TechSpecs-Amend-0003.pdf

Little Goose Adjustable Spillway Weir (ASW) W912EF-16-R-0001 Amend-0003

SECTION TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

01 91 00.00 28

SHOP TESTING AND FIELD COMMISSIONING

11/12

PART 1 GENERAL

1.1 SUBMITTALS

1.2 ERECTING ENGINEER

PART 2 PRODUCTS

2.1 SHOP TESTING PLAN

2.2 FIELD COMMISSIONING PLAN

2.3 TEST EQUIPMENT

PART 3 EXECUTION

3.1 SHOP TESTING

3.2 FIELD COMMISSIONING

3.2.1 Pre-Commissioning

3.2.2 ASW Commissioning

3.2.2.1 Installation Procedure

3.2.2.2 Operational Testing

3.2.2.3 Emergency Operation Testing

3.2.2.4 Return to Storage

3.2.2.5 Post Operational Inspection

3.2.2.6 Re-installation

3.2.2.7 Re-verification Operational Testing

3.2.2.8 Contractor Lead Unloaded Instruction

3.2.2.9 Contractor Lead Storage Instruction

3.2.2.10 Contractor Lead Installation Instruction

3.2.2.11 Government Lead Unloaded Operational

3.2.2.12 Government Lead Loaded Operation

3.2.3 Field Commissioning Report

-- End of Section Table of Contents --

SECTION 01 91 00.00 28

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01 91 00.00 28

SHOP TESTING AND FIELD COMMISSIONING

11/12

PART 1 GENERAL

This specification covers all of the Shop Testing and Field Commissioning requirements for the ASW structure, electrical and mechanical components, lifting devices, and control systems.

1.1 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-03 Product Data

Shop Testing Plan ; G, DB

Field Commissioning Plan ; G, DB

SD-06 Test Reports

Field Commissioning Report ; G, DB

SD-07 Certificates erecting engineers qualifications ; G ME

1.2 ERECTING ENGINEER

a. Furnish the services of a competent erecting engineer to supervise and direct the erection and installation of this equipment. The erecting engineer shall be present for all installation erection , inspection, and testing activities associated with both the shop testing and field commissioning.

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

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

d. The erecting engineer shall be a licensed professional engineer having have a minimum of 10 years of experience in development of hoisting systems. Submit the erecting engineers qualifications including a copy of the license and a brief resume including the engineers hoisting experience.

SECTION 01 91 00.00 28

PART 2 PRODUCTS

2.1 SHOP TESTING PLAN

Submit a plan for completing all of the required shop tests within this contract. The Shop Testing Plan shall be submitted at least 60 days prior to the initial shop test and shall contain an overall shop testing schedule, anticipated date for each shop test, a brief description for each shop test, a schedule showing the anticipated date for each shop test, estimated length of time required, special equipment to be used, key personnel required for each test, and any general notes or comments that may be of interest to Government personnel who may witness a particular shop test. Components subject to shop testing may have specific painting requirements before and/or after shop testing; refer to specifications sections specific to individual components. The plan shall include sketches and a written description of the testing arrangement, the loads that will be used and the method of developing those loads, and a checklist of points to be monitored during the test with columns for each point being labeled as acceptable or un-acceptable. The plan shall be reviewed and signed by the erecting engineer as required in herein. The Shop Testing Plan shall be submitted in the following format on 8.5x11 paper:

TITLE COVER

1. Table of Contents

2. Shop Test Schedule

- show anticipated date for each shop test

3. Shop Test Descriptions

3.1 Shop Test 1

- show anticipated length of time required for shop test

- list any special equipment to be used

- list key personnel required for shop test

- notes and comments

3.2 Shop Test 2

- show anticipated length of time required for shop test

- list any special equipment to be used

- list key personnel required for shop test

- notes and comments 3.x Shop Test x

- show anticipated length of time required for shop test

- list any special equipment to be used

- list key personnel required for shop test

- notes and comments

2.2 FIELD COMMISSIONING PLAN

Submit a plan for field commissioning the ASW structure, electrical and mechanical components, lifting devices, and control systems. The Field Commissioning Plan shall show all of the tests and sequence of testing as required by PART 3, EXECUTION of this specification. The Field Commissioning Plan shall show the pre-commissioning activities, any special equipment to be used, any anticipated use of Government facilities or equipment (i.e., intake gantry crane, power source, etc.), key personnel required, estimated time required for completing all of the field commissioning requirements, any general notes or comments that may be of interest to Government personnel who will witness the commissioning, and a commissioning plan checklist to be completed during the commissioning process. The field commissioning plan shall be reviewed and signed by the Erecting Engineer. The Field Commissioning Plan shall be

