A.0.24_Amend-0002_TechSpec.pdf

McNary 350 Ton Bridge Crane Skew Correction W912EF-16-R-0026 Amend-0002

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 01 20.72 26

BRIDGE CRANE MECHANICAL AND STRUCTURAL MODIFICATION

PART 1 GENERAL

1.1 GENERAL INFORMATION

1.2 REFERENCES

1.3 SUBMITTALS

1.4 DESIGN CRITERIA

1.4.1 General

1.4.2 Unit Stresses

1.4.2.1 Walkways, Ladders and Platforms

1.4.2.2 Bolts

1.4.2.3 Welds

1.4.2.4 Detailing Requirements

1.4.2.5 Mechanical Parts of the Bridge Drive Machinery

1.4.2.6 Stress Concentration Factors

1.4.3 Bolted Connections

1.5 QUALITY ASSURANCE

1.5.1 General

1.5.2 Drawing Index

1.5.3 Drawings

1.5.4 Design Calculations

1.5.4.1 Finite Element Analysis (FEA)

1.5.5 Product Data

1.5.6 Final Approved Versions of Contractor Prepared Drawings

1.5.7 Final Calculations

1.6 OPERATIONS AND MAINTENANCE MANUALS

1.7 SPARE PARTS

PART 2 PRODUCTS

2.1 BRIDGE CRANE WALKWAY GUARDRAILS AND STAIRS MODIFICATION

2.1.1 General

2.1.2 Walkway Guardrails and Stairs

2.2 BRIDGE DRIVE

2.3 MACHINERY EFFICIENCIES

2.4 SPEED REDUCERS

2.4.1 Speed Reducer Rating

2.4.2 Speed Reducer Features

2.4.3 Gear Cases

2.4.3.1 Drain Valves, Plugs and Drip Pans

2.4.4 Speed Reducer Seals

2.4.5 Speed Reducer Lubrication

2.4.6 Speed Reducer Nameplate

2.4.7 Speed Reducer Certified Prints

2.5 ANTI-FRICTION BEARINGS

2.5.1 Speed Reducer Anti-Friction Bearings

2.5.2 Bridge Truck Anti-Friction Bearings

2.5.3 Seals

2.6 KEYS AND KEYSEATS

SECTION 41 01 20.72 26

G4EDDRJR

Line

2.7 SHAFT COUPLINGS

2.7.1 General

2.7.2 Flexible Couplings

2.8 BRIDGE TRUCK EQUALIZER PINS AND BUSHINGS

2.9 WHEELS

2.9.1 Wheel Hardness Testing

2.10 AXLES

2.11 LUBRICATION

2.11.1 General

2.11.2 Speed Reducers

2.11.2.1 New Lubricating Oil

2.11.2.2 Speed Reducer Oil Sampling

2.11.2.3 Speed Reducer Oil Testing

2.11.2.4 New Lubricating Oil Cleanliness

2.11.3 Grease

2.12 CALIBRATION MARKER MONUMENTS AND CRANE ALIGNMENT TARGETS

2.13 ANCHORS FOR CALIBRATION MARKER MONUMENTS

PART 3 EXECUTION

3.1 BRIDGE CRANE MODIFICATIONS

3.1.1 General Background

3.1.2 General Sequence of Work

3.2 CRANE ALIGNMENT MEASUREMENTS

3.2.1 General

3.2.2 Crane Frame, End Truck and Wheel Alignment Measuring Procedure

3.2.2.1 Crane Frame Squareness

3.2.2.2 End Truck, Wheel Alignment and Span

3.2.2.3 Wheel Dimensions

3.2.3 Preliminary Alignment Measurements

3.2.4 Crane Measurement Results and Alignment Recommendation

3.2.5 Post-Modification Alignment Measurements

3.3 END-TIE MODIFICATIONS AND CRACK REPAIR

3.4 END TRUCK MODIFICATIONS

3.4.1 Bridge Drive Trucks

3.4.2 Bridge Idler Trucks

3.4.3 Bridge Truck Equalizer Pins and Bushings

3.4.4 Equalizer Pin Line Boring (Optional)

3.4.5 Crane Jacking Procedure For Removal of End Trucks

3.5 CALIBRATION MARKER MONUMENTS AND CRANE ALIGNMENT TARGETS

3.5.1 General

3.5.2 Installation Details

3.5.3 Crane Squaring Procedure

3.6 CRANE END STOPS

3.7 TIGHTENING OF FASTENERS

3.8 CLEANUP

-- End of Section Table of Contents --

SECTION 41 01 20.72 26

SECTION 41 01 20.72 26

BRIDGE CRANE MECHANICAL AND STRUCTURAL MODIFICATION

PART 1 GENERAL

1.1 GENERAL INFORMATION

This SECTION covers the mechanical and structural work for the modifications of the two (2) 350-ton powerhouse bridge cranes at McNary Lock and Dam. The Contractor shall engineer and design modifications and submit computations and drawings as stated in paragraph SUBMITTALS below.

Furnish detailed shop drawings showing all details required to perform the modification work.

