W912QR02069826_SOW_Appendix1-0000.pdf

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Attached to: D/B Electrical Improvements at Markland Locks and Dam
Solicitation number: W912QR-02069826
Issued by: Department of the Army Corps of Engineers Engineering District Louisville

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W912QR02069826_Appendix_II(A)-0000.pdf	PDF	Sep 1, 2020
W912QR02069826_Appendix_III-0000.pdf	PDF	Sep 1, 2020
W912QR02069826_Appendix_I(E)-0000.pdf	PDF	Sep 1, 2020
W912QR02069826_Appendix_I(B)-0000.pdf	PDF	Sep 1, 2020
W912QR02069826_SOW-0000.pdf	PDF	Sep 1, 2020
W912QR02069826_Appendix_IV-0000.pdf	PDF	Sep 1, 2020
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W912QR02069826_Appendix_II(B)-0000.pdf	PDF	Sep 1, 2020
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W912QR02069826_Appendix_I(G)-0000.pdf	PDF	Sep 1, 2020
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Solicitation For Electrical Improvements at Markland Locks and Dam, Warsaw, KY

P2: 128624

Design-Build RFP

Statement Of Work - Appendix 1 - Summary of Electrical Work

Ready To Advertise

01 September 2020

W912QR-02069826

MATOC

W912QR20D0021 thru 0024

ARIMS: 1200

Disposition: Permanent

W912QR02069826-0000

Scope of Work Appendix I - Summary of Electrical Work

1.0 – Overview of Work

All information below and in subsequent pages of this appendix shall be confirmed by the contractor during the site visit. Any discrepancies between what is described below and actual conditions shall be taken into account by the designer and contractor to provide a fully functional system. The contractor shall be responsible for the design and installation of the motor control center (MCC), lock emergency gate components, dam controls (local and remote) dam pier power distribution equipment, bulkhead crane power busway, and bulkhead crane controls.

All design and construction work shall be in accordance with the most current editions of following:

- NEMA ICS – Industrial Control and System General Requirements

- NFPA 70 – National Electrical Code

- NFPA 70E – Electrical Safety in the Workplace

- UL 508A – Standards for Safety – Industrial Control Panels

- UFC 3-501-01 – Electrical Engineering

- UFC 3-560-01 – Electrical Safety, O&M, with Change 5

- EM385-1-1 – Safety and Health Requirements

Design efforts shall also include short circuit calculations and power system coordination for power distribution equipment. Power coordination shall be discussed with the government prior to implementing final circuit breaker selection/settings.

Short circuit calculations shall be provided during the design and upon completion of installation.

Designer of record is responsible for performing calculations. Calculations shall include all components of the lock electrical system, including existing utility transformers, existing service disconnects, MCCs, and existing loads. Utility POC is: Kentucky Utilities, 859-367-1200 or 800- 383-5582, Scott Sparks, 859-983-0818.

The Markland Locks and Dam utility service consists of a 3 phase, 501 kVA transformer with a wye/delta configuration. System voltage is 12470/480 VAC.

The project has an emergency power generator, rated 300 kW. Switching between the utility and generator power is via an automatic transfer switch located in the powerhouse generator/hydraulic pumping room.

1.1 - Project Main Motor Control Center Scope

Markland Locks and Dam has an existing MCC in the powerhouse. The MCC is bottom fed and has eleven sections, sections that have a front and back bucket associated with them. This MCC provides electrical power to lock operational equipment such as hydraulic pump motors, a pressure holding pump, an air compressor, raw water pump, lock wall and navigation lighting, and also provides power feeders to the dam for equipment operation amongst other loads. See sheets OM-250.1/16 through OM-250.1/19 in Appendix I - Lock Construction As Builts for one line diagrams. The existing main circuit breaker is a 600A trip, 800A frame, rated for 480 volts.

The utility service and generator equipment buckets are located on the front side of the MCC in the three right (upstream) sections when looking at the MCC. The utility service and generator

W912QR02069826-0000

tel:+1-859-367-1200 tel:+1-800-383-5582 tel:+1-800-383-5582 have metering buckets designated above the main and emergency power distribution sections.

The 4th, 5th and 6th sections from the right sections of the MCC are designated for the hydraulic pump motor equipment, and utilize reduced voltage motor starters to start the hydraulic pumps.

