Tech Specs Amendment 0004.pdf

McNary Navigation Lock Power and Controls Upgrade W912EF23B0011 amd 0003

PROJECT TABLE OF CONTENTS

DI VI SI ON 01 - GENERAL REQUI REMENTS

01 00 00.00 28 GENERAL REQUIREMENTS

01 11 01.00 28 SUPPLEMENTARY REQUIREMENTS

01 14 00.10 28 PROJECT SITE RESTRICTIONS

01 14 00.90 28 INTEGRATING ANTITERRORISM (AT) AND OPERATIONS SECURITY

(OPSEC)

01 22 00.00 28 MEASUREMENT AND PAYMENT

01 32 01.00 28 PROJECT SCHEDULE

01 33 00 SUBMITTAL PROCEDURES

01 35 29.10 28 GOVERNMENTAL SAFETY REQUIREMENTS

01 42 00 SOURCES FOR REFERENCE PUBLICATIONS

01 45 01.00 28 RESIDENT MANAGEMENT SYSTEM CONTRACTOR MODE (RMS CM)

01 45 04.00 28 CONTRACTOR QUALITY CONTROL

01 51 00.00 28 TEMPORARY UTILITIES

01 55 10.00 28 CONTRACTOR WORK, ACCESS AND STORAGE AREAS

01 57 20.00 28 ENVIRONMENTAL PROTECTION

01 78 00.00 28 CLOSEOUT SUBMITTALS

01 78 23.00 28 OPERATION AND MAINTENANCE DATA

01 79 00.00 28 DEMONSTRATION AND TRAINING

01 91 00.00 28 SYSTEMS TESTING AND COMMISSIONING

DI VI SI ON 02 - EXI STI NG CONDI TI ONS

02 41 00.00 28 DEMOLITION

02 82 13.01 28 CLASS II ASBESTOS ABATEMENT

DI VI SI ON 03 - CONCRETE

03 30 00.01 28 CAST-IN-PLACE CONCRETE

03 60 00.01 28 CONCRETE CORE DRILLING

DI VI SI ON 05 - METALS

05 05 20.00 28 POST-INSTALLED ANCHORS IN CONCRETE

05 50 01.00 28 METAL AND MISCELLANEOUS FABRICATION

DI VI SI ON 07 - THERMAL AND MOI STURE PROTECTI ON

07 92 00.00 28 JOINT SEALANTS

DI VI SI ON 09 - FI NI SHES

09 30 10.00 28 QUARRY TILING

DI VI SI ON 13 - SPECI AL CONSTRUCTI ON

13 30 10.00 28 SECONDARY OIL CONTAINMENT

13 34 23.00 28 PREFABRICATED STRUCTURES (CONTROL STANDS)

13 48 00.00 28 SEISMIC RESTRAINT FOR MECHANICAL AND ELECTRICAL EQUIPMENT

DI VI SI ON 25 - I NTEGRATED AUTOMATI ON

25 05 11.00 28 CYBERSECURITY

DI VI SI ON 26 - ELECTRI CAL

PROJECT TABLE OF CONTENTS Page 1

26 05 00.00 28 GENERAL ELECTRICAL WORK

26 05 13.00 28 MEDIUM-VOLTAGE CABLE

26 05 19.00 28 INSULATED WIRE AND CABLE

26 05 36.00 26 CABLE TRAY FOR ELECTRICAL SYSTEMS

26 08 00 APPARATUS INSPECTION AND TESTING

26 12 19.10 THREE-PHASE PAD-MOUNTED TRANSFORMERS

26 23 15.00 28 HIGH RESISTANCE GROUNDING (HRG) SYSTEM - LOW VOLTAGE

(480V)

26 24 13 SWITCHBOARDS

26 24 16.00 28 INTERIOR DISTRIBUTION SYSTEM

26 24 19.00 40 MOTOR CONTROL CENTERS

26 28 01.00 10 COORDINATED POWER SYSTEM PROTECTION

26 29 23 VARIABLE FREQUENCY DRIVE SYSTEMS UNDER 600 VOLTS

DI VI SI ON 27 - COMMUNI CATI ONS

27 21 10.00 28 FIBER OPTIC DATA TRANSMISSION SYSTEM

27 51 16 RADIO AND PUBLIC ADDRESS SYSTEMS

DI VI SI ON 28 - ELECTRONI C SAFETY AND SECURI TY

28 10 05 ELECTRONIC SECURITY SYSTEMS (ESS)

