35 01 41.10 MACHINERY INSPECTION AND REALIGNMENT revised.pdf

KYL Machinery Inspection and Realignment Kentucky Lock W912Q520Q0053 Livingston County, Kentucky

PROJECT TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

35 01 41.10 MACHINERY INSPECTION AND REALIGNMENT

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SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

35 01 41.10

MACHINERY INSPECTION AND REALIGNMENT

PART 1 GENERAL

1.1 SCOPE

1.1.1 Inspection

1.1.2 Realignment

1.1.2.1 Temporary Acceptable Tolerances

1.2 PRICE AND PAYMENT PROCEDURES

1.2.1 Inspection

1.2.1.1 Payment

1.2.1.2 Unit of Measure

1.2.2 Alignment

1.2.2.1 Payment

1.2.2.2 Unit of Measure

1.2.3 Option 1 - Small Coupling Replacement

1.2.3.1 Unit of Measure

1.2.4 Option 2 - Large Coupling Replacement

1.2.4.1 Unit of Measure

1.3 REFERENCES

1.4 SUBMITTALS

1.4.1 Submittals Requiring Approval

1.4.2 Submittals for Information Only

1.5 APPLICABLE DRAWINGS

1.5.1 Miter Gate Machinery

1.5.2 Culvert Valve Machinery

1.5.3 Tow Haulage Machinery

1.6 PRE-BID SITE VISIT

1.6.1 Uncertain Measurements

1.7 QUALIFICATIONS

1.8 COORDINATION WITH OTHER CONTRACTORS

1.9 PERIOD OF PERFORMANCE

1.9.1 Schedule

1.10 SITE WORK

1.10.1 General

1.10.2 Machinery Conditions

1.10.3 COVID-19 Precautions

1.11 SAFETY

1.12 SECURITY

1.12.1 Background Investigations

1.12.2 Convict Labor

1.12.3 Escorting

1.12.4 E-verify

1.12.5 Reports of Crime

1.13 CONDUCT OF CONTRACT EMPLOYEES

PART 2 PRODUCTS

2.1 COUPLINGS

SECTION 35 01 41.10 Page 1

PART 3 EXECUTION

3.1 QUALITY CONTROL

3.1.1 Inspection Procedures

3.1.2 Field Measurements

3.1.3 Machinery Lifts

3.2 TESTS, INSPECTION AND VERIFICATION

3.2.1 Coupling Inspection

3.2.2 Gearbox Inspection

3.2.3 Coupling Inspection Report

3.2.4 Gearbox Inspection Report

3.2.5 Post Alignment Reports

3.3 PROTECTION OF PROPERTY

3.3.1 Existing Equipment

3.3.2 Damage or Loss of Contractor's Supplies and Property

3.4 DISPOSAL OF DAMAGED COUPLING

3.5 POINT OF CONTACT

3.6 ATTACHMENTS

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SECTION 35 01 41.10 Page 2

35 01 41.10

MACHINERY INSPECTION AND REALIGNMENT

PART 1 GENERAL

1.1 SCOPE

1.1.1 Inspection

The contractor shall provide all necessary labor, material, and equipment necessary to inspect the following items: the couplings for the miter gate machinery, culvert valve machinery, and tow haulage machinery. The contractor shall also inspect all gearboxes through the inspection ports.

a. Couplings: couplings of the miter gate machinery, culvert valve machinery and tow haulage unit shall be completely disassembled and removed from the shaft for cleaning and inspection. The coupling that exits the motor and connects to the high speed gearbox, and the two couplings that connect the high speed gear box to the low speed gear box shall be inspected. See paragraphs 3.2.1 "Coupling Inspection" for more information. If a coupling is found to be damaged and requiring replacement. The contractor will reassemble the machinery with a spare coupling provided by the Government. The contractor must confirm if the coupling will properly fit the shafts. The contractor will then submit a reference for a new coupling to the government for approval to replace the spare coupling. Upon government approval, the contractor will purchase and then replace the spare coupling with the new coupling. If a spare coupling is not available, the Contractor shall reassemble the machinery with the damaged coupling if possible and then go through the submittal process. Only reassemble the machinery with a damaged coupling if a spare coupling is not available. Inform the COR prior to this action for approval.