SECTION 01 91 00.00 28

submitted in the following format on 8.5x11 paper:

TITLE COVER

1. Table of Contents

2. Commissioning Tests and Sequence

- show each test and sequence of commissioning

- show estimated time for completing each test

3. Special Equipment Required

- list any special equipment required for particular tests

4. Use of Government Facilities and Equipment

- list any Government facilities and equipment that may be required

5. Key Personnel Required

- list key personnel required for shop test

- notes and comments

6. Notes and Comments

7. ASW Commissioning Plan Checklist

2.3 TEST EQUIPMENT

Unless specific equipment and instrumentation is required elsewhere, ensure instrumentation and equipment used for shop testing and field commissioning meets the minimum following standards:

a. Sufficient quality and accuracy to test and measure system performance within the tolerances required to determine adequate performance.

b. Calibrated on the manufacturer's recommended intervals with calibration tags permanently affixed to the instrument being used.

c. Maintained in good repair and operating condition throughout the duration of use on this project.

Provide all standard testing equipment required for performing shop testing and field commissioning. Datalogging equipment or software required to test equipment will be provided by the Contractor, and not become the property of the Government.

PART 3 EXECUTION

3.1 SHOP TESTING

Perform all required shop tests required within the individual specification sections. The shop tests and specific instructions for each test to be included in the Shop Testing Plan are given in the specification sections listed below:

SECTION 05 59 13.00 28 , FABRICATION OF HYDRAULIC STEEL STRUCTURES

Alignment Test Hoist Assembly Initial Operation and Load Test ASW Lifting Beam Initial Operation and Load Test

SECTION 26 29 23.00 28 , VARIABLE FREQUENCY DRIVE SYSTEMS UNDER 600

VOLTS

VFD Factory Test Plan VFD Test Performance Verification Tests Endurance Test

SECTION 35 01 42.00 28 , Spillway Weir Hoist SYSTEMS

Drum Synchronicity Static Load Test Limited Load Test Dynamic Load Test Track Dog load Test Lifting Beam Operation Open Spur Gear Alignment

SECTION 35 01 43.01 28 , WIRE ROPE FOR GATE OPERATING DEVICES

Attaching and Proof Loading Terminations

SECTION 40 94 43.01 28 , PROGRAMMABLE LOGIC CONTROLLERS (PLC)

PLC Testing

Specific shop tests not listed above are not required to be included in the Shop Testing Plan. Some tests may be performed in conjunction with others based on the stage of assembly and sequence of fabrication.

3.2 FIELD COMMISSIONING

The following sections describe the requirements for commissioning the ASW structure, mechanical and electrical components, and operations and maintenance training. During the tests, readings of motor RPM, current, and voltage as well as torque sensor readings, VFD torque reading, bearing body temperature, and Crest position shall be recorded and included in the field commissioning report. Record data every 10 minutes of hoist operation, or at changes in operation. The field commissioning shall be overseen by the erecting engineer as specified herein.

3.2.1 Pre-Commissioning

Initial layout may be accomplished by floating crane, the project's intake gantry crane, mobile crane, or a combination thereof. Pre-Commissioning activities shall occur in the following sequence:

1. Complete all on-site work including electrical, mechanical, and system controls.

2. Perform the initial load testing and inspection of the Hoist Assembly and ASW Lifting Beam per specifications Section 05 59 13.00 28 .

3. Place the ASW stoplogs in their respective storage locations using the ASW Lifting Beam.

5. Place Crest Assembly dogged off in the storage pit at the North Non-overflow Monolith, using the ASW Lifting Beam.

6. Place ASW Lifting Beam and Hoist Assembly on deck at a location approved by the COR and accessible for rigging to the intake gantry crane.