The 7th section contains the raw water pump, air compressor, pressure holding pump, and contactor timers for the siren. The 8th section of the MCC contains the power and lighting feeders to the dam. Section 9 and 10 house the lighting panels and disconnect switches for the auxiliary and main lock chambers respectively. The 11th section of the MCC currently has no equipment.

The first three sections of the MCCs back elevation, starting from the left (upstream) most side, contains a heat exchanger, powerhouse heater circuit breaker and a temporary power feeder.

The 4th, 5th and 6th sections contain the dam remote tainter gate control and monitoring systems.

The 7th sections contains five power receptacles, the main and auxiliary gate hoists circuit breakers, the upstream and downstream gauging station circuit breakers, and a spare circuit breaker. The 8th section has no circuits attached to it. The 9th, 10th and 11th sections contain the interlock system for the lock chambers.

Scope for the MCC includes rehabilitation of the equipment and feeder buckets (replacement of power and motor circuit controls). Replacement of the entire MCC is not an option due to the presence of existing lock controls, safety interlocks, and traffic lighting systems, which shall remain intact. The main circuit breaker shall be sized accordingly taking into consideration the existing service, existing MCC horizontal and vertical buses, generator capacity (300 kW), and automatic transfer size (600A), as well as the equipment demands. The main circuit breaker shall be provided with a maintenance mode which lowers the instantaneous trip current to its lowest setting without having to open the main circuit breaker bucket door. Feeder circuit breakers powering existing equipment shall be sized according to NFPA 70 – National Electrical Code. Motor starters and overloads shall be sized per NFPA 70 and the existing motor size.

Replacement reduced voltage starters shall incorporate bypass functions which engage after motor has reached operating speed. All wiring on retrofitted circuits internal to the MCC and internal to the powerhouse electrical room shall be replaced and sized in accordance with NFPA 70 and NEMA ICS. Existing wiring on replaced circuits which exit the powerhouse shall remain.

Circuits which incorporate auxiliary signaling for remote starting shall have their auxiliary signals reattached, and shall have the same functionality and operability. Buckets are not required to be replaced during rehabilitation. Existing circuit equipment is allowed to be replaced on a case by case basis as opposed to fabrication of a whole bucket/circuit. Replacement of circuit breakers which are operated by bucket handle operators may require fabrication of new bucket doors to accommodate circuit breaker operation via bucket door operators. All new exterior bucket handle operators shall be of standard size and shall be heavy duty type. Operators shall be lockable with standard size padlock. No operators of reduced size shall be accepted. All existing switching/indicator lights for each circuit shall be replaced. See sheet PH-E-502 for list of circuits to be replaced along with notes regarding each circuit. Contractor shall determine final equipment list for replacement during site visits. Prior to installation, the contractor shall mark and document the phase conductors of the incoming main line and subsequent circuits.

Phases shall follow same path to equipment to ensure connections are correct prior to machinery activation (pump/motor rotational direction shall not change at any time for any retrofitted circuit). Any damage to the equipment incurred by not following the above mentioned procedure shall be repaired by the contractor without additional cost to the government.

The MCC shall be provided with modern electrical metering. Meters shall be provided for the main circuit breaker in the MCC and the following loads: all hydraulic pumps, pressure holding pump, air compressor and raw water pump. The main circuit breaker meter shall provide the following readouts: 3 phase voltage, 3 phase current, 3 phase power in kVA/kW/kVAR, and power factor. All subsequent metering shall be capable of three phase voltage and three phase amperage.

Lighting panelboards: the powerhouse has three lighting panelboards providing power to smaller loads; two of which, the main and auxiliary lock chamber panelboards, are within the MCC. The main and auxiliary lock panelboards are fed from separate transformers mounted exterior to the MCC in the MCC room. The two panelboards integral to the MCC shall be replaced. The replacement panels shall be large enough for all existing circuits, along with 20% spare capacity for future loads. If the 20% spare capacity is unattainable, the spare capacity shall be added to get as close to 20% as possible. All existing circuits powered from the existing panelboards shall be rerouted to the new panel integral to the MCC within galvanized conduit sized appropriately per circuit. All branch and feeder circuit breakers shall be replaced in kind with respect to type (ground fault monitoring type if applicable) and capacity. Main panel circuit breakers shall be adjustable trip type and final settings shall be determined by the government.