b. Gearboxes: all low speed gearboxes and high speed gearboxes of miter gate machinery and culvert valve machinery shall be inspected through the inspection ports. Planetary gearbox of the tow haulage will also visually inspected. See paragraph 3.2.2 "Gearbox Inspection" for more information on the work to be included for the inspection. The scope of work does not require disassembling of the gearboxes for inspection.

c. Inspection reports: Provide inspection reports that will include the conditions of the couplings and gearboxes. See paragraph 3.2.3 "Coupling Inspection Report" and paragraph 3.2.4 "Gearbox Inspection Report" for more information on what should be included in the reports.

1.1.2 Realignment

The shafts where the couplings are inspected shall be realigned within the maximum tolerances in Table 1. Realignment shall be performed after the couplings are fully inspected and reinstalled. The lock personnel can aid in any necessary machinery lifts in order to align the machinery properly.

This shall be confirmed during the pre-bid site visit.

The shaft alignment shall have maximum tolerances corresponding to the

SECTION 35 01 41.10 Page 3 shaft rpm. Reference Table 1 Maximum Tolerances.

Table 1 Maximum Tolerance

Shaft Speed (RPM) Angularity (mils/inch) (0.001/1")

Offset (mils) (0.001")

0 - 600 1.5/1" 5.0

600 - 900 1.0/1" 3.5

900 - 1200 0.7/1" 3.0

1200 - 1800 0.5/1" 2.5

Contractor shall provide post alignment reports at the completion of the project. The post alignment reports shall include at a minimum the new offset alignment (mils) and angular alignment (mils/in) and the procedure to address the misalignment issue.

1.1.2.1 Temporary Acceptable Tolerances

In the event of product failure at the time of realignment and correction is estimate to be more than the four hour window, the following table describes temporary acceptable tolerances. If the issue cannot be corrected in the allotted time, then the machinery will be allowed to operate under these tolerances temporarily. The contractor will be responsible for correcting this issue and ensuring that the shaft tolerances conform to the values described in Table 1 Maximum Tolerances.

Table 2 Temporary Acceptable Tolerances

Shaft Speed (RPM) Angularity (mils/inch) (0.001/1")

Offset (mils) (0.001")

0 - 600 2.0/1" 8.0

600 - 900 1.5/1" 6.5

900 - 1200 1.0/1" 5.0

1200 - 1800 0.7/1" 3.5

1.2 PRICE AND PAYMENT PROCEDURES

1.2.1 Inspection

1.2.1.1 Payment

Payment shall be made for costs associated with the inspection as indicated in the paragraph "SCOPE" which include inspection of the couplings, inspection of the gearboxes, and inspection reports. Mobilization, demobilization, bond payment, clean up, etc. shall be incidental to this payment.

SECTION 35 01 41.10 Page 4

1.2.1.2 Unit of Measure

Job.

1.2.2 Alignment

1.2.2.1 Payment

Payment shall be made for costs associated with the realignment of the stated machinery shafts and the post alignment reports as indicated in the paragraph "SCOPE".

1.2.2.2 Unit of Measure

Job.

1.2.3 Option 1 - Small Coupling Replacement

Payment shall be made for costs associated with the replacement of the small couplings that connect the motor to the high speed gear box or the epicyclic gearbox. There are a total of 9 small couplings.

1.2.3.1 Unit of Measure

Each.

1.2.4 Option 2 - Large Coupling Replacement

Payment shall be made for costs associated with the replacement of the two large couplings that connect the high speed gear box to the low speed gearbox. There are a total of 16 large couplings.

1.2.4.1 Unit of Measure

Each.

1.3 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.

U.S. ARMY CORPS OF ENGINEERS (USACE)

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

1.4 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.

