TechSpecs-Amend-0001.pdf

Little Goose Adjustable Spillway Weir (ASW) W912EF-16-R-0001 Amend-0001

SECTION TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

SECTION 01 11 01.00 28

SUPPLEMENTARY REQUIREMENTS

05/31/16

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 FIELD VERIFICATION OF SITE CONDITIONS

1.4 DEFINITIONS

1.5 REGULAR CLEANUP AND DEBRIS DISPOSAL

1.6 GOVERNMENT FURNISHED PROPERTY

1.7 EQUIPMENT LIST

1.8 TESTING OF EQUIPMENT

1.9 DISPOSITION OF REMOVED EQUIPMENT

1.10 PROTECTION AND RESTORATION OF EXISTING FACILITIES

1.10.1 Pre-Work And Post Work Surveys

1.11 FIRE CONTROL

1.12 TRAINING

1.13 PROJECT SUPERINTENDENT

1.14 KEY PERSONNEL SUBSTITUTION

1.15 POST AWARD MEETINGS

1.15.1 Pre-Work Meeting

1.15.2 Pre-Construction Meeting

1.15.2.1 Minutes

1.15.2.2 Demobilizing And Remobilizing

1.16 WEEKLY PRODUCTION MEETINGS

1.16.1 Minutes

1.17 ADDITIONAL MEETINGS

1.18 PARTNERING

1.18.1 General

1.18.2 Partnering Meetings

PART 2 PRODUCTS (Not Used)

PART 3 EXECUTION (Not Used)

ATTACHMENTS:

Weekly Meeting Agenda Template

-- End of Section Table of Contents --

SECTION 01 11 01.00 28

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SECTION 01 11 01.00 28

SUPPLEMENTARY REQUIREMENTS

05/31/16

PART 1 GENERAL

The work covered by this section of the specifications consists of work common to more than one section of these TECHNICAL SPECIFICATIONS.

1.1 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.

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 Safety and Health Requirements Manual

The Contractor shall be responsible for complying with the current edition and all changes posted on the web as of the effective date of this solicitation.

1.2 SUBMITTALS

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

submittals having an "I" designation are for information only.

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

Property Management Plan ; I C

Equipment List ; I C

Pre-Work Survey Photos And Report; I C

Project Superintendent ; I C

SD-07 Certificates

Key Personnel Substitution ; G C

SD-11 Closeout Submittals

Post-Work Survey Photos And Report; I C

Training Manuals ; G C

1.3 FIELD VERIFICATION OF SITE CONDITIONS

The Contractor shall field verify all elevations, dimensions, and coordinates of existing features indicated on the contract drawings that

SECTION 01 11 01.00 28

affect new construction. Any deviations shall be updated as per Section 01 78 00.00 28 , CLOSEOUT SUBMITTALS, paragraph MAINTAIN WORKING AS-BUILT

CONTRACT DRAWINGS AND FIO DRAWINGS.

1.4 DEFINITIONS

a. Qualified Person.

As defined in EM 385-1-1 ; "DEFINITIONS", unless otherwise specified.

1.5 REGULAR CLEANUP AND DEBRIS DISPOSAL

With the exception of materials specifically indicated or specified to be salvaged for reuse in construction, or turned over to the Government, all wastes and demolished materials shall become the property of the Contractor and shall be removed from the job site daily in accordance with Federal, State, and local regulations. The Contractor shall furnish waste containers. All waste containers provided by the contractor shall be emptied daily.

1.6 GOVERNMENT FURNISHED PROPERTY

Submit a Property Management Plan in accordance with FAR Clause 52.245-1 Government Property.

1.7 EQUIPMENT LIST

The Contractor shall furnish a complete list of all equipment to be used on the project 30 days prior to commencement of on-site work. The Contractor shall submit a revised list in the event of change of equipment. Lists shall include rented equipment as well as lease-purchase or sale-leaseback equipment. The initial list and the revised lists shall indicate dates equipment is assigned to or removed from the project and adequate identification or description of each item of equipment including manufacturer's name (abbreviated), model number, manufacturer's serial number, year of manufacture, and Contractor's assigned serial or record number.

1.8 TESTING OF EQUIPMENT

Before any machinery or mechanized equipment is put to use on the job, it shall be inspected and tested by a qualified person and determined to be in safe operating condition. Cranes or derricks shall be tested by the Contractor or a qualified testing agency in accordance with EM 385-1-1 .

Equipment shall be large enough to safely handle proposed picks or tasks without exceeding the crane rating established by these tests.

1.9 DISPOSITION OF REMOVED EQUIPMENT

Unless otherwise specified in other sections of the specifications, all existing equipment removed and not reinstalled shall become the property of the Contractor, removed from the Project site, and disposed of in a legal manner. Materials that cannot be removed daily may be temporarily stored on-site at an approved area. Salvaged materials shall not be sold on the project site.

1.10 PROTECTION AND RESTORATION OF EXISTING FACILITIES

Reference FAR 52.236-9 Protection of Existing Vegetation, Structures, Equipment, Utilities, and Improvements (Apr 1984). Existing soil and grade conditions shall not be altered or damaged except as required to provide long term stability of the stored TSW components.

1.10.1 Pre-Work And Post Work Surveys

The Contractor shall conduct a pre-work survey prior to start of on-site work and a post-work survey following physical completion of the work and prior to demobilizing from the work site. The surveys shall be conducted in the presence of the Contracting Officer's Representative (COR) or other designated Government representative. The results of the surveys shall be documented by digital photographs and descriptive narrative reports. A color copy of the survey photographs and narrative reports shall be submitted to the Contracting Officer (KO) within 5 days after survey has been completed.

