A.02.10 Technical Specifications (Amendment 0003).pdf

Lower Mon Spi l l way Gat e hoi st s 1- 8, 1st Gear Reducer Mod W912EF20B0011 Amend-0003

SECTI ON TABLE OF CONTENTS

DI VI SI ON 35 - WATERWAY AND MARI NE CONSTRUCTI ON

SECTI ON 35 01 41. 00 28

ELECTROMECHANI CAL OPERATI NG MACHI NERY FOR LOCKS AND DAMS

PART 1 GENERAL

1. 1 REFERENCES

1. 2 SUBMI TTALS

1. 3 QUALI TY ASSURANCE

1. 3. 1 Manuf act ur er and Assembl y

1. 4 DELI VERY, STORAGE, AND HANDLI NG

1. 4. 1 Del i ver y, St or age and Handl i ng of Equi pment

1. 4. 1. 1 Packagi ng

1. 4. 1. 2 Shi ppi ng, Pr eser vat i on, and St or age

1. 5 DETAI L DRAWI NGS

1. 6 MATERI ALS ORDERS

1. 7 MANUFACTURER' S LI TERATURE AND EQUI PMENT DATA

1. 8 QUALI FI CATI ON OF WELDERS AND WELDI NG OPERATORS

PART 2 PRODUCTS

2. 1 SPEED REDUCERS

2. 1. 1 Gat e Hoi st Speed Reducer

2. 1. 1. 1 Gener al

2. 1. 1. 2 Reducer Housi ng

2. 1. 1. 3 Reducer Mount i ng

2. 1. 1. 4 Mot or Mount i ng

2. 1. 1. 5 Br ake Mount i ng

2. 1. 2 Gear i ng

2. 1. 3 Reducer Shaf t s

2. 1. 4 Shaf t Bear i ngs

2. 1. 5 Gear box Lubr i cat i on Syst em

2. 1. 6 Seal s

2. 1. 7 Heat er

2. 1. 8 Br eat her

2. 1. 9 Lubr i cat i on

2. 2 ELECTRI C MOTORS

2. 2. 1 Rat i ngs

2. 2. 2 Const r uct i on

2. 2. 3 El ect r i c Mot or Fact or y Test s

2. 2. 3. 1 No Load Test

2. 2. 3. 2 Locked Rot or Test

2. 2. 3. 3 Hi gh Pot ent i al Test

2. 2. 3. 4 St at or Wi ndi ng Resi st ance Test

2. 3 BRAKES

2. 3. 1 El ect r ohydr aul i c Act uat or

2. 3. 2 Encl osi ng Case

2. 3. 3 Mechani cal Const r uct i on

2. 4 GUARDS AND COVERS

2. 5 PAI NTI NG

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PART 3 EXECUTI ON

3. 1 MACHI NE WORK

3. 1. 1 Fi ni shed Sur f aces

3. 1. 1. 1 Fl aws on Machi ned Sur f aces

3. 1. 2 Unf i ni shed Sur f aces

3. 2 SHOP ASSEMBLY AND TESTS

3. 2. 1 Gener al

3. 2. 2 Ant i - Sei ze Lubr i cant

3. 2. 3 Accept ance

3. 3 I NSTALLATI ON AND ALI GNMENT PROCEDURE

3. 4 EQUI PMENT PROTECTI ON PLAN

3. 5 FUNCTI ONAL CHECKLI ST

3. 6 EQUI PMENT WARRANTY

3. 7 OPERATI ONS AND MAI NTENANCE DATA

- - End of Sect i on Tabl e of Cont ent s - -

SECTI ON 35 01 41. 00 28

SECTI ON 35 01 41. 00 28

ELECTROMECHANI CAL OPERATI NG MACHI NERY FOR LOCKS AND DAMS

PART 1 GENERAL

1. 1 REFERENCES

The publ i cat i ons l i s t ed bel ow f or m a par t of t hi s speci f i cat i on t o t he ext ent r ef er enced. The publ i cat i ons ar e r ef er r ed t o wi t hi n t he t ext by t he basi c desi gnat i on onl y.

AMERI CAN GEAR MANUFACTURERS ASSOCI ATI ON ( AGMA)

AGMA 2015/ 915- 1 ( 2002A) Accur acy Cl assi f i cat i on Syst em - Tangent i al Measur ement Tol er ance Tabl es f or Cyl i ndr i cal Gear s

AGMA 6013 ( 2016) St andar d f or I ndust r i al Encl osed Gear Dr i ves

ANSI / AGMA 2001 ( 2004D; R 2010) Fundament al Rat i ng Fact or s and Cal cul at i on Met hods f or I nvol ut e Spur and Hel i cal Gear Teet h

ANSI / AGMA 2003 ( 2010D) Rat i ng t he Pi t t i ng Resi st ance and Bendi ng St r engt h of Gener at ed St r ai ght Bevel , ZEROL Bevel , and Spi r al Bevel Gear Teeth

ANSI / AGMA 6001 ( 2008E; R 2014) Desi gn and Sel ect i on of Component s f or Encl osed Gear Dr i ves

ANSI / AGMA 9005 ( 2016) I ndust r i al Gear Lubr i cat i on

ASME I NTERNATI ONAL ( ASME)

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

ASME B4. 1 ( 1967; R 2009) Pr ef er r ed Li mi t s and Fi t s f or Cyl i ndr i cal Par t s

ASME B46. 1 ( 2009) Sur f ace Text ur e, Sur f ace Roughness, Wavi ness and Lay

ASTM I NTERNATI ONAL ( ASTM)

