Orwell Dam Worm Gear Boxes

The Manufacturer shall furnish two (2) replacement worm gear speed reducers and associated spare gear reducer seals for the Orwell Dam tainter gate operating machinery. 2.0 REFERENCES. AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA) AGMA 2015/915-1 (2002A) Accuracy Classification System - Tangential Measurement Tolerance Tables for Cylindrical Gears AGMA 908 (1989B; R 1999) Information Sheet: Geometry Factors for Determining the Pitting Resistance and Bending Strength of Spur, Helical and Herringbone Gear Teeth ANSI/AGMA 2001 (2004D; R 2010) Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth ANSI/AGMA 2003 (2010D) Rating the Pitting Resistance and Bending Strength of Generated Straight Bevel, ZEROL Bevel, and Spiral Bevel Gear Teeth ANSI/AGMA 6001 (2008E; R 2014) Design and Selection of Components for Enclosed Gear Drives ANSI/AGMA 6013 (2006A; R 2011) Standard for Industrial Enclosed Gear Drives ANSI/AGMA 9002 (2004B; R 2011) Bores and Keyways for Flexible Couplings (Inch Series) ANSI/AGMA 9005 (2002E; R 2013) Industrial Gear Lubrication 3.0 GENERAL. Description, sizes and quantities of the required supply contract work items shall be as specified herein and in accordance with the attached reference documentation located in Part 2 - REFERENCE DOCUMENTATION. All supply contract work items shall be supplied directly by the worm gear speed reducer manufacturer. Removal of existing worm speed gear reducers and installation of the replacement worm gear speed reducers shall be performed by others. 4.0 SUBMITTALS. Government approval is required for the submittals listed below. Submittals shall be submitted electronically to the Government Technical Point of Contact. Manufacturer's Literature and Equipment Data Provide catalog cuts, dimensional drawings and material data for the proposed equipment that clearly indicates compliance with the requirements of these specifications and the drawings. AGMA ratings for gear quality of all gears and gear reducers and other pertinent information pertaining to the equipment shall be submitted. Manufacturer's Installation Procedures Provide detailed manufacturer's instructions concerning the installation and alignment procedures for the equipment to be furnished. Provide any special instructions for initial oil servicing, such as flushing requirements and procedures. Operation and Maintenance (O&M) Manual Submit an operation and maintenance manual in accordance with Paragraph 6.7, Operation and Maintenance Manual. Warranty. Submit warranty information in accordance with Paragraph 6.8, Warranty. 5.0 GOVERNMENT TECHNICAL POINT OF CONTACT. All submittals and technical questions regarding this scope of work shall be directed to the Government Technical Point of Contact listed below: Tom Lytle Mechanical Engineer U.S. Army Corps of Engineers 180 5th Street East, Suite 700 Saint Paul, Minnesota 55101-1638 contact@example.gov (651)-290-5027 6.0 WORM GEAR SPEED REDUCERS. The worm gear speed reducers supplied shall be of the exact make and model as those currently installed, except where variance is required. Information pertinent to the supply of replacement worm gear speed reducers is located in this paragraph and in PART 2 - REFERENCE DOCUMENTATION. Worm gear speed reducers shall be designed and manufactured in accordance with all applicable standards referenced in Paragraph 2.0 REFERENCES. All items shall be supplied in a new and unused condition. Refurbished or reconditioned worm gear reducers, to include gear reducer subcomponents, shall not be accepted. 6.1 Existing Worm Gear Speed Reducer Data. The following information applies to BOTH existing worm gear speed reducers. Manufacturer: Delroyd Type: Single Reduction Worm Gear Speed Reducer Model: E40 - S21 * Ratio: 9-2/3:1 Torque Output: No less than 4,000 in-lbs @ 1,150 RPM Input Speed (* The "S21" designator indicates a "special" design that is proprietary to the manufacturer. In this case there is evidence in local records that these worm gear speed reducers were originally supplied with longer than standard low speed output shafts. S21 models may also contain other non-standard features. The manufacturer shall be responsible for ensuring that characteristics of the new replacement worm gear speed reducers match those of the gear reducers that were originally supplied.) The following information applies only to the existing RIGHT SIDE worm gear speed reducer. Serial Number: 191841A Installation: Horizontal Rotational Configuration: B-1 ** Fan: Yes The following information applies only to the existing LEFT SIDE worm gear speed reducer. Serial Number: 191841B Installation: Horizontal Rotational Configuration: B-2 ** Fan: Yes (** As shown in the Delroyd Single Reduction Speed Reducers catalog, P-700-DWG.) 6.2 Variance from Existing Gear Reducers. For additional redundancy, a double high speed shaft shall be included on the LEFT SIDE replacement worm gear speed reducer. The extended shaft on the fan side of the gear reducer shall be coupled with a connection suitable for operation with a 3/4-inch square drive electric drill operator (see sketches titled "Variance from Existing Gear Reducers" in Part 2 - REFERENCE DOCUMENTATION). Provide removable guard over extended shaft. All modifications from standard models to include high speed shaft extension, installation of the 3/4-inch square drive coupler, modifications to the fan vent cover, and installation of the shaft guard shall be designed and completed by the manufacturer prior to delivery. 