A02 SOW Tainer Gate Brakes and Side Seal Heaters.pdf

Scope of Work Replacement of Tainter Gate Brakes and Side Seal Heaters

Carlyle Lake

1. Scope Requirements. The contractor shall furnish and install tainter gate holding brakes complete with enclosure, brake wheels, and enclosure heaters as specified. The contractor is responsible for the following:

a. Removal and disposal of old holding brakes

b. Supply and install new holding brakes, enclosures, and enclosure heaters

c. Supply and install new cabling from DC brake rectifier to new holding brakes, and new cabling from existing Tainter Gate Controller enclosures to new brake enclosure heaters.

1.1 Site Visit. A pre-bid site visit is schedule for Thursday, August 2nd at 10:00 AM to see the location of the proposed project and help answer any questions related to the scope of work. Participants will meet at the U.S. Army Corps of Engineers, Carlyle Lake Project Office, 801 Lake Rd, Carlyle IL 62231. Please contact Courtney Wilson (618) 284-7160 to confirm attendance for planning purposes.

1.2 Contracting Officer. The term “Contracting Officer” (KO) means the person executing this contract on behalf of the Government, and any officer or civilian employee who is properly designated Contracting Officer. The term also includes, except as otherwise provided in this contract, the authorized representative of the Contracting Officer (COR) acting within the limits of his authority.

1.3 Safety. All work shall be performed in accordance with the safety requirements set forth in the Corps of Engineers Manual, EM 385-1-1, entitled “Safety and Health Requirements Manual”, 30 November 2014.

1.4 Site Access. Coordination with the COR shall be required for access to the dam to complete the installation. The Government will require the submission of a work schedule to include times, dates, and duration for access of these areas. This document shall be submitted at least 48 hours prior to start of work.

1.5 Security. The Contractor and all associated sub-contractors shall receive a brief/training (provided by the RA) on the local suspicious activity reporting program. This locally developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the project manager, security representative or law enforcement entity. This training shall be completed within 30 calendar days of contract award and within 30 calendar days of new employees commencing performance with the results reported to the COR NLT 5 calendar days after the completion of the training.

1.6 Submittals for Approval. Complete catalog cuts and descriptive data covering the brake, heaters, electrical cabling, necessary appurtenances, and paint system shall be submitted to the Contracting Officer for approval within seven (7) days of award. Contractor shall not make any purchases until the submittal is approved by the Government. The device data shall include necessary cuts, photos, and drawing to indicate clearly the construction of the brake, dimensional outline drawings, materials, input current, minimum voltage required for brake release, and all other features for which approval is required.

2. Order and Coordination of Work. The Contractor shall coordinate all work with the Contracting Officer. The Contractor shall give 7 days’ notice to start work to the Contracting Officer before starting work.

a. The Contractor shall produce a project schedule which clearly indicates the sequence of all activities, indicates how all work on the project will be accomplished within the required period of performance, and which satisfies the requirements listed in this document.

b. Access to the catwalk shall be coordinated with the project office to enter the facilities.

The project office shall be given 48 hours’ notice before work begins on each gate.

c. The Contractor is responsible for the proper disconnections of the machinery prior to removal of the holding brake.

d. Only one gate shall be taken out of service at a time. The Contractor must complete the installation, and final acceptance tests of the new brake before taking out of service the next spillway gate. Two gates shall remain operational at all times.

e. All parts shall be on site for complete installation prior to taking a gate out of service.

Removal of the existing holding brake and installation of the new holding brake shall be accomplished within one (8 hour) day.

f. Work shall be performed between the hours of 7:00 AM – 4:00 PM Monday through Friday unless specifically authorized by the Contracting Officer.

