RTA-Certfied_Final_Tplans_Nickajack_High_Speed_Gearbox_Replacement.pdf

Plans For

US Army Corps of Engineers

Nashville District

W912P5-17-X-XXXX

July 2017

Nickajack High Speed Gearbox Replacement

Tennessee River Basin

Tennessee River

Jasper, Tennessee

UPPER AND LOWER GATE, OPERATING MACHINERY, HIGH SPEED GEARBOX DETAILS

UPPER AND LOWER GATE, OPERATING MACHINERY, ARRANGEMENT

CONTRACT DRAWINGS:

REFERENCE DRAWINGS:

65W559

65W551

SH. NO. DH-705

64N557

64N556

64N553

64N552

64N551

64N550

PHILADELPHIA GEAR DRIVE, UNIT 3206T

UPPER AND LOWER GATE, OPERATING MACHINERY, MACHINERY DETAILS SH 2

UPPER AND LOWER GATE, OPERATING MACHINERY, MACHINERY DETAILS - SHEET - 1

UPPER AND LOWER GATE, OPERATING MACHINERY, ANCHOR BOLT ARRGT & DETAILS

UPPER AND LOWER GATE, OPERATING MACHINERY, SECTOR, PINION, AND MISC PARTS

UPPER AND LOWER GATE, OPERATING MACHINERY, ARRANGMENT

UPPER AND LOWER GATE, OPERATING MACHINERY, DESIGN DATA

Submitted:

(2.) The approval signatures appearing in the signature block on this sheet constitute approval of all drawings listed in the sheet index.

designations of individuals appear on these project documents within the scope of their employment as required by ER 1110-1-8152.

(1.) This project was designed by the Nashville District of the U.S. Army Corps of Engineers. The initials or signatures and registration

Note:

Project Engineer

Approval Recommended:

Vanessa C. Bateman P.E., P.G.

Chief, Civil Design Branch

Approved:

Robert W. Baulsir III P.E.

Chief, Electrical/Mechanical Section

Bradley J. Cressman

RTA - Certified Final

12'-0"

28'-0"

5'-11" 6'-3" 6'-9" 2'-3"

Š

1'-0"

2'-3"

10"

6'-10"

5ƒ"

1'-3ƒ" 2'-5•"

2'-8"

3" 1'-2•"

SCALE:

DO NOT ALTER MANUALLY

C.A.D. DRAWING

ISSUED BY:

R

TENNESSEE VALLEY AUTHORITY

FOSSIL AND HYDRO ENGINEERING

AUTOCAD R

DATE

PLOT FACTOR:

REVIEWED BY: APPROVED BY:

AS CONST

EXCEPT AS NOTED

NO.

REV.

DATE

R

R

DRWNDSGN CHKD RVWDSUPV APPD

PROJECT

ISSD

ID

CD

REV

DISCIPLINE

INTERFACE

SUBMITTED BY:

APPROVED BY:

DESIGNED BY:

DRAWN BY:

CHECKED BY:

CHIEF, ENGINEERING CONSTRUCTION DIVISION

H

F

G

E

3 4 5 6

D

C

B

A

2 3 4 5 6

7 8

REV NO.TASK COMPLETED BY:

F

E

7 8 9 10

D

C

B

11 12

A

US Army Corps of Engineers

Nashville District

P l o t

T i m e

P l

D a t e

F i l e

N m e

:5

:1

P M c d o c u m e n t s a n d s e t t in g s h e c x j d h p w w o r k c e lr n d m s

W .d g n

65W551 M

M14

W_TVA

---NCBKLS-0

065W551

XX

DTM

INITIAL ISSUE

EQUIPMENT NOTES:

64N551-1 THROUGH 11A ABOVE, PREVENT COMPLETE TVA DETAILING.

MACHINERY FURNISHED. LACK OF FIRE DIMENSIONS, PARTICULARLY ON MKS

8. MANUFACTURER'S DRAWINGS ARE TO BE COMPLETE AND CORRECT FOR THE

MACHINERY FURNISHED.

