TPlans_RTA-Certified Final_Pickwick Lock Sector Gear Replacement_combined.pdf

US Army Corps of Engineers

Nashville District

CONTRACT DRAWINGS:

DRAWING INDEX

64E250-3 UPPER AND LOWER GATE, OPERATING MACHINERY, SECTOR, PINION, AND MISC PARTS

Plans For

Tennessee River

Pickwick Lock

Sector Gear Replacement

Counce, TN

Pickwick Project

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:

Robert W. Baulsir III P.E.

Chief, Civil Design Branch

Approved:

Mark P. Evans P.E.

Chief, Electrical/Mechanical Section

Jace T. Courtright

64E250-3 UPPER AND LOWER GATE, OPERATING MACHINERY, SECTOR, PINION, AND MISC PARTS

REFERENCE DRAWINGS:

FOR INFORMATION ONLY DRAWINGS:

64E250-2 UPPER AND LOWER GATE, OPERATING MACHINERY, ARRANGEMENT

11206-1 KENTUCKY LOCK, SECTOR GEAR

11206-2 KENTUCKY LOCK, RIM AND WEB WELDMENT PIECES

11206-3 KENTUCKY LOCK, RIM AND WEB WELDMENT PIECES

11206-E1 KENTUCKY LOCK - SECTOR GEAR, REPLACEMENT

11206-4 KENTUCKY LOCK, STIFFENER PLATE, SECTOR ARM MOUNTING PLATE, AND HUB WELDMENT PIECES

11206-5 KENTUCKY LOCK, BUSHING, SECTOR PIN, PINION, KEEPER PLATE, & TURNED BOLTS

64E250-5 UPPER AND LOWER GATE, OPERATING MACHINERY, STRUT ASSEMBLY & DETAILS

64E250-5 UPPER AND LOWER GATE, OPERATING MACHINERY, STRUT ASSEMBLY & DETAILS

June 2021

W912P5-21-Q-0036

Certified Final Documents - RTA

CONTRACT NOTES:

1. ALL HATCHED AREAS NOT IN CONTRACT.

2. ALL QUANTITIES AND MATERIALS FOR MK. NUMBERS UNDER

THIS CONTRACT CAN BE FOUND ON SPECIFICATION 35 20 15.

3. FOR SECTOR GEAR (MK. 9R) CASTING IS PREFERRED BUT

WELDING FABRICATION WILL BE ACCEPTABLE. SEE

SPECIFICATION 35 20 15 FOR MORE INFORMATION AND

SUBMITTAL REQUIREMENTS.

CONTRACT NOTES:

1. ALL HATCHED AREAS NOT IN CONTRACT.

2. ALL QUANTITIES AND MATERIALS FOR MK.

NUMBERS UNDER THIS CONTRACT CAN BE

FOUND ON SPECIFICATION 35 20 15.

REFERENCE O

NLY

F F

E E

D D

C C

B B

A A

BIRMINGHAM, ALABAMA

MANUFACTURER OF

STEWARD MACHINE CO., INC.

GEAR REDUCERS

ST

I

AN

IN

T

CIAISC Quality Certified SBR CBR F P2 P3

UT

E

S L

O

SN

E C

EF T

TR

T

ION

NI

UC

C.

OM

M

EB

E O

R

ME A

R

DEDNUO

FR

F

KENTUCKY LOCK - SECTOR GEAR

REPLACEMENT

NASHVILLE DISTRICT - LYON COUNTY, KY

1/16SCALE:

1/13/2015 11206-E1

REV. NO.RWB

US ARMY CORPS OF ENGINEERS

LOCATION:

DRAWN:

CUSTOMER:

SUBJECT:

CHECKED: JLG DATE:

DWG.

NO.