1.4.1 Submittals Requiring Approval

Submittals requiring approval shall be submitted per the following procedure: Each submission by the Contractor shall be accompanied by a letter of transmittal containing a list of the items submitted, giving

SECTION 35 01 41.10 Page 5 titles and numbers as applicable. Transmittals shall be addressed to the person designated by the Contracting Officer. All submittals shall be provided via e-mail unless otherwise requested or approved. Decisions on these submittals, either approval or disapproval, will be given by the Government's Representative within 15 calendar days (30 calendar days for shop drawings). Each item submitted with "Approved," "Approved Except as Noted," or "Returned for Correction." The notations "Approved" and "Approved Except as Noted" authorize the Contractor to proceed with the work covered by such drawings, subject to the corrections, if any, indicated thereon or described in the letter of the transmittal. When the submittal has been "Returned for Correction", the Contractor shall make the necessary revisions and shall resubmit for approval in the same routine as before. Every revision made during the life of the contract shall be shown by the number, date, and subject in a revision block and a notation shall be made in the drawing margin to permit rapid location of the revision. The time consumed by the Contractor in submitting and obtaining approval of submittals shall be included in the time allowed for completion of the contract.

1.4.2 Submittals for Information Only

Submittals not requiring government approval shall be submitted for information only.

SD-01 Preconstruction Submittals

Qualifications; G, ECD-E Please submit the qualifications along with the Contractor's bid prior to award.

Schedule; G, ECD-E

Inspection Procedures; G, ECD-E

SD-03 Product Data

Couplings; G, ECD-E

SD-06 Test Reports

Coupling Inspection Report; G, ECD-E

Gearbox Inspection Report; G, ECD-E

Post Alignment Reports ; G, ECD-E

1.5 APPLICABLE DRAWINGS

1.5.1 Miter Gate Machinery

a. 64W255 - Upper and Lower Gate Operating Machinery Arrangement

b. 64W258 - Upper and Lower Gate Operating Machinery Sector, Pinion and Misc

c. 64W262 - Upper and Lower Gate Operating Machinery Base Sheet 1

d. 64W263 - Upper and Lower Gate Operating Machinery Base Sheet 2

e. FI-11000-00 - High Speed Reducer

f. D412185 - Low Speed Reducer

SECTION 35 01 41.10 Page 6

1.5.2 Culvert Valve Machinery

a. 64W282 - Segmental Valve Operating Machinery Drive Assembly

b. 64N284 - Segmental Valve Operating Machinery Misc. Machinery Parts

c. 64N288 - Segmental Valve Operating Machinery Base Sheet 1

d. 64N289 - Segmental Valve Operating Machinery Base Sheet 2

e. FI-11005-6 - Segmental Valve High Speed Reducer

f. FI-11008-0 - Segmental Valve Low Speed Reducer

1.5.3 Tow Haulage Machinery

a. 2030145AP - Drum Winch Shop Drawing

1.6 PRE-BID SITE VISIT

The pre-bid site visit is recommended to verify the equipment prior to placing the bid. This will provide important information of what is required to perform the work. However, it is not required to bid on this job.

1.6.1 Uncertain Measurements

The Downstream River Miter Gate High Speed Gearbox is different from the other three gate high speed gearboxes. The shaft size is similar to the other three; however the contractor will visually observe the size of the output shafts during the pre-bid site visit, and confirm the dimensions during the inspection and realignment process. Where measurements are unknown, the contractor shall make a note of them during the pre-bid site visit, and confirm the dimensions during the work to be performed.

1.7 QUALIFICATIONS

A statement certifying that the contractor possesses the capability to perform the work of similar scope and quality shall be submitted with the contractors quote. The statement shall include examples of similar work performed within the past 36 months. List of qualifications shall be submitted with the contractor's bid prior to award.

1.8 COORDINATION WITH OTHER CONTRACTORS

Coordination with other Contractors in the area will be required. The Contractor has primary responsibility to initiate the coordination and communication in a timely manner with the Contracting Officer's Representative to schedule activities and minimize or eliminate conflicts.

The Contracting Officer's Representative may determine that the Contractor should communicate directly with others. The COR shall be timely informed of all communications or actively involved in the communications.