1.11 FIRE CONTROL

Each piece of internal combustion engine driven equipment used at the work site shall be equipped with a fire extinguisher in accordance with recommendation National Fire Protection Association (NFPA) as appropriate. The minimum approved rating of extinguishers shall not be less than 5-B:C.

1.12 TRAINING

The Contractor shall provide the services of one or more authorized start-up engineers as necessary to provide training in programming, operation and maintenance. The training shall be provided for operators and maintenance personnel prior to project operation of the ASW. Provide two, eight-hour class sessions; one class for operators and maintenance personnel and one for system managers and engineers. Each class session shall include approximately (15 employees). The Government will provide for the training location. The Contractor shall submit training manuals and documentation for approval 30 days prior to scheduled classes and shall furnish sufficient training materials at the training classes for all students plus a minimum of 3 copies for project files. Where audio/visual materials are used in training classes, 3 copies of such materials shall be furnished to the Project for use in future training.

It shall be the Contractor's responsibility to coordinate the training sessions with the Project to ensure minimum conflicts with ongoing Project work. One week prior to the training, the Contractor shall submit a training agenda for review. Training must include all requirements from other sections within these specifications. Training is not limited to the requirements from other sections and must include all necessary information for a complete understanding of the programming, operations and maintenance of the ASW.

1.13 PROJECT SUPERINTENDENT

At all times during performance of this contract and until the work is completed and accepted the Contractor shall assign and have on the worksite a competent superintendent as per FAR Clause 52.236-6 "Superintendence by the Contractor". Submit Superintendent name and contact information prior to start of on-site construction. The Project Superintendent may also be the Installation Supervisor Erecting Engineer

SECTION 01 11 01.00 28

as long as the Project Superintendent also meets the qualifications for the Installation Supervisor Erecting Engineer .

1.14 KEY PERSONNEL SUBSTITUTION

If the Contractor plans on replacing any Key personnel (Project Superintendent, Installation Supervisor Erecting Engineer , SSHO, CQC System Manager, or CQC staff Members) they must have the approval of the KO.

Personnel shall possess the qualifications that meet or exceed those stated in the specifications for the position of the individual they are replacing. Submit qualifications of new personnel at least 15 calendar days in advance of date of replacement.

1.15 POST AWARD MEETINGS

1.15.1 Pre-Work Meeting

Within 15 days after receipt of Notice to Proceed, the Contractor shall attend a Pre-Work meeting. Senior Level members of the Contractor's staff involved with this contract shall participate in this meeting to discuss the overall contract requirements. The Government will lead this meeting and take the meeting minutes.

1.15.2 Pre-Construction Meeting

The Project Superintendent shall coordinate with the KO and establish the date of the Pre-Construction Meeting. The meeting will be held at the project site at least one (1) week prior to mobilizing to the job site.

The Project Superintendent shall lead the Pre-Construction Meeting discussing the Contractor's plan on executing the work at the project site, schedule, required clearances and timeframe for them, and plan for implementing safety and quality control. The Government will have key members from the Project staff to discuss environmental and clearance issues. Key members of the contractor staff shall attend this meeting including the Quality Control (QC) System Manager, Site Safety and Health Officer (SSHO) and any other members determined by the Government to be required.

1.15.2.1 Minutes

The Project Superintendent shall be responsible for taking the meeting minutes and shall send them electronically within 48 hours of the meeting to the Government's Project Engineer, Quality Assurance Representative, and Resident Engineer.

1.15.2.2 Demobilizing And Remobilizing

Anytime the Contractor demobilizes from the site and remobilizes at a later date, another Pre-Construction meeting shall be held and shall follow the requirements listed above.

1.16 WEEKLY PRODUCTION MEETINGS

During all onsite construction work the Project Superintendent shall lead a weekly production meeting using the attached "Weekly Meeting Agenda Template" to brief the Government on the status of the project. All elements listed in the agenda shall be thoroughly discussed. For example, the Project Superintendent shall provide the Government a three (3) week "look-ahead" that describes all the planned construction activities, SECTION 01 11 01.00 28 onsite and offsite, over the next three (3) weeks. These activities shall align to the overall construction schedule submitted under SECTION 01 32 01.00 28 PROJECT SCHEDULE, and if the three (3) week "look-ahead" differs from the construction schedule, the construction schedule shall be updated to include these changes by the next scheduled update. Key members of the Contractor's staff shall attend this meeting, including the Quality Control System Manager, who is responsible for discussing QC aspects of the work as outlined under SECTION 01 45 04.00 28 CONTRACTOR QUALITY CONTROL and SSHO. The Government reserves the right to require any person from the Contractor's staff, such as the Project Manager, Engineer, scheduler, etc., or key subcontractor personnel to attend this meeting, if Government feels their participation is required.

1.16.1 Minutes

The Project Superintendent shall be responsible for taking the meeting minutes and shall send them electronically within 24 hours of the meeting to the Government's Project Engineer, Quality Assurance Representative, and Resident Engineer.

1.17 ADDITIONAL MEETINGS

The Contractor shall record the minutes of all meetings, including all conference calls, that occur between the Contractor and Government.

Minutes shall be sent electronically within 24 hours of the meeting to the KO for concurrence. E-mail subject line shall include project name and meeting topic.

1.18 PARTNERING

1.18.1 General

The Government intends to encourage the foundation of a cohesive partnership with the Contractor and its subcontractors by informally partnering this contract. This partnership will be structured to draw on the strengths of each organization to identify and achieve reciprocal goals. The objectives are effective and efficient contract performance and intended to achieve completion within budget, on schedule, and in accordance with plans and specifications. This partnership would be bilateral in makeup and participation will be totally voluntary. If Partnering is pursued, meetings would be held as identified in the following paragraph.