1.2 REFERENCES

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

AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)

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

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

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

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

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

AGMA 6001 (2008e; R 2014) Design and Selection of Components for Enclosed Gear Drives

AGMA 6013 (2006a; r 2011) Standard for Industrial Enclosed Gear Drives

AGMA 9005 (2002e; R 2013) Industrial Gear Lubrication

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 316 (1989) ASD Manual of Steel Construction

AMERICAN WELDING SOCIETY (AWS)

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

ASME INTERNATIONAL (ASME)

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

ASME B17.1 (1967; R 2003) Keys and Keyseats

ASTM INTERNATIONAL (ASTM)

ASTM A 504/A 504M (2008) Standard Specification for Wrought Carbon Steel Wheels

ASTM A 307 (2010) Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength

ASTM A 325 (2010) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A 434 (2006) Standard Specification for Steel Bars, Alloy, Hot-Wrought or cold-Finished, Quenched and Tempered

ASTM A 490 (2012) Standard Specification for Structural Bolts, Alloy Steel, Heat Treated, 150 ksi Minimum Tensile Strength

ASTM D 445 (2006) Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and the Calculation of Dynamic Viscosity)

ASTM D 664 (2007) Standard Test Method for Acid Number of Petroleum Products by Potentiometric Titration

ASTM D 2509 (2003; R 2008) Standard Test Method for Measurement of Load-Carrying Capacity of Lubricating Grease (Timken Method)

ASTM D 4057 (2006) Standard Practice for Manual Sampling of Petroleum and Petroleum Products

ASTM D 4950 (2008) Standard Classification and Specification for Automotive Service Greases

ASTM D 5185 Determination of Additive Elements, Wear Metals, and Contaminants in Used Lubricating Oils and Determination of Selected Elements in Base Oils by Inductively Coupled Plasma Atomic Emission Spectrometry (ICP-AES)

ASTM D 6304 (2007) Standard Test Method for Determination of Water in Petroleum Products, Lubricating Oils, and Additives by Coulometric Karl Fischer Titration

ASSOCIATION FOR IRON AND STEEL TECHNOLOGY (AIST)

TR-06 (2005) Specifications for Electric Overhead Traveling Cranes for Steel Mill Service

CRANE MANUFACTURERS ASSOCIATION OF AMERICA (CMAA)

CMAA 70 (2010) Top Running and Bridge and Gantry Type Multiple Girder Electric Overhead Traveling Cranes, No. 70

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 4406 (1999) Hydraulic Fluid Power - Fluids - Method for Coding the Level of Contamination by Solid Particles - Second Edition

ISO 11171 (1999; Corrigendum 1 2001) Hydraulic Fluid Power - Calibration of Automatic Particle Counters for Liquids - First Edition

U.S. ARMY CORPS OF ENGINEERS (USACE)

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

1.3 SUBMITTALS

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

submittals having an "I" designation are for information only. A designation following the "G" or "I" designation identifies the office that will review the submittal for the Government. The submittals listed in the below Articles shall be submitted within the timeframes specified in this SECTION. The Contractor is responsible for reviewing paragraph

3.1.2 GENERAL SEQUENCE OF WORK and submitting within the specified timeframes. Submit the following in accordance with SECTION 01 33 00

SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Crane Frame, End Truck and Wheel Alignment Measuring Procedure ; G

HDC

North Crane Measurement Results and Alignment Recommendation ; G HDC

South Crane Measurement Results and Alignment Recommendation ; G HDC

North Crane Existing Wheel Dimensions (FIO-071) ; I HDC

South Crane Existing Wheel Dimensions (FIO-071) ; I HDC

Crane Jacking Procedure ; G HDC

Speed Reducer Manufacturer Installation Instructions ; I HDC

Speed Reducer Oil Sampling and Test Plan ; I HDC

Crane Wheel Hardness Testing/Reporting Plan ; I HDC

Equalizer Pin Line Boring Procedure ; I HDC

SD-02 Shop Drawings In accordance with paragraph QUALITY ASSURANCE.

North Crane Arrangement Drawings ; G HDC

South Crane Arrangement Drawings ; G HDC

North Crane Detailed Drawings ; G HDC

South Crane Detailed Drawings ; G HDC

SD-03 Product Data In accordance with paragraph PRODUCT DATA.

Anti-Friction Bearings ; G HDC

Seals ; I HDC

Wheels ; G HDC

Shaft Couplings ; I HDC

Bridge Truck Equalizer Pins and Bushings ; G HDC

Lubrication ; I HDC

Speed Reducers ; G HDC

Speed Reducer Certified Prints ; G HDC

Anchors for Calibration Marker Monuments ; G HDC

SD-05 Design Data

Design Calculations ; G HDC

Final Calculations ; G HDC

North Crane Axle and Wheel As-Machined Final Dimensions ; G HDC

South Crane Axle and Wheel As-Machined Final Dimensions ; G HDC

Bolt Tension Chart ; I HDC

SD-06 Test Reports

North Crane Wheel Hardness Test Report ; G HDC

South Crane Wheel Hardness Test Report ; G HDC

North Crane Oil Test Results (New Oil Delivery) ; I HDC

South Crane Oil Test Results (New Oil Delivery) ; I HDC

North Crane Equalizer Pin/Bushing Inspection Report ; G HDC

South Crane Equalizer Pin/Bushing Inspection Report ; G HDC

North Crane Post-Modification Alignment Report ; G HDC

South Crane Post-Modification Alignment Report ; G HDC

SD-07 Certificates

Registered Professional Engineer ; I HDC

Hardness Testing Instrument Calibration Certification ; I HDC

North Crane Wheel Axle Material Certification ; I HDC

South Crane Wheel Axle Material Certification ; I HDC

SD-08 Manufacturer's Instructions

Crane Squaring Procedure ; G HDC

1.4 DESIGN CRITERIA

1.4.1 General

The design loads and speeds shall be based on the rated capacities and speeds specified in SECTION 41 01 20.71 26 BRIDGE CRANE DATA, TESTING AND TRAINING. For the purpose of design of bridge drive mechanical parts, loads resulting from the maximum torque of the motors shall be taken as 200 percent of the rated full load torque of the motors. Design loads shall be computed with each trolley in such position as will give maximum loading or stress in any part of the bridge drive machinery and with due allowance for eccentricity of application. If there are conflicts between design criteria listed here and listed in referenced documents, the most conservative approaches shall govern.