The construction of the Lock Addition will be ongoing for the life of this contract. The Contractor shall not impact the progress of the Lock Addition contract. Special attention is required to ensure that all activities, especially those involving work with and around lifting equipment, meet the requirements for safety as directed in EM 385-1-1.

1.9 PERIOD OF PERFORMANCE

Period of performance is 120 calendar days after the contract is awarded.

SECTION 35 01 41.10 Page 7

1.9.1 Schedule

The Contractor shall submit for approval a schedule of all work to be performed. The schedule shall detail time required for submittals, approvals, material purchases, inspection, and realignment. The lock will be on a scheduled outage for the realignment process. Contractor must submit a 6 (six) week notice prior to starting work on the culvert valve, miter gate, and tow haulage machinery. When work is performed on the culvert valve machinery, the lock will be operating with either one filling or one emptying valve, so this will give the lock ample time to notify any authorities necessary. When work is being performed on the miter gate or tow haulage machinery, one, four-hour lock outage per day will be acceptable. Any outage shall not exceed this four hour time frame. The contractor shall be responsible for performing the requested work within this time period.

Lock outages are also contingent on the operation of Barkley Lock. If Barkley Lock is experiencing an outage, then Kentucky Lock is not permitted to have an outage. By submitting a 6 (six) week notice prior to starting work, this will give the navigation industry ample time to prepare for any scheduled outages.

1.10 SITE WORK

1.10.1 General

While working on Government equipment contractor will adhere to safety standards EM 385-1-1. All coordination while on site shall be conducted through the lock master and his staff. Working hours shall be Monday-Thursday from 0600hrs-1600hrs except for federal holidays. Any work outside these hours shall be submitted for approval.

1.10.2 Machinery Conditions

The machinery being worked on will be in the closed position for the duration of the inspection and realignment procedure and will not be moved or returned to service until the contractor has completed the realignment of the machinery. The contractor shall notify the COR upon completion. US Army Corps of Engineers personnel will be responsible for lock-out and tag-out procedures. No work can be performed on the machinery until it is locked-out and tagged-out.

1.10.3 COVID-19 Precautions

Contractors shall take precautions to avoid the spread of COVID-19. Social distance where possible. The contractor shall adhere to any precautions described by the COR.

1.11 SAFETY

The contractor must adhere to safety requirements in EM 385-1-1. The contractor shall closely coordinate with the lock master to conduct the work safely in accordance with Nashville District Operations safe work procedures.

1.12 SECURITY

Security requirements are based on the assumption that the Contractor will be onsite working less than 60 calendar days. In the event the Contractor

SECTION 35 01 41.10 Page 8 is required to work onsite for a longer period of time, contact the Project Representative for the purpose of adjusting these requirements.

All contractor and associated sub-contractor employees shall comply with all applicable project and local security policies and procedures (provided by the district representative). The contractor shall also provide all information required for background checks to meet installation/facility access requirements to be accomplished by the District Security Management Office. Contractor workforce must comply with all personal identity verification requirements (FAR Clause 52.204-9, Personal Identity Verification of Contractor Personnel) as directed by DOD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any installation or facility change, the Government may require changes in contractor security matters or processes.

1.12.1 Background Investigations

Since the work is being done within a controlled area but is expected to last less than six months, the investigation requirements fall under Category B1 for US Citizens and Category C for Foreign Nationals. Contract employees will need to be supervised/ escorted by a Corps employee while within the restricted area. In the event it is determined the contract will extend beyond six months, the contractor will need to comply with the requirements in Category B2 for US Citizens. Guidance and forms for the requirements are available on the Nashville District Public Website:

http://www.lrn.usace.army.mil/BusinessWithUs/ContractSecurityRequirements.aspx

1.12.2 Convict Labor

Because the work is being performed in a restricted area, there are restrictions on use of persons either imprisoned or previously convicted of a felony. The Contractor shall not employ in the performance of this contract any person undergoing a sentence of imprisonment imposed by any court of a State, the District of Columbia, Puerto Rico, the Northern Mariana Islands, American Samoa, Guam, or the U.S. Virgin Islands, or the US Federal Government. The Contractor shall not employ in the performance of this contract any person who has been convicted of a felony imposed by any court of a State, the District of Columbia, Puerto Rico, the Northern Mariana Islands, American Samoa, Guam, the U.S. Virgin Islands, or the US Federal Government.t