28 23 23.00 28 CLOSED CIRCUIT TELEVISION SYSTEMS

DI VI SI ON 31 - EARTHWORK

31 00 00.00 28 EARTHWORK

DI VI SI ON 32 - EXTERI OR I MPROVEMENTS

32 12 16.11 28 ASPHALT PAVING

32 17 23.00 28 PAVEMENT MARKINGS

32 92 23 SODDING

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

35 01 41.00 10 ELECTROMECHANICAL OPERATING MACHINERY FOR LOCKS AND DAMS

DI VI SI ON 40 - PROCESS I NTERCONNECTI ONS

40 94 43.01 28 PROCESS CONTROLLERS - PROGRAMMABLE LOGIC CONTROLLERS (PLC)

-- End of Project Table of Contents --

PROJECT TABLE OF CONTENTS Page 2

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SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

35 01 41.00 10

ELECTROMECHANICAL OPERATING MACHINERY FOR LOCKS AND DAMS

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 QUALITY ASSURANCE

1.3.1 Manufacturer and Assembler

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Delivery, Storage and Handling of Equipment

1.4.1.1 Packaging

1.4.1.2 Shipping, Preservation, and Storage

PART 2 PRODUCTS

2.1 EQUIPMENT

2.1.1 Machinery

2.1.2 Electrical Equipment

2.1.3 Nameplate

2.2 SPEED REDUCERS

2.2.1 Bascule Bridge Speed Reducers

2.2.2 General

2.2.3 Reducer Housing

2.2.4 Gearing

2.2.5 Reducer Shafts

2.2.6 Shaft Bearings

2.2.7 Gearbox Lubrication System

2.2.8 Seals

2.2.9 Breather

2.2.10 Lubrication

2.2.11 Portable Filtering Unit

2.3 SHAFTS

2.4 SHAFT COUPLINGS

2.5 ELECTRIC MOTORS

2.5.1 Ratings

2.5.2 Construction

2.5.3 Electric Motor Factory Tests

2.5.3.1 No Load Test

2.5.3.2 Locked Rotor Test

2.5.3.3 High Potential Test

2.5.3.4 Stator Winding Resistance Test

2.5.4 Existing Machinery

2.6 BRAKES

2.6.1 Electrohydraulic Actuator

2.6.2 Release Magnets and Rectifier

2.6.3 Enclosing Case

2.6.4 Mechanical Construction

2.7 GUARDS AND COVERS

SECTION 35 01 41.00 10 Page 1

2.8 STRUCTURAL BASES AND SUPPORTS

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 General

3.1.2 Installation and Alignment Procedure

3.1.3 Crane Availability

3.2 TESTS, INSPECTIONS, AND VERIFICATIONS

3.2.1 Speed Reducer Shop Testing

3.2.2 Speed Reducer Field Testing

3.2.3 Startup And Acceptance Test

3.3 MISCELLANEOUS PROVISIONS

3.3.1 Lubrication

3.4 FIELD TRAINING

3.5 OPERATIONS AND MAINTENANCE DATA

-- End of Section Table of Contents --

SECTION 35 01 41.00 10 Page 2

35 01 41.00 10

ELECTROMECHANICAL OPERATING MACHINERY FOR LOCKS AND DAMS

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 6013 (2006A; R2016) Standard for Industrial Enclosed Gear Drives

AGMA ISO 1328-1-B14 (2010A) Cylindrical Gears - ISO System of Flank Tolerance Classification - Part:

Definitions and Allowable Values of Deviations Relevant to Flanks of Gear Teeth

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

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

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

ANSI/AGMA 9000 (2011D) Flexible Couplings - Potential Unbalance Classification

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

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

ASTM INTERNATIONAL (ASTM)

ASTM A668/A668M (2021a) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM D3951 (2018) Commercial Packaging

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 112 (2017) Standard Test Procedure for Polyphase Induction Motors and Generators

SECTION 35 01 41.00 10 Page 3

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 (2016) Motors and Generators - Revision 1: 2018; Includes 2021 Updates to Parts 0, 1, 7, 12, 30, and 31

1.2 SUBMITTALS

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

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

SD-01 Preconstruction Submittals

Equipment Manufacturer's And Fabricator's Qualifications ; G, ME

Installation And Alignment Procedure ; G, ME

SD-03 Product Data

Tail Lift Speed Reducer ; G, ME

Main Leaf Speed Reducer ; G, ME

Shear Pin Speed Reducer ; G, ME

Tail Lift Motor ; G, ME

Main Leaf Motor ; G, ME

Shear Pin Motor ; G, ME

Brakes ; G, ME

Shaft Couplings ; G, ME

Gearbox Lubrication System ; G, ME

Lubricating Oil For Speed Reducers ; G, ME

SD-06 Test Reports

Pre-Functional Checklist ; G, ME

Functional Checklist ; G, ME

Speed Reducer Shop Testing ; G, ME

Speed Reducer Field Testing ; G, ME

Startup And Acceptance Test ; G, ME

SD-11 Closeout Submittals

SECTION 35 01 41.00 10 Page 4

Commissioning Document ; G, ME

1.3 QUALITY ASSURANCE

1.3.1 Manufacturer and Assembler

Manufacturing and assembly of the Bascule Bridge machinery units must be performed by a Contractor and fabrication company that has been normally and regularly engaged in assembly, and manufacture of heavy machinery over the preceding 5 years. Submit Equipment Manufacturer's and Fabricator's Qualifications showing evidence and years of experience for each of the equipment manufacturers and fabricators. Identify any certifications, standards, and/or professional organizations the manufacturers comply with or are members of.