1.4.2 Unit Stresses

1.4.2.1 Walkways, Ladders and Platforms

Unit stress in structural parts for walkways, ladders platforms and similar parts not affected by primary loads shall be designed to 100% of AISC 316 allowable stresses.

1.4.2.2 Bolts

Allowable stresses in bolts shall be no more than 75 percent of AISC 316 allowable stresses. Allowable stresses in structural bolts not connecting members carrying primary loads shall be designed to 100% of AISC 316 allowable stresses.

1.4.2.3 Welds

Design of welded joints shall be in accordance with the applicable provisions of AWS D1.1/D1.1M , except that allowable stresses in welds shall be no more than 75 percent of AISC 316 allowable stresses.

Allowable stresses in welds designed to meet fatigue provisions shall be designed to 100% of AISC 316 and AWS D1.1/D1.1M allowable stresses. Welds on parts subject to cyclic loads that are in stress categories D, E, or F as per AWS D1.1/D1.1M shall be labeled on the drawings. Allowable stresses in welds not connecting members carrying primary loads shall be designed to 100% of AISC 316 allowable stresses.

1.4.2.4 Detailing Requirements

The detailing of walkways and platforms structural components and connections shall conform to the requirements of AISC 316 .

1.4.2.5 Mechanical Parts of the Bridge Drive Machinery

Mechanical parts of the bridge drive machinery shall be designed for rated load, with a factor of safety of 5 based on the ultimate strength of the materials, provided that each part or component shall be proportioned to withstand the stresses produced by the maximum torque of the motors with resultant stresses not exceeding 75 percent of the yield point of the materials involved. See paragraph AXLES for additional design requirements.

1.4.2.6 Stress Concentration Factors

Stress concentration factors shall be used where applicable, including but not being limited to changes in shaft sections and keyways.

1.4.3 Bolted Connections

Design of bolted connections shall be as follows:

a. Machine bolts or fitted bolts shall be used for assembly connections on machine parts, frames, attaching machine parts, and similar items.

b. ASTM A 325 or ASTM A 490 type bolts shall be used on structural bolted connections carrying primary loads.

c. ASTM A 307 , ASTM A 325 , or machine bolts shall be used for bolted connections on ladders, guard rails, and similar structural items.

1.5 QUALITY ASSURANCE

1.5.1 General

All computations and drawings shall be stamped and signed by a registered professional engineer who has done the design themselves or supervised and reviewed work if done by other engineers. Registered professional engineers shall meet the following requirements:

a. Have experience and knowledge in performing engineering on cranes of similar size and capacity as the McNary bridge cranes. Experience must be on bridge cranes with minimum capacity of 100-Tons and minimum span of 6050-Feet. Experience on cranes other than bridge cranes may be submitted for consideration and the Contractor must explain the relevancy to this project; it will be the Government's discretion if it is considered relevant.

b. Has at least three years relevant experience in the design of new cranes and/or design of replacement components for existing cranes

SECTION 41 01 20.72 26

being rehabilitated. The three years experience must have occurred within the past 10 years to be considered.

Provide a resume for each registered professional engineer submitted.

Resume must show they have the minimum years experience; include name of firm they were employed by, name of project(s) they worked on, contract number, project location, contract point of contact (POC) with contact information (address, phone number, e-mail), crane type and capacity, and describe relevant crane experience.

1.5.2 Drawing Index

All drawing sets shall include a drawing index. The index shall be part of the accompanying drawing set, having a title block, border, and sheet number compatible with the drawing set.

1.5.3 Drawings

Submit drawings for all modification work, no matter how minor. The drawing set shall consist of arrangement drawings and detailed mechanical-structural drawings such as fabricated component drawings for assembly. Show assembly views and all details required for modification work, including but not being limited to, assembly drawings of shop fabricated components and layout and installation of components. When detailed drawings are submitted they shall be submitted with arrangement drawings and parts lists. All material and components used in an assembly shall be approved on the shop drawing. Show plan and elevation views of the crane, indicating locations and layout of all components, with dimensions. Indicate adequate working clearances. Drawings shall include detailed locations of all drilling and welding required in structural members. Weights of items shall be included on the drawings. Bill of materials or parts lists shall be included on the drawings, consisting of total quantity, manufacturer, part number, and summation of weight of all items or equipment. Drawings of replaced components shall be provided.

The use of reference drawings in lieu of providing new drawings will not be acceptable.

a. Submit north crane detailed drawings and north crane arrangement drawings .

b. Submit south crane detailed drawings and south crane arrangement drawings .

1.5.4 Design Calculations

Submit design calculations for all mechanical and structural components provided as per this contract for approval. Submit design calculations for new components (or system of components) concurrent with the drawings and product data specific to the designed component (or system of components). Include within the calculations a list of assumptions made, a list of all codes and standards referenced, equations, specified efficiencies, limits, factors of safety, component ratings, sources of values used, free body diagrams or sketches of each load case. Clearly define all equations, constants, and variables in the calculations with sources cited. When applicable, calculations must examine load path back to existing equipment. Calculations must show that the crane meets the capacities and speeds as listed in SECTION 41 01 20.71 26 BRIDGE CRANE

DATA, TESTING AND TRAINING.

1.5.4.1 Finite Element Analysis (FEA)

When FEA data is submitted, it must be submitted in addition to, not instead of, the design calculations defined in the previous paragraph.

Present FEA in report format. FEA report must include clear indication of all load scenarios, visual and narrative description of load location and application, boundary conditions / fixtures, global mesh attributes, detailed mesh attributes where mesh refinement is required, reasoning for mesh refinement, verification that actual material is consistent with material used in the model, narrative explanation of any peak stresses noted, and narrative explanation of any peak deflections noted. Submit electronic files for any FEA performed. Accompany any FEA data submitted with sample written calculations that support the FEA analysis.