ASTM A668/ A668M ( 2017) St andar d Speci f i cat i on f or St eel For gi ngs, Car bon and Al l oy, f or Gener al I ndust r i al Use

ASTM D3951 ( 2015) Commer ci al Packagi ng

I NSTI TUTE OF ELECTRI CAL AND ELECTRONI CS ENGI NEERS ( I EEE)

I EEE 112 ( 2017) St andar d Test Pr ocedur e f or

Pol yphase I nduct i on Mot or s and Gener at or s

NATI ONAL ELECTRI CAL MANUFACTURERS ASSOCI ATI ON ( NEMA)

NEMA MG 1 ( 2016; SUPP 2016) Mot or s and Gener at or s

1. 2 SUBMITTALS

Gover nment appr oval i s r equi r ed f or submi t t al s wi t h a " G" desi gnat i on;

submi t t al s havi ng an " I " desi gnat i on ar e f or i nf or mat i on onl y. A desi gnat i on f ol l owi ng t he " G" or " I " desi gnat i on i dent i f i es t he of f i ce t hat wi l l r evi ew t he submi t t al f or t he Gover nment . Submi t t he f ol l owi ng i n accor dance wi t h SECTI ON 01 33 00 SUBMI TTAL PROCEDURES:

SD- 01 Pr econst r uct i on Submi t t al s

Shop Test I nf or mat i on; G, ME

I nst al l at i on and Al i gnment Pr ocedur e; G, ME

Equi pment Pr ot ect i on Pl an; G, ME

Funct i onal Checkl i st ; I , ME

SD- 02 Shop Dr awi ngs

Det ai l Dr awi ngs; G, ME

Mat er i al s Or der s; I , ME

Shi ppi ng Bi l l s ; I , ME

SD- 03 Pr oduct Dat a

Manuf act ur er ' s Li t er at ur e and Equi pment Dat a; G, ME

El ect r i c mot or s; G, ME

SD- 05 Desi gn Dat a

Gear box Lubr i cat i on Syst em; G, ME

Lubr i cat i ng Oi l f or Speed Reducer s; G, ME

Reducer Mount i ng; G, ME

SD- 06 Test Repor t s

El ect r i c Mot or s; I , ME

Shop Assembl y and Test s; I , ME

SD- 07 Cer t i f i cat es

Equi pment Manuf act ur er ' s and Fabr i cat or ' s Qual i f i cat i ons; G, ME

Pr ovi de evi dence and year s of exper i ence f or each of t he equi pment manuf act ur er s and f abr i cat or s. I dent i f y any cer t i f i cat i ons, st andar ds, and/ or pr of essi onal or gani zat i ons t he manuf act ur er s compl y wi t h or ar e member s of .

Qual i f i cat i on of Wel der s and Wel di ng Oper at or s; G, M

Submi t cer t i f i cat i ons f or wel der s and wel di ng oper at or s pr i or t o commenci ng f abr i cat i on.

EQUI PMENT WARRANTY; G, M

1. 3 QUALI TY ASSURANCE

1. 3. 1 Manuf act ur er and Assembl y

Manuf act ur i ng and assembl y of t he t ai nt er gat e hoi st machi ner y uni t s shal l be per f or med by a Cont r act or and f abr i cat i on company t hat has been nor mal l y and r egul ar l y engaged i n assembl y, and manuf act ur e of heavy machi ner y over t he pr ecedi ng 10 year s. Changes t o t he di mensi ons shown on t he dr awi ngs and i n t he Bi l l of Mat er i al s f or t he Gat e and Val ve Machi ner y ( i ncl udi ng st r uct ur al suppor t s) r equi r es wr i t t en appr oval f r om t he Cont r act i ng Of f i cer . Submi t Equi pment Manuf act ur er ' s and Fabr i cat or ' s Qualifications showi ng evi dence and year s of exper i ence f or each of t he equi pment manuf act ur er s and f abr i cat or s. I dent i f y any cer t i f i cat i ons, st andar ds, and/ or pr of essi onal or gani zat i ons t he manuf act ur er s compl y wi t h or ar e member s of .

1. 4 DELI VERY, STORAGE, AND HANDLI NG

1. 4. 1 Del i ver y, St or age and Handl i ng of Equi pment

Pr ot ect equi pment and component s f r om cor r osi on, def or mat i on, and ot her t ypes of damage. St or e i t ems i n encl osed and secur ed ar eas f r ee f r om cont act wi t h soi l . Pr ovi de moi st ur e pr oof weat her pr ot ect i on f or al l equi pment st or ed i n out door l ocat i ons. Tr anspor t , handl e and st or e al l equi pment i n accor dance wi t h t he manuf act ur er ' s wr i t t en i nst r uct i ons.

Remove and r epl ace damaged i t ems wi t h new i t ems. Shi p each subassembl y compl et el y assembl ed. Submi t t he shi ppi ng bi l l s wi t h t he del i ver y of f i ni shed assembl i es t o t he s i t e. The mot or , gear r educer and br ake shal l be shi pped as a s i ngl e assembl y.

