Amendment_2_Revised_Specifications_and_Reference_Drawings.pdf

LQP Sluice Gates-1

LAC QUI PARLE

SLUICE GATE SUPPLY

CONTRACT

SCOPE OF WORK

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

PART 2 PRODUCTS

2.1 GENERAL

2.1.1 Gate Frame

2.1.2 Pedestal Base Plates

2.1.3 Lift Stem and Couplings

2.1.4 Stem Guides

2.1.5 Stem Covers

2.1.6 Fasteners

2.1.7 AWWA C542 Electric Operator

2.1.8 Welding

PART 3 EXECUTION

3.1 DELIVERY LOCATION

3.2 INSTALLATION

3.2.1 Installation Instructions

3.3 TOOLS

3.4 SPARE PARTS

3.4.1 Mechanical

-- End of Table of Contents –

LQP Sluice Gates-2

SLUICE GATES

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 in the text by basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM A 193 (2015) Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications

ASTM A 276 (2010) Standard Specification for Stainless Steel

Bars and Shapes

ASTM F 593 (2013) Standard Specification for Stainless Steel

Bolts, Hex Cap Screws, and Studs

ASTM F 594 (2009) Standard Specification for Stainless Steel

Nuts

American Water Works Association (AWWA)

AWWA C542 (2009) Electric Motor Actuators for Valves and Slide Gates

AWWA C561 (2014) Fabricated Stainless Steel Slide Gates

American Welding Society (AWS)

AWS D1.6 (2007) Structural Welding Code Stainless Steel

1.2 SUBMITTALS

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

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

SD-01 Data

Design Data; G.

Design computations and technical data showing factors of safety, calculations of bending moments, shear, and resulting stresses, deflection, and gate lifting loads shall be submitted to the Contracting Officer. Provide catalog cuts and material data for the proposed actuators that clearly indicates compliance with these specifications. Provide performance data sheets, wiring diagrams, and dimensional drawings of proposed actuators to include gate lifting load calculations. This submittal shall be approved by the Government prior to the commencement of fabrication.

SD-01 Data

LQP Sluice Gates-3

Welding Procedures; FIO

Submit welding procedures showing conformance to AWS D1.6. This submittal shall be submitted to the Government prior to the commencement of fabrication.

Welding Procedure Qualification Records; G

Submit all welding procedure qualification records for all non-prequalified joints. This submittal shall be approved by the Government prior to the commencement of fabrication.

Welder Qualification Records; FIO

Submit welding operator test results showing each individual welding operator working on the job is qualified to make the joints required. This submittal shall be submitted to the government prior to contract completion.

Welding Filler Metal Test Results; FIO

Submit manufactures data for each welding filler metal lot used on the job indicating physical and chemical test results. This submittal shall be submitted to the government prior to contract completion.

Mill Certifications; G

Submit mill certifications for all plate and rolled shape material used on the job. This shall be tracked by heat number.

All pertinent physical and chemical test results must show conformance to the above referenced ASTM Specifications. This submittal shall be approved by the Government prior to commencing fabrication.

Non-Destructive Testing Technician Credentials; FIO

Submit the name and AWS certificates for all non-destructive testing technicians that worked on the job. This submittal shall be submitted to the government prior to contract completion.

Non-Destructive Testing Reports; FIO

Submit copies of all non-destructive testing reports. Reports shall reference joints on the shop drawings and any rejectable defects will be highlighted and described such that they can be readily located on the gate. Follow up post repair test reports resulting from the identification of rejectable flaws shall be clearly identified as post repair tests. This submittal shall be submitted to the government prior to contract completion.

SD-04 Drawings

Shop Drawings; G.

Shop drawings shall be submitted for sluice gates, frames, new portion of the stems, couplings, actuators, and keys indicating all dimensions and tolerances, weld callouts, LQP Sluice Gates-4 details for mounting, material specifications, construction and installation procedures. All full penetration splices shall be clearly labeled. Shop drawings shall include complete anchor bolt installation details with all procedures and instructions. Catalog data, including specifications and full descriptive data, shall be submitted and approved for all materials and equipment furnished before fabrication of the sluice gates begins. Individual gate and frame part numbers shall reference the mill heat number from which the stock was cut. The heat number is not required for mechanical items included in the actuator assemblies.