1.5.5 Product Data

Submit complete descriptive literature and specifications of each product or system of products including but not being limited to the items listed in the submittal article. Product data literature shall include original, legible manufacturer's cut sheets and data sheets to clearly indicate physical construction, operation, mechanical and structural characteristics and associated hardware, as applicable. Include manufacturer's catalog numbers and designations, and clearly cross-reference with shop drawings as appropriate. Product data submitted shall clearly show conformance with these specifications, including, but not being limited to, product manufacturers' declarations of conformance to applicable technical standards. Product data will be used for supporting approval of components shown or listed on the drawings.

Acceptance of product data alone does not give approval for procurement of associated materials and equipment. Approval of items for which product data is submitted will be by approving drawings that list these items on the drawing material lists.

1.5.6 Final Approved Versions of Contractor Prepared Drawings

Submit final approved versions of Contractor prepared drawings.

Contractor prepared drawings shall be updated if there are any outstanding comments. Modifications to approved Contractor prepared drawings made during fabrication and installation shall be immediately recorded for inclusion into final versions of Contractor prepared drawings. A set of 11 by 17 inch final approved versions of Contractor prepared drawings shall be inserted in the Operation and Maintenance Manuals.

1.5.7 Final Calculations

Assemble all design calculations with a table of contents and submit for review to verify that all calculations have been assembled, and to verify that they have incorporated all outstanding comments and changes to the design. Title the submittal as final calculations. Upon approval of the final calculations, they shall be inserted as a separate section in the the Operation and Maintenance Manuals.

1.6 OPERATIONS AND MAINTENANCE MANUALS

Operations and maintenance manuals shall be submitted in accordance with

SECTION 01 78 23.00 28 OPERATION AND MAINTENANCE DATA.

1.7 SPARE PARTS

a. Furnish and deliver spare parts to the site, suitably packaged for long-term protection and storage. Legibly label packaging to identify the spare parts. Furnish all spare parts of the same material and workmanship, meeting the same requirements, and interchangeable with the corresponding original parts furnished for systems as outlined in this SECTION. Include a list of the furnished spare parts in the Operation and Maintenance Manuals in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES. Include at a minimum the following spare parts:

(1) Two sets of all repairable gearbox oil seals for bridge drives.

(2) Two sets of all repairable mounted bearing oil seals for wheel assemblies.

(3) One spare bridge drive gearmotor.

(4) Two couplings for each type used.

b. In addition to the above, provide any spare parts not included in the above list but recommended by equipment manufacturers.

c. Deliver spare parts with documentation to facilitate entry into existing government warehouse system. This documentation must include a spreadsheet (in a digital, editable Microsoft Office document as well as a hard copy format) containing each part provided. At a minimum, columns must list part name, part number, list price, manufacturer name, phone, and address.

PART 2 PRODUCTS

2.1 BRIDGE CRANE WALKWAY GUARDRAILS AND STAIRS MODIFICATION

2.1.1 General

In order to install the new mechanical bridge drive components as required, the walkway guardrails and stairs must be modified to provide clearances needed to maintain safe access to the bridge drive machinery.

The contract drawings show conceptual bridge drive motors and speed reducers (gearmotors) and identify potential/necessary modifications to provide clearance and access to the new machinery. The Contractor shall complete the design of the bridge drive and determine if walkway guardrails and stairs modifications are required. Design the walkway guardrail and stairs modifications and submit for approval.

2.1.2 Walkway Guardrails and Stairs

Any new permanent or modified steel walkway guardrails or stairs provided as part of this contract shall comply with the provisions in EM 385-1-1 and this SECTION. Modified and/or new walkway guardrails or stairs shall be designed to be installed flush to existing equipment.

2.2 BRIDGE DRIVE

Design the driving mechanisms so that the travel will be steady and free from vibration or racking in any part of the structure while traveling at all operating speeds from zero hook load up to crane rated capacity; with hook loads positioned anywhere within the normal main hoist hook coverage between the 78'-0" design span. The tractive effort provided to overcome the rolling friction of the bridge crane wheels and mechanical losses of the drive shall be a minimum of 15 lb per ton. In computing the loads on a CMAA A4 drive arrangement 100 percent of the torque of each motor shall be considered as applied to each drive. Provide flexible couplings at the motors. Drive arrangements shall be by means of a shaft mounted speed reducer with motor and torque arm assembly; with speed reducer/motor assembly mounted on each corner drive truck. There shall be no tendency for the crane structure to get out of line while traveling along the entire runway length under any operating condition. Provide the drive with brakes as specified in paragraph BRAKES. See contract drawings for conceptual layout of new bridge drive machinery arrangement.

2.3 MACHINERY EFFICIENCIES

The machinery efficiencies used for calculating the horsepower of the bridge motors shall not exceed those given below for the respective components:

E = 0.95 n for spur, spiral bevel, helical or herringbone gears with roller bearings.

Where: E = efficiency;

n = number of pairs of gears in the speed reducer.

2.4 SPEED REDUCERS

Speed reducers shall be commercially produced standard speed reducers, designed in accordance with AGMA 6013 and AGMA 6001. The contract drawings show conceptual layout of new bridge drive machinery. The speed reducers shown on the drawings are SEW Eurodrive X4KH140/HU/T and the motor is DRE180M4BE20HR/FF/EG7C/2W. The Contractor shall design and submit for approval a bridge drive motor/reducer assembly that meets the requirements of this SECTION and SECTION 41 01 20.73 26 BRIDGE CRANE DRIVE CONTROL UPGRADE. Field verify all dimensions and conditions and submit product data for new speed reducers. Open gears will not be allowed.