7. DISTANCES OMITTED ON DIMENSION LINES AND ELEVATIONS AND DIMENSIONS

AND BRAKE OF DRIVE UNIT AFTER LINES AND ELEVATIONS AND DIMENSIONS

6. DOWELS TO BE PROVIDED IN DIAGONALLY OPPOSITE FEET OF MOTOR, REDUCER,

5. ALL SHAFTS TO BE KEYED TO COUPLINGS AND GEARS WITH SQUARE KEYS.

HEXAGON, UNLESS OTHERWISE NOTED.

4. ALL BOLT HEADS AND NUTS TO BE AMERICAN STANDARD REGULAR SEMIFINISHED

FOR BOLTS AND CLASS 2B FIT FOR NUTS UNLESS OTHERWISE NOTED.

3. ALL THREADS TO BE AMERICAN STANDARD COARSE-THREAD SERIES, CLASS 2A FIT

TOLERANCES, ALLOWANCES, AND GAUGES FOR METAL FITS.

2. ALL FITS TO BE IN ACCORDANCE WITH AMERICAN STANDARD CLASSIFICATION FOR

OTHERWISE NOTED.

1. ALL STRESS RELIEVING TO BE DONE AFTER WELDING AND BEFORE MACHINING.

GENERAL NOTES:

•" = 1'-0"

02 1 2 4FT

SCALE: •''=1'-0''

PLAN

RIVER WALL OPP HAND EXCEPT AS NOTED

COMMON WALL AS SHOWN

BUMPERS WITH MINIMUM OF STRUT LENGTHENING.

OPENING LEAF - GATE LEAF TO STOP AND BE HELD FIRMLY AGAINST WALL

ADJUSTMENT ACCORDING TO DRAWING (64N544).

(AFTER FINAL GATE ALIGNMENT AND BOTTOM SEAL

CLOSING LEAF - GATE LEAF TO COME TO REST IN FULLY MITERED POSITION

SWINGING EACH GATE LEAF INDEPENDENTLY IN AIR AS FOLLOWS:

TVA FIELD TO ADJUST CONTROL LIMIT SWITCH MK 8 ( OR ALTERNATE 8A ) BY

FIELD NOTES:

NICKAJACK PROJECT

EL. 638.96 | LOWER GATE MACH RECESS

EL. 640.46 | UPPER GATE MACH RECESS

{ SECTOR GEAR AND STRUT,

EL. 637.33 - LOWER RECESS

EL. 638.83 - UPPER RECESS

TOP OF BULKHEAD,

EL.636.75 | UPPER RECESS

EL.636.25 | LOWER RECESS

MK64N556-5

MK64N552-8

MK64N556-6 &-10

MK64N556-9

MK64N556-3MK64N556-8

MK64N556-7

MK64N557-6

MK64N556-1R

EL. 636.0 | LOWER RECESS

EL. 636.5 | UPPER RECESS

MK64N552-9

MK64N554-4

MK 1R

SECTION B-B

SECTION C-C

C

C

A

A

B B

F L

O W

MK64N552-18

MK64N552-17

AGITATING OIL PUMP

CONTROL CABINET

EL.636.5 | UPPER RECESS

EL.635.0 | LOWER RECESS

OIL HEATER

MK64N552-11

MK64N552-12

LUB OIL PUMP

FORCED-FEED

AND SWITCH

OIL PRESS GAUGE

MK 1R

MK 3

MK64N557-8

MK64N557-9

DRAIN

OIL

SUMP

FRAME BY TVA

GRATING AND

FOR COMMON & RIVER WALLS

MK 64557-1 TO BE IDENTICAL

ALL MACHINERY ON DRIVE BASE

MK 4

MK64N557-7

MK 2

MIN

MK 9

MK 8

MK 10

MK64N557-1

SEE MECH DWG

GUTTER DRAIN BY TVA.