SD-19 Operation and Maintenance

Manuals Operation and Maintenance

Manuals; G.

The Contractor shall submit, prior to delivery of gates to the project work site, three copies of a manual containing complete information in connection with the installation, operation, lubrication, adjustment, routine and special maintenance, disassembly, repair, and seal replacement for the gates, actuators, and accessories.

Flysheets shall be placed before instructions covering the subject. The sheets shall be approximately 8-1/2 x 11" with large sheets of drawings folded in. At a minimum each set shall include the following:

a. Operating and maintenance instructions for each piece of equipment including lubrication instructions with list of proper lubricants.

b. Installation instructions including anchor bolts.

c. All Manufacturer's bulletins, cuts, and descriptive data

d. Parts lists and recommended spare parts.

e. One copy of each shop drawing.

1.2.1 Submittal Procedures

The contractor shall allow five working days for government review of each submittal. If any submittal is returned as disapproved the contractor shall allow three working days for government review of each subsequent resubmittal. All submittals shall be recorded in the attached submittal register, which will be maintained by the GOVERNMENT TECHNICAL POINT OF CONTACT. Submittals shall be provided to the designated GOVERNMENT TECHNICAL POINT OF CONTACT, to be identified after contract award.

PART 2 - PRODUCTS

2.1 General

Furnish three (3) new 48x48” sluice gates and six (6) new 72x96” sluice gates, complete with AWWA C542 gate operators, operator stands, stems, LQP Sluice Gates-5 couplings, wall brackets, fasteners, and all other parts required for installation. Removal of existing sluice gates, stems, pedestals, and operators will be by others. Installation of the new sluice gates and operators will be by others. New sluice gates shall be designed and configured to be direct replacements for existing sluice gates. The new sluice gates and new operators shall be designed to fit to the existing concrete structure in the same location as the existing equipment with no dimensional alterations to the existing structures. Furnish all associated fasteners required to attach the new equipment to the existing structure. The new slide gates shall traverse from full closed to full open and from full open to full closed in a smooth continuous fashion without binding or sticking.

Existing sluice gate details are indicated on the following reference drawings:

TABLE 1: CONTRACT REFERENCE DRAWINGS (AS-Builts)

REFERENCE DRAWING

NUMBER

REFERENCE DRAWING TITLE

M34-L-LQP-40/8 AS-BUILT AND EXISTING CONDITION

M34-P-LQP-68/1 DAM PLAN AND ELEVATION

M34-P-LQP-68/2 OPERATOR PLATFORM MODIFICATION

M34-P-LQP-68/3 SLUICE GATE MOTORIZATION

M34-S-LQP-68/10 VICINITY AND LOCATION MAP

M34-S-LQP-68/14 TRASH RAKE AND DEFLECTOR PLATES

New sluice gates and operators including gate, stem, and operators shall conform to requirements of or AWWA C561 (for stainless steel gates) and AWWA C542. Gates and accessories shall be of the following design:

a. New sluice gates shall be rising stem.

b. New sluice gates shall be wall mounted same as existing sluice gates.

c. New sluice gate frames shall have flat back flange frames same as existing sluice gates.

d. Frames shall be sufficiently rigid to preclude distortion during installation

e. All gate and frame members shall be 0.25-inch minimum thickness conforming to ASTM A276 Type 304 or 316.

Component parts shall be designed for the seating and unseating heads shown in TABLE 2 in this section using a minimum factor of safety of 5.

Provide sluice gate seal design with opening and closing seal friction force coefficients no greater than 0.6. Stem design shall include a factor of safety of 5 against failure in addition to the column buckling strength reduction effects as given by the Euler formula. The stem slenderness ratio (L/R) shall not exceed 200.

TABLE 2: NEW SLUICE GATE REQUIREMENTS

Opening size Width x Height

Quantity required

Seating head Ft.H20

Unseating head Ft.H20

48” x 48” 3 25 0 72” x 96” 6 15 0

LQP Sluice Gates-6

Seating head and unseating head are defined as the distance from the center of the sluice gate, in its closed position, to the maximum water surface elevation.