DETAILS:

JOB 11206-CNO. 2

KENTUCKY LOCK

SECTOR GEAR REPLACEMENT

LYON COUNTY, KY

US ARMY CORPS OF ENGINEERS

NASHVILLE DISTRICT

CONTRACT NO. W912P5-14-C-0024

2 7/13/2018 AS-BUILT SWC

1 3/2/16 UPDATED BOM AND CALLOUTS RWB

REVISIONS

REV DATE DESCRIPTION BY

4 - SECTOR GEAR REPLACEMENT

90.00"

84.000"

SECTOR GEAR 11206-1-1PINION 11206-4-3

BUSHING 11206-4-1

SECTOR PIN 11206-4-2

KEEPER PLATE (BACK SIDE) 11206-4-4

12" (REF)38.500"

32" 54" (REF)

.6

" 42

1/

RE

F)

RE

F)

PINION COVER

(EXISTING)

SECTOR GEAR COVER

(EXISTING)

PINION SHAFT

(EXISTING)

TURNED BOLT 11206-4-5

TURNED BOLT 11206-4-6

SECTOR ARM

(EXISTING)

STRUT PIN

(EXISTING)

STRUT SPINDLE

(EXISTING)

UPPER STRUT END

(EXISTING)

MACHINERY BASE

(EXISTING)

BILL OF MATERIAL

MARK NO QTY DESCRIPTION NO PER UNIT UNIT WT. ABM OR PO. NO.

11206-E1-1 24 CAP SCREW 6

3/4-10UNC-2B HEX SOCKET FLAT HD 2 3/4" LONG

11206-E1-2 8 PIPE PLUG 2

1/4"-18 NTP

℄ OF PINION

℄ OF PINION

℄ OF SECTOR GEAR

EL 372.00'

℄ SECTOR

GEAR

FACE OF

VALVE PIT

REF: CONTRACT DRAWINGS

02-L22.4-25/6.1 6A.1

APPROVED FOR FABRICATION

CAP SCREW 11206-E1-1

PIPE PLUG 11206-E1-2

(INSTALL FOR SHIPPING)

AS-BUILT

FOR IN

FORMATIO

N O

SECTION A-A

DETAIL M

TYPICAL INDUCTION HARDENED SECTION

F F

E E

D D

C C

B B

A A

BIRMINGHAM, ALABAMA

MANUFACTURER OF

STEWARD MACHINE CO., INC.

GEAR REDUCERS

ST

I

AN

IN

T

CIAISC Quality Certified SBR CBR F P2 P3

UT

E

S L

O

SN

E C

EF T

TR

T

ION

NI

UC

C.

OM

M

EB

E O

R

ME A

R

DEDNUO

FR

F

KENTUCKY LOCK

NASHVILLE DISTRICT - LYON COUNTY, KY

1/10SCALE:

1/13/2015 11206-1

REV. NO.RWB

SECTOR GEAR

US ARMY CORPS OF ENGINEERS

LOCATION:

DRAWN:

CUSTOMER:

SUBJECT:

CHECKED: JLG DATE:

DWG.

NO.

DETAILS:

JOB 11206-CNO.

DECIMAL:

±0.005"

MACHINING TOLERANCES

UNLESS OTHERWISE SPECIFIED

FRACTIONAL: ±1/32"

ANGLES: ±1/2° 6

KENTUCKY LOCK

SECTOR GEAR REPLACEMENT

LYON COUNTY, KY

US ARMY CORPS OF ENGINEERS

NASHVILLE DISTRICT

CONTRACT NO. W912P5-14-C-0024

BILL OF MATERIAL

ABM OR PO. NO.UNIT WGT. LBSNO PER UNITDESCRIPTIONQTYMARK NO.

ONESECTOR GEAR411206-1-1

115571FORGING AISI 4130 H4a1 296991PL 6" X 90 5/8" X 136 5/8" A364Web

Lenghtened 340121FORGING AISI 4130 H4b2 411251PL 3 3/4" X 38" X 54 1/4" A364Ra3R 511251PL 3 3/4" X 38" X 54 1/4" A364La3L 61708PL 3" X 3 3/4" X 54 1/4" A3632b3 71716PL 3" X 3 3/4" X 9 3/16" A3664c3