1. 4. 1. 1 Packaging

Pr ovi de equi pment and subassembl i es wi t h adequat e pr ot ect i ve pads, suppor t s, and bl ocki ng. Secur el y r est r ai n equi pment and subassembl i es t o pr event di st or t i on or damage t o t he pai nt ed sur f aces i n t r ansi t . Any l oss or damage dur i ng shi pment , i ncl udi ng damage t o t he pai nt ed sur f aces, i s t he r esponsi bi l i t y of t he Cont r act or . Repl ace or r epai r l ost or damaged i t ems wi t hout cost t o t he Gover nment . Coat al l par t s wi t h a r ust pr event at i ve, wr ap i n heavy- dut y pl ast i c, and secur el y cont ai n i n wooden cr at es. Cl ear l y mar k each cr at e wi t h i t s cont ent s ( i ncl udi ng cont r act number and Cor ps mar k number ) on t he out si de, wi t h a non- f er r ous met al t ag, engr aved wi t h t he cont ent s, and secur ed t o t he cr at e wi t h non- f er r ous scr ews. Pr ovi de a means f or i nspect i on of t he cr at e' s cont ent s wi t hout dest r oyi ng t he cr at e. Pack al l accessor i es and spar e par t s separ at el y i n cont ai ner s pl ai nl y mar ked " ACCESSORI ES ONLY, " or " SPARE PARTS ONLY. " Package each spar e par t or spar e par t assembl y i n a dur abl e t r eat ed wooden cr at e wi t h met al l i c , pl ast i c or sui t abl e out er shel l f or weat her t i ght pr ot ect i on and wi t h pr ovi s i ons f or handl i ng and l ong- t er m st or age ( 60 mont hs) . Pr ovi de and del i ver t o t he s i t e t he component and assembl y spar e par t s as del i neat ed on t he dr awi ngs. Pl ace a separ at e packi ng l i s t , l i st i ng t he cont ent s of each cr at e, i n a moi st ur e- pr oof envel ope secur el y f ast ened t o t he out si de of t he cr at e. St andar d commer ci al packagi ng i n accor dance wi t h ASTM D3951 i s accept abl e except wher e a di f f er ent met hod or st andar d of packagi ng i s speci f i ed.

1. 4. 1. 2 Shi ppi ng, Pr eser vat i on, and St or age

Pr ovi de al l packi ng, cr at i ng, et c. , necessar y t o ensur e saf e shi pment of equi pment . The cr at es shal l become t he pr oper t y of t he Gover nment unl ess speci f i cal l y wai ved. Fi l l or pr ot ect t he equi pment wi t h t he necessar y f l ui ds, coat i ngs, and/ or pr eser vat i ves t o mai nt ai n i n a st abl e condi t i on wi t hout cor r osi on, det er i or at i on, or degr adat i on f or an ext ended per i od of st or age of up t o 12 mont hs. Pr ot ect st or ed equi pment f r om t he weat her , humi di t y, t emper at ur e var i at i on, di r t and dust , or ot her cont ami nant s.

1. 5 DETAI L DRAWI NGS

Det ai l ed shop dr awi ngs f or gear s, shaf t s, shal l be submi t t ed and appr oved pr i or t o f abr i cat i on.

1. 6 MATERI ALS ORDERS

Submi t copi es of pur chase or der s, mi l l or der s, shop or der s and wor k or der s f or mat er i al s pr i or t o t he use of t he mat er i al s i n t he wor k.

1. 7 MANUFACTURER' S LI TERATURE AND EQUI PMENT DATA

Pr ovi de cat al og cut s and mat er i al dat a f or t he pr oposed equi pment t hat c l ear l y i ndi cat es compl i ance wi t h t he r equi r ement s of t hese speci f i cat i ons and t he dr awi ngs. AGMA r at i ngs f or gear qual i t y of al l gear s and gear r educer s shal l be submi t t ed.

Pr ovi de t he names of t he manuf act ur er s of al l machi ner y and ot her equi pment whi ch i t cont empl at es i ncor por at i ng i nt o t he wor k, t oget her wi t h per f or mance capaci t i es and ot her per t i nent i nf or mat i on per t ai ni ng t o t he equipment.

1. 8 QUALI FI CATI ON OF WELDERS AND WELDI NG OPERATORS

Submi t cer t i f i cat i ons f or wel der s and wel di ng oper at or s pr i or t o commenci ng f abr i cat i on.

PART 2 PRODUCTS

2. 1 SPEED REDUCERS

2. 1. 1 Gat e Hoi st Speed Reducer

2. 1. 1. 1 General

The speed r educer shal l be a s i ngl e r educt i on, r i ght angl e wor m gear t ype, ent i r el y sel f cont ai ned i n an oi l t i ght , st eel housi ng desi gned t o mai nt ai n shaf t s and bear i ngs i n accur at e al i gnment . Pr ovi de t he gear r at i o as 7: 1 mi nus 4 per cent . Desi gn, r at e and manuf act ur e t he speed r educer s f or 15 hp at 1650 r pm i n accor dance wi t h AGMA 6013 wi t h al l component s meet i ng t he r equi r ement s of ANSI / AGMA 6001. The gear i ng must be r at ed i n accor dance wi t h ANSI / AGMA 2003 and ANSI / AGMA 2001. I n al l cases wher e t hese st andar ds or t hi s speci f i cat i on ar e i n conf l i c t wi t h one anot her t he mor e conser vat i ve desi gn st andar d t akes pr ecedence.

2. 1. 1. 2 Reducer Housi ng

The r educer housi ng must be heavy dut y cast st eel , cast i r on or wel ded st eel f abr i cat i on and have dowel pi ns at al l par t i ng seams f or accur at e gear and bear i ng al i gnment . Spl i t t he r educer housi ng t o f aci l i t at e di sassembl y f or mai nt enance and r epai r . Desi gn t he base t hi ckness and wi dt h wi t h adequat e r i gi di t y and st i f f ness t o not cont r i but e addi t i onal st r ess on t he mount i ng bol t s. Al l sur f aces must be smoot h and f l at and easy t o c l ean. Pr ovi de t he upper and l ower housi ngs wi t h l ar ge, r ugged l i f t i ng l ugs. Pr ovi de al l r equi r ed oi l dr ai ns, f i l l por t s, br eat her s, heat er por t s, f i l t er i ng por t s, and i nspect i on cover s i n t he housi ng.