1.18.2 Partnering Meetings

Within 30 days of receipt of Notice to Proceed, the initial partnering meeting will be scheduled. The Contractor's key personnel will attend a face-to-face partnering meeting (typically one day in duration) together with key Government personnel, to discuss project goals and communication. Follow-up meetings will be held periodically, as required, throughout the duration of the contract, as agreed to by the Contractor and the Government.

PART 2 PRODUCTS (Not Used)

PART 3 EXECUTION (Not Used)

-- End of Section --

Weekly Meeting agenda template

Schedule - Work scheduled over the next week Three week look ahead Overall Schedule Review

Submittals Review- Submittal Register Submittals approved by QC Outstanding Submittals RFI’s Letters

Coordination - Clearances required over the next week, include the following:

A description of the work to be performed under the Clearance.

Determine the correct energy isolation points needed to perform the work safely.

Physical barriers, protective grounds, piping blanks, or bulkheads that shall be used, including locations.

Determine the procedure and method of testing for stored energy if applicable.

The date and time the Clearance shall be required.

The estimated length of time the system or equipment shall be out of service and the time to return the system or equipment to service in an emergency.

Coordination issues

Safety- Review of AHA’s for ongoing work Pending AHA’s

Required for new work Status of Gov’t approval

Safety issues

QC -

Preparatory meetings Held over last week- status of meeting minutes

Required over the next week Initial meetings over the next week Follow up over the next week Rework list Review Deficiency tracking log

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SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 01 42.00 28

SPILLWAY WEIR HOIST SYSTEMS

05/31/2016

PART 1 GENERAL

1.1 REFERENCES

1.2 SYSTEM DESCRIPTION

1.2.1 Operations and Maintenance (O&M) Manuals

1.2.2 Design Criteria

1.3 SUBMITTALS

1.4 PRE-FABRICATION REQUIREMENTS

1.4.1 Shop Drawings

1.4.2 3D CADD Mechanical Model

1.5 DELIVERY, STORAGE, AND HANDLING

PART 2 PRODUCTS

2.1 ELECTRICAL EQUIPMENT

2.2 Steel Fabrication

2.3 Drums

2.4 SPEED REDUCERS

2.4.1 General

2.4.2 Reducer Housing

2.4.3 Gearing

2.4.4 Reducer Shafts

2.4.5 Reducer Shaft Bearings

2.4.6 Gearbox Lubrication System

2.4.7 Seals

2.4.8 Breather

2.4.9 Parallel Shaft Reducer

2.4.10 Bevel Gearboxes

2.4.11 Worm Reducers

2.5 Open Spur Gears

2.5.1 Gear Design

2.5.2 Gear Rating

2.5.3 Gearing

2.5.3.1 Pinion Gears

2.5.3.2 Bull Gears

2.5.4 Gear Dimension, Quality, and Hardness Verification

2.6 PILLOWBLOCK BEARINGS

2.6.1 General Requirements

2.7 SHAFT COUPLINGS

2.7.1 General

2.8 LUBRICATION

2.9 WIRE ROPE ASSEMBLY

2.10 SHEAVES

2.11 SHAFTS

2.12 BRAKE

2.12.1 Electrohydraulic Actuator

SECTION 35 01 42.00 28

2.12.2 Enclosing Case

2.12.3 Mechanical Construction

2.13 ELECTRIC MOTORS

2.14 GUARDS AND COVERS

2.14.1 Open Gear Covers

2.14.2 Coupling Covers

2.14.3 Electrical Component Covers

2.15 Torque Sensor

2.16 Miscellaneous Materials

2.16.1 2.1 UHMW POLYETHYLENE

2.16.2 FRP Bearing Material

2.17 Fasteners

2.17.1 Bolts

2.17.2 Nuts

2.17.3 Washers

2.17.4 Cap Screws

2.18 Shims

2.19 Alignment Pins

2.20 Equipment Mounting Points

2.21 PAINTING

2.22 Spare Parts

2.22.1 Spare Bearings

2.22.2 Spare Couplings

2.22.3 Spare Torque Sensor

2.22.4 Spare Desiccant Breathers

2.22.5 Spare Lubricant

PART 3 EXECUTION

3.1 Erecting Engineer

3.2 Fabrication Tolerances

3.2.1 Drawings Tolerances

3.2.2 Fits

3.2.3 Geometric Tolerancing

3.3 Machinery Base Fabrication

3.4 Bolted Connections

3.5 Shear Blocks

3.6 Open Spur Gear Alignment

3.7 Guide Wheel Alignment

3.8 Load Limiting

3.9 SHOP ASSEMBLY AND TESTS

3.9.1 General

3.9.2 Test Plan

3.9.3 Drum Synchronicity Test

3.9.4 Static Load Test

3.9.4.1 Drum Dogging Load Test

3.9.4.2 Torque Sensor Load Calibration

3.9.5 Limited Load Test

3.9.6 Dynamic Load Test

3.9.7 Loss of Power

3.10 Track Dog Load Test

3.11 Lifting Beam Operation

3.12 Field Rope Tensioning

3.13 FIELD COMMISSIONING

3.14 FIELD TRAINING

3.15 ACCEPTANCE

-- End of Section Table of Contents --

SECTION 35 01 42.00 28

SECTION 35 01 42.00 28

SPILLWAY WEIR HOIST SYSTEMS

05/31/2016

PART 1 GENERAL

1.1 REFERENCES

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

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

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

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

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

AGMA 2011 (2014B) Cylindrical Wormgearing Tolerance and Inspection Methods

AGMA 6013 (2006A; R 2011) Standard for Industrial Enclosed Gear Drives

AGMA 6034-B92 1992.01.01 (R 2005)(R 2010) Practice for Enclosed Cylindrical Wormgear Speed Reducers and Gearmotors