2.4.1 Speed Reducer Rating

a. The rating of the speed reducer shall be based on the catalog rating of the speed reducer. The rating shall be equal to or exceed the maximum input power times an application factor of 1.50. The maximum input power shall be the rated horsepower output of the motor or on the full load torque of the motor, depending on the operating speed, taking into account the friction losses in the machinery connecting the motor to the respective speed reducer (it does not include friction losses within the respective reducer).

b. A value of 70 percent of the catalog rating shall be used for reducers for the bridge drives which are subject to reverse loading.

(I.e. 70 percent of the torque rating listed in the standard commercially available speed reducer catalog must be used when sizing and selecting a speed reducer for bridge drives subject to reverse loading.)

c. The overhung loading application factor shall be per the speed reducer manufacturer's recommendation.

d. In addition, the speed reducer shall be sized such that the rated torque (factory torque setting) of the brake will not exceed the catalog torque rating of the speed reducer divided by the speed reducer reduction ratio.

2.4.2 Speed Reducer Features

a. Standard speed reducers shall be a standard catalog product of a speed reducer manufacturer, with special shafts to suit. Speed reducers shall be of the right angle bevel-helical gear type entirely self contained in an oil-tight, steel or cast iron housing designed to maintain shafts and bearings in accurate alignment. The pitch line velocity of spur gears shall not exceed 760 feet per minute at rated load and speed.

b. Unless otherwise approved, the housings shall be in accordance with the provisions of paragraph GEAR CASES.

c. Bearings shall be of the anti-friction type.

2.4.3 Gear Cases

The speed reducer gear cases shall be oil-tight and provided with seals, drain plugs, drip pans, breathers, oil level dip stick or sight glass, lifting lugs, and an oil-tight inspection cover which can be removed for inspection of the gears. Provide gear cases with means of cleaning and draining without dismantling the equipment. Gear cases shall be made of cast iron, cast steel, or of steel plate of welded construction and shall be designed to be sufficiently rigid to maintain proper alignment of the gearing under all load conditions.

2.4.3.1 Drain Valves, Plugs and Drip Pans

Drain valves and plugs must be accessible and where necessary must be piped to convenient locations for draining oil. Fabricate drip pans of aluminum sheets for reduced weight and ease of handling; make removable.

Design drip pans to extend beyond the furthest point of the drain valve and drain plug to fully encompass the projected area of the gear case and drain valve and drain plug.

2.4.4 Speed Reducer Seals

The speed reducer gear cases will be monitored for leaks during the warranty period and any leaks shall be repaired. Any leaks which are inherent to the design and cannot be stopped shall be modified to prevent future leaks.

2.4.5 Speed Reducer Lubrication

Provisions shall be made for adequate lubrication of all gears and bearings throughout the range of operating speeds. Vertical reducers shall be provided with a positive displacement oil pump or other means to lubricate the upper gears and bearings. The pump shall be mounted external to the reducer and shall have a pressure gage mounted on the discharge side. See paragraph LUBRICATION for specifications on speed reducer lubricating oil.

2.4.6 Speed Reducer Nameplate

Provide each reducer with a permanently attached nameplate containing the following information: the name of the manufacturer, the reduction ratio, the rated capacity, speed, and the service rating or service class.

2.4.7 Speed Reducer Certified Prints

Submit speed reducer manufacturer certified prints and speed reducer assembly drawings. Include bills of materials, dimensions, weights, speed reducer nameplate information, and quantity of oil required.

2.5 ANTI-FRICTION BEARINGS

2.5.1 Speed Reducer Anti-Friction Bearings

Speed reducer anti-friction bearings shall be of standard type most suitable for the respective application and shall have both inner and outer races. Ball and roller bearings shall conform to the applicable requirements of ABMA 19.1 , ABMA 19.2 and ABMA 20. The manufacturer's published ratings shall be used in determining the bearing capacity. Fixed bearings shall be secured against a shaft shoulder by means of a locknut and bearing lockwasher as described in ABMA 8.2 . Floating bearings shall be secured against a shaft shoulder by means of a retaining ring or locknut and lockwasher, except that floating bearings at intermediate points on long shafts may be secured with a tapered sleeve and locknut and lockwasher. Bearings, except as noted below, shall have a L-10 life of 5,000 hours and shall be designed for the loads and speeds resulting from the crane performance specified in SECTION 41 01 20.71 26 BRIDGE CRANE

DATA, TESTING AND TRAINING.

2.5.2 Bridge Truck Anti-Friction Bearings

Bridge truck anti-friction bearings shall be of the spherical roller type conforming to ABMA 20, and shall be replaced in kind. Reference FIO-062, FIO-067, FIO-068, FIO-069 and FIO-070. Field verify all dimensions and bearing part numbers before procurement (during Preliminary Alignment Measurements specified in PART 3 of this SECTION). Bearing fits shall be as recommended by the manufacturer for the application. One bearing on each wheel axle shall be fixed, the other bearing shall be arranged to allow for expansion or float of the axle. Fixed bearings shall be secured against a shaft shoulder by means of a locknut and bearing lockwasher as described in ABMA 8.2 . Floating bearings shall be secured against a shaft shoulder by means of a retaining ring, locknut and lockwasher, or designed spacer to provide clamping force between speed reducer and bearing (for drive axles where the floating bearing is located between the speed reducer and wheel the bearing shall be secured with designed spacer).

2.5.3 Seals

Bearings shall have oil tight enclosures and double lipped seals; a synthetic rubber spring loaded element to retain the grease and another synthetic rubber element to exclude foreign matter.

2.6 KEYS AND KEYSEATS

Keys and keyseats shall conform to ASME B17.1 .