Lighting transformers are external to the MCC and are rated 50 kVA for the main and auxiliary lock chamber panelboards with a 480/120-208 voltage ratio. Each transformer is fed via an existing feeder circuit breaker integral to the MCC for each panel. Reconnection between the disconnecting circuit breaker bucket to the transformer and the transformer to the lighting panel shall be per NFPA 70 requirements.

In addition to power distribution, the controls for the dam remote operational systems shall undergo upgrades. Current dam remote controls and tainter gate height status are controlled/monitored via the control room in the powerhouse which shall be replaced in kind.

The dam controls in the MCC include: the tainter gate position display, raise-stop-lower push buttons, remote control power light, and the remote tainter gate activation alarm light/siren. Gate height signaling equipment and wiring shall be replaced with one that utilizes fiber optic cable to transfer the data on the dam structure into the powerhouse. Remote operation signaling wiring between the powerhouse and each dam pier shall also be replaced. Refer to dam, lock, and powerhouse sheets for information regarding approximate fiber optic/control cable routing and gate height indication/control.

The existing arc flash rating for the MCC shows that there is an existing arc flash incident energy rating of 49 cal/cm^2 in the MCC main bus circuit breaker. The government suggests disconnecting the MCC ahead of the main circuit breaker and replacing the main circuit breaker first before restoring the utility connection; turning the instantaneous trip settings on the adjustable trip circuit breaker to the lowest setting in the process. Once completed, the circuit breaker make and model installed shall be reported to the government. The government shall use this information to rerun the arc flash scenario to report back what the new instantaneous energy of the system is. This will ensure the proper personal protection equipment is used while working in the MCC according to NFPA 70E. The contractor shall be responsible for providing their own appropriately rated personal protective equipment required during the construction efforts.

Lock lighting and traffic lighting control hardware is powered and controlled from within the MCC, and are not part of the scope of the project. Any damages to these systems shall be reported immediately to the government and repaired immediately. Coordinate with the government to schedule if there are times the system must be turned off to complete work.

1.2 - Dam Scope

The dam consists of a thirteen pier system (Labeled piers are left end pier, piers 1 thru 11 and right end pier). The first pier starts from the river lock wall located on the Kentucky side of the river to the last which culminates at the hydro power plant on the Indiana side of the river. There are submergible and non-submergible tainter gates with 40hp and 30hp drive motors respectively. Work on the dam structure shall involve renovation of power and control systems for both the bulkhead bridge crane which traverses the dam service bridge, and all tainter gate piers. All work and testing of each gate shall be completed and signed off on prior to the contractor moving onto the next gate.

Tainter gate shall be bottomed out resting on the dam sill by site personnel prior to contractor commencing work on replacement of the pier power distribution equipment or control panel equipment. Only one tainter gate shall be worked on at any given time. Bulkheads must be installed by project personnel utilizing the bulkhead crane at the gate where work is being performed on prior to any gate testing being performed at said tainter gate. All running of the bulkhead crane, piggy back crane, and tainter gate machinery shall be performed by project personnel. The removal of the equipment doghouses via the bulkhead crane/piggy back crane will also be required for the contractor to access the tainter gate drive motors, traveling nut limit switches, and location of the existing rotational transducer/future single turn encoder. The running of equipment by project personnel shall be requested two weeks prior to performing the requested operations. See subsequent sections for more information.

1.2.1 - Bulkhead Crane Work

The bulkhead crane shall undergo repairs involving both the power and control systems of the mechanism. The existing horizontal power busway providing 3 phase power to the crane shall be replaced. Replacement power busway shall be provided with a grounding bus for equipment grounding in addition to the phase buses (existing busway does not include a grounding bus for equipment grounding). The existing busway is fed via a 200 amp feeder circuit breaker located on dam pier 6. The busway feeds the bulkhead crane main distribution panel which currently has a 225 amp main circuit breaker. This panel feeds the hydraulic traversing system, the main hoist and brake, the lifting beam, a step down transformer for cab 120 VAC power, and cab heater. Additionally, the piggy back crane feed is tapped from the power busway directly upstream of the crane main distribution panel. Designer of record shall incorporate the piggy back crane power circuit into the bulkhead crane main distribution panel. Designer shall take into account capacity at pier 6, as well as bulkhead crane loads and standard operating procedure (demand factors) when sizing replacement equipment. Currently the bulkhead traverse function and piggy back crane are used at the same time in some instances. The existing bulkhead crane lifting beam is electrically actuated and provided with power via a power cable reel. The existing reel is powered via an existing circuit rated 15 amps at 480 vac. A replacement reel shall be provided, and retract via a spring loaded spool as opposed to motor driven one.