3. Brake Specifications. The brakes shall be Cutler-Hammer GH505 or approved equal. The brakes shall be an 8 inch wheel diameter, shoe type, spring set, and shall be operated on existing Cutler Hammer GH515ED17-1 DC brake rectifier. The brakes shall be rated 71.1 lb/ft continuous operated, and an input and holding current of 0.4 Amps at 91VDC. The torque rating is based on open construction, one hour intermittent duty, and is no less than 150% of the full load torque of the motor. The brakes shall feature non-corrodible fittings, manual hand releases, water tight covers with shaft seals, and supplied with heaters for the specified motor.

3.1. Brake Wheel. The brake wheels shall be similar or equal to Cutler-Hammer GH505JX, featuring an 8-inch diameter made of ductile iron.

3.2. Brake Shafts. Table 3.2 describes the shaft diameter measurements for each of the brakes to ensure proper alignment of the brake.

Table 3.2 - Shaft Measurements

Brake No. Shaft Measurement 1 1.629” 2 1.629” 3 1.639” 4 1.632”

3.3. Adjustments. Means shall be provided for varying the holding torque and adjusting the position of the shoes to compensate for wear, unless the design is such that compensation for shoe wear is automatic.

3.4. Complete Brake Tests. Brakes shall be tested to ensure effectiveness by checking operation of release at the specified rated brake torque and 85% terminal voltage, and heat run at the specified rated brake torque and voltage. Resistance measurements of release windings and dielectric test of release, leads, and terminal block should also be included.

3.5. Designation and Markings. Nameplates should be provided for each brake and attached to part of the brake. It shall indicated the manufacture’s name, identification symbols, serial number, salient design features such as type, frame, torque, rating, voltage, phase, and frequency, and pertinent information for adjustments if required.

3.6. Release.

3.6.1. DC Magnet. Releasing magnets of the DC magnet operated brake shall be of the shunt type and standard stock design. The new brake shall be compatible with the existing rectifier unit Cutler Hammer model GH515ED17-1 or contractor shall include new rectifier with brake. The rectifier unit shall have a proper rating suitable for operation on 440-volt, single phase, 60 cycle electrical power. The complete unit (brake and rectifier) shall be suitable for connection to the control circuit or 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 shall be continuous and shall 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 rectifier shall be mounted in the respective motor controller watertight and dust-tight enclosing case.

Conductors from the hoist motor controller to the brake shall be replaced and be sized per manufacturer recommendations. Drawings for the electrical install and general arrangement of the brakes can be found in Appendix A-1.

3.6.1.1. Magnet Installation. When installing new magnets, magnet faces may not make even contact due to standard machining tolerances. To avoid stresses and bearing wear resulting from such misalignment, energize brake to close magnet faces. Loosen bolts holding lever arms to outside armature. This will allow magnets to seat properly. Bolts shall be securely tightened. For optimum operation, brakes of any manufacture should be readjusted to normal magnet travel as often as a reasonable maintenance schedule will allow

3.6.1.2. Terminal Leads. Connecting leads from the releasing magnet shall extend outside of the enclosing case and terminated on a terminal block located in a watertight, four-position terminal box. The terminal box should be bolted or equally secured to the outside of the enclosure. The conduit entrance to the brake terminal box should be threaded. The leads inside the brake enclosure shall be in flexible steel conduit. New terminal lead cables shall be provided and rated as per the brake manufacturer’s recommendation.

3.6.1.2.1. Terminal Lead Installation. Power leads are brought into conduit box or terminal board at side of brake and connected to two bare terminals. Two coil leads are already connected at the factory for cumulative magnetic flux. This connection need not be disturbed except when removing coil from brake. After making line connection, leave sufficient slack in leads between coil and conduit box to allow free movement of leads with magnet motion.

3.6.2. Manual Hand Release. A manual hand release should be provided for each brake and only operable when enclosure is removed. During installation, when brake must be released for longer time or with more shoe clearance, release brake with manual release bushing.