A

A

M

28 29 30 31 32 33 34 35 36 37 38

WELD REPAIR LOCATIONS

GEAR # 1 GEAR # 2 GEAR # 3 GEAR # 4

TOOTH # 1

FACE # 2

TOOTH # 7

FACE # 13

TOOTH # 48

FACE # 96

TOOTH # 3

FACE # 5

TOOTH # 5

FACE # 9

TOOTH # 32

FACE # 63

TOOTH # 32

FACE # 64

TOOTH # 29

FACE # 57

TOOTH # 1

FACE # 1

TOOTH/FACE LOCATION EXAMPLE

1 2 3

6 7/13/2018 AS-BUILT SWC

5 7/24/15 RACK DATA AND WELD SYMBOLS CHANGED, AS

BUILD DIMENSIONS ADDED RWB

4 4/16/15 EDITED PLATE NOMENCLATURE RWB

3 4/7/15 DIMENSIONS AND MACHINE MARKS ADDED RWB

2 3/31/15 SECTION VIEW, DIMENSIONS, AND QUANTITIES

UPDATED RWB

1 3/18/15 MATERIAL AND WELD SYMBOL CHANGES RWB

REVISIONS

REV DATE DESCRIPTION BY

1 P2-W101-B/GF

4 - SECTOR GEAR - 11206-1-1

1"

1"

10.500 - 10.502"

1/2 P2-W126-B

TYP

1/2

P2-W126-B/GF

TYP

6"

9"

TYP

20 1/2" 65 1/2"

WORK THIS DWG WITH DWGS 11206-2 & 3

1 P2-W101-B/GF

3/4 3/4

P2-W101-B

TYP

1 P2-W101-B/GF

b2 a2 b3 c3

1/2 1/4

P2-W128-B/GF

P2-W101-B/GF

TYP

SHOP NOTES:

PREFIX ALL MARKS WITH 11206-

(EXAMPLE: 11206-a2)

1) SEE DWG 11206-E1 FOR ALL GENERAL NOTES

2) WELD IN ACCORDANCE WITH D1.1/D1.1M (2010)

3) ALL WELDS TO BE NDT AS FOLLOWS: VISUAL 100%

MT 100%

4) STRESS RELIEVE BY HEAT TREATMENT AFTER WELDING

AND PRIOR TO MACHINING

5) HUB AND RIM FORGINGS TO BE SUBJECT TO UT AS PER

ASTM A388-11 STRAIGHT BEAM METHOD WITH

ACCEPTANCE/REJECTION CRITERIA PER ASTM A788-10 S20 BR

6) ENTIRE TOOTH PROFILE SHALL BE CUT TO THE SPECIFIED

DIMENSIONS AND SURFACE HARDENED TO A HARDNESS

BETWEEN 480 AND 520 BHN (PIN). SECTOR GEARS SHALL BE

MATCH MARKED WITH THE CORRESPONDING PINION GEARS.

SUITABLE MEASURES SHALL BE TAKEN TO CONTROL THE

DISTORTION DURING THE HARDENING PROCESS. TEETH

MACHINING SHALL BE PERFORMED AFTER ALL WELDING IS

COMPLETE.

3/4

P2-W101-B/GF

TYP

3/4 3/4

P2-W101-B/GF

TYP

3/4 3/4

P2-W101-B/GF

TYP

RACK DATA

20° INVOLUTE A.G.M.A. STUB TEETH MK. 11206-1-1

NUMBER OF TEETH 50

NORMAL DIAMETRAL PITCH 3/4

NORMAL PRESSURE ANGLE 20°

PITCH DIAMETER 144"

OUTSIDE DIAMETER 146.134"

CHORDAL ADDENDUM 1.074"

WHOLE DEPTH 2.4"

BACKLASH 0.035"

CHORDAL TOOTH THICKNESS

INCLUDING BACKLASH 2.059"

SPAN MEASUREMENT INCLUDING

BACKLASH

OVER (12) TEETH

47.248"

AGMA QUALITY No. 6

14"

18 1/2" DIA BC

DRILL & TAP

3/4" DIA X 10UNC-2B

THREAD 1 1/2" DP.,

BOTH ENDS OF HUB

SPACE 120° APART

℄ OF SECTOR GEAR ARM

℄ OF SECTOR GEAR

2"

45° TYP

15° TYP

℄ OF WEB ARM

℄ OF STIFFENER PLATE

72.000" RAD

73.067" RAD

3/4 P2-W101-B

TYP

P2-W101-B/GF

TYP

1/4

P2-W101-B/GF

TYP

1/2

CHAMFER TO CLEAR

WELD (TYP)

DRILL AND REAM (12) 1 29/32" HOLES IN FIELD

TO MATCH EXISTING SECTOR ARM HOLES

34°

17.480 - 17.500"

16.621 - 16.623"

.4

.5

26" a1

.8

.8

8.