1.12.3 Escorting

All contract employees, including subcontractor employees who are not in possession of the appropriate security clearance or access privileges, will be escorted in areas where they may be exposed to classified and/or sensitive materials and/or sensitive or restricted areas.

1.12.4 E-verify

The Contractor must pre-screen potential employees to work on this contract using the E-verify Program (http:www.uscis.gov/e-verify) website to meet the established eligibility requirements. The Contractor must ensure that the employee has two valid forms of Government issued identification prior to enrollment to ensure the correct information is entered into the E-verify system. An initial list of verified/eligible contract employees must be provided to the COR no later than 3 business days after the initial

SECTION 35 01 41.10 Page 9 contract award.

1.12.5 Reports of Crime

Please ensure ALL reports of theft, suspected theft, vandalism, or ANY crime of Government OR Contractor property, OR crime against/by Contractor personnel is forwarded to the District Security Office. This information is critical for threat and risk assessments and may assist in obtaining funds for additional security measures.

1.13 CONDUCT OF CONTRACT EMPLOYEES

All contract employees and subcontractors shall conduct themselves in a proper manner at all times. No alcoholic or intoxicating beverages or substances or illegal drugs or controlled substances not prescribed by a physician shall be possessed, consumed, or be under the influence of any such substance while on Government property.

The Contractor shall remove from the site any individual whose continued employment is deemed by the appointed receiving agent to be contrary to the public interest or inconsistent with the best interests of the U.S. Army Corps of Engineers.

The Contracting Officer or the appointed receiving agent will require the Contractor to immediately remove from the work site anyone who is incompetent or who endangers persons or property or whose physical or mental condition is such that it would impair the employee's ability to satisfactorily perform the work. Notification to the Contractor will be made in writing if time and circumstances permit. Otherwise, notification will be verbal and will be confirmed in writing as soon as possible. No such removal, however, will reduce the Contractor's obligation to perform all work required under this contract and immediate replacement shall be made as required.

PART 2 PRODUCTS

2.1 COUPLINGS

Where couplings are found to be in poor condition, the contractor shall replace them in the same outline, size, and construction shown on the drawings. Submit the replacement couplings for Government approval. The replacement of the couplings are an optional bid item.

Chevron Ultra Duty Grease EP NLGI 2 shall be used.

PART 3 EXECUTION

3.1 QUALITY CONTROL

3.1.1 Inspection Procedures

Contractor shall submit the inspection procedures for approval prior to starting the inspection. Submittal shall need to include general description of the work to be performed, the method used to align the shafts, a detailed description of the method and the equipment to be used for the inspection of the couplings and gearboxes, and the requirement for lock outage (as applicable).

SECTION 35 01 41.10 Page 10

3.1.2 Field Measurements

The contractor shall field verify all measurements necessary to complete the work described. The contractor shall notify the Government of any incorrect dimensions found in the drawings.

3.1.3 Machinery Lifts

Lock personnel will be able to perform any necessary lifts to aid the contractor in their work. This shall be confirmed during the pre-bid site visit.

3.2 TESTS, INSPECTION AND VERIFICATION

Failure of any part to pass the requirements specified will be cause for rejection until action taken by the Contractor to correct the issues has been approved by the Contracting Officer's Representative (COR).

3.2.1 Coupling Inspection

Thoroughly inspect all couplings in the miter gate, culvert valve, and tow haulage machinery. Inspect for any cracks or wear in the shaft. Inspect all gaskets and sealing rings for cracking or excessive wear. Document your findings in the coupling inspection report, and clean and then reinstall the coupling with the appropriate amount of grease.