ASME INTERNATIONAL (ASME)

ASME B4.1 (1967; R 2009) Preferred Limits and Fits for Cylindrical Parts

ASME B17.1 (1967; R 2008) Keys and Keyseats

ASME B18.2.1 (2010) Square and Hex Bolts and Screws (Inch Series)

ASME Y14.5 (2009) Dimensioning and Tolerancing

ASTM INTERNATIONAL (ASTM)

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

ASTM A325 (2010) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A490 (2012) Standard Specification for Structural Bolts, Alloy Steel, Heat Treated, 150 ksi Minimum Tensile Strength

ASTM A563 (2007a) Standard Specification for Carbon and Alloy Steel Nuts

ASTM A1018/A1018M (2010) Standard Specification for Steel, Sheet and Strip, Heavy-Thickness Coils, Hot-Rolled, Carbon, Commercial, Drawing, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, and Ultra-High Strength

ASTM F436 (2011) Hardened Steel Washers

ASTM F835 (2012) Alloy Steel Socket Button and Flat Countersunk Head Cap Screws

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

RCSC S348 (2009) RCSC Specification for Structural Joints Using ASTM A325 or A490 Bolts

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE J429 (2011) Mechanical and Material Requirements for Externally Threaded Fasteners

SAE J995 (2012) Mechanical and Material Requirements for Steel Nuts

1.2 SYSTEM DESCRIPTION

The equipment to be furnished under this specification consists of a single gate hoist unit composed of two wire rope and drum hoist units moving together as a single hoist. The hoist shall consist of two rope drums driven by open gears which are in turn driven by large parallel gear reducers. The parallel reducers are driven by a common worm gear reducer with an electric motor at the primary driver. Appurtenant features including lifting eyes and a drum dogging system are also required.

Furnish the units complete, including base supports, geared drives, brakes, motors, shafts, bearings, wire rope, electrical equipment, controls, covers, guards, and other necessary items. Manufacture of the vertical gate machinery units shall be provided to the Contractor by a firm that has been normally and regularly engaged in design, assembly, and manufacture of heavy machinery over the preceding 3 years. Dimensions shown on the drawings including structural supports shall not be changed without written approval from the Contracting Officer (KO). Where available from the manufacturer, each piece of equipment shall be provided with a metallic nameplate firmly attached. The nameplate shall bear the manufacturer's name, model designation, serial number, unit rating, application factor, reduction ratio's, and any other applicable information.

1.2.1 Operations and Maintenance (O&M) Manuals

For specifications on the furnishing of installation, operations and maintenance instructions, see SECTION 01 78 23.00 28 OPERATION AND

MAINTENANCE DATA.

1.2.2 Design Criteria

a. Equipment, where modified by the Contractor and submitted for approval, shall be designed for the normal loads with a minimum factor of safety of 5 based on the ultimate strength of the material. In addition, each part or component (excluding wire rope), shall be designed for a unit stress not in excess of 75 percent of the yield point of the material under loads resulting from the maximum torque of the motor at its limited state. Allowances for shock and impact will not be required. Standard commercial manufactured products shall be selected based on the manufacturer's published catalog ratings, additional safety factors are not required. All equipment modification design calculations shall be submitted for approval.

b. All equipment will be located outside and be expected to operate between ambient temperatures from -10 to 110 degrees F .

c. The normal design load on each rope drum is 100,000 pounds of rope pull divided between each of two ropes. The loads are composed of the dead weight of the gate, hydraulic forces, rolling friction in the gate wheels, and seal friction. The hoists are required to raise the gates at a speed of between 0.9 and 1.1 feet/minute .

1.3 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" of "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-02 Shop Drawings

Drums; I, ME

Parallel Shaft Reducer ; I, ME

Bevel Gearboxes ; I, ME

Sheaves ; I, ME

BRAKE; I, ME

Torque Sensor ; I, ME

3D CADD Mechanical Model ; G, ME

Final Shop Drawings ; G, ME

Worm Reducers ; I, ME

Pinion Gears ; I, ME

Bull Gears ; I, ME

Guards And Covers ; G, ME

Gear Drawings ; I, ME

SD-03 Product Data

Parallel Shaft Reducer ; G, ME

Bevel Gearboxes ; I, ME

Worm Reducers ; G, ME

Brake ; G, ME

Shaft Couplings ; I, ME

FRP Bearing Material ; I, ME

Torque Sensor ; I, ME

SD-05 Design Data

3D CADD Mechanical Model ; I, ME

Gear Calculations ; G, ME

Gear Dimension, Quality, And Hardness Verification Procedure ; I, ME

SD-06 Test Reports

Drum Synchronicity Test ; G, ME

Static Load Test ; G, ME

Dynamic Load Test ; G, ME

Final Alignment Test Report ; G, ME

Track Dog Load Test ; G, ME

Lifting Beam Operation ; G, ME

Limited Load Test ; G, ME

Gear Dimension, Quality, And Hardness Verification Reports ; G, ME

SD-10 Operation and Maintenance Data as specified in SECTION 01 78 23.00 28.00 28