7. Install Wheel Tracks on Crest Assembly using the internal wheel track dogging system.

3.2.2 ASW Commissioning

The ASW commissioning will begin after the pre-commissioning activities are complete. The spillway tainter gate will be closed and the area between the ASW and the spillway tainter gate will be watered up (pressure on ASW structure will be equalized). Due to the sequence and time requirements for various step, the ASW commissioning process will span multiple days. Coordinate anticipated dates and commissioning sequence with the COR and include in the Field Commissioning Plan as required above. The ASW commissioning sequence shall occur in the following sequence:

3.2.2.1 Installation Procedure

During the installation procedure specified below conduct a time in motion study of the individual components and the overall installation. Record the time required for each of the following procedures: configuring the ASW Lifting Beam for each component pick, rigging/connecting each component to the Lifting Beam for transport, tranportation of each component, de-rigging/disconnecting each component from the Lifting Beam, total time required to install each component, and the total time to fully install the ASW. Record these times in the Field Commissioning Report.

1. Confirm the initial load testing and inspection of Hoist Assembly and ASW Lifting Beam per specifications Section 05 59 13.00 28 Subsection 3.8.

2. Configure the ASW Lifting Beam to transport the ASW Stoplogs.

Retrieve the Base Stoplog from its storage location and lower it into spillway #1.

3. Using a diver, verify that the Base Stoplog is sitting level with all bottom bearing shoes in contact with the embedded steel sill beam and sitting plumb, within 0.5 inches of contact with the vertical embedded bearing plates.

4. Retrieve the Intermediate Stoplog from its storage location and lower it into spillway #1.

5. Retrieve the Top Stoplog from its storage location and lower it into spillway #1. Connect the airline to the stoplog as it is lowered into the slot. When the top of the stoplog nears the deck elevation, perform the Seal System Tests as specified in section 22 15 10.00 28 .

6. Configure the ASW Lifting Beam to transport the Crest.

7. Retrieve the Crest with attached Wheel Tracks from its storage location and lower it into Spillway #1. Protect the Top Stoplog airline as the crest is lowered into position.

8. When the Tracks bear on the Top Stoplog, cease lowering the assembly and connect the Track Retaining Plates to secure the Tracks to the piers. Continue to lower the Crest about 6 inches and retract the Track Dogs. Raise the Crest and extend the dogging beams, lower the Crest onto the dogging beams.

9. Unpin the Lifting Beam Links from the Crest lifting eyes and connect the Crest Extension Links between the Crest lifting eyes and the ASW Lifting Beam.

10. Raise the Crest slightly and retract the dogging beams. Lower the crest to within about 6 inches of elevation 646 and extend the Track Dogs. Continue to lower the Crest onto the dogs. Disconnect the ASW Lifting Beam from the Crest and place into storage. Record the actual Crest elevation at which the Crest engages the Track Dogs in the Final Commissioning Report.

11. Retrieve the Hoist from its storage location and place it above the Crest in spillway #1. Lower the Hoist onto the piers. Connect the electrical system to enable Hoist usage. Using the Hoist, lower the lifting clevis into alignment with the extension links and pin the Crest Extension Links to the Hoist. Using the Hoist lift the Crest off the Track Dogs about 6 inches and retract the dogs. Hold the Crest with the hoist for 15 minutes and verify that all the electronics are operating and the Torque Sensors are reading properly. At this point perform the Field Rope Tensioning Test as specified in Section 35 01 42.00 28.

12. Lower the Crest to elevation 622 and hold for 15 minutes. Verify all the electronic measurements.

13. Raise the Crest to elevation 639 (full operating height) and hold for two hours. Verify the electronic measurements and visual inspections.

14. Lower the Crest to elevation 618 (minimum operation elevation).

Maintain tension on the ropes while the Crest is in the lowered position. Hold that position for at least two hours or until the next day. Verify the electronic measurements and visual inspections.

3.2.2.2 Operational Testing

1. Raise Crest Assembly to elevation 639.0 and inflate the pneumatic seal.

2. Perform the following operations using the local control panel

3. Open spillway tainter gate 2-3 inches (by Government operator) and start placing hydrostatic load on the ASW structure. The Contractor and Government personnel will monitor the ASW structure as it is loaded and will shut the spillway tainter gate if any visual concerns are evident. Government operator will stand by to close the gate if problems arise.

4. After all water between the ASW and the spillway tainter gate has been evacuated, hold for 1 hour and verify that the ASW structure does not have excessive leakage (more than 50 gallons per minute).