3.2.2 Gearbox Inspection

Visually inspect all gearboxes in the miter gate, culvert valve, and tow haulage machinery through inspection ports. Inspect the entire gearbox to ensure there are no oil leaks. Examine the inspection port cover and determine whether all bolts are tight and the cover is properly sealed.

Clean the inspection port cover and surrounding area, and do not contaminate the gearbox interior while removing the cover. Visually inspect the condition of all the gear teeth by turning the input shaft by hand or other means necessary. The condition of all the gear teeth should be documented in the gearbox inspection report. Document your findings in the gearbox inspection report. Then cover the inspection port and ensure to tighten all bolts to the proper torque.

3.2.3 Coupling Inspection Report

A coupling inspection report shall include sufficient detail in words, photographs, or other methods to fully describe the condition of all couplings inspected. There shall be a report for each set of machinery couplings (Ex: Landside Filling Valve Machinery Couplings). The reports shall include a section discussing recommended work. The report shall include a section detailing suggested materials and equipment to be maintained at the worksite for ideal maintenance/operation of the equipment.

3.2.4 Gearbox Inspection Report

A gearbox inspection report shall include sufficient detail in words, photographs, or other methods to fully describe the condition of all gearboxes inspected. There shall be a report for each set of machinery gearboxes (Ex: Landside Filling Valve Machinery Gearboxes). The reports shall include a section discussing recommended work. The report shall include a section detailing suggested materials and equipment to be maintained at the worksite for ideal maintenance/operation of the equipment.

SECTION 35 01 41.10 Page 11

3.2.5 Post Alignment Reports

The contractor shall submit the post alignment reports for approval. There shall be a total of 9 post alignment reports. This corresponds with one for each miter gate machinery assembly, one for each culvert valve machinery assembly, and one for the lock tow haulage assembly. At a minimum the report shall include the alignment tolerances for offset and angularity of each component that is realigned after the realignment work. The report shall also include any recommendations or concerns for future maintenance and condition of the couplings.

3.3 PROTECTION OF PROPERTY

3.3.1 Existing Equipment

The Contractor shall provide control to ensure any Government furnished equipment, property, or items are utilized only for contract purposes. All incidents of theft (or suspected theft) of Government furnished materials, supplies, or equipment from project lands shall be reported to the COR.

Upon completion (including any extensions of contract term) or termination of the contract for any reason, and except for fair wear and tear, the Contractor shall return all Government furnished equipment, and any unused material or supplies in the same condition as received. Any discrepancies (except for fair wear and tear), damages or deficiencies in the inventory will be chargeable against the Contractor.

3.3.2 Damage or Loss of Contractor's Supplies and Property

The Contractor is responsible for taking the action necessary to protect Contractor supplies, materials and equipment, and the personal property of Contractor employees from loss, damage or theft. The Government assumes no responsibility for theft, damage, etc., of the above. All incidents of theft (or suspected theft) of contractor materials, supplies, or equipment from project lands shall be reported to the COR.

3.4 DISPOSAL OF DAMAGED COUPLING

If a coupling is found to be damaged, and it is replaced with a new coupling, then the old, damaged coupling shall become the property of the contractor. The contractor is responsible with disposing the coupling in accordance with all federal, state, and local guidelines.

3.5 POINT OF CONTACT

US Army Corps of Engineers 265 Kentucky Lock Road Grand Rivers, KY 42045 POC: Caleb Skinner, Phone: (270) 362-4222 Email: john.c.skinner@usace.army.mil

3.6 ATTACHMENTS

a. Tow Haulage Electric Motor Cutsheet - Weg 50 HP, 1800 RPM

b. Brevini S-Series epicyclic Gear Unit Model No. SC6004MP Detail 1

c. Brevini S-Series epicyclic Gear Unit Model No. SC6004MP Detail 2

d. Brevini S-Series epicyclic Gear Unit Model No. SC6004MP Detail 3

e. ENG Form 4025 Transmittal Form

f. Submittal Register

SECTION 35 01 41.10 Page 12

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1.13 CONDUCT OF CONTRACT EMPLOYEES