2.1.1 Gate Frame

Wall frame for sluice gates shall be flat back flange type, with the flange (facing the wall) machined to a plane to provide a true seating surface for the sluice gate frame. Frame flanges shall be designed to mount to a flat vertical concrete wall. Thimbles or other embedded interface structures shall not be required. Design and provide all materials to seal up to ¼-inch thick gaps at the sluice gate to concrete wall interface.

Provide all pre-drilled anchor bolt holes in the sluice gate frames.

Existing sluice gate anchor bolts may not be reused and may be cut off flush with the concrete surface. New anchor bolt locations shall not coincide with known existing anchor bolt locations. All existing anchor bolt locations have not been identified. Known anchor bolt locations are indicated on M34-S-LQP-68/14. For 6’x8’ sluice gates presume the existing top anchor bolt locations are the same as the existing bottom anchor bolt locations. For 4’x4’ sluice gates the top and bottom anchor bolt locations are not documented. For known existing anchor bolt locations provide new anchor bolt locations approximately equally spaced between existing anchorages or as approved. For spans where existing anchor bolt locations are not documented, provide predrilled holes in the gate frames spaced approximately 6-inches on center or as approved.

All sluice gate seals and elastomers shall be designed so they can be replaced in the field without disassembling the gate frame.

Provide lifting lugs on gate frames and gate leaves to allow single point hoisting of individual parts during installation.

2.1.2 Pedestal Base Plates

New operator stands shall be designed to be attached to the existing top of concrete elevation using new pedestal base plates and the existing anchor bolts. Existing anchor bolts and pedestal base plates are indicated on M34-P-LQP-68/2. Furnish new pedestal base plates same as existing pedestal base plates but with the operator stand bolt hole patterns configured to match to new operators.

2.1.3 Lift Stems and Couplings

Furnish all new lift stems, stem couplings, keys and fasteners required to connect the new gates to the new operators. The contractor is responsible to furnish new upper threaded stem sections and new lower unthreaded stem sections for all sluice gates. Stems shall be ASTM A276 Type 316 stainless steel. Fasteners shall be ASTM F593 / F594 Type 316.

Stem couplers shall be stainless steel construction as approved. The configuration of the existing gate lift stems and couplings are indicated on the reference drawings. Top of concrete elevation is (946.7 feet) for all sluice gates is indicated on M34-L-LQP-40/8. Invert elevation of the 6x9’gates (922.7 feet) is indicated on M34-L-LQP-40/8. Invert elevation of the 4x4’ sluice gates not precisely indicated on M34-L-LQP-40/8.

Assume invert elevation of 4x4’ sluice gates is elevation (914.9(+/-)0.5 feet). The contractor shall consider these dimensions and the height of

LQP Sluice Gates-7 the pedestal base plate system when calculating required stem lengths.

For each sluice gate stem furnish two stem stop nuts for upper and lower end of travel adjustment. Stem nuts shall be equipped with a suitable method to lock their position to the stem once properly adjusted, and shall fit inside the specified stem covers.

2.1.4 Stem Guides

Provide three adjustable wall mount stem guide assemblies for each sluice gate. Each stem guide assembly shall be adjustable in two perpendicular horizontal directions to properly align to the stem without requiring shims at the wall bracket to wall interface. Stem guides shall be equipped with replaceable bronze insert bushings with inside diameter sized for 0.01/0.02-inch clearance (or as approved) with gate stems.

2.1.5 Stem covers

Furnish clear polycarbonate stem covers for each gate furnished. Stem covers shall have permanent hash marks scribed each 0.1-foot.

2.1.6 Fasteners

All sluice gate components will be mounted to existing structures with pre-drilled holes and epoxy anchor fastenings. Expansion anchors will not be used. The contractor shall design and furnish all anchor bolts, anchor bolt epoxy materials, and other fasteners for installing the sluice gate frames and stem guides. The contractor shall design the gate anchorages to include quantities, locations, bolt diameter, and embed depths.

All bolts and nuts used in the sluice gate leaves, frames and stem guides shall be ASTM F593/ F594 Type 316 stainless steel. All fasteners shall be furnished with ASTM A276 Type 316 flat washers.

Furnish all epoxy anchor materials and instructions required to attach these sluice gate frames and stem guides. Each anchor shall include the rod, nut, washer, and epoxy material. Anchor rods shall be ASTM A193-B8 or as approved. Anchor nuts shall be ASTM F594 Type

316. Anchor washers shall be ASTM A276 Type 316.

2.1.7 AWWA C542 Electric Operator

Actuators shall comply with AWWA C542 open-close service 25% duty cycle operation, and shall have NEMA 4X enclosures. Actuator shall be designed for 240 volt single phase operation. Actuators shall be designed and equipped with heaters and other necessary provisions for outdoors installation in -40 to +100 degree Fahrenheit ambient conditions, such as drain holes and gaskets. Actuators shall be equipped with backup manual operation hand wheel and manually operated mode selector lever. Actuators shall be equipped with hinged tamperproof cover (10 gage welded steel or as approved) with padlock hasp to enclose all controls, pushbuttons and selector switches to prevent unauthorized operation and vandalism of the controls. Actuators shall contain field adjustable internal limit switches to set gate open and close positions.

2.1.8 Welding

All welding shall conform to American Welding Society D1.6. Any welded joints shall only be made by welding operators qualified through testing to make such joints.

LQP Sluice Gates-8

2.1.8.1 Non-Destructive Testing

a. Extent of Testing – 100% of all welded joints shall undergo a visual inspection (VT). 25% of all fillet welds shall undergo dye penetrant testing. 25% of all butt joints shall undergo ultrasonic or radiographic testing. All NDT shall be performed by a technician holding credentials as an AWS Level II Non-destructive testing technician.

b. Flaw Acceptance Size Criteria – Flaw acceptance size criteria shall be in accordance with AWS D1.6

3 EXECUTION

3.1 DELIVERY LOCATION

Equipment furnished under this contract shall be delivered to the Corps facility at the following address:

Lac Qui Parle Project Office 9055 1st St. W. PO Box 177 Watson, MN 56295-0177

Delivery shall be between 7am and 3pm on Monday through Friday, excluding government holidays. The contractor shall provide any required material handling equipment such as cranes or forklifts needed to offload the gates from the delivery trucks.

3.2 INSTALLATION

3.2.1 Installation Instructions

The setting, installation, assembly, lubrication, and testing of the gates and actuators shall be in accordance with the gate manufacturer instructions as approved by the Contracting Officer. These instructions shall be submitted for approval prior to gate delivery.

The Contractor-furnished instructions shall include recommended setting and assembly of the gate frame, the stem guide anchor bolts, and all stem couplings. The Contractor shall be available for telephone and video chat consultation for troubleshooting installation issues for the duration of the installation sequence. Provide name and contact information for the designated Contractor point of contact. The gate manufacturer’s erecting engineer shall conduct one eight-hour site visit to inspect and certify final gate installation and operation. The Government will provide the Contractor notification ten (10) calendar days before required site visit.

3.3 TOOLS

One set of wrenches and special tools required for the operation and maintenance of the sluice gates installed under this contract shall be furnished.

3.4 SPARE PARTS

All spare parts associated with the sluice gates shall be furnished inside a protective crate with a hinged top. The following lists the minimum type and quantity of required spare parts that the Contractor shall supply for each of the required gate actuators.

3.4.1 Mechanical

LQP Sluice Gates-9

a. Replacement seals and sliding interfaces for each sluice gate. Include all elastomer (UHMW or otherwise) sections precut to length and configuration required for installation.

b. Replacement stem guide bushing for each stem guide furnished, predrilled to match gate stem diameters.

c. Replacement completely-machined stem lift nut for each gate furnished.

d. Replacement stem cover for each gate furnished.

e. Individually packaged lubricants, for each type, in quantities necessary to complete installation and start-up.

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Submittal No.

Description Designation Date

Submitted Approval

Disposition Notes

1 Design Data G 2 Welding Procedures FIO

3 Welding Procedure Qualification Records FIO 4 Welder Qualification Records FIO 5 Welding Filler Metal Test Results FIO 6 Mill Certifications G

Non Destructive Testing Technician Credentials FIO

8 Non-Destructive Testing Reports FIO 9 Shop Drawings G

10 Operation and Maintenance Manuals G

Lac Qui Parle Sluice Gate Supply Contract Submittal Register