5. Raise the spillway tainter gate to full open position (by Government operator), then lower the crest assembly to elevation

622.0 and hold for 1 hour. Verify that electronic measurements and visual inspection of the ASW structure are satisfactory. As the crest is lowered take readings from the torque sensors at 1 foot intervals. Verify that the load readings remain greater than 10kips. Record these readings in the Field Commissioning Report.

6. Lower the crest assembly to elevation 618.0 and hold for 1 hour.

Verify that electronic measurements and visual inspection of the ASW structure are satisfactory. As the crest is lowered take readings from the torque sensors at 1 foot intervals. Verify that the load readings remain greater than 10kips. Record these readings in the Field Commissioning Report.

7. Raise Crest Assembly to elevation 639.0. Close the spillway tainter gate and and water up between the tainter gate and ASW by lowering the Crest approximately 6 inches below forebay water surface elevation.

8. After successful completion of the previous operations, perform them a second time using the Control Room control panel. All wait times specified above may be reduced to 10 minutes for the Control Room Operation.

3.2.2.3 Emergency Operation Testing

1. With the Crest spilling water at elevation 618, connect the intake gantry crane main hoist blocks directly to the Hoist Assembly picking eyes.

2. Engage the Drum Dogs and release the brake to ensure all the load is through the drum dogs. Then re-engage the brake. Disconnect the Hoist power connection.

3. Begin to lift the Hoist/Crest assembly up to elevation 639. Stop every 2 feet and observe the crane load indicators. Record those readings in the Field Commissioning Report.

4. With the Crest at elevation 639 and flow over the ASW shut off, the Government will close the spillway tainter gate. Lower the Crest to approximately 6 inches below Forebay elevation and water up between the tainter gate and the ASW.

5. Continue to raise the Crest past elevation 646 and extend the Track Dogs. Lower the Crest onto the Track Dogs.

6. Disconnect the Hoist from the Crest Extension Links. This will require some means to unload the linkage pins and support the lifting clevises. The contractor shall develop a procedure to do this. Any special equipment required for this operation shall be provided to the Government.

7. Lower the Hoist onto the deck. This operation will require some means to manage the extended wire ropes without damaging them. The contractor shall develop a procedure to do this. Any special equipment required for this operation shall be provided to the Government.

8. Retrieve the ASW Lifting Beam and configure it to transport the

Crest. Connect the ASW Lifting Beam to the Crest Extension Links and raise the Crest so that the dogging beams may be extended.

Lower the dogging beams onto the deck.

9. Remove the Crest Extension Links from the Crest and store them.

Couple the ASW Lifting Beam to the Crest and lift the dogging beams off the deck to retract them.

10. Fully lift the Crest to its maximum height for transport and place the Crest into storage.

3.2.2.4 Return to Storage

Reversing the procedure listed above in paragraph "Installation Procedure", return all the ASW components to their stored locations.

3.2.2.5 Post Operational Inspection

Once all the components are stored, perform an arm's length visual structural, mechanical, and weld inspection of all the ASW components. The Contractor must provide qualified personnel and equipment for this inspection. Government personnel will accompany the Contractor personnel to provide a parallel inspection. Add the results of this inspection to the Field Commissioning Report.

3.2.2.6 Re-installation

Following the procedure specified above in paragraph "Installation Procedure" re-install the ASW in Spillway bay #1.

3.2.2.7 Re-verification Operational Testing

With the ASW returned to service perform a complete motion test of the ASW Crest without spilling water. With the local control panel move the Crest from elevation 639 to elevation 618 and back. Verify that all the limits and controls are functioning properly. Perform a second raise and lower cycle of the ASW operation using the control room control panel.

3.2.2.8 Contractor Lead Unloaded Instruction

The Contractor must give Government personnel instruction on how to operate the controls and point out conditions that require special attention, such as limits. This instruction is to include engaging and disengaging the Drum Dogs and the Track Dogs. The instruction must include one cycle full motion of the Crest utilizing the local control panel followed by a second full motion cycle utilizing the control room control panel.

3.2.2.9 Contractor Lead Storage Instruction

The Contractor must provide instruction to Government personnel as they operate the intake crane and operate the ASW in order to move the ASW components from an operating condition to a stored condition. Following the sequence specified above in paragraph "Return to Storage", the Government will move the ASW components into their respective storage locations.