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Delivery, Storage and Handling of Equipment

Protect equipment and components from corrosion, deformation, and other types of damage. Store items in enclosed and secured areas free from contact with soil. Provide moisture proof weather protection for all equipment stored in outdoor locations. Transport, handle and store all equipment in accordance with the manufacturer's written instructions.

Remove and replace damaged items with new items. Ship each subassembly completely assembled.

1.4.1.1 Packaging

Provide equipment and subassemblies with adequate protective pads, supports, and blocking. Securely restrain equipment and subassemblies to prevent distortion or damage to the painted surfaces in transit. Any loss or damage during shipment, including damage to the painted surfaces, is the responsibility of the Contractor. Replace or repair lost or damaged items without cost to the Government. Coat all parts with a rust preventative, wrap in heavy-duty plastic, and securely contain in wooden crates. Clearly mark each crate with its contents (including contract number and Corps mark number) on the outside, with a non-ferrous metal tag, engraved with the contents, and secured to the crate with non-ferrous screws. Provide a means for inspection of the crate's contents without destroying the crate. Pack all accessories and spare parts separately in containers plainly marked "ACCESSORIES ONLY," or "SPARE PARTS ONLY."

Package each spare part or spare part assembly in a durable treated wooden crate with metallic, plastic or suitable outer shell for weathertight protection and with provisions for handling and long-term storage (60 months). Provide and deliver the component and assembly spare parts as delineated on the drawings. Place a separate packing list, listing the contents of each crate, in a moisture-proof envelope securely fastened to the outside of the crate. Standard commercial packaging in accordance with ASTM D3951 is acceptable except where a different method or standard of packaging is specified.

1.4.1.2 Shipping, Preservation, and Storage

Provide all packing, crating, e.g., necessary to ensure safe shipment of equipment. The crates become the property of the Government unless

SECTION 35 01 41.00 10 Page 5 specifically waived. Fill or protect the equipment with the necessary fluids, coatings, and/or preservatives to maintain in a stable condition without corrosion, deterioration, or degradation for an extended period of storage of up to 12 months. Protect stored equipment from the weather, humidity, temperature variation, dirt and dust, or other contaminants.

PART 2 PRODUCTS

2.1 EQUIPMENT

2.1.1 Machinery

Furnish complete units including base supports, geared drives, brakes, motors, shafts, bearings, electrical equipment, controls, covers, guards, portable filtering unit and other necessary items to provide a complete and operable system.

2.1.2 Electrical Equipment

Conform electrical equipment, including limit switches, motor starters, conduit, conductors, controls, to the requirements of Section 26 05 00.00 28 GENERAL ELECTRICAL WORK and Section 26 24 19.00 40 MOTOR

CONTROL CENTERS.

2.1.3 Nameplate

Provide an engraved or raised metallic nameplate that is mechanically attached to each piece of equipment. Include the manufacturer's name, model designation, serial number, unit rating, application factor, reduction ratio's, and any other applicable information on the nameplate.

2.2 SPEED REDUCERS

2.2.1 Bascule Bridge Speed Reducers

Submit product data for the following:

Tail Lift Speed Reducer Main Leaf Speed Reducer Shear Pin Speed Reducer

Submit drawings, manufacturer's literature, and design data necessary to clearly show conformity with the requirements of this specification.

Submit AGMA ratings for gear quality of all gears and gear reducers.

Include the names of the manufacturers of all machinery and other equipment contemplated for incorporation into the work, performance capacities and other pertinent information about the equipment. As a minimum, include the following:

Manufacturer's Name

Type

Model Number

Exact Ratio

Efficiency

Mechanical Rating - Durability - HP, Specify SAC

SECTION 35 01 41.00 10 Page 6

Mechanical Rating - Strength - HP, Specify SAT

Rating Calculations per applicable AGMA Standard

Life Factors CL, KL

Reliability Factors CF, KR

Type of Gearing and Heat-Treatment

Type of Bearings

Minimum L-10 Bearing Life

Method of Lubrication

Size and Number of Mounting Bolts

Weight and Air Volume of Unit without Oil

Weight and Air Volume of Unit with Oil

Outline Dimensional Print

Keys and Keyway Dimensions

Type of Breather

Quantity Being Furnished

AGMA and ISO Lubrication Oil/Viscosity rating

Type of Lubricant

2.2.2 General

Provide speed reducers that are entirely self contained in an oil tight, steel housing designed to maintain shafts and bearings in accurate alignment. Provide with a horse power rating matching the associated prime mover and AGMA service factor of 1.50. Provide the gear ratio as indicated plus or minus 1.5 percent. Design, rate and manufacture the speed reducers in accordance with AGMA 6013 with all components meeting the requirements of ANSI/AGMA 6001 . The gearing must be rated in accordance with ANSI/AGMA 2003 and ANSI/AGMA 2001 . In all cases where these standards or this specification are in conflict with one another the more conservative design standard takes precedence.

2.2.3 Reducer Housing

The reducer housing must be heavy duty cast steel or welded steel construction and have dowel pins at all parting seams for accurate gear and bearing alignment. Split the reducer housing to facilitate disassembly for maintenance and repair. Design the base thickness and width with adequate rigidity and stiffness to not contribute additional stress on the mounting bolts. All surfaces must be smooth and flat and easy to clean. Provide the upper and lower housings with large, rugged lifting lugs. Provide all required oil drains, fill ports, breathers, heater ports, filtering ports, and inspection covers in the housing.

SECTION 35 01 41.00 10 Page 7

Provide a main oil drain at the lowest point possible on the reducer housing. Fit the main oil drain with a 1-inch stainless steel ball valve with a pressure-temperature rating of 2000 psig at 100 degrees F . Plug the valve on the open end. Housing must include 1-inch filter ports with 1-inch stainless steel ball valve to be connected to the portable filtering unit where specified, otherwise cap the ends. Also provide the lower bearings with drainable deepwell bearing end caps as indicated.

Locate drain and fill plugs for speed reducers so as to be readily accessible on the completed units and provide with extension piping where required. Manifold and pipe the drains to a single point with a shutoff valve and threaded cap on the exterior of the housing so that it is easily accessible. The design of the reducer housing should minimize potential for water intrusion as the reducers will be continuously exposed to all weather conditions. This includes raising the upper bearing caps on top of the housing to prevent standing water from seeping into the enclosure.

Internally raise lower bearings within the housing to prevent bearings from being the lowest point in the housings. Top side inspection covers are not acceptable. Provide side inspection access covers.

2.2.4 Gearing

Provide spur or helical gearing made from high strength alloy steel that is heat teated to produce a case hardened gear. After cutting grind gears to achieve a minimum class A in accordance with AGMA ISO 1328-1-B14 .

2.2.5 Reducer Shafts

Make shafts from high-strength alloy steel in accordance with ASTM A668/A668M and of sufficient size and as indicated to insure rigid alignment. All keyways must have fillet radii. Provide keys for all shafts. Design shafts in accordance with the requirements of ANSI/AGMA 6001 . All shafts must have standard keyways and keys in accordance with ASME B17.1 , Class II.

2.2.6 Shaft Bearings

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

2.2.7 Gearbox Lubrication System

Provide each gear box with a lubrication system designed by the gearbox manufacturer. Design the lubrication system to function properly at both nameplate speed ratings using the specified lubricating oil. All gears and lower bearings must be oil lubricated. All upper bearings must be oil and/or grease lubricated. Provide all required oil slingers, dams, and passages. Provide grease lines and lubrication fittings 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. Equip the reducer with a sight gauge and dipstick in order to observe and measure the oil level. Also, fit the speed reducer with an oil sample valve arrangement. The valve must 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. Locate the oil sample port on the reducer housing 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.

SECTION 35 01 41.00 10 Page 8

2.2.8 Seals

Provide spring loaded grease-purged dual lip seals for all shaft extensions. Design and size all seals to withstand the pressure head developed when the speed reducer is completely filled with oil (storage condition) without leaking.

2.2.9 Breather

Provide all reducers 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 must filter particles down to 3 microns in size. The hygroscopic agent must change color signifying when the unit requires replacement, i.e., when the desiccant is saturated with moisture. Air flow stoppage through the breather under freezing conditions is not allowed.

2.2.10 Lubrication

Lubricating oil for speed reducers must have good resistance to foaming under normal operating conditions and be noncorrosive to speed reducer components. Provide the oil in accordance with the gearbox manufacturer's requirements unless otherwise specified herein. Submit lubricant characteristics, physical properties and product data. Provide lubricant suitable for infrequent intermittent duty operation of the speed reducers with an ambient temperature range from minus 10 degrees F to plus 110 degrees F . Lubricate couplings and bearings in accordance with the manufacturer's instructions.