Pr ovi de a mai n oi l dr ai n at t he l owest poi nt possi bl e on t he r educer housi ng. The desi gn of t he r educer housi ng shoul d mi ni mi ze pot ent i al f or wat er i nt r usi on as t he r educer s wi l l be cont i nuousl y exposed t o al l weat her condi t i ons. Top si de i nspect i on cover s ar e not accept abl e.

Pr ovi de si de i nspect i on access cover s. Al l di mensi ons i ndi cat ed must r emai n as shown as a mi ni mum f or pr oper machi ner y al i gnment .

2. 1. 1. 3 Reducer Mount i ng

The r educer shal l have a hol l ow out put shaf t t hat mat ches t he i nput shaf t of t he exi st i ng second r educer and f l ange mount t o t he second r educer at t he i nput shaf t . Cont r act or shal l pr ovi de an adapt er pl at e t o at t ach t he r educer t o t he second r educer . Adapt er pl at e shal l be desi gned t o suppor t t he wei ght of t he mot or , r educer and br ake assembl y. See cont r act dr awi ngs f or second r educer det ai l s. Submi t r educer mount i ng pl at e desi gn i ncl udi ng cal cul at i ons.

2. 1. 1. 4 Mot or Mount i ng

The mot or shal l be C- Face mount ed t o t he i nput shaf t of t he r educer .

2. 1. 1. 5 Br ake Mount i ng

The r educer shal l have an ext ended i nput shaf t on t he opposi t e s i de of t he mot or f or mount i ng t he br ake wheel on. Pr ovi de a br acket mount ed t o t he r educer t o suppor t t he br ake mechani sm and housi ng.

2. 1. 2 Gearing

Pr ovi de gear i ng made f r om hi gh st r engt h al l oy st eel t hat i s har dened by f l ame wi t h subsequent quenchi ng and t emper i ng t o pr oduce a t hr ough har dened gear . Gr i nd t he gear s af t er gear cut t i ng t o achi eve a mi ni mum ANSI / AGMA Qual i t y 11 i n accor dance wi t h AGMA 2015/ 915- 1.

2. 1. 3 Reducer Shaf t s

Make shaf t s f r om hi gh- st r engt h al l oy st eel i n accor dance wi t h ASTM A668/ A668M and of suf f i c i ent s i ze and as i ndi cat ed t o i nsur e r i gi d al i gnment . Al l keyways must have f i l l et r adi i . Pr ovi de keys f or al l shaf t s. Desi gn shaf t s i n accor dance wi t h t he r equi r ement s of ANSI / AGMA 6001. Al l shaf t s must have st andar d keyways and keys i n accor dance wi t h ASME B17. 1, Cl ass I I . Submi t al l f abr i cat ed di mensi ons of t he keyways and keys.

2. 1. 4 Shaf t Bear i ngs

The shaf t bear i ngs must be hi gh capaci t y ant i f r i c t i on r ol l er bear i ngs

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Line sui t abl e f or bot h r adi al and t hr ust l oads. Al l bear i ngs must have a mi ni mum L- 10 bear i ng l i f e of 75, 000 hour s based on t he l ar gest f ul l l oad motor horsepower pr ovi ded by t he speci f i ed mot or .

2. 1. 5 Gear box Lubr i cat i on Syst em

The l ubr i cat i on syst em must be a spl ash t ype syst em usi ng a synt het i c hydr o- car bon l ubr i cant conf or mi ng t o t he r equi r ement s of ANSI / AGMA 9005.

Desi gn t he l ubr i cat i on syst em t o f unct i on pr oper l y at namepl at e speed r at i ngs usi ng t he speci f i ed l ubr i cat i ng oi l . Al l gear s and bear i ngs must be oi l l ubr i cat ed. Pr ovi de al l r equi r ed oi l s l i nger s, dams, and passages. Equi p t he r educer wi t h a s i ght gauge and di pst i ck i n or der t o obser ve and measur e t he oi l l evel . Al so, f i t t he speed r educer wi t h an oi l sampl e val ve ar r angement . The val ve must be a st ai nl ess st eel bal l val ve wi t h a pr essur e- t emper at ur e r at i ng of 2000 psi g at 100 degr ees F and be f i t t ed wi t h a pl ug on t he open end. Locat e t he oi l sampl e por t on t he r educer housi ng such t hat an oi l sampl e can be dr awn ( t hr ough t he sampl e val ve) f r om a poi nt t hat i s appr oxi mat e 1/ 2 of t he oper at i ng oi l l evel i n t he r educer . Fi t t he mai n oi l dr ai n wi t h a 1- i nch st ai nl ess st eel bal l val ve wi t h a pr essur e- t emper at ur e r at i ng of 150 psi g at 100 degr ees F.

Pl ug t he val ve on t he open end. Locat e dr ai n and f i l l pl ugs f or speed r educer s so as t o be r eadi l y accessi bl e on t he compl et ed uni t s and pr ovi de wi t h ext ensi on pi pi ng wher e r equi r ed. Mani f ol d and pi pe t he dr ai ns t o a s i ngl e poi nt wi t h a shut of f val ve and t hr eaded cap on t he ext er i or of t he housi ng so t hat i t i s easi l y accessi bl e.

2. 1. 6 Seals

Pr ovi de spr i ng l oaded dual l i p v i t on seal s f or al l shaf t ext ensi ons.