Parallel Shaft Reducer ; data package 1 G, ME

Worm Reducers ; data package 1 G, ME

Bevel Gearboxes ; data package 1 G, ME

BRAKE;data package 1 G, ME

SHAFT COUPLINGS;data package 1 G, ME

Torque Sensor ; data package 1 G, ME

Spare Bearings ; I, ME

Spare Couplings ; I, ME

Spare Torque Sensor ; I, ME

Spare Desiccant Breathers ; I, ME

Spare Lubricant ; I, ME

1.4 PRE-FABRICATION REQUIREMENTS

1.4.1 Shop Drawings

Shop Drawings shall be submitted for review and acceptance prior to beginning fabrication. For shop drawings that are not acceptable, they shall be corrected and re-submitted. Contractor shall submit detailed shop drawings showing individual hoist component fabrication details and assembly view. Shop drawings for the hoist components shall include fabrication and assembly details and type, grade and class of material as appropriate. Shop drawings shall include connection and mounting points where mechanical components connect to structural components. Provide assembly drawings indicating the sequence of fabrication and provide details for connecting the adjoining fabricated components in the shop.

Elements of fabricated items inadvertently omitted on contract drawings shall be detailed by the fabricator and indicated on the shop drawings.

For components that rely on other components, such as a mechanical component and its structural support, drawings for both components must be submitted at the same time. Drawing approval for a component will not be given unless approval can also be given to its mating or support component. The drawings shall be checked against the assembly tolerances in the plans and utilize the geometry from the installed machinery. The shop drawings shall be accompanied by a statement from the contractor that the geometry in the drawings has been checked against the assembly tolerances in the plans and meets those tolerances. If there is a discrepancy between the plans and the assembly tolerances, the statement shall indicate where the discrepancy occurred and that it has been corrected. At the completion of the contract, "as-built" Final Shop Drawings shall be submitted showing the actual, installed geometry.

1.4.2 3D CADD Mechanical Model

At the completion of the contract an "as-built" 3D CADD Mechanical Model shall be submitted, showing the actual, installed geometry. The electronic file shall be submitted as a single ".dgn" file in Microstation version V8i 3D electronic file format and shall contain an assembly of each of the hoist components as listed below. This model shall be submitted and coordinated with the structural model such that the structural model shows the machinery and mounting points and the mechanical model show structural arrangement and clearances. Each element within the model shall be drawn as a solid with volumetric properties. Shell elements without volumetric properties will not be accepted. For a 3D model that is not accepted, that model shall be corrected and re-submitted. The file shall have a unique

Microstation level and color assigned for each component as listed below:

1. Hoist Support Beams

2. Sheave Assemblies

3. Drum and Rope Assemblies

4. Open Gears

5. Gear Support Bases

6. Machinery Bases and Support

7. Bearings

8. Torque Sensor Assemblies

9. Rotating Machinery

10. Lifting Eye Assemblies

11. Drum Dogging Assemblies

12. Track Dogging Assemblies

13. Pneumatic Seal Assemblies

14. Lifting Beam Linkage Assemblies

15. Miscellaneous Components

1.5 DELIVERY, STORAGE, AND HANDLING

PART 2 PRODUCTS

2.1 ELECTRICAL EQUIPMENT

Electrical equipment, including limit switches, position sensors, motor starters, conduit, conductors, variable frequency drives, controls, etc., shall conform to the requirements of Section 26 20 00.00 28 Electrical Distribution System, 26 24 19.00 28 Motor control Centers, 26 29 23.00 28 Variable Frequency Drive Systems Under 600 Volts, and 26 60 13.00 28 Low-Voltage Motors.

2.2 Steel Fabrication

All fabricated steel components used within the hoist system shall conform to the fabrication and testing requirements of Section 05 59 13.00 28 Fabrication of Hydraulic Steel Structures.

2.3 Drums

Drums shall be fabricated in accordance with the drawings. Drum grooving shall be performed such that the grooves are true to the alignments shown so that as the drum is rotated, each of the two ropes attached to the drum will wrap onto the drum at the same rate. 100% of Complete Joint Penetration (CJP) welds must be inspected using Ultrasonic Testing (UT).

100% of Partial Joint Penetration (PJP) welds must be inspected using either Dye Penetrant testing or Magnetic Partical Testing. All welds must be 100% visually inspected.

2.4 SPEED REDUCERS

2.4.1 General

Reducers shall be entirely self contained in an oil tight, steel housing designed to maintain shafts and bearings in accurate alignment. The gear ratio shall be as indicated plus or minus 1.5 percent. The speed reducers shall be designed, rated and manufactured in accordance with AGMA 6013. The gearing shall be rated in accordance with AGMA 2003 and AGMA 6013. AGMA 2001 is not to be used for rating and design of the components of the speed reducers. In all cases where these standards or

SECTION 35 01 42.00 28

this specification are in conflict with one another the more conservative design standard shall take precedence.

2.4.2 Reducer Housing

The reducer housing shall be heavy duty cast steel or welded steel construction and shall have dowel pins at all parting seams for accurate gear and bearing alignment. The base of the reducer shall be of sufficient thickness and width in order to reduce the stress on the mounting bolts. All surfaces shall be smooth and flat and easy to clean.

The upper and lower housings shall have large, rugged lifting lugs. All required oil drains, fill ports, breathers, heater ports, filtering ports, and inspection covers shall be provided in the housing. A main oil drain shall be provided at as low a point as possible on the reducer housing.

The main oil drain shall be fitted with a 1-inch stainless steel ball valve with a WOG rating of 2000 psi . The valve shall be plugged on the open end. Housing shall include 1-inch filter ports with 1-inch stainless steel ball valve to be connected to a filtering unit when required, otherwise the ends shall be capped. The design of the reducer housing should minimize potential for water intrusion as the reducers will be continuously exposed to the out-of-doors ambient conditions. Top inspection access covers shall be provided.