Contractor shall perform motor winding insulation testing for bulkhead crane drive motors. Motor testing shall be in accordance with specification Task Order Scope of Work, Appendix I – Summary of Electrical Work, Attachment 3 – Motor Winding Insulation Testing. If the bulkhead crane drive motors fails motor winding insulation testing it shall be refurbished. The government shall be provided with the motor winding insulation testing data and shall make the final determination on whether a motor is to be rehabilitated or not. Motor refurbishment shall include the following: disassembly, cleaning of all parts, new sealed bearings, rewind stator windings, reinsulating windings (dipping, baking, vacuum pressure impregnation), new rodent screens, new heater, repaint, and balancing of the reassembled motor

Replacement of the existing control hardware/control wiring shall be replaced in kind. Efforts include: logic for crane traverse, logic for crane lifting/lowering, crane cab control station hardware/interface equipment (pushbuttons, levers, indication lights, etc.), and all wiring upstream, internal to, and downstream of control panels shall be replaced. In addition to the rehabilitation of the crane systems noted above, an inspection of the bulkhead crane shall be performed. The following systems shown but not limited to shall be evaluated: all mechanical components, structure of crane, hydraulic system, load sensors, upper weight limit switch, upper/lower travel limit switches, cable drums, reels, drive motors. List indicates main components of the crane, and secondary components may not be listed. Report shall be generated from inspection data and be turned over to government. Any issues revealed during inspection no associated with the power/controls rehabilitation will be corrected by the government.

All crane inspections and work shall be completed by a crane refurbishment company. This company shall perform inspections per ASNT, Level II, non-destructive and be US Department of Labor certified to inspect, test and certify maritime shore based cranes which require certification under federal regulation 29 CFR part 1918. Crane work must be completed in accordance with ASME B30.2. If option 0001 is executed for the bulkhead crane drive motor, a load test shall be performed after bulkhead crane rehabilitation is complete. Load test shall be performed under the direction of and witnessed by crane inspector mentioned above. The load shall consist of all dam emergency bulkheads. Bulkhead shall be installed in a tainter gate bay under no flow (tainter gate on sill). Coordinate tainter gate bay with COR and project Lockmaster. Once bulkheads have been installed, the tainter gate shall be raised above furthest test point. Bulkheads shall be raised 3 feet and stopped for 5 minutes. Contractor shall insure no movement of brake drum while under load. After 5 minute stoppage has been completed, contractor shall lower bulkheads 1.5 feet and stop for 5 minutes to repeat brake test. Upon completion of raise/lower testing, the load test shall be considered complete. For additional requirements of crane load testing, see Engineering Manual EM 385-1-1, section 16.F.03.

Documentation from the crane inspector indicating that the load testing was completed and passed shall be provided to the government.

Tainter gate work must be completed after the bridge crane renovation. The operation of the bulkhead crane will be integral for placing the bulkheads in front of the tainter gates during final testing of each tainter gate. The tainter gate doghouse covers shall also require the aid of the piggy back crane to be removed. This crane is located on the top of the bulkhead crane and will not be capable of operation when the bulkhead crane is being renovated. The piggy back crane may also be needed to remove tainter gate drive motors for refurbishment.

1.2.2 - Pier Power Distribution Equipment Scope

The pier power distribution system shall have its existing feeder selector circuit breakers removed and replaced with a manual circuit breaker type transfer switch. Replacement manual transfer switches shall operate via a dead front mechanism. Equipment which require exposing personnel to live parts during operation shall not be allowed. The scope also includes adding a 200 amperage receptacle to each tainter gate pier located next to an existing 50 amperage receptacle. Refer to sheet DAM-E-502 for additional information regarding the location of the receptacle.