Desi gn and si ze al l seal s t o wi t hst and t he pr essur e head devel oped when t he speed r educer i s compl et el y f i l l ed wi t h oi l ( st or age condi t i on) wi t hout l eaki ng.

2. 1. 7 Heater

El ect r i c heat i ng el ement s ( i f r equi r ed f or condi t i ons) must have a maxi mum wat t densi t y of 10 W/ sq. i n. and have a suppl y vol t age of 480 Vol t AC, 3phase. Reducer s wi l l be i nst al l ed out door s wi t h ambi ent t emper at ur es r angi ng f r om - 10 F t o 115 F.

2. 1. 8 Breather

Pr ovi de al l r educer s wi t h a hygr oscopi c br eat her wi t h t hr eaded f i t t i ngs f or i nst al l at i on t o pr event pr obl ems caused by moi st ur e and par t i cul at e mat t er cont ami nat i on i n t he r educer when i t br eat hes i n and out due t o t emper at ur e f l uct uat i ons. The br eat her must f i l t er par t i c l es down t o 3 microns i n s i ze. The hygr oscopi c agent must change col or s i gni f y i ng when t he uni t r equi r es r epl acement , i . e. , when t he desi ccant i s sat ur at ed wi t h moi st ur e. Ai r f l ow st oppage t hr ough t he br eat her under f r eezi ng condi t i ons i s not al l owed.

2. 1. 9 Lubrication

Lubr i cat i ng oi l f or speed r educer s must have good r esi st ance t o f oami ng under nor mal oper at i ng condi t i ons and be noncor r osi ve t o speed r educer component s. Pr ovi de t he oi l i n accor dance wi t h t he gear box manuf act ur er ' s r equi r ement s unl ess ot her wi se speci f i ed her ei n. Submi t l ubr i cant char act er i st i cs, physi cal pr oper t i es and pr oduct dat a. Pr ovi de l ubr i cant i n compl i ance wi t h ANSI / AGMA 9005 and be AGMA 5EP. Pr ovi de l ubr i cant sui t abl e f or i nf r equent i nt er mi t t ent dut y oper at i on of t he speed r educer s wi t h an ambi ent t emper at ur e r ange f r om mi nus 10 degr ees F t o pl us 110 degr ees F. Lubr i cat e coupl i ngs and bear i ngs i n accor dance wi t h t he manuf act ur er ' s i nst r uct i ons.

2. 2 ELECTRI C MOTORS

Mot or must be Hor i zont al shaf t , squi r r el cage i nduct i on, hi gh sl i p, hi gh t or que, 460 vol t , 3 phase, 60 Her t z t ype mot or cont r ol l ed by acr oss t he l i ne magnet i c st ar t er . The mot or shal l be C- Face mount ed t o t he r educer .

The mot or must be r at ed f or cont i nuous dut y and conf or m t o t he appl i cabl e r equi r ement s of NEMA MG 1. The mot or must be r at ed at a mi ni mum of 8 per cent and maxi mum of 13 per cent s l i p f or wi ndi ngs. The encl osur e must be t ot al l y encl osed, f an cool ed, and weat her pr oof t ype. Pr ovi de t he mot or s wi t h a r emovabl e st ai nl ess st eel dr ai n. Remove t he dr ai n as speci f i ed by t he mot or manuf act ur er . Mot or i nst al l at i on i s i n an ext er i or l ocat i on subj ect ed t o t he weat her el ement s. Speed/ t or que char act er i st i cs must be as descr i bed her ei n. Pr ovi de condui t box f or i ncomi ng power wi t h two 1- 1/ 2 i nch di amet er hol es f or i nst al l at i on of wat er t i ght f i t t i ngs on t he power cor d. Pr ovi de condui t box f or heat er power wi t h t wo 3/ 4 i nch di amet er hol es f or i nst al l at i on of wat er t i ght f i t t i ng on t he heat er power cor d. Locat e condui t boxes on t he si de of t he mot or as i ndi cat ed. Seal t he mot or shaf t wi t h a l abyr i nt h t ype seal wher e t he shaf t penet r at es t he f r ont and back of t he mot or .

2. 2. 1 Ratings

The gat e mot or s must be r at ed at 15 hor sepower at 1650 RPM based on 1800 RPM synchr onous speeds. The 100 per cent f ul l l oad speed val ues pr oposed f or t he new mot or shal l not be l ess t han 1650 RPM and not mor e t han RPM at t he speci f i ed hor sepower val ues. Locked r ot or t or que must be i n a r ange f r om 200 t o 300 per cent of f ul l l oad mot or t or que f or hi gh speed.

I t i s pr ef er r ed t o opt i mi ze char act er i st i cs at f ul l l oad condi t i ons and al l ow l ocked r ot or t or que t o be i n t he pr evi ousl y speci f i ed r ange i f t her e ar e desi gn t r ade- of f ' s bet ween f ul l l oad t or que and l ocked r ot or t or que values.

2. 2. 2 Construction

Mot or f r ame si ze must be a mi ni mum of a NEMA 286UDZ f or t he gat es.

