall be included in the functional test data portion of the Operations and Maintenance Manual. See SECTION 01 78 23.00 28 OPERATION AND MAINTENANCE DATA: Testing and Performance Data.

3.13 GEAR LUBRICATION

3.13.1 Gearbox

After gearbox installation, the contractor shall completely fill the gearboxes with Government-furnished AGMA 5EP type lubrication.

3.13.2 Open Gear Set

All open gearing shall be lubricated with Government provided Royal Purple brand Open Gear Guard XP type gear lubricant.

3.14 POSITION AND LIMIT SETTING

The contractor shall install as necessary the wire rope, tensioning hardware, and connecting hardware on the counterweight and gate. Once installed the limit switches and controls shall be adjusted to maintain the starts, stops and distance of travel that originally existed. The contractor shall provide a 5 hour window for Lower Monumental personnel to verify the setup of the controls and limit switches. The contractor shall notify the government of the inspection window a minimum of 3 working days prior to the inspection window.

3.15 TENSIONING PROCEDURES

3.15.1 Wire Rope Lubrication

Prior to wire rope load balancing, the exterior surface of the ropes shall be cleaned, then lubricated with GFP lubricants. Clean and lubricate the entire length of the wire rope from the counter weight connection to the gate connection. Ropes shall be cleaned with a wire brush and petroleum solvent or steam cleaning. All wire ropes shall be lubricated with the Government provided Kirkpatrick wire rope lubricating system, including a jumbo JUL low viscosity lubrication collar kit (Kirkpatrick part number 9111-JL) for the application of low viscosity penetrating lubricant into the wire rope strands under high pressure. The Government will furnish Kirkpatrick Dynaguard "E" lubricant in sufficient quantity to lubricate all wire ropes. The Contractor shall purchase ten (10) groover kits, Kirkpatrick part number GR214RL, for use while cleaning the wire ropes.

All unused groovers shall be turned over to the Government upon completion of contract work. The wire ropes shall be installed in the same order and with the same connection locations as prior to contract work. After installation, the exterior surface of the ropes shall be re-lubricated with Government provided Kirkpatrick Dynaguard Blue lubricant in accordance with manufacturers recommendations. All wire rope lubricants shall conform to MIL-PRF-18458C Type II requirements.