1.2.3 - Tainter Gate Drive Motor Testing/Refurbishment Scope

Contractor shall perform motor winding insulation testing for all tainter gate drive motors. Motor testing shall be in accordance with specification Task Order Scope of Work, Appendix I – Summary of Electrical Work, Attachment 3 – Motor Winding Insulation Testing. The tainter gate drive motors which fail motor winding insulation testing shall be refurbished. The government shall be provided with the motor winding insulation testing data and shall make the final determination on whether a motor is to be rehabilitated or not. The government shall make a determination within two weeks of receipt of the motor testing. Motor testing document shall include testing for all motors. Motor refurbishment shall include the following: disassembly, cleaning of all parts, new sealed bearings, rewind stator windings, reinsulating windings (dipping, baking, vacuum pressure impregnation), new rodent screens, new heater, repaint, and balancing of the reassembled motor, Motor couplings on refurbished motors shall be replaced in kind. Motor reinstallation shall include re-alignment with machinery input shaft. Alignment shall be as such to meet recommended tolerances per shaft coupler manufacturer. Misalignment shall be measured and indicated to government via report, which shall provide both actual misalignment and coupler manufacturer tolerances and clearances. The project possesses a spare 40 hp tainter gate drive motor. Contractor will be allowed to utilize this motor during refurbishment of first submergible gate drive motor. Spare motor shall be tested and its testing results submitted to the government to determine its current status and if it requires refurbishment prior to utilizing it. When a 40 hp motor is removed for refurbishment, the spare motor shall be installed in its place and relabeled as the tainter gate drive motor it replaces. The last 40 hp drive motor replaced will become the spare 40 hp motor. Due to there not being a spare motor for the non-submergible gates, the 30 hp motors will be reinstalled from the location they are removed.

1.2.4 - Tainter Gate Control Panel Scope

Tainter gate controls upgrade shall include replacement of the local controls at each gate control panel (piers 1 thru 11 and right end pier - 12 total), along with a traveling nut limit switch assembly used for gate height, high level limit switch, and over travel limit switch. All switches shall be replaced. The existing traveling nut limit switch shall be replaced with a rotating cam type limit switch assembly. Each tainter gate has two panels present: a local control panel, and a panel with controls hardware present in order to operate each gate from the powerhouse located on the middle wall of the lock portion of the project. Control equipment shall be replaced in kind. All wiring upstream, internal to, and downstream of control panels shall be replaced.

Original lock and dam construction drawings have been provided as Drawing Appendices I and II respectively. Dam remote control drawings have been provided as Drawing Appendix III.

Drawings have been provided for reference only and shall be verified in the field during the designer of record’s site visits.

Tainter gate remote height indication controls shall be upgraded with a system which utilizes fiber optic cable to send a signal of the tainter gate height to the powerhouse. The tainter gate height will be measured from the sill elevation of the tainter gates to 75 vertical feet above the sill for each tainter gate. The encoder used to convert drum rotations into tainter gate height shall be a single turned encoder to avoid reprogramming if there is a power outage.

Approximate drum rotation measurements to gate height have been provided by the government for reference only. Designer is to verify the amount of cable actually going around the drum for their design. Work required to upgrade system includes: replacement of the height indication equipment at each drive pier, routing of fiber optic cabling from each pier to the lock powerhouse on the middle wall, and hardware to covert the native 4-20mA signal from the replacement transducer to fiber optic signaling and back to 4-20mA, along with DC power supplies for the converters. Contractor shall also replace existing numerical displays and provide replacement process controller displays in the lock powerhouse. These process controllers shall be programmed to display gate height utilizing the drum rotational data.

1.2.5 - Dam “Danger” Signage Scope

Existing “Danger” signage on the upstream portion of the service bridge and downstream portion of the state roadway bridge shall be decommissioned. This includes removal of its light bulb lamps, lighting contactor, disconnect switch, and feeder wiring. The signage panels and mounting brackets shall remain.

1.3 - Lock Emergency Gate Scope

Each lock chamber currently possesses emergency gates to stop flow in the event of a miter gate failure. Gates are located on the upstream side of each lock chamber. The piers adjacent to each set of gates on the land and river walls house the drive machinery and controls for each gate. The main lock possesses both upstream and downstream gate leaves. The auxiliary lock only has a downstream gate leaf (upstream gate leaf is no longer functional and is not part of the scope of this project). The emergency gate control cabinet hardware, control panel and gate control instrumentation shall be replaced with modern equivalents for each functional emergency gate leaf. Existing hardware in leaf cabinet and includes circuit breakers and motor starters. Existing instrumentation includes high limit switch and traveling nut limit switch for control point signaling. Traveling nut limit switch shall be replaced with a rotating cam limit switch type described in the tainter gate rehabilitation scope/drawings. Refer to lock sheets for reference of emergency gate control cabinet interiors.