3.2.2.10 Contractor Lead Installation Instruction

The Contractor must provide instruction to the Government personnel as they operate the intake crane and operate the ASW in order to move the ASW component from a stored location to the installed location in Spillway Bay #1. Following the sequence specified above in paragraph "Installation Procedure", the Government will move the ASW components into Spillway bay #1 and perform all connection required to make the ASW ready for operation.

3.2.2.11 Government Lead Unloaded Operational

The Contractor must provide oversight as the Government duplicates the procedures specified above to perform a full range of motion test with the spillway gate closed. Using the procedure specified above in paragraph "Re-Verification Operational Testing", the Government will perform two full range of motion tests of the ASW Crest. The first test will be using the local control panel and the second test will be using the control room control panel. The test will verify all limits and control functionality of the ASW.

3.2.2.12 Government Lead Loaded Operation

1. The Contractor must provide oversight as the Government duplicates the procedures specified above to perform a full range of motion test of the ASW with the spillway gate opened and the ASW loaded.

Using the procedure specified above in paragraph "Operational Testing", the Government will perform two, full range of motion tests of the ASW crest. The first test will be using the local control panel and the second test will be using the control room control panel. The test will verify all limits and control functionality of the ASW.

2. The contractor must provide instruction and oversight to the

Government personnel as they duplicate the emergency operation procedures specified above in paragraph "Emergency Operation Testing". The Government will perform the emergency procedures utilizing the Contractor provided rope management and lifting clevis support procedures and equipment. After raising the Crest to it transport elevation, the Government will return the ASW to its operating position.

3. At the end of this testing the Government will position the ASW at elevation 639 and close the spillway gate. This will mark the end of the commissioning procedures with the ASW ready for operation at the beginning of the spill season.

3.2.3 Field Commissioning Report

The contractor shall provide a field commissioning report detailing the commissioning activities. The report shall consist of a daily log of the activities, including times that various activities are started and completed. Any issues that develop shall be detailed in the log as well as any corrective actions performed. Any data recorded over the course of the installation and commissioning shall be included in the report. The report shall be signed by the Erecting Engineer.

-- End of Section --

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 01 42.00 28

SPILLWAY WEIR HOIST SYSTEMS

06/02/2016

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 WELDING

3.5.1 General

3.5.2 Filler Metal

3.5.3 Qualification of Welders and Welding Operators

3.5.4 Workmanship Requirements

3.5.4.1 Welding Procedure

3.5.4.2 Preheat and Interpass Temperature

3.5.4.3 Stress-Relief Heat Treatment

3.5.4.4 Temporary Welds

3.5.4.5 Tack Welds

3.5.5 Inspection of Welding

3.5.5.1 Visual Examination

3.5.5.2 Nondestructive Examination

3.5.5.3 Supplemental Examination

3.5.6 Structural Steel Welding Repairs

3.6 Shear Blocks

3.7 Open Spur Gear Alignment

3.8 Guide Wheel Alignment

3.9 Load Limiting

3.10 SHOP ASSEMBLY AND TESTS

3.10.1 General

3.10.2 Test Plan

3.10.3 Drum Synchronicity Test

SECTION 35 01 42.00 28

3.10.4 Static Load Test

3.10.4.1 Drum Dogging Load Test

3.10.4.2 Torque Sensor Load Calibration

3.10.5 Limited Load Test

3.10.6 Dynamic Load Test

3.10.7 Loss of Power

3.11 Track Dog Load Test

3.12 Lifting Beam Operation

3.13 Field Rope Tensioning

3.14 FIELD COMMISSIONING

3.15 FIELD TRAINING

3.16 ACCEPTANCE

-- End of Section Table of Contents --

SECTION 35 01 42.00 28

SPILLWAY WEIR HOIST SYSTEMS

06/02/2016

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 E 165 (2009) Standard Test Method for Liquid Penetrant Examination

ASTM E 709 (2008) Standard Guide for Magnetic Particle Examination

ASTM F436 (2011) Hardened Steel Washers

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

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2010; Errata 2011) Structural Welding Code - Steel

AWS QC1 (2007) Standard for AWS Certification of Welding Inspectors

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-01 Preconstruction Submittals

Qualification Of Welders And Welding Operators ; I, C

Welding Procedure ; G, C

Certified Welding Inspector's Certification And Qualifications ; I, C

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

Nondestructive Examination ; 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 industry best practices and to the requirements specified herein.

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 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 meet the gear design requirements specified above . 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

SECTION 35 01 42.00 28

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.