2.2.11 Portable Filtering Unit

Provide portable filtering unit for use with the specified gear reducers.

a. The portable filtering unit must be 1.5 horsepower , 110-120 volt, 1,140 RPM high efficiency, positive displacement, rotary internal gear type pump with a mechanical seal. Provide a pump capable of delivering 8 gallons per minute flow rate. The pump must be self-priming and designed to handle liquids of 35 SSu to 1000 SSu viscosity, while able to develop 25 inches of mercury vacuum at zero psi . Equip the filtering unit with an ON/OFF switch, High/Low pressure switch, two interchangeable filter housings, one set of hose assemblies on a portable rolling cart frame.

b. Equip the one set of filter element with replaceable 5 micron filter cartridges. The portable filtering unit separates water from the oil by coalescing and gravity separation. The water sinks to the bottom and accumulates until it is periodically bled off. The coalescing chamber must be able to handle dissimilar liquids with a specific gravity difference of 0.09 and greater, leaving the effluent with less than 10 ppm of the discontinuous phase. The coalescing element has an indefinite life, with replacement required only when it becomes plugged with solid particles. Provide a multiple element filter with a non-channeling seal. A non-channeling seal has the flow of oil carrying the contaminants into the depths of the filter media with no flow restriction from surface loading. Each element removes water from wet oils. The multiple element filter consists of four or six sections in one housing that all work at the same time. Design the

SECTION 35 01 41.00 10 Page 9 filters so that water and contaminants are absorbed in the filter element. The capacity of the filter element should be approximately 1 gallon of water. A coalescing chamber is not necessary for the portable filtration system.

c. Provide the portable filtering unit secured on a dolly or wheeled cart with all the necessary fittings, hoses, and pipe to connect the unit to the reducer using standard hand tools.

2.3 SHAFTS

Provide heat treated alloy steel shafts with a factor of safety of 5 when maximum load condition stresses are compared to the ultimate strength of the material and the stresses produced by the breakdown torque of the motor do not exceed 75 percent of the material yield strength. Assume maximum load condition is rated capacity of the attached motor. Equations used for design must meet the requirements of the ASME shafting code.

Apply a combined shock-and-fatigue factor of 1.25. Limit the maximum shaft bending moment shaft deflection to 0.01 in/ft of length at the maximum rated load. The torsional shaft deflection must not exceed 0.08 deg/ft of shaft length. Ensure input shaft sizes and configurations are compatible with associated motors. Ensure output shaft sizes and configurations are compatible with the associated intermediate drive shaft.

2.4 SHAFT COUPLINGS

Connect the speed reducer to the motor by flexible coupling. Provide couplings with a service factor of 2 and sized for the rated capacity of the associated motor. Do not exceed 80 percent of yield strength at maximum overload conditions. Assume maximum overload condition is the breakdown torque of the associated motor applied to the coupling. Provide couplings which transmit torque by means of a steel grid spring fitted into groves in the periphery of the coupling hubs or by means of external gears on hubs engaging in internal gears on the coupling sleeves or by hubs engaged with flexible self-lubricating members. Couplings with sleeves held in place by snap rings are not acceptable. Enclose and seal couplings to exclude contaminants and retain the lubricant under both static and operating conditions. Flexible couplings must be ANSI/AGMA 9000 class 7 or better.

Submit manufacturer's literature, and product data necessary to clearly show conformity with the requirements of this specification. Include the names of the manufacturers of all machinery and other equipment contemplated for incorporation into the work, performance capacities and other pertinent information about the equipment. As a minimum, include the following:

Manufacturer's Name

Type

Model Number

Bore Sizes and Tolerances

Number of Keyways

SECTION 35 01 41.00 10 Page 10

Keyway Sizes and Tolerance

Recommended Shaft Size and Tolerance

Recommended Key Size and Tolerance

Recommended Key Material

Keyways Filleted -

Materials of Construction

Catalog Rating - Torque, HP/100 RPM

Service Factor Based on Catalog Rating

Angular Misalignment

Parallel Offset Misalignment

Axial Movement

Torque and HP/100 RPM Capacity of Low Speed Coupling with Anticipated Shaft Fits

Type of Lubrication

Assembly Procedure of Hub with Shaft

Weight

Outline Dimensions Print

Quantity Being Furnished

2.5 ELECTRIC MOTORS

Motor must be Horizontal shaft, squirrel cage induction, high slip, high torque, 460 volt, 3 phase, 60 Hertz type motors. Motors which have VFD drives are required to be inverter rated.The motor must be rated for continuous duty and conform to the applicable requirements of NEMA MG 1.