2.4.3 Gearing

All gearing shall be made from high strength alloy steel, carburized, hardened, and ground after gear cutting; ANSI/AGMA Quality 11 in accordance with AGMA 2015/915-1 , minimum. The pinions shall be integrally cut on the pinion shaft. Spiral bevel gears shall be made from high strength alloy steel with case hardened teeth, crown lapped for quality and smooth operation.

2.4.4 Reducer Shafts

Shafts shall be made from high-strength alloy steel and shall be of sufficient size to insure rigid alignment. All keyways shall have fillet radii. Keys shall be provided for all shafts. All shafts shall have standard keyways and keys in accordance with ASME B17.1 , Class II.

2.4.5 Reducer Shaft Bearings

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

2.4.6 Gearbox Lubrication System

The lubrication system shall be a splash type system using a standard gear lubricant. The lubrication system shall be designed to function properly at nameplate speed rating using the required lubricating oil.

All gears and bearings shall be oil lubricated. All required oil slingers, dams, and passages shall be provided. Grease lines and lubrication fittings shall be provided 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. The reducer shall be equipped with a sight gauge and dipstick in order to observe and measure the oil level. The speed reducer shall also be fitted with an oil sample valve arrangement. The valve shall be a 1/4-inch stainless steel ball valve with a pressure-temperature rating of 2000 psig at 100 degrees F and be fitted with a plug on the open end. The oil sample port on the reducer housing shall be located such that an oil sample can be drawn (through the sample valve) from a point that is approximate 1/2 of the operating oil level in the reducer.

2.4.7 Seals

Spring loaded grease-purged dual lip seals shall be provided for all shaft extensions. All seals shall be sized and designed to withstand the pressure head developed when the speed reducer is completely filled with oil (storage condition) without leaking.

2.4.8 Breather

All reducers shall be provided with a hygroscopic breather with threaded fittings for installation to prevent problems caused by moisture and particulate matter contamination in the reducer when it breathes in and out due to temperature fluctuations. The breather shall filter particles down to 3 microns in size. The hygroscopic agent shall change color signifying when the unit requires replacement, i.e., when the desiccant is saturated with moisture. There shall be no air flow stoppage through the breather under freezing conditions.

2.4.9 Parallel Shaft Reducer

The speed reducer shall be provide for a minimum of three gear reductions, and be of the parallel shaft type. The power and torque ratings of the reducers along with the nominal reduction ratio shall be as indicated. The direction of rotation of each of the parallel reducers shall be such that both drums rotate to "pay out" rope together at the same rate. The reducer shall have double extended input shafts. The output shafts shall be arranged as indicated. The drum open gear pinion shall be keyed to and mounted directly on the reducer output shaft.

2.4.10 Bevel Gearboxes

The bevel gear speeds and ratings shall be as indicated. Where custom shaft lengths are required, the shafts shall be provided by the gear box manufacturer.

2.4.11 Worm Reducers

Worm gears shall be of cast bronze or shall have bronze rim with inner portion of cast steel or nodular cast iron. Worms shall be of hardened ground alloy steel or high-test heat-treated nodular cast iron. Worm Gearing shall pass inspection in accordance with AGMA 2011. Worm gearing shall be designed in accordance with AGMA 6034-B92 . Worm reducers shall have double extended input shafting and double extended output shafting.

2.5 Open Spur Gears

2.5.1 Gear Design

The contractor shall provide a gear design for the open bull and pinion gears. The design shall include gear drawings and gear calculations . The drawings and calculations shall be stamped by a licensed professional engineer. The design shall use the gear data table on plan sheet MJ401 as approximate starting values. The design shall verify suitability of the design presented in the drawings is appropriate or develop modifications as necessary. The contractor design must minimize any changes to the geometric footprint of the indicated design. Gears shall be designed in accordance with AGMA 2001(2004d).

2.5.2 Gear Rating

a. The pitting resistance power rating of gears shall not be less than the motor horsepower times 0.8. The bending strength rating of gears shall not be less than the motor horsepower times 1.0.

b. In calculating the pitting resistance power rating of gears, a value of not less than 1.0 shall be used for the overload factor, size factor, safety factor for pitting, reliability factor, surface condition factor for pitting resistance, and temperature factor. A value of 1.0 shall be used for the stress cycle factor for pitting resistance.

c. In calculating the bending strength power rating of gears, a value of not less than 1.0 shall be used for the overload factor, size factor, safety factor for bending strength, reliability factor, and temperature factor. A value of 1.0 shall be used for the stress cycle factor for bending strength.

d. In addition, the gears shall be designed such that the bending stress produced by the rated torque (factory adjusted torque setting) of the brakes will not exceed 50 percent of the yield point of the material.

e. Also, the gears shall be designed such that the bending stress produced by the load limited bull gear torque of 2,632,800 inch pounds will not exceed 75 percent of the yield point of the material.

f. The material yield points used shall be the allowable yield strength of the materials given in AGMA 2001(2004d) and AGMA 6013, except that for surface hardened gears the yield point shall be that of the base material.

g. For gear life calculation assume a bull gear life of 20,000 rotations.

2.5.3 Gearing

Make all spur gearing from high strength alloy steel that is hardened to match the indicated values. Gear material, hardness, and geometric requirements are to be as indicated. Spur gear teeth must be of the involute form. Grind the gears after gear cutting to achieve a minimum ANSI/AGMA Quality A10 in accordance with AGMA 2015/915-1 . Harden the gear teeth as required so that the hardness measurement at any point meets requirements after finishing. All gears must be supplied as match marked sets. The ends of the pinion teeth must be end relieved to prevent end loading. Crown the gear teeth. Make keys of ASTM A108, UNS G10180 ( ASTM A1018/A1018M ), keystock. Certified material test results for the drive pinion and drive pinion shaft are required.