5" (R

EF

2 1/2"

3 3

.7

.7

1/

2" (R

EF

1/

2" (R

EF

ZONE 1: 0-1/8" DEPTH

480-520 BHN FOR SECTOR GEAR

20-30 BHN HIGHER FOR MATCH MARKED PINION

ZONE 2: 1/8"-1/4" DEPTH

NOT TO EXCEED 50 BHN DROP FROM ZONE 1

a3R (a3L FAR SIDE)

APPROVED FOR FABRICATION

TOOTH # 1

FACE # 1

FACE # 2 FACE # 5

TOOTH # 3

FACE # 6

FACE # 3 FACE # 4

TOOTH # 2

AS-BUILT

FOR IN

FORMATIO

AS-BUILT

FOR IN

FORMATIO

DETAIL A

TYPICAL WELD ACCESS HOLES

UNLESS NOTED OTHERWISE

FILLED WELDS SHALL BE

RETURNED THROUGH WELD ACCESS HOLES

SECTION B-B

DETAIL C

F F

E E

D D

C C

B B

A A

BIRMINGHAM, ALABAMA

MANUFACTURER OF

STEWARD MACHINE CO., INC.

GEAR REDUCERS

ST

I

AN

IN

T

CIAISC Quality Certified SBR CBR F P2 P3

UT

E

S L

O

SN

E C

EF T

TR

T

ION

NI

UC

C.

OM

M

EB

E O

R

ME A

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DEDNUO

FR

F

KENTUCKY LOCK

NASHVILLE DISTRICT - LYON COUNTY, KY

1/16SCALE:

1/13/15 11206-3

REV. NO.RWB

STIFFENER PLATE, SECTOR ARM MOUNTING

PLATE, AND HUB WELDMENT PIECES

US ARMY CORPS OF ENGINEERS

LOCATION:

DRAWN:

CUSTOMER:

SUBJECT:

CHECKED: JLG DATE:

DWG.

NO.

DETAILS:

JOB 11206-CNO.

DECIMAL:

±0.005"

MACHINING TOLERANCES

UNLESS OTHERWISE SPECIFIED

FRACTIONAL: ±1/32"

ANGLES: ±1/2° 3

KENTUCKY LOCK

SECTOR GEAR REPLACEMENT

LYON COUNTY, KY

US ARMY CORPS OF ENGINEERS

NASHVILLE DISTRICT

CONTRACT NO. W912P5-14-C-0024

A

B B

A

C

3 7/21/15 AS BUILT RWB

2 4/7/15 VIEW DELETED, FEATURES EDITED RWB

1 3/31/15 DIMENSIONS, TOLERANCES, AND DRAWING DETAILS

UPDATED RWB

REVISIONS

REV DATE DESCRIPTION BY

4 - SECTOR ARM MOUNTING PLATE - a3R (AS SHOWN) 4 - SECTOR ARM MOUNTING PLATE - a3L (OPP HAND)

3 3/4"

USE WITH 11206-1 AND 11206-2

64 - STIFFENER - c3

32 - STIFFENER - b3

3 3/4"

3"

/8

3/

3"

3/4"

3/ 4"

3 3/4"

1" RAD

1 1/4"

1/

4"

1/ 2"

1/2"

30°

.571"

30°

1/ 2"

NOTE:

BURNED PARTS ARE SHOWN AS-IS, IN

PROGRESS

APPROVED FOR FABRICATION

/4

45°

6" RAD

7" RAD

22°

70 5/8" RAD @ cp

7" RAD

60" RAD @ wp wp cp

53 1/2"

69"

35°

36.000"

3 3/16"

2"

℄ SECTOR GEAR

℄ SECTOR GEAR ARM

℄ SECTOR GEAR

AS-BUILT

FOR IN

FORMATIO

SECT A-A

SECT B-B

SECT C-C

F F

E E

D D

C C

B B

A A

BIRMINGHAM, ALABAMA

MANUFACTURER OF

STEWARD MACHINE CO., INC.