The motor must be rated at a minimum of 8 percent and maximum of 13 percent slip for windings. The enclosure must be totally enclosed, fan cooled, and weatherproof type. Provide the motors with a removable stainless steel drain. Remove the drain as specified by the motor manufacturer. Submit product data for the following:

Tail Lift Motor Main Leaf Motor Shear Pin Motor

Variance from the indicated motor speed is permitted but it must be coordinated with the corresponding speed reducer to maintain output speed and torque. If a variance is requested submit per paragraph 1.8 Variations Requests of 01 33 00 SUBMITTAL PROCEDURES. Ensure the corresponding speed

SECTION 35 01 41.00 10 Page 11 reducer is submitted at the same time following the same variance procedure.

Submit drawings, manufacturer's literature, and design data necessary to clearly show conformity with the requirements of this specification.

Include the names of the manufacturers of all machinery and other equipment contemplated for incorporation into the work, performance capacities and other pertinent information about the equipment. As a minimum, include the following:

Manufacturer's Name

Type

Frame Number

Unique Serial Number

Certified Factory Motor Test Data, High Speed & Low Speed

Motor Performance Curves, High Speed & Low Speed

Enclosure Type

Input Voltage, Phases, Frequency

Full Load Amps, High Speed & Low Speed

Locked Rotor Amps, High Speed & Low Speed

Insulation Type

Temperature Rise

Drive Output Shaft Size/Tolerances

Space Heater Manufacturer/Type/Size (KW)

Input KW, Input Voltage

Conduit Box Size-Motor

Conduit Box Size-Heater

Drain Description (Manufacturer and Type)

Full Load Torque, High Speed & Low Speed

Upper Limit Torque, High Speed & Low Speed

Lower Limit Torque, High Speed & Low Speed

Locked Rotor Torque, High Speed & Low Speed

Percentage Slip, High Speed & Low Speed

Outline Dimensional Print

Weight of Motor

SECTION 35 01 41.00 10 Page 12

Quantity Being Furnished

2.5.1 Ratings

Provide motors rated for the indicated horsepower at the indicated speed.

Locked rotor torque must be in a range from 200 to 300 percent of full load motor torque. It is preferred to optimize characteristics at full load conditions and allow locked rotor torque to be in the previously specified range if there are design trade-off's between full load torque and locked rotor torque values.

2.5.2 Construction

Provide antifriction type motor bearings incorporating a suitable method for lubrication. Bearing ratings must meet or exceed a L-10 life of 30,000 hours at full radial load. Provide the motor with a visible nameplate indicating motor horsepower, voltage, phase, hertz, RPM, full load amps, frame size, manufacturer's name and model number, service factor, and serial number. Submit motor performance data at the time the motors are submitted. The data includes: percent efficiency, percent amperes, percent power factor, and percent slip plotted against 0 to maximum allowable motor overload above 100 percent for both high and low speed windings; and torque (ft-lb.) and amperes plotted against 0-100 percent synchronous speed.

2.5.3 Electric Motor Factory Tests

Factory test all motors to ensure that they are free from electrical and mechanical defects. Perform tests in compliance with IEEE 112 and NEMA MG 1. Document test results in accordance with the guidance indicated in IEEE 112 and NEMA MG 1. Testing includes the following.

Additionally, perform all tests normally conducted by the manufacturer as part of its quality control program, but not specified herein.

2.5.3.1 No Load Test

At no load and rated frequency and 100 percent rated voltage; record the current, voltage, frequency, kilowatt input, and RPM.

2.5.3.2 Locked Rotor Test

With the motor blocked and at rated test frequency and 50 percent rated voltage; record the voltage, current, frequency, and kilowatt input.

Repeat for 100 percent rated voltage.

2.5.3.3 High Potential Test

Record voltage and duration.

SECTION 35 01 41.00 10 Page 13

2.5.3.4 Stator Winding Resistance Test

Record resistance in ohms between the stator winding terminals. Record the temperature in degrees C.

2.5.4 Existing Machinery

Remove existing machinery as indicated. See below table of existing motors. Table is provided for convenience and is not a complete list of machinery to be removed.

Existing Machinery Name Plate Data mfg. Model Frame HP Voltage FL Amp FL Speed qt

Tail lift Machinery

Motor

General Electric

5KG326E931 326 7.5 220/440 28.8/14.4 675 3

General Electric

5KG324SAG520 324T 10 230/460 36.6/18.3 705 1

Main Lift Machinery

Motor

General Electric

5MR1504CB1 504Z 25 440 40 580 4

Shear Pin Machinery

Motor

General Electric

5KG254E901 254 7.5 220/440 21.8/10.9 1730 1

2.6 BRAKES

Provide brakes that are self-adjusting, shoe type, spring set, released by a sealed electrohydraulic AC thruster actuator, AC magnet operated release, or with AC-rectified solenoid release and are completely enclosed in a water-tight and dust-tight enclosing case arranged for floor mounting. The brake must be alternating current type rated for 460-volts, 3-phase, 60 Hertz. Provide brakes with the indicated operating torque ratings. Base the torque rating on open construction continuous duty.