2.7 SHAFT COUPLINGS

2.7.1 General

Couplings shall be capable of developing the full strength of the shafting which they connect and shall be pressed and keyed thereon. Press fit shall be Class FN2 minimum per ASME B4.1 . In determining the coupling capacity, the manufacturer's published rating shall be divided by a service factor of 1.5, or factor recommended by manufacturer, whichever is greater. Motor and reducer shafts shall extend all the way through the coupling halves. Couplings with sleeves held in place or retained by snap rings will not be permitted. Coupling components shall be stamped with the manufacturers name and part number. Easily removable hatches or split coupling guards shall be provided to allow inspection of the coupling and monitor coupling grease. Application of couplings shall be in accordance with manufacturers recommended practice unless otherwise noted herein.

2.7.2 Flexible Couplings

Flexible couplings shall consist of two flex coupling halves, be forged steel and shall transmit torque by means of external gears on hubs mating internal gears on the coupling sleeves. Sleeves shall be fastened so that they cannot work or slip off. Couplings shall be enclosed and sealed to retain the lubricant and shall be oil tight under both static and operating conditions. A flex/flex coupling shall be provided at each motor-to-reducer assembly.

2.8 BRIDGE TRUCK EQUALIZER PINS AND BUSHINGS

The allowable bearing pressure for equalizer pins in steel frames shall not exceed 9,000 psi of projected area for the fixed portions, and 5,000 psi for the movable portions. Bridge truck equalizer (pivot) pin components include:

a. Journal bushings shall be lined with self-lubricating material and shall be inserted in the truck bores. The journal bushing shall be thin-walled and backed with aluminum bronze. The equalizer (pivot) pins shall be stainless steel or chromed steel.

b. The self-lubricating material shall be capable of operating under loads in excess of 20,000 psi as calculated using projected area. The self-lubricating layer shall be permanently and securely bonded to the metal of the pin or the backing sleeve. The self-lubricating material shall be high-load, low friction material such as Kamatics Karon V, Gar-Max or approved equal. Self-lubricating tape is not acceptable.

2.9 WHEELS

Wheels shall be 27 inches in diameter. Wheels shall be double-flanged and made from solid wrought wheel blanks conforming to the applicable requirements of ASTM A 504/A 504M , Class C, rim treated, except the tread and inner flange must be uniformly surface hardened to 58 to 62 Rockwell C. The effective depth of surface hardness shall be approximately 3/16-inch, +/- 1/16-inch. Wheels shall have flat/straight tread as shown, turned or ground to true and uniform diameter, matched within 0.001 inches (0.002 inches for idler wheels). The tread width shall exceed the railhead width by no more than 1-1/4 inch (the existing bridge crane rail is USS 175 pounds per yard).

2.9.1 Wheel Hardness Testing

Test wheel hardness after wheels and axles are assembled. Test wheel hardness using a calibrated hardness testing instrument; calibrated within one (1) year of performing wheel hardness testing. Submit hardness testing instrument calibration certification . Test each wheel separately with test results for each wheel presented independently. Take measurements in four (4) quadrants, with measurements in each quadrant including the wheel tread and both flanges. Each measurement location shall include a minimum five (5) measurements and averaged, for a total of 15 measurements per quadrant. Record measurements in table format and submit in a test report. Submit a crane wheel hardness testing/reporting plan to check compliance with these specification, no later than 30 days prior to performing crane wheel hardness testing. Submit north crane wheel hardness test report and south crane wheel hardness test report for review and approval. Do not install the final assembled wheel/axle assembly on the crane until the respective crane wheel hardness test report is approved. The Government will respond to the crane wheel hardness test report submittal within five (5) business days from receiving the submittal.

2.10 AXLES

Design axles in accordance with CMAA 70, Paragraph 4.11, where design includes static stress and fatigue stress checks for normal operating conditions. The surface condition factor must not exceed 1.0 and the crane class factor must be 1.125. Include applicable stress concentration factors and a combined shock and fatigue factor with calculations. Use a combined shock and fatigue factor of 1.75 for bridge drives with reversing loads.

Manufacture bridge truck drive and idler wheel axles from hot-rolled steel conforming to 4340 ASTM A 434 Class BD and heat treat to a minimum tensile strength of 170,000 psi and minimum yield strength of 125,000 psi, unless Contractor's bridge drive design requires higher tensile and yield strengths. Submit north crane wheel axle material certification and south crane wheel axle material certification showing chemical composition and mechanical properties. Shaft fillet radii at bearings must be the maximum size recommended by the bearing manufacturer for the bearing being used.

Fit axles to the truck wheels with an ASME B4.1 , Class FN 2, medium forced fit. Key the driving wheels to the axles in addition to the forced fit.

Submit north crane axle and wheel as-machined final dimensions to verify specified fit prior to assembly of wheels to axles. Submit south crane axle and wheel as-machined final dimensions to verify specified fit prior to assembly of wheels to axles.

2.11 LUBRICATION

2.11.1 General

Lubrication shall be provided for bridge drive speed reducers and gear- or grid-type couplings, bearings, and other mechanical operating parts of the bridge drive. Lubricants shall be compatible with what is currently used at the project. If the Contractor wishes to use an "or equal" product, data shall be furnished showing that the proposed product is compatible with the lubricants currently used at the project.

2.11.2 Speed Reducers

2.11.2.1 New Lubricating Oil

Speed reducer lubricating oil minimum characteristics shall be as specified in the manufacturer's lubrication specifications. If the reducer manufacturer recommends a higher viscosity lubricant, furnish a listing of acceptable lubricants for the Government to select from.

Existing speed reducer lubricating oil is Mobile 634 ISO VG 460.

2.11.2.2 Speed Reducer Oil Sampling

Upon delivery of new lube oil to the Project site, and prior to filling speed reducers with new oil, oil samples shall be collected in accordance with ASTM D 4057 , Manual Sampling of Petroleum and Petroleum Products, and shall be tested as specified in paragraph SPEED REDUCER OIL TESTING below. The sampling method/process shall include the following:

1. Collect oil samples from the original container(s) that the new oil was delivered in.

2. Two (2) samples shall be taken and labeled. One sample, of sufficient volume, for completing all of the oil tests described in paragraph SPEED REDUCER OIL TESTING below, and one sample, of equal volume, to be withheld by the project for future verification and testing if needed.