2.5.3.1 Pinion Gears

Machine the inside rim of the gear to match the mounted shaft. Verify machining dimensions to assure proper mounting. Pinion gears shall be through hardened. The pinion material shall be a minimum of grade 2 material. The material hardness shall be based on the contractors gear design. Scribe the pitch line, and two indexing lines offset 1/8-inch to each side, on the top of the gear teeth of all mated gears to aid in installation alignment.

2.5.3.2 Bull Gears

Bull gears shall be case carburized. The core and case hardness and case depth shall be based on the contractors gear design. The gear shall be fabricated of a minimum of grade 2 material.

2.5.4 Gear Dimension, Quality, and Hardness Verification

The following is applicable to the manufacture and inspection of new gears:

a. All gear dimensions shall be verified and documented.

b. Gear tooth geometry shall be verified and documented. A computer numerically controlled (CNC) gear inspection machine shall be used to verify profile, runout, pitch variation, tooth alignment (lead), total composite, and tooth-to-tooth composite. A report shall be generated for each gear and pinion and shall indicate the actual gear quality number the gear/pinion meets. Submit Gear Dimension, Quality, and Hardness Verification Procedure .

c. Gear tooth hardness shall be verified and documented.

d. Gear Dimension, Quality, and Hardness Verification Reports shall be compiled, submitted and inserted in the operation and maintenance manuals.

e. The Government shall be provided the opportunity to witness these inspections. The Government shall be notified at least 14 calendar days in advance of the dates of the inspections.

2.6 PILLOWBLOCK BEARINGS

2.6.1 General Requirements

Except as otherwise specified, bearings shall be of the two row, spherical, rolling element type and shall be permanently sealed and filled with lubricant. The manufacturer's ratings for loads and speeds shall be used in determining the bearing capacity. The minimum L-10 bearing life shall be 75,000 hours based on the the maximum dynamic load rating of the bearing. Service and installation factors shall be in accordance with the bearing manufacturer's recommendations. All bearings shall be equipped with labyrinth seals to exclude foreign matter and retain lubrication without leakage under both static and dynamic operating conditions. Ball bearing pillow blocks and flange blocks shall have solid steel housings with minimum of a two bolt base. Roller bearing pillow blocks shall be of the split solid steel construction with four bolt bases. Roller bearing housing caps shall be recessed into or dowelled to the bases and secured with not less than 4 bolts, SAE Grade 8. Bearings bases shall be rated for the full required static load applied in an uplift condition, loading the bolts in tension. This required load shall be based on the HOIST BEARING TABLE, on sheet MJ401.

2.7 SHAFT COUPLINGS

2.7.1 General

Shaft couplings shall be of the flanged exposed bolt, double engagement, gear type made of forged steel. Couplings shall be of the vertical or horizontal design depending on the shaft on which they are mounted.

Couplings shall transmit torque by means of external gears on hubs engaging in internal gears on the coupling sleeves. Gears shall be machined in accordance with applicable ANSI/AGMA standards. Couplings shall be of sufficient capacity to develop the full torque of the equipment to which they are attached and shall be pressed and keyed to the equipment shafts. The key fit shall be in accordance with ASME B17.1 , Class II. The fabricated dimensions of the key fit shall be submitted for review. Couplings shall be equipped with lube plugs and enclosed and sealed with an elastomeric O-ring to retain the lubricant and shall be oiltight under both static and dynamic operating conditions. Bolts shall be SAE grade 8. Misalignment for gear couplings shall be minimized by not exceeding the manufacturer's recommendations for installation limits pertaining to gap-hub separation, angular alignment, and parallel offset alignment measurements. Couplings shall not require balancing at the speeds at which they are to operate. Machinery alignment shall be such that balancing is not required. Where couplings attach to extension shafts the the couplings shall be of the "Fixed X Flex" type. The fixed end hub shall be mounted on the extension shafting.

2.8 LUBRICATION

Lubricating oil for speed reducers shall be as recommended by the gearbox manufacturer. It shall have good resistance to foaming under normal operating conditions and shall be non-corrosive to speed reducer components. The oil shall be suitable for infrequent intermittent duty operation of the speed reducers with an ambient temperature range from -10 degrees F to 110 degrees F . Drain and fill plugs for speed reducers shall be located so as to be readily accessible on the completed units and shall be provided with extension piping where required. Couplings and bearings shall be grease lubricated in accordance with the manufacturer's instructions. Where possible, the contractor shall coordinate with the COR to provide lubricant that is already in use and stocked at Little Goose Dam.

2.9 WIRE ROPE ASSEMBLY

For specifications on the wire rope and terminations see Section

35 01 43.01 28 WIRE ROPE FOR GATE OPERATING DEVICES.

2.10 SHEAVES

Sheaves shall be of cast, forged, rolled, or welded steel. Sheave grooves shall be accurately machined for the wire rope diameter provided, smoothly finished, and free of surface defects. The groove contact area shall be flame hardened to a minimum 50 Rockwell C for a depth of 0.060 inches minimum with a minimum contact arc of 140 degrees. Sheaves shall be provided with the hub geometry as indicated.

2.11 SHAFTS

All fabricated shafting, including transmission shafts, brake shafts, gear shafts, and limit switch shafts, shall be as indicated. Fillets shall be provided where changes in section occur. All keyways shall have fillet radii. All shafts shall have standard keyways and keys in accordance with ASME B17.1 , Class II.