The brake must be self-adjusting such that compensation for shoe wear is automatic. Provide a manually operated hand release, external to the brake enclosure. The brake torque field setting cannot be less than 125 percent of the full load torque of the motor when referred to the shaft on which the brake wheel is mounted.

Submit drawings, manufacturer's literature, and design data necessary to clearly show conformity with the requirements of this specification.

Include the names of the manufacturers of all machinery and other equipment contemplated for incorporation into the work, performance capacities and other pertinent information about the equipment. As a minimum, include the following:

Manufacturer's Name

Type

SECTION 35 01 41.00 10 Page 14

Model Number

Continuous Duty Torque Rating

Torque Adjustment Range

Supply Voltage

Type of Conduit Box

Type of Lining

Type of Bearing

Type of External Brake Release Mechanism

Brake Wheel Size

Type of Bore

Bore Size

Brake Wheel Material

Brake Wheel Model Number

Space Heater Manufacturer/Type/Size (KW)

Type of Enclosure

Enclosure Model Number

Torque Gauge Included

Torque Scale Included

Weight of Brake

Weight of Enclosure

Outline Dimensional Print of Brake

Outline Dimensional Print of Enclosure

Quantity Being Furnished

2.6.1 Electrohydraulic Actuator

Consists of an electric motor that drives an impeller inside a fluid filled, heavy-duty, cast aluminum housing. The rotation of the impeller must develop hydraulic pressure to extend a cylinder which releases the brake by overcoming the main spring. Provide an adjustable valve to allow setting the brake timing. Completely enclose the actuator in the housing. .

2.6.2 Release Magnets and Rectifier

Provide releasing magnets of the AC shunt type and of standard stock

SECTION 35 01 41.00 10 Page 15 design. Supply direct current by means of a self-contained rectifier unit of proper rating and suitable for operation on 460-volt, 3-phase, 60-hertz, alternating current electrical power. The complete unit (brake and rectifier) must be suitable for connection to the power circuit of the motor with which the brake is used so that the brake will set or release when the motor is de-energized or energized, respectively. The rating of the rectifier and the brake releasing magnet must be in accordance with the brake rating requirements specified and be sufficient to release and hold the brake in the released position with 85 percent of rated voltage impressed on the incoming terminals of the rectifier. The brake must operate satisfactorily at up to 110 percent of rated voltage. Provide a forcing contactor for operation of the DC operated magnet.

2.6.3 Enclosing Case

Provide a NEMA Type 4 enclosing case with watertight grease pressure lubricated shaft seals of a standard manufacturer. Hold the cover in place by heavy hinge bolts and wing nuts. Provide enclosing case for 115 volt AC space heaters. Heaters are provided by the brake manufacturer.

Provide a bottom mounted drain and breather unit on the enclosure to allow condensate water to drain, but prevent outside water from entering the enclosure. Provide the enclosure with a shaft seal for each shaft penetration through the enclosure.

2.6.4 Mechanical Construction

Except for brake wheels, shoes, and electrical parts, no cast iron is allowed in brake construction. All pins, fittings and other miscellaneous small metal parts must be of corrosion-resisting metal. Fit bearings with bronze or other approved bushings to prevent any binding of moving parts.

Antifriction bearings of corrosion-resisting construction may be used.

Provide means for lubrication for all bearings, unless bearings are of a self or pre-lubricated type. Provide and attach a nameplate of corrosion resisting material to a part of the brake which ordinarily will not be replaced. The nameplate must indicate all necessary information required by this specification. Provide a manual release mechanism to allow removal of wheel or permit lining replacement without readjusting torque setting. Magnet coil must be epoxy coated.

2.7 GUARDS AND COVERS

Provide safety guards or covers where necessary to protect the operators from accidental contact with moving parts. Provide openings in guards and covers as necessary to provide access to parts requiring lubrication or regular maintenance.

2.8 STRUCTURAL BASES AND SUPPORTS

For specific requirements for welded structural steel bases, frames, and supports see Section 05 50 01.00 28 METAL AND MISCELLANEOUS FABRICATION.

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 General

Install in accordance with approved Installation and Alignment Procedure.