GEAR REDUCERS

ST

I

AN

IN

T

CIAISC Quality Certified SBR CBR F P2 P3

UT

E

S L

O

SN

E C

EF T

TR

T

ION

NI

UC

C.

OM

M

EB

E O

R

ME A

R

DEDNUO

FR

F

KENTUCKY LOCK

1/16SCALE:

1/13/2015

11206-4 REV 4

REV. NO.RWB

BUSHING, SECTOR PIN, PINION, KEEPER

PLATE, & TURNED BOLTS

US ARMY CORPS OF ENGINEERS

LOCATION:

DRAWN:

CUSTOMER:

SUBJECT:

CHECKED: JLG DATE:

DWG.

NO.

DETAILS:

JOB 11206-CNO.

DECIMAL:

±0.005"

MACHINING TOLERANCES

UNLESS OTHERWISE SPECIFIED

FRACTIONAL: ±1/32"

ANGLES: ±1/2° 4

KENTUCKY LOCK

SECTOR GEAR REPLACEMENT

LYON COUNTY, KY

US ARMY CORPS OF ENGINEERS

NASHVILLE DISTRICT

CONTRACT NO. W912P5-14-C-0024

A A

B

B

C

C

BILL OF MATERIAL

ABM OR PO. NO.UNIT WGT. LBSNO PER UNITDESCRIPTIONQTYMARK NO.

2262BUSHING 811206-4-1

CAST BRONZE B22/UNS 863008

1963ONESECTOR PIN411206-4-2

ALLOY STL FORGING ASTM A668 CLASS H4

1447ONEPINION411206-4-3

FORGING AISI 4130 H4

53ONEKEEPER PLATE411206-4-4

PL 2" x 5" x 19" A572/GR 36 CL H4

21"-8UNC-2A x 4" CAPSCREW WITH LOCK WASHER ASTM A354 GR BC8

1710TURNED BOLT4011206-4-5

2" DIA HEX HD BOLT BLANK x 16 9/16" ASTM A354 GR BC40

1 3/4"-5UNC-2B HVY HEX NUT40

1 3/4" DIA SPLIT WASHER ZINC PLATE STEEL40

182TURNED BOLT811206-4-6

2" DIA HEX HD BOLT BLANK x 17 13/16" ASTM A354 GR BC 8

1 3/4"-5UNC-2B HVY HEX NUT8

1 3/4" DIA SPLIT WASHER ZINC PLATE STEEL8

4 04/29/15 CHANGED PINION DATA CDS

3 4/7/15 GENERAL REVISIONS AS PER DRAWING REVIEW RWB

2 3/31/15 BOM QUANTITIES, MATERIALS, GREASE PORT,

DISTANCES, KEYWAYS, AND BORES UPDATED RWB

1 3/18/15 CHANGES TO MATERIAL RWB

REVISIONS

REV DATE DESCRIPTION BY

4 - SECTOR PIN - 11206-4-2

(MK 25/6-4) 4 - KEEPER PLATE - 11206-4-4

(MK 25/6-2)

8 - BUSHING - 11206-4-1

ASTM B22 UNS 86300 (MK 25/6-3)

4 - PINION - 11206-4-3

(MK 25/6-2)

.1

18.500" DIA BC

2"

5"

2"

D

IA

2"

45"

.9

3.

4"

21 1/2"

1/2" x 45°

CHAMFER

(TYP)

14"PITCH LINE SCRIBED ALONG

BOTH SIDES OF GEAR TEETH

IN 60° V SHAPE 0.030" DEEP

TO AID IN PROPER ALIGNMENT

.0

4.

3"

(A

FT

ER

P

R

ES

S

FI

T)

1.245 - 1.250"

9"

.6

6.