Currently, each lock’s emergency gate(s) is/are controlled via a control panel located on the base of the emergency gate pier. This control panel shall be replaced in kind. Additionally, each replacement panel shall be provided with a keyed switch to turn the control power on/off.

The main and auxiliary lock emergency gate trash screen hoists and associated power busways shall be replaced with a modern day equivalent. Existing power busway consists of three phase buses. Replacement power busways shall be provided with grounding buses for equipment grounding in addition to the phase buses.

A work plan shall be created to show a schedule of work on the project. Scope of project will require loss of service for different operational aspects of the lock and dam. Any planned loss of service shall be submitted in writing to the government a minimum of 14 days prior to the scheduled work. The government shall approve all losses of service prior to the work being completed.

2.0 - Operability Endurance Testing:

Upon completion of each portion of the scope, the contractor shall demonstrate to the contracting representative the functionality of the updated system. This includes operating each gate or crane without incident. Additionally, systems with remote operation capability (tainter gate operation from lock powerhouse), shall be operated without incident. All testing operations shall be in accordance with the testing listed below.

The contractor shall use the endurance test to demonstrate the overall system reliability of the completed system. The endurance test shall be conducted in phases. Provide an operator to man the system 8 hours per day during daytime operations, including weekends and holidays, during Phase I endurance testing, in addition to any Government personnel that may be made available. The Government may terminate testing at any time when the system fails to perform as specified. Upon termination of testing by the Government or by the Contractor, commence an assessment period as described for Phase II. Upon successful completion of the endurance test, deliver test reports and other documentation, as specified, to the Government prior to acceptance of the system.

The operability endurance test (OET) demonstrate the system reliability of the completed system. The endurance test shall be conducted in phases. Testing shall be completed for each gate upon installation completion and inspection by site personnel. The contractor shall inform the government upon installation completion of each tainter gate, emergency gate, the bulkhead crane, and replaced circuitry in the powerhouse motor control center

2.1 - Bulkhead Crane Testing

Testing for the bulkhead crane shall be performed once controls and power distribution equipment retrofit has been completed.

- Traversing of the crane on the entire service bridge for replacement power busway functionality.

- Stacking and unstacking/storing bulkhead sections

- Installing all bulkhead sections in a tainter gate bay

- While bulkhead sections are installed, raise tainter gate, then raise bulkhead sections 5’

(allowing water to flow under), then lowering bulkhead sections to stop flow of water through gate bay.

- Limit switch functionality (high level)

The above mentioned bulkhead crane testing shall be performed 10 times without incident.

Phase II (Assessment): After the conclusion of Phase I, identify failures, determine causes of failures, repair failures, and deliver a written report to the Government. The report shall explain in detail the nature of each failure, corrective action taken, results of tests performed, and shall recommend the point at which testing should be resumed. After delivering the written report, convene a test review meeting at the job site to present the results and recommendations to the Government. The meeting shall not be scheduled earlier than 5 business days after receipt of the report by the Government. The Government reserves the right to cancel the test review meeting if no failures or deficiencies occur during the Phase I testing. If the Government chooses to do so, the Contractor will be notified in writing. Based on the Contractor's report and the test review meeting, the Government will determine if retesting is necessary and the restart point. The Government reserves the right to require that the Phase I test be totally or partially rerun. Do not commence any required retesting until after receipt of written notification by the Government. After the conclusion of any retesting which the Government may require, the Phase II assessment shall be repeated as if Phase I had just been completed.

2.2 - Tainter Gate Testing

Project personnel shall install the emergency bulkheads prior to commencement of each test.

Currently there is a complete set of bulkheads for a single gate. Gate testing for each gate shall be completed prior contractor commencing rehabilitation efforts of next gate. Contractor to provide an operator to man the system 8 hours per day during daytime operations. A government representative shall be present during entire testing. Contractor shall submit testing schedule to COR for approval. The Government may terminate testing at any time when the system fails to perform as specified. Upon termination of testing by the Government or by the Contractor, commence an assessment period as described for Phase II. Upon successful completion of the endurance test, deliver test reports and other documentation, as specified, to the Government prior to acceptance of the system.

1. Initial Test of Raising/Lowering : Gate shall be operated to 1' above the sill initially. When 1' above sill has been reached, the system shall stop per local control. Contractor shall lower gate back to sill. Contractor shall perform this 5 times utilizing local control and five times utilizing remote control before moving on to next testing procedure.