Temper at ur e r i se must be no gr eat er t han 176 degr ees F. Pr ovi de an i nt er nal heat er of t he st r i p t ype as par t of t he mot or . The heat er must have a mi ni mum capaci t y of 90 W and have separ at e l eads t er mi nat i ng i n a separ at e condui t box. Heat er power suppl y must be 120 vol t , 60 Her t z, s i ngl e phase. Use Cl ass F i nsul at i on t hr oughout t he mot or . I mpr egnat e mot or wi ndi ngs wi t h t he i nsul at i ng compound by t he vacuum/ pr essur e i mpr egnat i ng met hod. Repeat t he pr ocedur e unt i l al l voi ds i n t he wi ndi ng ar e compl et el y f i l l ed wi t h t he i nsul at i ng mat er i al . Mot or bear i ngs must be t he ant i f r i c t i on t ype and i ncor por at e a sui t abl e met hod f or l ubr i cat i on. Bear i ng r at i ngs must meet or exceed a L- 10 l i f e of 30, 000 hour s at f ul l r adi al l oad. Pr ovi de t he mot or wi t h a v i s i bl e namepl at e i ndi cat i ng mot or hor sepower , vol t age, phase, her t z, RPM, f ul l l oad amps, f r ame si ze, manuf act ur er ' s name and model number , ser vi ce f act or , and ser i al number . Submi t mot or per f or mance dat a at t he t i me t he mot or s ar e submi t t ed. The dat a i ncl udes: per cent ef f i c i ency, per cent amper es, per cent power f act or , and per cent s l i p pl ot t ed agai nst 0 t o maxi mum al l owabl e mot or over l oad above 100 per cent f or bot h hi gh and l ow speed wi ndi ngs; and t or que ( f t - l b. ) and amper es pl ot t ed agai nst 0- 100 per cent synchr onous speed f or bot h hi gh and l ow speed wi ndi ngs.

2. 2. 3 El ect r i c Mot or Fact or y Test s

Fact or y t est al l mot or s t o ensur e t hat t hey ar e f r ee f r om el ect r i cal and mechani cal def ect s. Per f or m t est s i n compl i ance wi t h I EEE 112 and NEMA MG 1. Document t est r esul t s i n accor dance wi t h t he gui dance i ndi cat ed i n I EEE 112 and NEMA MG 1. Test i ng i ncl udes t he f ol l owi ng.

Addi t i onal l y, per f or m al l t est s nor mal l y conduct ed by t he manuf act ur er as par t of i t s qual i t y cont r ol pr ogr am, but not speci f i ed her ei n.

2. 2. 3. 1 No Load Test

For each wi ndi ng at no l oad and r at ed f r equency and 100 per cent r at ed vol t age; r ecor d t he cur r ent , vol t age, f r equency, k i l owat t i nput , and RPM.

2. 2. 3. 2 Locked Rot or Test

For each wi ndi ng ( hi gh and l ow speed) ; wi t h t he mot or bl ocked and at r at ed t est f r equency and 50 per cent r at ed vol t age; r ecor d t he vol t age, cur r ent , f r equency, and ki l owat t i nput . Repeat f or 100 per cent r at ed vol t age.

2. 2. 3. 3 Hi gh Pot ent i al Test

For each wi ndi ng ( hi gh and l ow speed) : Recor d vol t age and dur at i on.

2. 2. 3. 4 St at or Wi ndi ng Resi st ance Test

For each wi ndi ng ( hi gh and l ow speed) : Recor d r esi st ance i n ohms bet ween t he st at or wi ndi ng t er mi nal s. Recor d t he t emper at ur e i n degr ees C.

2. 3 BRAKES

Pr ovi de br akes t hat ar e sel f - adj ust i ng, shoe t ype, spr i ng set , r el eased by a seal ed el ect r ohydr aul i c AC t hr ust er act uat or and ar e compl et el y encl osed i n a wat er - t i ght and dust - t i ght encl osi ng case ar r anged f or f l oor mount i ng. The br ake must be al t er nat i ng cur r ent t ype r at ed f or 460- vol t s, 3- phase, 60 Her t z. The br ake must have an oper at i ng t or que r at i ng of 75 foot-pounds wi t h t he br ake wheel bor ed f or mount i ng on t he br ake shaf t .

Base t he t or que r at i ng on open conf i gur at i on cont i nuous dut y. The br ake must be sel f - adj ust i ng such t hat compensat i on f or shoe wear i s aut omat i c.

Pr ovi de a manual l y oper at ed hand r el ease, i nt er nal t o t he br ake encl osur e. The br ake t or que f i el d set t i ng cannot be l ess t han 150 per cent of t he f ul l l oad t or que of t he mot or when r ef er r ed t o t he shaf t on whi ch t he br ake wheel i s mount ed.

2. 3. 1 El ect r ohydr aul i c Act uat or

Consi st s of an el ect r i c mot or t hat dr i ves an i mpel l er i nsi de a f l ui d f i l l ed, heavy- dut y, cast al umi num housi ng. The r ot at i on of t he i mpel l er must devel op hydr aul i c pr essur e t o ext end a cyl i nder whi ch r el eases t he br ake by over comi ng t he mai n spr i ng. Pr ovi de an adj ust abl e val ve t o al l ow set t i ng t he br ake t i mi ng. Compl et el y encl ose t he act uat or i n t he housi ng. The f l ui d must be sui t abl e f or oper at i on i n t emper at ur es t o minus 40 degr ees F.

2. 3. 2 Encl osi ng Case

Pr ovi de a NEMA Type 4 encl osi ng case wi t h wat er t i ght gr ease pr essur e l ubr i cat ed shaf t seal s of a st andar d manuf act ur er . Hol d t he cover i n pl ace by heavy hi nge bol t s and wi ng nut s. Pr ovi de encl osi ng case f or 115 vol t AC space heat er s. Space heat er s t ot al capaci t y must be a mi ni mum of 62 wat t s. Heat er s ar e pr ovi ded by t he br ake manuf act ur er . pr ovi de a bot t om mount ed dr ai n and br eat her uni t on t he encl osur e t o al l ow condensat e wat er t o dr ai n, but pr event out si de wat er f r om ent er i ng t he encl osur e. Pr ovi de t he encl osur e wi t h a shaf t seal f or each shaf t penet r at i on t hr ough t he enclosure.