MK 5

MK 6

MK 7

EL 636.75 | UPPER RECESS

EL 635.25 | LOWER RECESS

{ PINTLE

AUXILIARY LOCK

UPPER AND LOWER GATE

OPERATING MACHINERY

ARRANGMENT

CHIEF, CIVIL DESIGN BRANCH

CELRN

EL.638.0 | UPPER RECESS

EL.636.5 | LOWER RECESS

1R

MK64N552-

GEAR

{ SECTOR

MK64N552-16

MK 64N554-A

STRUT ASSEMBLY

MK 64N557-A

FIELD ADJUSTMENT, SEE

FOR LIMIT SWITCH ARRG'T &

NORMAL STRUT LENGTH = 22'-9„"

STRUT LENGTH = 22'-9‰"(GATE OPEN)

22'-9"(GATE MITERED)

STRUT LENGTH =

F A

C E

O F

L

K

W A

L L

COUPLING GAURD NOT SHOWN

SEE 68N329

BULKHEAD BY TVA,

CONTRACTION JOINT{ REDUCER

RPM MOTOR SPEED

23°| FOR 600 SYN

RPM MOTOR SPEED

131°| FOR 1800 SYN

110'-1" FACE TO FACE OF CONCRETE

S

W F

U P

P E

R

W F

L O

W

H

C E

S

X

C E

T E

D

T

W

L

L O

W

C E

S S

W F

U P

P

E

N

B U

L K

H E

B Y

V

N

B

F L

O A

T I

G

A

U

P

C E

S S

E L

W

C E

S S

M K

N

E L

U P

P

C E

S S

E L

L O

W

C E

S S

E L

U

P

W

O A

T I

A F

T

E L

U P

P

L O

W

O A

T I

A F

T M

K

N

W F

M K

N

M K

N

M K

N

A

E L

U P

P

C E

S S

E L

L O

W

C E

S S

M K

N

M K

N

M K

N

M K

N

E L

U P

P

C E

S S

E L

L O

W

C E

S S

J O I

N T

C O

N T

R A

C T I

DANIEL T. MOORE KRISTEN L. SMITH NICOLE C. BERGER

JAMES R. WADDLE P.E.

VANESSA C. BATEMANBJC

JDH

JUL 17

OIL DRAIN

TVA. SEE MECH DWG.

DRAIN TO TAILWATER BY

TOP OF DRAIN

VALVE

OIL DRAIN FROM REDUCER

EL. 636.5 | UPPER RECESS

EL. 635.0 | LOWER RECESS

COMMON WALL

FLOW

{ AUX LOCK

GATE OPERATING MACHINERY

RIVER WALL

STA. 7+75.0 D

{ PINTLES LOWER GATE

STA. 1+00.0 D

{ PINTLES UPPER GATE

SCALE: 1" =100'

KEY PLAN

JUL 17 BJC JDH

*THIS DRAWING HAS BEEN REDRAWN IN CAD AND SUPERCEDES DRAWING 64N551.

MK 10 - LIMIT SWITCH MOUNT, -4 RED'D. SEE DWG 65W559.

EITHER DRIVERSHAFT A NEW COUPLING SHALL BE SELECTED - 4 REQD.

REDUCER OUTPUT AND •" LIMIT SWITCH INPUT. IF MANUFACTURE CHANGE

MK 9 - CURVED JAW GS SERIES LOVEJOY 24 / 32 COUPLING TO BE SIZE WITH 1"

FULL CLOSE TO FULL OPEN.-4 REQD.

(OR EQUAL). RATIO AS REQUIRED FOR INPUT OF MIN. 250 REVOLUTIONS FROM

MK 8 - LIMIT SWITCH, ROTARY TYPE, 4 CIRCUITS, GEMCO 1980404-X-R-(RATIO)-R2

LEVER WITHOUT LATCH, WESTINGHOUSE TYPE HI-83 (OR EQUAL )-4 REQD.

MK 7 - MOTOR BRAKE, 440 VOLTS, WATERPROOF ENCLOSURE, MANUAL RELEASE

OF TVA SPEC - 5 REQD (1 SPARE).