Thoroughly clean all parts to be installed. Remove packing compounds, SECTION 35 01 41.00 10 Page 16 rust, dirt, grit and other foreign matter. Clean holes and grooves for lubrication. Examine enclosed chambers or passages to make sure that they are free from damaging materials. Where units or items are shipped as assemblies they will be inspected prior to installation. Disassembly, cleaning and lubrication will not be required except where necessary to place the assembly in a clean and properly lubricated condition. Do not use pipe wrenches, cold chisels or other tools likely to cause damage to the surfaces of rods, nuts or other parts used for assembling and tightening parts. Tighten bolts and screws firmly and uniformly but take care not to overstress the threads. When a half nut is used for locking a full nut place the half nut first followed by the full nut. Lubricate threads of all bolts except high strength bolts, nuts and screws with an appropriate lubricant before assembly. Coat threads of corrosion-resisting steel bolts and nuts with an approved anti-galling compound. Driving and drifting bolts or keys will not be permitted.

3.1.2 Installation and Alignment Procedure

Submit the Installation and Alignment Procedure. In the submittal provide detailed manufacturer's instructions concerning the installation and alignment procedures for the equipment to be furnished. Items include gear reducers, shafts, brakes, motors, couplings, and limit switches. The procedure must include consideration of all the other work that is obligated to be performed at the site Lock. Base the procedure on a proper sequence of construction that will complete the work with safety, efficiency, and in full accordance with these specifications.

3.1.3 Crane Availability

The Government's existing cranes will not be available for use in installation of the machinery.

3.2 TESTS, INSPECTIONS, AND VERIFICATIONS

3.2.1 Speed Reducer Shop Testing

Submit a shop test report fully documenting the test. In addition to or as part of the Contractor's normal shop testing procedure, test the reducers at rated speed with no load to check for potential problems prior to field testing. Check gear contact patterns, sound level, lubrication and cooling, and all other operational characteristics. Notify the Contracting Officer 2 weeks prior to performing the shop test.

3.2.2 Speed Reducer Field Testing

Field test the speed reducers at rated speed and load to demonstrate that reducer operation, lubrication, cooling, and instrumentation meet contract requirements. Ensure the duration of the test is long enough to reveal verifiable gear contact patterns. Inspect gear contact patterns and provide to the Contracting Officer. Ensure gear contact patterns are at least 70 percent of face width. Ensure spiral bevel gears have a central toe contact pattern with contact of 50 percent of face width at full load. Photograph and include as part of the field test report the observed gear contact patterns. Document all data collected for load and speed measurement, lubrication, oil temperature and flow, ambient temperature, cooling water temperature and flow, gear contact patterns, and any other data required to show compliance with specifications.

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3.2.3 Startup And Acceptance Test

Submit the pre-functional checklist for approval that includes checks, recordings, measurements and verifications to be performed prior to start

up. Signature by all parties is required for acceptance. Complete all Pre-Functional checklists prior to performing Functional operational tests. Following the completion of installation, checkout, adjustment, and setting the limit switches, controls, interlocks, perform a startup and acceptance test on each machinery unit. Perform the startup and acceptance test in accordance with the approved commissioning functional checklist , record and submit the results on test result forms of the procedure. Signature by all parties is required for acceptance. Include a demonstration of proper functioning of the limit switches, controls, interlocks in the acceptance test. For acceptance, the machinery unit(s) must be successfully operated through a minimum of three complete cycles to satisfy the Contracting Officer that the requirements of the contract have been met and that the performance of the equipment is satisfactory for the purpose intended. Inspect each piece of equipment for smooth operation and proper alignment and check all necessary clearances to ensure vibration, binding, or excessive heat does not occur in any moving part. During the test, provide readings of motor current, RPM, voltage, and bearing temperature. Stop the test immediately if there is any undue noise, vibration, or heat developed in any of the equipment. After correction of alignment and/or all other causes for the interruption of the test, reinspect the unit and resume testing when permitted by the Contracting Officer.

Upon successful completion of the field tests, the Bascule Bridge machinery, accessory items and equipment will be examined by the Contracting Officer, Contractor, and Project Personnel, if found to comply with the contract it will be accepted by signature of all parties in a prepared commissioning document . Signatures and Acceptance will not occur until all found deficiencies have been corrected. submit copies of the signed commissioning document document to the Contracting Officer.

3.3 MISCELLANEOUS PROVISIONS

3.3.1 Lubrication

Lubricate all the components of the equipment requiring lubrication using only the lubricants specified.

3.4 FIELD TRAINING

Provide field training in accordance with 01 79 00.00 28 DEMONSTRATION AND TRAINING after system is functionally complete but prior to final acceptance.

3.5 OPERATIONS AND MAINTENANCE DATA

For each unique piece of equipment specified herein provide Data Package 3 in accordance with Section 01 78 23.00 28 OPERATION AND MAINTENANCE DATA as a part of the O&M submittals specified in that section.

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SECTION 35 01 41.00 10 Page 18

2.5.4 Existing Machinery