3. Sample bottles shall not be filled with more oil than 75 percent of its volume.

4. Submit a Speed Reducer Oil Sampling and Test Plan for approval prior to commencing with oil sampling and testing.

5. Submit North Crane Oil Test Results (new oil delivery) a minimum of five (5) calendar days prior to filling the north crane speed reducers with new oil.

6. Submit South Crane Oil Test Results (new oil delivery) a minimum of five (5) calendar days prior to filling the south crane speed reducers with new oil.

2.11.2.3 Speed Reducer Oil Testing

The laboratory analysis for each oil sample shall be performed in accordance with Annex E of AGMA 9005, Industrial Gear Lubricant. The minimum oil tests required for all oil samples shall include the following:

1. Viscosity per ASTM D 445 , Kinematic Viscosity of Transparent and Opaque Liquids.

2. Water Content per ASTM D 6304 , Determination of Water in Petroleum Products, Lubricating Oils, and Additives by Coulometric Karl Fischer Titration.

3. Acid Number per ASTM D 664 , Acid Number of Petroleum by Potentiometric Titration.

4. Additive and Wear Elements per ASTM D 5185 , Determination of

Additive Elements, Wear Metals, and Contaminants in Used Lubricating Oils and Determination of Selected Elements in Base Oils by Inductively Coupled Plasma Atomic Emission Spectrometry

(ICP-AES).

5. Particle Count (with ISO Solid Contamination Code).

Cleanliness of oil samples shall be evaluated in accordance with ISO 4406 :99. Only instruments calibrated in accordance with the ISO 11171 standard shall be used for testing, which are capable of measuring and reporting particles sizes of greater than 4 micron, greater than 6 micron, and greater than 14 micron.

2.11.2.4 New Lubricating Oil Cleanliness

Filter the bridge drive speed reducer lubricating oil to ISO --/15/12 (per ISO 4406:99) using a 5 micron filter. Submit documentation showing filter micron rating is approved by lubricating oil manufacturer prior to filtering new oil. If the speed reducer manufacturer permits an oil cleanliness different than specified the Contractor may submit a letter indicating such, along with a written request for variance. The Government reserves the right to approve or deny the request for variance. Include the speed reducer oil cleanliness (ISO code) requirements specified by the speed reducer manufacturers in the

OPERATIONS AND MAINTENANCE MANUAL.

2.11.3 Grease

a. Lubrication for bridge drive mechanical operating parts shall be by means of grease, and industrial button-type fittings and relief valves shall be provided. Provide new copper tubing and associated fittings for grease supply lines. Grease supply line sizes shall be same as existing. Provide new grease line supports.

b. New grease lines shall be routed to existing manifold blocks and labeled. Relocate manifolds to the face of the bridge girder adjacent the stairs, as shown. Route grease supply lines in a neat and uniform manner. All grease lines shall be de-burred, cleaned with compressed air and purged with new grease to verify metal debris from tube cutting is completely removed.

c. General purpose grease shall be NLGI No. 2 high temperature Lithium complex type meeting the highest performance categories of ASTM D 4950 Automotive Grease Classification System, GC-LB. The grease shall provide extreme pressure (EP) performance and be rated for high Timken O.K. load of 70 pounds minimum per ASTM D 2509 . The base fluid viscosity range shall be 400 cSt at 40 degrees C and 24.3 cSt at 100 degrees C, with a viscosity index of 76. The general purpose grease shall be compatible with what is currently in use on the bridge cranes at McNary Lock and Dam.

d. Gear- or grid type couplings shall use coupling grease suitable for the application and as recommended by the gearmotor manufacturer.

Provide coupling grease that is compatible with what is currently in use on the bridge cranes at McNary Lock and Dam.

2.12 CALIBRATION MARKER MONUMENTS AND CRANE ALIGNMENT TARGETS

Crane marker monuments (CMM) and crane alignment targets (CAT) shall be designed for manually checking crane alignment and squaring. Three (3)

CMM pairs shall be provided for each crane (total of six pairs for job) and installed as defined in PART 3 of this SECTION. Two (2) CATs shall be provided for each crane, and installed as defined in PART 3 of this SECTION. Construct CMMs and CATs from formed 11 Gage steel, as shown.

The size of the CMMs and CATs is conceptually shown on the contract drawings, however shall be designed large enough to be easily viewable from the operator cab on the upstream end of the crane to the downstream CMM/CAT location approximately 78-feet away. Paint the north crane CMMs and CATs with gloss bright white center and gloss black border, as shown.

Paint the south crane CMMs and CATs with gloss blaze orange center and gloss black border, as shown.

Submit drawings for the north and south crane CMM and CAT. Include details for CMM mounting locations on the corbel, procedures, materials, and survey data for installation and alignment of CMMs to CAT locations on the crane. Include mounting details and materials for installing CATs onto bridge trucks as shown.

2.13 ANCHORS FOR CALIBRATION MARKER MONUMENTS

Provide anchors with a maximum diameter of 3/8". Provided anchor type must be expansion, undercut, or epoxy anchor type only; plastic and screw type anchors are not permitted. Install the anchor according to the manufacturer's recommendations. Use a suitable anchor type for the environmental conditions. Do not exceed the minimum edge distance; this applicable to both the edge of the corbel and the grout/concrete barrier.