3.7. Enclosure Specifications. The NEMA 4 enclosure shall be watertight, dust tight, moisture resistant, and arranged for floor mounting. It shall be constructed of cast iron or welded steel sheets that are no less than 1/8 inch in thickness. The enclosure should allow accessibility to brake mechanism from above when upper half or cover of enclosure is removed. The joint between the two halves shall be made of a synthetic rubber gasket that is no less than ¼ inch in width. Heavy hinge bolts and wing nuts attached to the fixed half of the enclosure shall hold it in place. A drain plug should be provided in the lower part of the enclosure. Water tight and dust tight shaft seals shall be provided on each part of the housing and arranged for pressure lubrication and adjustable for alignment relative to the shaft. All small metal parts should be made of corrosion resistant metal. An enclosure heater shall be included and wired to existing terminals 341 and X2 located in existing Tainter Gate Controller enclosure. New enclosure heater cabling shall be provided and shall be type XLPE insulation rated for the amerage of the heater per NFPA 70. Some corresponding dimensions of the exiting enclosure are below in Table 3.7. The existing enclosure is welded to two (2) support bars that are bolted to the mounting base. These bars are spaced 3 ½ inch from each other and are 1 ½ inch in height and width. These dimensions will be important for alignment of the new brake.

Figure 3.7 - NEMA 4 Brake Enclosure Dimensions

Table 3.7 - Existing NEMA 4 Brake Enclosure Dimensions

Approximate Dimensions in Inches C H K P R

2.5 28 31.25 6 15.75

3.7.1. Finishes and Paints. The enclosure case should be treated to render the steel resistant to corrosion. The finish on the water tight cover should consist of degreasing followed by a treatment with an approved iron and zinc phosphate solution and a rinse with a chromic acid solution, bonderizing, or an equivalent process. Immediately after the rinse, when dry, all surfaces should be given a coat of a zinc chromate primer conforming to the requirements of Federal Specification TT- P-645. (Formula No. 84/47), followed by two coats of clear varnish and one coat of medium light gray enamel. Submit the paint system for Government approval.

3.8. Mounting. Brake must be mounted on flat surface parallel to shaft. The center line should pass midway between mounting holes within 1/16 inch. Standard mounting is right hand. When facing commutator end of motor, the brake magnet is on right side with conduit box next to motor. Shoe bolts are inserted with heads away from motor to allow removal of shoes without dismounting brake. Left hand or opposite standard mounting with magnet on left involves insertion of shoe bolts from opposite side and interchanging of conduit box and travel equalizer plate. Left hand brake may be ordered as opposite standard from factory or converted in field.

3.9. Coils. Coil(s) shall be epoxy-encapsulated for permanent protection against dust, water, grease, oil and mechanical impact. Existing shunt style resistors shall be utilized.

Replacement coil shall be an E006026 or equal and utilize existing shunt brake resistor.

3.10. Warranty. Standard manufacturer’s one year warranty shall be supplied for all items purchased or installed and provided to the Government.

3.11. Test Reports. After the holding brakes have been shipped to the jobsite and have been installed, the Contractor shall demonstrate to the Contracting Officer the operation of the new holding brakes. The Contracting Officer will at that time direct operation and testing of the holding brakes.

Graves, Daniel R CIV CEMVS CEMVD (USA) TG Side Seal Heaters to be further evaluated during HSS inspection scheduled for summer 2021, not to be included in this SOW.

PROJECT POINTS OF CONTACT

Courtney Wilson US Army Corps of Engineers Carlyle Lake Project Office

(618) 284-7160 Courtney.M.Wilson@usace.army.mil

TECHNICAL POINTS OF CONTACT

Kyla James Mechanical Engineer US Army Corps of Engineers St. Louis District 314-331-8248 Kyla.L.James@usace.army.mil

Daniel Graves Electrical Engineer US Army Corps of Engineers St. Louis District 314-331-8269 Daniel.R.Graves@usace.army.mil mailto:Courtney.M.Wilson@usace.army.mil