2. 3. 3 Mechani cal Const r uct i on

Except f or br ake wheel s, shoes, and el ect r i cal par t s, no cast i r on i s al l owed i n br ake component s. Al l pi ns, f i t t i ngs and ot her mi scel l aneous smal l met al par t s must be of cor r osi on- r esi st i ng met al . Fi t bear i ngs wi t h br onze or ot her appr oved bushi ngs t o pr event any bi ndi ng of movi ng par t s.

Ant i f r i c t i on bear i ngs of cor r osi on- r esi st i ng const r uct i on may be used.

Pr ovi de means f or l ubr i cat i on shal l be pr ovi ded f or al l bear i ngs, unl ess bear i ngs ar e of an sel f or pr e- l ubr i cat ed t ype. Pr ovi de and at t ach a namepl at e of cor r osi on r esi st i ng mat er i al t o a par t of t he br ake whi ch or di nar i l y wi l l not be r epl aced. The namepl at e must i ndi cat e al l necessar y i nf or mat i on r equi r ed by t hi s speci f i cat i on. Pr ovi de a manual r el ease mechani sm t o al l ow r emoval of wheel or per mi t l i ni ng r epl acement wi t hout r eadj ust i ng t or que set t i ng. Magnet coi l must be epoxy coat ed.

2. 4 GUARDS AND COVERS

Pr ovi de saf et y guar ds or cover s wher e necessar y t o pr ot ect t he oper at or s f r om acci dent al cont act wi t h movi ng par t s. Pr ovi de openi ngs i n guar ds and cover s as necessar y t o pr ovi de access t o par t s r equi r i ng l ubr i cat i on or r egul ar mai nt enance.

2. 5 PAINTING

See SECTI ON 09 97 02. 00 28 PAI NTI NG: HYDRAULI C STRUCTURES f or pai nt specifications.

PART 3 EXECUTI ON

3. 1 MACHI NE WORK

Tol er ances, al l owances and gauges f or met al f i t s bet ween pl ai n, non- t hr eaded, cyl i ndr i cal par t s shal l conf or m t o ASME B4. 1 f or t he c l ass of f i t shown or r equi r ed unl ess ot her wi se shown on appr oved det ai l dr awi ngs. Wher e f i t s ar e not shown t hey shal l be sui t abl e as appr oved.

Tol er ances f or machi ne- f i ni shed sur f aces desi gnat ed by non- deci mal di mensi ons shal l be wi t hi n 1/ 64 i nch. Suf f i c i ent machi ni ng st ock shal l be al l owed on pl aci ng pads t o ensur e t r ue sur f aces of sol i d mat er i al .

Fi ni shed cont act or bear i ng sur f aces shal l be t r ue and exact t o secur e f ul l cont act . Al l dr i l l ed hol es shal l be accur at el y l ocat ed.

3. 1. 1 Fi ni shed Sur f aces

Sur f ace f i ni shes i ndi cat ed or speci f i ed shal l be i n accor dance wi t h ASME B46. 1. Val ues of r equi r ed r oughness hei ght s ar e ar i t hmet i cal aver age devi at i ons expr essed i n mi cr oi nches. These val ues ar e maxi mum. Lesser degr ees wi l l be sat i sf act or y unl ess ot her wi se i ndi cat ed. Compl i ance wi t h sur f ace r equi r ement s shal l be det er mi ned by sense of f eel and vi sual i nspect i on of t he wor k compar ed t o Roughness Compar i son Speci mens i n accor dance wi t h t he pr ovi s i ons of ASME B46. 1. Val ues of r oughness wi dt h and wavi ness hei ght shal l be consi st ent wi t h t he gener al t ype of f i ni sh speci f i ed by r oughness hei ght . Wher e t he f i ni sh i s not i ndi cat ed or speci f i ed i t shal l be t hat whi ch i s most sui t abl e f or t he par t i cul ar sur f ace, pr ovi de t he cl ass of f i t r equi r ed and be i ndi cat ed on t he det ai l dr awi ngs by a symbol whi ch conf or ms t o ASME B46. 1 when machi ne f i ni shi ng i s pr ovi ded. Fl aws such as scr at ches, r i dges, hol es, peaks, cr acks or checks whi ch wi l l make t he par t unsui t abl e f or t he i nt ended use wi l l be cause f or r ej ect i on.

3. 1. 1. 1 Fl aws on Machi ned Sur f aces

Al l f l aws on sur f aces wi t h a machi ned f i ni sh shal l be r epai r ed and machi ned t o t he r equi r ed f i ni sh. The Cont r act i ng Of f i cer s Repr esent at i ve may wave t he r equi r ement t o r epai r speci f i c i ndi v i dual f l aws i f det er mi ned t o be i nsi gni f i cant .

3. 1. 2 Unf i ni shed Sur f aces

Al l wor k shal l be l ai d out t o secur e pr oper mat chi ng of adj oi ni ng unf i ni shed sur f aces unl ess ot her wi se di r ect ed. Wher e t her e i s a l ar ge di scr epancy bet ween adj oi ni ng unf i ni shed sur f aces t hey shal l be chi pped and gr ound smoot h or machi ned t o secur e pr oper al i gnment . Unf i ni shed sur f aces shal l be t r ue t o t he l i nes and di mensi ons shown and shal l be chi pped or gr ound f r ee of al l pr oj ect i ons and r ough spot s. Depr essi ons or hol es not af f ect i ng t he st r engt h or usef ul ness of t he par t s shal l be f i l l ed i n an appr oved manner .