6.3 Additional Tainter Gate Operating Machinery Information. Prime Mover: Electric Motor, 5 HP, 1200 RPM Duty: Occasional, <1/2 Hour per Day Location (Outdoor/Indoor): Outdoor, Uncovered Location (Geographical): Minnesota, USA Ambient Temperature during Operation: -20'F - 110'F 6.4 Lubricants. The worm gear speed reducers shall be delivered free of all internal lubricants. The Government shall install lubricating oil after installation in accordance with the manufacturer's recommendations. The manufacturer shall submit any special instructions for initial servicing, such as flushing requirements and procedures. Hard copies of the initial servicing instructions shall also be included within the worm gear speed reducer packaging upon delivery. 6.5 Nameplates. Each worm gear speed reducer shall have the manufacturer's name, address, model number, catalogue number, and serial number attached to the gearbox housing. Plates shall be made from corrosion resistant metal with raised or depressed lettering and contrasting background. Nameplates shall be permanently attached. 6.6 Coatings. The worm gear speed reducers shall be provided with the manufacturer's standard, factory-applied coating system suitable for equipment installed in an outdoor environment. 6.7 Operation and Maintenance Manual. Unless otherwise specified, all operation and maintenance manuals must be comprehensive to the worm gear speed reducers. The following information shall be included in the O&M manual. a. Safety precautions b. Startup, shutdown, and post-shutdown procedures c. Normal operations d. Emergency operations e. Environmental conditions f. Lubrication data (to include initial servicing instructions) g. Preventive maintenance plan and schedule h. Cleaning recommendations i. Troubleshooting guides and diagnostic techniques j. Maintenance and repair procedures k. Removal and replacement instructions l. Spare parts and supply list m. Product submittal data n. O&M submittal data o. Parts identification p. Warranty information 6.8 Warranty. Provide warranty against defective materials, design or workmanship. Length of warranty shall be the standard manufacturer's warranty period and shall not be less than one (1) year. Upon receipt of notice from the Government of failure of any of the parts during the warranty period, new replacement parts shall be furnished and installed promptly at no additional cost to the Government. 7.0 SPARE PARTS. The manufacturer shall supply spare seals at the same time as the replacement worm gear speed reducers. All spares shall be individually packaged for long-term storage and labeled. It is assumed that the lip type oil seals on the high speed shaft at both the input and fan side interfaces are identical. If this correct, supply the following spare seals in the quantities listed: Part Unit of Issue Quantity High Speed Shaft Seal EA 6 Low Speed Shaft Seal EA 2 If the lip type oil seals on the high speed shaft are different on the input and the fan sides, notify the Government technical point of contact and supply the following spare seals in the quantities listed: Part Unit of Issue Quantity High Speed Shaft Seal (Input Side) EA 3 High Speed Shaft Seal (Fan Side) EA 3 Low Speed Shaft Seal EA 2 8.0 DELIVERY, STORAGE AND HANDLING 8.1 Shipment. Shipping shall be FOB Destination and pricing shall include the cost of delivery. Shipment address and point of contact for delivery and inspection is: John Fromuth U.S. Army Corps of Engineers Orwell Dam 14780 Orwell Road Fergus Falls, Minnesota 56537-7228 contact@example.gov (218)-736-6463 Each worm gear speed reducer shall be separately packaged and separately palletized for ease of handling. Unloading of the worm gear speed reducers at the project site shall be completed by Government personnel. The Contractor shall notify the government of the shipment at least 48 hours before the scheduled delivery date. All materials specified in this scope of work shall be delivered in one shipment. Delivery shall be between the hours of 8:00 A.M. and 3:00 P.M. Monday through Friday, except on Government holidays. Any delivery arriving after 3:00 P.M. will not be accepted by Government personnel until the next work period as designated above. 8.2 Delivery Date. The materials specified in this contract shall be delivered at the earliest possible date but no later than 15 September 2017. 8.3 Inspection, Delivery and Acceptance. Upon delivery to the project area, the worm gear speed reducers shall be visually inspected for damage in the presence of the Contracting Officer. The worm gear speed reducers will be accepted if, upon inspection, it is found to be in full compliance with the contract requirements and no damage is evident.