PART 3 EXECUTION

3.1 BRIDGE CRANE MODIFICATIONS

3.1.1 General Background

The bridge cranes were rehabilitated in 2005 and included complete replacement of the end trucks and bridge drive controls. The bridge drive control design and taper drive wheels have caused the cranes to travel skewed on the rails resulting in accelerated wear on the wheels and rail.

Additionally, there is evidence each crane frame is racking from the skewing, and cracks have developed in the end-ties.

3.1.2 General Sequence of Work

The structural and mechanical modifications to each crane are defined in the following paragraphs of this SECTION. The work applies to both cranes unless noted. The bridge drive electrical controls upgrades are defined in SECTION 41 01 20.73 26 BRIDGE CRANE DRIVE CONTROL UPGRADE.

Complete the structural and mechanical modifications in the following sequence (list is not all inclusive), unless otherwise approved:

1. Within 45 days after the receipt of Notice to Proceed submit the Crane Frame, End Truck and Wheel Alignment Measuring Procedure.

2. Within 100 days after the receipt of Notice to Proceed complete the Preliminary Alignment Measurements of both cranes to document existing alignment and tracking conditions. Each crane will be available to the Contractor for a short duration defined as the "early on-site work window" as specified in 52.211-10 COMMENCEMENT, PROSECUTION, AND COMPLETION OF WORK, and work shall be conducted during the normal

Government schedule as defined in SECTION 01 14 00.10 28 PROJECT SITE RESTRICTIONS, paragraph "Government's Work Schedule". Only one crane will be made available to the Contractor at a time. Coordinate with the COR for dates of crane availability. Upon completion of Preliminary Alignment Measurements the crane must be returned to normal operating service.

3. Submit the Crane Measurement Results and Alignment Recommendation for each crane not more than 10 days after completing the Preliminary Alignment Measurements of the crane.

4. Within 145 days after the receipt of Notice to Proceed all design submittals, product and shop drawing submittals must be submitted.

5. The first crane will not be made available to the Contractor for construction work until ALL of the following are complete and approved:

a. Crane Measurement Results and Alignment Recommendation submittal is approved.

b. Design submittals including product and drawing submittals are approved.

c. Crane jacking procedures and pre-construction submittals are approved.

d. Shop fabricated components are complete inspected and shop tested (including factory testing of bridge drive controls).

(Excluding finish fabrication of eccentric bore bearing cartridges for which final dimensions will not be known until the end trucks and wheel alignments are re-measured after completing end-tie modifications.)

6. Each crane will be made available to the Contractor for skew correction modification work for a maximum duration specified in 52.211-10 COMMENCEMENT, PROSECUTION, AND COMPLETION OF WORK, and work shall be conducted during the normal Government schedule as defined in SECTION 01 14 00.10 28 PROJECT SITE RESTRICTIONS, paragraph "Government's Work Schedule". This work window includes all demolition, installation, final inspections, no-load testing, acceptance testing and load testing. The general sequence of modification work shall be as follows (list is not all inclusive), unless otherwise approved:

a. End-tie modifications and crack repairs.

b. Removal and installation of electrical equipment as specified in SECTION 41 01 20.73 26 BRIDGE CRANE DRIVE CONTROL UPGRADE.

c. Re-measure crane frame, end truck and wheel alignments upon completion of end-tie modifications. Check against Preliminary Alignment Measurements. Modify bridge truck and wheel alignment method as needed. Revise bridge truck eccentric bore bearing cartridge drawings as needed.

d. Perform wheel/axle replacements and other necessary end truck modifications as approved. Install new speed reducers and motors.

e. Perform final measurement of crane frame square, and measure end truck and wheel alignment for post assembly alignment.

f. Install calibration marker monuments and crane alignment targets.

g. Perform final inspections and testing as defined in SECTION

41 01 20.71 26 BRIDGE CRANE DATA, TESTING AND TRAINING.

3.2 CRANE ALIGNMENT MEASUREMENTS

3.2.1 General

Perform preliminary alignment measurements of each crane to document existing alignment and tracking conditions prior to end-tie and bridge drive modifications. Analyze the preliminary alignment measurement results and provide a recommendation for "best fit alignment methods" to improve crane frame and end truck/wheel alignment. Upon completion of all work, perform post-modification alignment measurements of each crane. See paragraph 3.1.2 of this SECTION for details of duration and sequence of all crane alignment measurements to be performed.

3.2.2 Crane Frame, End Truck and Wheel Alignment Measuring Procedure

All crane alignment measurements (both preliminary and post-modification) shall include crane frame squareness measurements, end truck wheel alignment, wheel span measurements and any other measurements or surveys necessary to determine alignment and tracking condition of each crane.

Submit a Crane Frame, End Truck and Wheel Alignment Measuring Procedure by the date specified in paragraph 3.1.2. Procedure shall include product literature for tools and equipment necessary to complete measurements (including accuracy of measuring instruments), calibration certificates for measuring instruments (calibrated within one year of performing measurements), step-by-step detailed sequence, sketches and plans for recording alignment measurements and all other requirements defined in the following paragraphs.

3.2.2.1 Crane Frame Squareness

Measure squareness of the bridge crane frame in plan view, once after traveling in one direction for three bays and again after traveling for three bays in the opposite direction. Squareness measurements shall consist of taking the diagonals from corner to corner where the end tie connects to the main girder at the bottom of the end tie. The angle from the main girder to the end tie shall also be measured for each corner of each bridge crane. Provide report of measurements taken inclusive figures depicting measurements taken and note the bays traversed and the bay at which measurements were taken. Accuracy of measurements shall be +/- 1/32 inches.

3.2.2.2 End Truck, Wheel Alignment and Span

Perform field measurements for all crane wheels (16 per crane) including wheel alignment and span distance. Wheel alignment measurements shall be made relative to parallel reference lines placed on the outside of the bridge span. Remove rail sweeps to perform measurements and reinstall upon completion.