2.12 BRAKE

The brakes shall be self-adjusting, shoe type, spring set, released by a sealed electrohydraulic actuator and shall be completely enclosed in a water-tight and dust-tight enclosing case arranged for floor mounting.

The brake shall be alternating current type rated for 460 volts, 3 phase, 60 Hertz. The brake shall have an minimum operating torque rating of 860 inch pounds and a maximum operating torque rating of 900 inch pounds. The brake wheel shall be bored for mounting on the brake shaft. The torque rating shall be based on open construction continuous duty. The brake shall be self-adjusting such that compensation for shoe wear is automatic. Hand release, external to the brake enclosure, shall be provided. This brake shall be configured so that it sets 1 second after the brake on the brake motor.

2.12.1 Electrohydraulic Actuator

Electrohydraulic actuator shall consist of an electric motor that drives an impeller inside a fluid filled, heavy-duty, cast aluminum housing. The rotation of the impeller shall hydraulically extend a cylinder which shall release the brake by overcoming the main spring. An adjustable valve shall be provided to allow setting the brake timing. The actuator shall be completely enclosed in the housing. The fluid shall be suitable for operation in temperatures between -10 and 110 degrees F .

2.12.2 Enclosing Case

A NEMA Type 4 enclosing case shall be provided with watertight grease pressure lubricated shaft seals. The cover shall be held in place by heavy hinge bolts and wing nuts. Enclosing case for 115 volt AC space heaters shall be provided. Space heaters total power capacity shall be as recommended by the brake manufacturer. Heaters shall be provided by the brake manufacturer. A bottom mounted drain and breather unit shall be provided on the enclosure to allow condensate water to drain, but prevent outside water from entering the enclosure. The enclosure shall be provided with a shaft seal for each shaft penetration through the enclosure.

2.12.3 Mechanical Construction

Except for 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. 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. A nameplate of corrosion resisting material shall be provided and attached to a part of the brake which ordinarily will not be replaced. The nameplate shall indicate all necessary information required by this specification. A manual release mechanism shall be provided to allow removal of wheel or permit lining replacement without readjusting torque setting. The brake wheel shall be fabricated of corrosion resisting steel.

2.13 ELECTRIC MOTORS

For electric motor specifications see specification section 26 60 13.00 28 Low-Voltage Motors. The motor shall be a brake type motor with an integral brake. The brake shall meet the brake requirements specified herein. The brake shall have a torque rating of approximately 860 inch pounds.

2.14 GUARDS AND COVERS

Safety guards or covers shall be provided where necessary to protect the operators from accidental contact with moving parts in accordance with OSHA 1910.212. Openings shall be provided in guards and covers as necessary to provide access to parts requiring lubrication or regular maintenance. The covers shall be fabricated of a minimum of 1/8 inch steel sheet metal. The guards must be designed to allow removal for maintenance while the ASW is in place. Required covers include but are not limited to the following.

2.14.1 Open Gear Covers

The Contractor shall design and install covers for the open gears. The cover shall be designed to contain the gear lubricant and to keep rain and mist off of the gears. The cover shall be split between a fixed bottom half and removable top half. The top half shall provided for gear inspection hatches to observe the loaded face for each gear. The cover shall provide for a seal around shafting penetrations.

2.14.2 Coupling Covers

The Contractor shall design and install covers for each of the couplings in the machinery system. Covers must be easily removable to facilitate component inspection. Covers must be designed to contain any grease that is spun off the coupling through the seals.

2.14.3 Electrical Component Covers

The Contractor shall design and install covers for electrical components mounted on the machinery, including the position encoder, rotary limit switch, anti two-block switch, and torque sensors. These covers shall be designed to be removable for maintenance requirements, and to prevent direct contact between rain or mist and the component.

2.15 Torque Sensor

The torque sensors shall allow for torque measurement in a rotating shaft.

The torque sensors shall provide a 4 to 20 mA electrical output signal.

The sensor shall be in line with the power train and couple to the drive shafting as indicated. The torque sensor shall have a minimum torque rating of 8,000 in-lbf. Contactor shall provide sensor with accessories, 4X NEMA connector with plug of same manufacture of sensor with two pieces of 20 feet long wires waterproof cable to connect with sensor. Connector shall install in control receptacle panel

2.16 Miscellaneous Materials

2.16.1 2.1 UHMW POLYETHYLENE

Ultra High Molecular Weight Polyethylene (UHMW-PE) material shall have a cross-linked polymer with a molecular weight equal to or greater than 4.5 million and be formulated from 100% virgin material and be U. V. protected.

2.16.2 FRP Bearing Material

FRP bearing material shall be a laminated plastic composite formed by impregnating fabric with thermosetting resin. The composite shall incorporate solid lubricants to reduce the coefficient of friction and reduce wear. Material shall provide a compressive strength perpendicular to the laminate of approximately 35,000 psi and a tensile strength of approximately 10,000 psi. Water absorption shall be less than 0.1%. FRP bearing material shall provide for a sliding coefficient of friction of less than 0.1. Where fits are specified for FRP bearings, those fits shall be with the FRP material in the maximum material condition assuming full swell as a result of water absorption. Where FRP bearing material is called for without lubrication, all of the above requirements shall be met except the material shall be provided without solid lubricants.

2.17 Fasteners

2.17.1 Bolts

Bolts shall be ASTM A490, ASTM A325, SAE J429 , and ASME B18.2.1 . SAE graded bolts shall be either Grade 7, or Grade 8.