SPECIFICATIONS FOR KENTUCKY LOCK MITER GATE PARALLEL HIGH-SPEED GEAR REDUCERS 1.0 General: Kentucky Lock is a high lift navigation lock on the Tennessee River at mile 22.4 in Grand Rivers, Kentucky. The miter gates located on the ends of the lock chamber are operated by using an electric motor connected to a combination of gear reducers, which in turn allow additional gate machinery to swing the miter gate open and closed. The majority of the lock's high-speed gear reducers are original equipment of 1940s vintage and in need of replacement. 2.0 Scope: The contractor shall be required to provide four (4) parallel gearboxes. The new parallel gearboxes shall meet or exceed the ratings of the existing gearboxes. The input and output shaft arrangements and dimensions shall match the existing gearbox. The overall dimensions shall match the existing gearboxes. The new gearboxes shall be delivered to the address listed below in Section 10, and are to be delivered within 150 days of the award of the contract. 3.0 Requirements: 3.1 Machinery: The parallel gearboxes are part of a machinery set used to operate any of the miter gates. Four (4) gearboxes matching the technical specifications will be required. The replacement parallel gearboxes shall meet or exceed the ratings of the existing gearboxes. The input and output shaft arrangements and dimensions shall match the existing gearbox. The overall dimensions shall match the existing gearboxes. For technical information pertaining to the gearboxes see Appendix A: Gearbox Information 3.2 Housing: All materials used or furnished shall be designed for an outdoor, damp/humid environment. The equipment shall be designed to operate at ambient temperatures from -10 to 120 degrees F. 3.3 Coating: The machinery shall be coated with an exterior grade, grey enamel finish. There shall be a 2 mils. coating of universal primer prior to painting the machinery. The finish shall have 2 coats, between 2 and 3 mils in total, of a 30% silicon alkyd. The Contractor shall provide a small quantity (1 gallon) of paint to repaint any areas where the finish is damaged during installation of the machinery at the project. The inner coating of the gearbox shall be coated with a finish that is suitable for gear oils and EP gear oils, so that no flaking or premature delamination will occur. 4.0 Drawings/Information to be Furnished by the Contractor: 4.1 The Contractor shall submit, within 15 days after contract award, shop drawings and calculations to The Tennessee Valley Authority, heretofore referred to as TVA, for approval. TVA will, within 15 working days after receipt, review and return the drawings to the Contractor stamped "Approved," "Approved with Corrections as Noted," or "Returned for Correction." The Contractor shall also submit for review by TVA copies of all calculations relevant to the design of the machinery. All calculations and drawings shall be approved and signed by a licensed Professional Engineer (PE). The coating recommendations for the inner and outer coating of each gearbox shall be submitted for approval. 4.2 Approval by TVA shall not relieve the Contractor of the responsibility for the correctness of the drawings furnished by the Contractor, nor for their compliance with specifications unless so stated at the time of approval. 4.3 After completion of the work, the Contractor shall submit 5 complete sets of shop drawings for each gearbox, schematics, operation and maintenance manuals, and spare parts lists. In addition, one reproducible drawing of each drawing shall be submitted. 4.4 Drawings shall be submitted rolled (not folded) in mailing tubes. The Contractor shall also submit drawings to TVA in AutoCAD .dwg format. 4.5 All preventative maintenance and lubrication data shall be provided. 5.0 Testing: 5.1 The Contractor shall be responsible for shop testing the machinery. Testing of equipment shall be witnessed by TVA and the United States Army Corps of Engineers, heretofore referred to as USACE. TVA shall be notified at least two weeks in advance of all shop testing. 5.2 A certified test report listing the results and numerical values of each test shall be provided to TVA prior to the delivery of the equipment. TVA shall approve the test results prior to delivery of the machinery. The Contractor shall perform at minimum the following tests: 5.2.1 Two separate run tests shall be performed on the machinery as per the industry standard. An oil sample before the start of the first test and after the second test shall be taken and delivered to TVA for sampling and approval from TVA. The temperature rise shall be taken during the run test. A vibration analysis shall be taken during the run test at all bearing locations. TVA reserves the option to take the vibration readings using our equipment. Operational date such as speed, torque, and other basic operational data shall be documented and provided to TVA. All of the aforementioned test results shall be provided to TVA for acceptance. 6.0 Approvals: 6.1 Work under this specification shall be subject to the approval of TVA acting in association with USACE, which is acting as purchaser of said equipment. 6.2 Approval by TVA and or USACE shall not relieve the Contractor for their compliance with specifications unless so stated and documented at the time of approval. 7.0 Codes and Standards: All equipment shall be listed for its use by a nationally recognized testing agency and adhere to ANSI, AGMA, and/or ASME standards. A list of the standards by which the gearboxes are designed and manufactured shall be provided to TVA as submittals. 8.0 Materials and Workmanship: 8.1 Materials used in the work shall be new, shall meet the requirements of the submitted standards, and shall be of kind, composition, and physical properties best adapted to their several purposes in accordance with best engineering practice. 8.2 Workmanship shall be first-class and shall be done by workmen skilled in their various trades. 8.3 All equipment shall be new, of current model, latest design, and shall be of standard, commercial, first-grade quality as to material, workmanship, and design, in accordance with the best engineering practice, and shall be such as has been proven to be suitable for the intended purpose. Similar models shall have been manufactured and in service for no less than five (5) years without defects or maintenance issues. 9.0 Contact Information: Submittals should be sent to the following: Tennessee Valley Authority Technical Point of Contact: Attn: Travis Simpson Travis Simpson 1101 Market Street
+1 (555) 000-0000 LP 1F Chattanooga, TN. 37405 10.0 Shipping / Delivery: Delivery will only be accepted Monday thru Thursday between the hours of 6:00 am to 4:00 pm. Delivery will be made to the following address: US Army Corps of Engineers Kentucky Lock, Attn: Mark Abshire 265 Kentucky Lock Road Grand Rivers, KY 42045 Appendix "A" - Gearbox Information Gearbox Namplate Data Electric Motor Namplate Data Manufacturer: Foote Bros. Manufacturer: Pacemaker Unit: 1 Model Number: 5148212007 Type: 12ND Type: CJ6D Serial Number: E81935A Frame: 404T Our Lube: 6 Volts: 460 Issue: 1 Amps: 42 Input RPM: 790 RPM: 850 Ratio: 18.37:1 Horsepower: 30 Horsepower: 30 SF: 1 Shipping Date: 10/19/1940 Code: G Insulation Class: F Duty: Continuous Temperature: 50 deg C