2. Maximum Raising Test: Contractor shall raise the gate to maximum height and allow the reconnected existing high limit switch to shut down the gate. The contractor shall be required to perform this three times utilizing local control and three times utilizing remote control.

3. Designated Height Test: Contractor shall raise the gate to a designated gate height per instruction of the government utilizing the encoder readings in the powerhouse. Gate height readouts shall be compared to known elevations in the field to ensure readouts are operating correctly. Coordinate with project personnel on known elevations to raise each gate to. The contractor shall be required to perform this three times utilizing local control and three times utilizing remote control.

2.3 - Lock Emergency Gate Testing

Phase I (Testing): The designer will determine the required Phase I testing period. The testing period should be based on the system size and complexity. The test shall be conducted 8 hours per day. Make no repairs during this phase of testing unless authorized by the Government in writing. Lock emergency gate testing shall be completed for all functional emergency gates (two in main chamber, one in auxiliary chamber). Test shall be performed for all three gates currently in operation. All operations will be performed in accordance with the lock Operation and maintenance manual and by Government Lock personnel. Contractor shall coordinate with government to set up emergency gate testing with respect to project preparation. Attachment 4 is an excerpt from the project Operation and Maintenance manual showing allowable configurations of emergency gates (plates 1 and 2), and has been provided for reference.

Testing will require additional efforts from project personnel to prepare chamber (pinning back gates), ensuring all locking equipment is in proper position, etc). Testing includes the following processes:

Main Chamber

Under "No Head" or "less than or equal to 1 ft of Head" (Maintain upper pool level)

- Raise Upper leaf up to maintenance level (full view of sheaves) Grease and inspect both sheave nest sides. (similar to Position 7)

- Lower Upper leaf to sill (on support pedestal)

- Raise Lower leaf to maintenance level (full view of sheaves) Grease and inspect both sheave nest sides. (similar to Position 6)

- Position Lower leaf and upper leaf and lock chamber to flush chamber (Plate 1, position

2 or 4 as applicable)

- Open upper miter gates and pin back (upper and lower pin)

- Lower chamber to lower pool by opening empty valves

- Open lower miter gates and pin back (upper pin only)

Under head differential

- Upon lowering the chamber water level to downstream pool elevation utilizing the emptying valves, and opening the downstream miter gates, the emergency lower emergency gate shall be lowered approximately 5’ to test the gate operation under flowing conditions. The emergency gate shall then be raised to the upper pool level to stop the flow through the chamber.

- Upstream leaf of main chamber emergency gate only to be tested with no head differential upstream and downstream of leaf. Coordinate with Lockmaster for equipment configuration and allowable maximum/minimum gate movement.

Auxiliary Chamber

- Under "No Head" or "less than or equal to 1 ft of Head" (Maintain upper pool level)

- Raise Lower leaf to maintenance level (full view of sheaves) Grease and inspect both sheave nest sides. (similar to Position 4)

- Position Lower leaf and lock chamber to flush chamber (Plate 2, position 2 or 3 as applicable)

- Open upper miter gates and pin back (upper and lower pin)

- Lower chamber to lower pool by opening empty valves

- Open lower miter gates and pin back (upper pin only)

Under head differential

Final setup and operation shall be determined by lock personnel. Contractor shall coordinate testing with project Lockmaster.

Government. After the conclusion of any retesting which the Government may require, the Phase II assessment shall be repeated as if Phase I had just been completed.

2.5 - Powerhouse Circuit Testing

- All retrofitted motor control center (MCC) circuits shall be tested upon their retrofit. All circuits shall be operated a minimum of 5 times with each their local control and 5 times with their remote and auxiliary activation (if present) signaling each. Circuit breakers shall be operated each time the circuit is tested.

Appendix I Attachments:

Attachment 1 – Calculated Tainter Gate Drum Rotation Data

Attachment 2 – Site Photos

Attachment 3 – Motor Winding Insulation Testing Procedure.

Attachment 4 – Project O&M Manual Excerpt – Lock Emergency Gates

Attachment 5 – Crane Testing Documentation

Short circuit calculations shall be provided during the design and upon completion of installation. Designer of record is responsible for performing calculations. Calculations shall include all components of the lock electrical system, including exist...

File details come from the government source that posted it. Updated Sep 2, 2020.