3. 2 SHOP ASSEMBLY AND TESTS

3. 2. 1 General

Each machi ner y assembl y consi st i ng of t he mot or , br ake, r educer , must be compl et el y assembl ed i n t he shop and t est ed as a uni t . Test uni t s at f ul l speed no l oad and f ul l speed r at ed l oad. Measur e and r ecor d v i br at i on l evel s. Submi t Shop Test I nf or mat i on. The Cont r act or shal l per f or m a shop t est and eval uat i on on t he uni t s f or t he Gover nment t o wi t ness. The Cont r act or shal l not i f y t he Gover nment a mi ni mum of t wo ( 2) weeks pr i or t o al l i nspect i ons of f abr i cat ed uni t s. The Gover nment may per f or m an on si t e eval uat i on of al l i nspect i on dat a f or each assembl y. The Gover nment ' s eval uat i on of i nspect i on dat a wi l l be compl et ed wi t hi n 14 cal endar days of t he Cont r act or s i nspect i on. Al l per f or mance and f unct i onal i t y r equi r ement s, i nspect i on dat a, cr i t er i a eval uat i on, di agr ams, and r ef er ence phot ogr aphs shal l be made avai l abl e by t he Cont r act or f or Gover nment use dur i ng t he on si t e eval uat i on of i nspect i on data.

3. 2. 2 Ant i - Sei ze Lubr i cant

Assembl e t hr eaded por t i ons of t he assembl i es usi ng an ant i - sei ze l ubr i cant t hat pr event s gal l i ng of par t s and cor r osi on, al l ows f or easy di sassembl y of par t s, and r educes f r i ct i on unl ess ot her wi se not ed or speci f i ed.

Ant i - sei ze l ubr i cant must be a st andar d pr oduct desi gned f or t he i nt ended use.

3. 2. 3 Acceptance

Al l r eadi ngs t aken f r om t he equi pment , component s or assembl i es ar e r equi r ed t o be wi t hi n t he speci f i ed l i mi t s. Fai l ur e of any par t t o meet t hese cont r act r equi r ement s i s cause f or r ej ect i on of t he ent i r e quant i t y unt i l act i on i s t aken t o cor r ect def ect s and pr event r ecur r ence and such act i ons have been appr oved by t he Cont r act i ng Of f i cer . Ret est i ng i s subj ect t o t he same r andom sampl i ng and t est i ng pr ocedur es as t he or i gi nal lots.

3. 3 I NSTALLATI ON AND ALI GNMENT PROCEDURE

Pr ovi de det ai l ed manuf act ur er ' s i nst r uct i ons concer ni ng t he i nst al l at i on and al i gnment pr ocedur es f or t he equi pment t o be f ur ni shed. I t ems i ncl ude gear r educer s, br akes and mot or s.

3. 4 EQUI PMENT PROTECTI ON PLAN

Pr ovi de det ai l ed i nf or mat i on on t he met hod pr oposed t o pr ot ect t he exi st i ng equi pment f r om such oper at i ons as power washi ng, abr asi ve bl ast c l eani ng, wel di ng, pl acement of concr et e, and pai nt i ng.

3. 5 FUNCTI ONAL CHECKLI ST

Cont r act or devel oped checkl i st f or checks, r ecor di ngs, measur ement s and ver i f i cat i ons t o be per f or med af t er st ar t up.

3. 6 EQUI PMENT WARRANTY

Submi t manuf act ur er ' s st andar d war r ant y or guar ant ee f or equi pment , e. g. , speed r educer s. War r ant i es shal l be f or a 5- year per i od f r om t he dat e of acceptance.

3. 7 OPERATI ONS AND MAI NTENANCE DATA

For speci f i cat i ons on t he f ur ni shi ng, i nst al l at i on, oper at i ons and mai nt enance i nst r uct i ons, r ef er t o Sect i on 01 78 00. 00 28 CLOSEOUT SUBMI TTALS. Unl ess ot her wi se speci f i ed, al l oper at i on and mai nt enance manual s must be compr ehensi ve t o t he el ect r o- mechani cal oper at i ng syst em wi t h i ndependent sect i ons f or each uni que pi ece of equi pment . Oper at i on and Mai nt enance manual s ar e t o compl y wi t h t he r equi r ement s of Sect i on 01 78 00. 00 28 CLOSEOUT SUBMI TTALS, par agr aph SUBMI TTAL OF OPERATI ON AND

MAI NTENANCE ( O&M) MANUALS AND PARTS CATALOGS.

Unl ess ot her wi se speci f i ed, al l oper at i on and mai nt enance manual s must be compr ehensi ve t o t he el ect r o- mechani cal oper at i ng syst em wi t h i ndependent sect i ons f or each uni que pi ece of equi pment . I ncl ude si x copi es of t he f ol l owi ng bound i nf or mat i on.

a. Saf et y pr ecaut i ons

b. Oper at or pr est ar t

c. St ar t up, shut down, and post - shut down pr ocedur es

d. Nor mal oper at i ons

e. Emer gency oper at i ons f . Envi r onment al condi t i ons

g. Lubr i cat i on dat a

h. Pr event i ve mai nt enance pl an and schedul e i . Cl eani ng r ecommendat i ons j . Tr oubl eshoot i ng gui des and di agnost i c t echni ques

k. Wi r i ng di agr ams and cont r ol di agr ams l . Mai nt enance and r epai r pr ocedur es

m. Removal and r epl acement i nst r uct i ons

- - End of Sect i on - - B