DUTY WITH SPECIAL CONDITION IN ACCORDANCE WITH SECTION 38

25/8. 33 HP 1800/600 SYN RPM, TEFC, FRAME 404U, CONTINUOUS,

MK 6 - DRIVE MOTOR, 440 VOLTS, SQUIRREL CAGE, 2 SPEED, 2 WINDING,

( OR EQUAL ) - 4 REQD.

MK 5 - FLEXIBLE COUPLING, LOVEJOY SIER-BATH GEAR TYPE F FLEX-FLEX, SIZE 2

MK 4 - SAME AS MK 3 EXCEPT FOR RIGID HALF BORE SIZE - 4 REQD.

(OR EQUAL) - 4 REQD.

MK 3 - FLEXIBLE COUPLING, LOVEJOY SIER-BATH GEAR TYPE F FLEX-FLEX, SIZE 3

REQD OPERATING OF MKS 1 AND 2 TO BE 1039 TO 1|1%.

TOTAL REDUCTION OF MKS 1 AND 2 TO BE 1030 TO 1|1%.

RATIO 14 TO 1 (OR EQUAL) -4 REQD. SEE DWG 65W559.

BONE OR HELICAL GEARS, PHILADELPHIA GEAR CORP 32067.

MK 2 - REDUCERS, PARALLEL SHAFT, SINGLE OR DOUBLE REDUCTION, HERRING-

MK 1L - SAME AS MK 1R ABOVE EXCEPT OPPOSITE HAND - 2 REQD.

RATIO 73.5 TO 1 (OR EQUAL) - 2 REQD

SECTION 25 OF TVA SPEC; PHILADELPHIA GEAR CORP 3621 UBHX,

PRESSURE SW FOR FAILURE INDICATION ALL IN ACCORDANCE WITH

ARE ON, ELEC HEATERS FOR LUB OIL , OIL PRESSURE GA, AND OIL

MOTOR- DRIVEN OIL PUMP FOR AGITATING LUB OIL WHEN ELEC HEATERS

MOTOR-DRIVE OIL PUMP FOR FORCED -FEED LUB OF GEARS AND BRGS,

HOUSING TO SUIT PINION GUARD (MK 64N557-6); EQUIPPED WITH

REDUCTION, OUTPUT SHAFT TO SUIT PINION (MK 64N552-12),

MK 1R - REDUCER, VERTICAL RIGHT ANGLE TYPE, DOUBLE OR TRIPLE

ALL MARK NOS. ON THIS DWG HAVE PREFIX 64N551 UNLESS OTHERWISE NOTED.

LCT

LCT

3.07"

1'-11•"

1'-3•"

9•"

9…"

5‹"1.967"

•" 7.472"

1"

1'-1•"

10"7‡" 5†"

1'-3†"

10ƒ"10ƒ"

1'-4‚" ƒ

1‡"

1'-ƒ"

10‚"

3•"

SCALE:

DO NOT ALTER MANUALLY

C.A.D. DRAWING

ISSUED BY:

R

TENNESSEE VALLEY AUTHORITY

FOSSIL AND HYDRO ENGINEERING

AUTOCAD R

DATE

PLOT FACTOR:

REVIEWED BY: APPROVED BY:

AS CONST

EXCEPT AS NOTED

NO.

REV.

DATE

R

R

DRWNDSGN CHKD RVWDSUPV APPD

PROJECT

ISSD

ID

CD

REV

DISCIPLINE

INTERFACE

SUBMITTED BY:

APPROVED BY:

DESIGNED BY:

DRAWN BY:

CHECKED BY:

CHIEF, ENGINEERING CONSTRUCTION DIVISION

H

F

G

E

3 4 5 6

D

C

B

A

2 3 4 5 6

7 8

REV NO.TASK COMPLETED BY:

F

E

7 8 9 10

D

C

B

11 12

A

US Army Corps of Engineers

Nashville District

P l i m e

P l t e

F i l e m e

:5

:5 c d o c u m e n t s a n d s e t t in g s h e c x j d h p w w o r k c e lr n d m s

W .d g n

M

M14

W_TVA

---NCBKLS-0

XX

DTM

INITIAL ISSUE

3" = 1'-0"