7"

D

IA

/2

D

IA

120°

(TYP)

1/4" WIDE x 1/8" DEEP GREASE GROOVES

TERMINATE GROOVES 1/4" FROM END OF

BUSHING

1 1/2"

60°

(TYP)

.0

PINION DATA

20° INVOLUTE STUB TEETH 11206-4-3

NUMBER OF TEETH 18

DIAMETRAL PITCH 3/4

PITCH DIAMETER 24.000"

OUTSIDE DIAMETER 26.133"

CHORDAL ADDENDUM 1.111"

WHOLE DEPTH 2.4"

BACKLASH 0.035"

CHORDAL TOOTH THICKNESS

INCLUDING BACKLASH 2.057"

SPAN MEASUREMENT

INCLUDING BACKLASH

OVER (2) TEETH

6.205"

AGMA QUALITY No. 6

8 - TURNED BOLT - 11206-4-6

(MK25/6-6)

2 3/8" 15 7/16"

40 - TURNED BOLT - 11206-4-5

(MK 25/6-5)

14 3/16"2 3/8"

1.938 - 1.943"

1.938 - 1.943"1 3/4"-5UNC-2A

THREAD

1 3/4"-5UNC-2A

THREAD

R1/4"

R1/8"

TYP GREASE GROOVE DETAIL

22" (REF)

R1/32"

DRILL (1) 3/8" DIA HOLE x 7 1/2" DP

THEN TAP 1/4"-18NPT

SEE NOTE 7

19 1/2"

DRILL (1) 9/16" DIA HOLE x 22" DEEP

THEN TAP 3/8"-18NTP

SEE NOTE 7

17 13/16"16 9/16"1 3/4"-5UNC-2B

HEAVY HEX NUT

A563 GR C

LOCK WASHER 1 3/4" DIA

1 3/4"-5UNC-2B

HEAVY HEX NUT

A563 GR C

LOCK WASHER 1 3/4" DIA

R1/32"

30°

(TYP)

DRILL (3) 25/32" DIA HOLES THRU

THEN C'SINK 82° x 27/64" DEEP

AS SHOWN ON 18.500" DIA BC

FOR 3/4 DIA SCREW RECESSED 1/32"

19"

DRILL (2) 1 1/16" DIA HOLES

THRU

1 1/2" (REF)

R1/8"

1/32" X 45°

CHAMFER

1.245 - 1.250"

1/64"1/64"

SHOP NOTES:

PREFIX ALL MARKS WITH 11206-

(EXAMPLE: 11206-a2)

1) SEE DWG 11206-E1 FOR ALL GENERAL NOTES

2) WELD IN ACCORDANCE WITH D1.1/D1.1M (2010)

3) ALL WELDS TO BE NDT AS FOLLOWS: VISUAL 100%

MT 100%

4) STRESS RELIEVE BY HEAT TREATMENT AFTER WELDING AND

PRIOR TO MACHINING

5) PIN AND PINION FORGING TO BE SUBJECT TO UT AS PER

ASTM A388-11 STRAIGHT BEAM METHOD WITH

ACCEPTANCE/REJECTION CRITERIA PER ASTM A788-10 S20 BR

6) TOOTH PROFILE SHALL BE CUT TO THE SPECIFIED

DIMENSIONS. PINION TEETH SHALL BE SURFACE HARDENED TO

A HARDNESS BETWEEN 20-30 BHN HIGHER THAN THE TEETH OF

THE MATCH MARKED SECTOR GEAR. SUITABLE MEASURES

SHALL BE TAKEN TO CONTROL THE DISTORTION DURING THE

HARDENING PROCESS.

7) TEMPORARY PLUGS 11206-E1-2 WILL BE USED FOR SHIPPING

30°30°

1/2" X 45° Chamfer

/2

RADIAL GROOVES AND

INTERNAL GROOVES

CONNECT

NOTE:

SEE DETAIL A ON DRAWING

11206-1 FOR FLAME

HARDENING DETAILS 3

APPROVED FOR FABRICATION

AS-BUILLT

FOR IN

FORMATIO