NICKAJACK PROJECT

CELRN

AUXILIARY LOCK

06 4 2 6IN

SCALE: 3''= 1'-0''

}†THRU X 6

UPPER AND LOWER GATE

OPERATING MACHINERY

HIGH SPEED GEARBOX DETAILS

CHIEF, CIVIL DESIGN BRANCH

BJC

JDH

MOUNT NOTE 5

SEE LIMIT SWITCH

MOUNT NOTE 3

SEE LIMIT SWITCH

NOTE: SEE LIMIT SWITCH MOUNT NOTES

MATERIAL: ASTM A36

MK. 64N551-10 MAKE: 4

LIMIT SWITCH MOUNT

NOTE 7

N O

T E

JUL 17

JUL 17 BJC JDH

65W559

65W559

DANIEL T. MOORE KRISTEN L. SMITH NICOLE C. BERGER

JAMES R. WADDLE P.E.

VANESSA C. BATEMAN

INPUT AND GEARBOX(MK. 64N551-2)

TO MATCH LIMIT SWITCH(MK. 64N551-8)

DRILL AND TOLERANCE EACH SIDE

LCT

LCT

FOR APPROVAL.

2. ALL DIMENSIONS ARE FOR REFERENCE. SUBMIT SHOP DRAWINGS

1. SEE DRAWING 65W551 FOR GENERAL ARRANGEMENT & NOTES.

NOTES:

MK. 64N551-4

KEY SLOT TO MATCH

MK. 64N551-9

KEY SLOT TO MATCH

SEE NOTE 8

SCALE: 1•" =1'-0"

MK. 64N551-8 MAKE: 4

ROTATING CAM LIMIT SWITCH

SEE NOTE 8

SCALE: 3" =1'-0"

MK. 64N551-9 MAKE: 4

GS CURVED JAW COUPLING

SEE NOTE 8

MK. 64N551-2 MAKE: 4

GEARBOX

‚ PLATE STEEL.

9. LIMIT SWITCH MOUNT SHALL BE FABRICATED FROM MINIMUM

HARDWARE PRIOR TO SHIPMENT.

FULLY ASSEMBLED BY CONTRACTOR TO INCLUDE REQUIRED MOUNTING

8. GEARBOX, LIMIT SWITCH, LIMIT SWITCH MOUNT, AND COUPLING SHALL BE

AS TO NOT INTERFERE WITH EXISTING STRUCTURES.

7. FURTHEST INSIDE EDGE SHALL NOT EXCEED 3•" FROM OUTPUT SHAFT {

PREVENT INTERFERENCE WITH EXISTING CONDUIT.

6. MOUNT SHAFT CENTERLINE TO TRAY BOTTOM SHALL NOT EXCEED 4" TO

LIMIT SWITCH ALIGNMENT WITH GEARBOX SHAFT DURING OPERATION.

5. MOUNT SHALL BE CONSTRUCTED WITH STIFFENING MEMBERS AS TO ENSURE

WITH EXISTING MOTOR FRAME.

4. MOUNT INSIDE EDGE SHALL BE SLANTED AS SHOWN TO AVOID INTERFERENCE

GEARBOX FRAME AS TO NOT INTERFERE WITH MOTOR PECKERHEAD.

3. OVERALL LIMIT SWITCH MOUNT LENGTH SHALL NOT EXCEED 1'-4‚" FROM

GOVERNMENT APPROVAL PRIOR TO FABRICATION.

2. FINAL MOUNT DIMENSION FROM MANUFACTURE SHALL BE SUBMITTED FOR

SUBMITTED FOR GOVERNMENT APPROVAL.

ANY CHANGES THAT ARE MORE EFFICIENT THEN GENERAL LAYOUT SHALL BE

TO GEARBOX FRAME AND SHALL BE PROVIDED BY GEARBOX MANUFACTURE.

1. GENERAL LAYOUT OF A LIMIT SWITCH MOUNT SHALL BE MOUNTED

LIMIT SWITCH MOUNT NOTES: